Learn how to setup and maintain your ZeroMist Oil Mist Collector, and get the most out of your unit.
TABLE OF CONTENTS
TABLE OF CONTENTS............................................................................................................................................................1
SHIPPING RECEIVING, AND INSPECTION..............................................................................................................................3
RECEIVING AND INSPECTION ...........................................................................................................................................3
BEFORE INSTALLATION BEGINS .......................................................................................................................................4
FEATURES AND SPECIFICATIONS..........................................................................................................................................6
GENERAL FEATURES ......................................................................................................................................................... 6
THREE STAGE FILTRATION PROCESS ....................................................................................................................................7
OVERVIEW:.......................................................................................................................................................................7
INSTALLATION ...................................................................................................................................................................... 8
GENERAL INSTALLATION GUIDELINES..............................................................................................................................8
TOOLS NEEDED FOR INSTALLATION.................................................................................................................................8
REQUIRED TOOLS: ........................................................................................................................................................ 9
OPTIONAL / RECOMMENDED TOOLS:........................................................................................................................10
WARNINGS AND LABELS ................................................................................................................................................12
MOVING THE ZEROMIST UNIT .......................................................................................................................................13
ASSEMBLING LARGER UNITS..........................................................................................................................................14
INSTALLING MOTOR HOUSING ......................................................................................................................................18
SPRAY NOZZLE SYSTEM (OPTIONAL)..................................................................................................................................18
DRAINAGE PUMP (OPTIONAL) ...........................................................................................................................................19
CALIBRATING PRESSURE GAUGES......................................................................................................................................20
MOUNTING ........................................................................................................................................................................21
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ELECTRICAL CONNECTION DIAGRAMS...............................................................................................................................22
POWER DISCONNECT SWITCH / EMERGENCY SHUT OFF SWITCH.................................................................................26
STARTUP / SHUTDOWN PROCEDURES...............................................................................................................................27
BLOWER ROTATION ...........................................................................................................................................................28
Maintenance ......................................................................................................................................................................29
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SHIPPING RECEIVING, AND INSPECTION
R ECEIVING AND INSPECTION
Congratulations on the purchase of your new Clean Air Industries ZeroMist!
Upon receipt of your new ZeroMist,
remove the master packaging list from the
unit and reconcile it with the total
shipment.
The master packing list is located on the
side of the product in a pouch. If the list
has been damaged or lost, there is also a
copy with the bill of lading.
Clean Air Industries ZeroMist units are shipped via freight and generally arrive on
a flatbed trailer. Generally the units are
partially crated, laid down and shipped
whole. Larger units may be taken apart
and shipped in separate pieces.
Remove the packaging from the unit, and
then remove the unit from the pallet.
Carefully inspect the unit and any other
items shipped with the unit for any
damage that may have incurred during
shipping. If damage is found , please
report it to the shipping company and Clean Air Industries immediately.
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(Optional) Electrical pumps, spray nozzles, plenums and legs are packaged separately and
are generally shipped with the unit on a separate pallet.
When purchasing multiple units, these items may be shipped on a separate truck and arrive
at a different time.
If a larger ZeroMist unit is purchased, and has to be shipped in multiple pieces, then a bolt
package will also be included.
B EFORE I NSTALLATION B EGINS
Prior to using your ZeroMist, it must be fully assembled and placed in its final operating
location. Be aware that the unit must be fastened to the floor with bolts before operating, so
we suggest you choose the final location accordingly.
Adequate electrical connections must be supplied to the ZeroMist. These connections are
defined in “Electrical Connections” of the manual.
For functionality and safety, Clean Air Industries does not recommend modifying the ZeroMist in any way. Never allow the unit to intake any flammable or explosive gasses.
When servicing or cleaning the machine, first make sure the unit is OFF. It is also
recommended to wear protective respiratory equipment and safety glasses.
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ZEROMIST DESCRIPTION
DISCLAIMER: The Clean Air Industries ZeroMist is designed to accumulate oil and mist
particles produced during manufacturing, and provide clean air to any
workshop environment. The ZeroMist also separates oil mist and water
emulsions in a variety of applications with its three stage filtration system.
During this process the oil or coolant is condensed and stored, ready to be
reused. If a pump was purchased, it will automatically send the captured oil
or coolant back into the tool sump.
The Clean Air Industries ZeroMist consists of:
Three Stage Filtration Housing
Motor / Blower System
Assorted Filters
Silencers
(Optional) Pre-filter
There are generally two inlet holes pre-cut on each ZeroMist,
located on the bottom sides of the plenum. This allows the
customer to choose which side would be best to run duct
work. The other open hole can then be capped with materials
sent. If the customer chooses not to have duct inlets pre-cut,
then the holes must be cut on site.
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FEATURES AND SPECIFICATIONS
GENERAL FEATURES
Three Stage Filtration Process
Differential Pressure Gauges
Silencer
Heavy Steel Construction with Powder-Coat Paint Finish
Customizable Filtac Oil / Smoke Coalescing Fiber Bed Filters
24” x 24” x 4” High Quality HEPA Filter
Electrical Panel
Filter Clamp Tool(s)
(Optional) Pre-filter
(Optional) Electrical Pump
(Optional) Spray Nozzle System
(Optional) VFD or MMP
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THREE STAGE FILTRATION PROCESS
O VERVIEW:
STAGE 1: Here custom filters collect oil or coolant
from the air. These filters are designed
to coalesce the mist, rather than absorb
it. Once enough of the mist is gathered,
it drips back down into the bottom of
the ZeroMist. Finally the recycled liquid
is drained out of the drain hole, to be
stored or pumped back into the tool
sump.
STAGE 2: Now the air passes through a much
finer coalescing filter. This filter is
designed to gather much smaller
particles from the air, sending down any
liquid that made it past Stage 1. After
Stage 2, the air is virtually 100% free
from oil or coolant mist.
STAGE 3: Lastly, the air passes through our high
quality HEPA filter. During this stage the
air is cleaned to a higher standard than
the surrounding air. The HEPA filter
captures upwards of 99% of fine, sub-
micro particles from the air. Traces of
smoke, bacteria, pollen and spores
are all trapped and unable to return
back into the workshop. The clean air
then exits the top of the unit, back into
the environment.
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INSTALLATION
G ENERAL I NSTALLATION G UIDELINES
Clean Air Industries ZeroMist units are generally shipped whole, a nd arrive on a flatbed trailer. These units can be unpackaged and assembled with very little installation. However, larger models have
to be split apart before shipping. When this is the case, more assembly is required.
T OOLS N EEDED FOR I NSTALLATION
The following tool list is given as a general outline. Additional tools may be used or substituted based on
availability. This tool list gives the basic tools needed for assembling your ZeroMist. Power tools are
recommended.
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R EQUIRED TOOLS:
Small Flat Head Screwdriver [for Electrical Connections]
Fork Lift Truck
Set of Lifting Chains
Examples
Utility Knife
7 / 16 ” Box Head Wrenches
9 / 16 ” Box Head Wrenches
(2)
(2)
1.5mm Allen Wrench
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O PTIONAL / R ECOMMENDED T OOLS:
7 / 16 ” Socket Bit
Ratchet
Cordless Drill
9 / 16 ” Drive Socket
9 / 16 ” Socket Bit
7 / 16 ” Drive Socket
Fork Lifting Tool or
Flashlight
(2) Moving Dollies
Lift Extensions
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Large Phillip’s Screwdriver
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W ARNINGS AND L ABELS
HIGH VOLTAGE: The voltage of the ZeroMist is dangerous once connected
to a power supply. Incorrect installation may cause damage to the
equipment, serious injury, or death. Consequently, it is essential to comply
with instructions in this manual, local and national safety rules, and follow
all safety procedures including proper lock out and tag out procedures.
Hazardous Voltage: The Variable Frequency Drive (VFD) uses large
capacitors which can hold a charge long after the power disconnect has
been used to disconnect power from the unit. Do not service the panel until
the VFD has fully discharged.
GROUND CONNECTION: Proper grounding of the equipment and electrical
panel is essential. Do not attempt to operate the equipment without
electrically grounding the panel. The connection to the earth ground must
be proper and provide a low impedance path to the earth to prevent
hazardous voltages from appearing on equipment
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M OVING THE Z ERO M IST U NIT
There are various ways to move the ZeroMist unit.
If the unit has NOT been unpacked and is still on the pallet, then it can easily be moved by
using a forklift truck. Place the forks under the pallet’s main beams and lift the unit. Keep in
mind the units weight may be unbalanced, make sure to adjust the forks to lift it
evenly.
If the unit has been unpacked from
the pallet, or if tight spaces forbid
moving the unit laying down, use a
forklift truck with lifting chains.
Here, attaching a “fork lifting tool”
to the forklift truck is useful. Attach
lifting chains from the fork lift tool
down to the four lifting lugs on top
of the unit. It is recommended to
use thick bolts that fit snugly into
the 1” holes within the lifting lugs.
Once connected, slowly lift the unit upright.
If you have purchased a larger model, then the unit arrived in multiple pieces. If this is the
case, move all pieces to its desired area with a forklift truck using either of the methods
above. Once it is there, remove it from the pallet and prepare to assemble the unit.
If installing the unit in a small area, the unit may have to be fully disassembled in an open
area and relocated to its desired area piece by piece. Moving dollies may also be
necessary if maneuvering the pieces in tight places. Move each section as far as possible
with a fork lift, then set each end down on the moving dollies and push it to your desired
location.
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A SSEMBLING L ARGER U NITS
If your ZeroMist arrived as one whole piece, skip this step. Proceed to “ Calibrating Pressure Gauges ”.
Make sure all parts of the unit are unpackaged from the pallets, and sitting upright in the
desired area of operation. First, locate the filter housing. Open the middle door of every
column, inside the door you will find a filter clamp tool.
Using the filter clamp tool, open and remove the filters from each chamber. To do this, align
the holes in the tool with the corresponding bolts in each chamber. You must lower each side
on every chamber for the filters to loosen.
NOTE: THIS SECTION IS ON HOW TO DISSASEMBLE THE UNITS SO THEY CAN BE
INSTALLED IN A SMALL AREA. IF YOU ARE INSTALLING YOUR UNIT IN AN AREA
WITH NO RESTRICTIONS , PROCEED TO “INSTALLING MOTOR HOUSING”.
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Once the filters have been removed, you must
detach each filter house column from the bottom
plenum. To do this, have someone climb inside the
filter housing and begin removing the bolts that
attach each column to the bottom plenum. Make sure
you label each column of filter housing based on
what side of the bottom plenum you detached it from.
(Left, Middle, Right, ect.) This will make it easier to
reassemble later.
(The bolt holes on the bottom
plenum, with the filter housing
removed.)
Unit with one filter housing column removed:
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Continue to remove the filter housing
columns until they are all completely
separated.
( Bottom plenum completely separated from
the filter housing columns.)
Now, remove the top door of each column
by applying pressure up and moving the
door back and forth. This will allow you to
later insert fork lift prongs into the top
chamber, and easily move the column.
(Filter columns separated from the bottom
plenum, with the top doors removed.)
Now it is time to cut a hole for the plenum or
duct work, if necessary. Generally the hole
will come pre-cut into the side of the bottom
plenum, but when customers are unsure
about the placement of the unit it can be
sent uncut. This allows the customer to
install the plenum or ductwork hole in the
side of their choosing. To do this, outline the
plenum or ductwork you wish to attach on
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the side of the bottom plenum, including bold holes. Take a grinder with a cutting wheel, and
cut just inside the outline you created. Lastly, drill out the holes for the bolts.
Now attach lifting chains to the bottom plenum, and move it to your desired location with a fork
lift. If a forklift is too large to fit in the area, moving dollies may be needed. Carefully set both
ends on a dolly and maneuver the bottom plenum into place.
Once you have the bottom plenum set in the area you wish to operate the unit, bring in the
filter columns one at a time and reinstall them onto it.
When remounting the filter columns, you must install the middle
column FIRST . It is also important to insert the bolts upright;
from the filter housing down, with the nuts being attached from
the bottom plenum. Do NOT tighten them yet. Make sure not to
damage the gasket.
After the middle column has been attached to the
bottom plenum, repeat the steps to attach the
remaining columns. Here you may find it difficult
to realign the filter housing bolt holes with the
bottom plenum bolt holes. This can be easily
fixed by inserting a large philips screwdriver into
the corner bolt holes, and prying them into
alignment. Once they are aligned, insert a bolt
into neighboring holes and repeat on each
corner. Once all the bolts have been replaced,
tighten them.
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INSTALLING MOTOR HOUSING
Installing the motor housing is very similar to
attaching the filter housing column to the
bottom plenum.
Using a forklift with lifting chains, raise the
motor housing and sit it down on top of the
filter housing.
Using your screwdriver to aid you, line up the
bolt holes and insert bolts into every hole.
Once all the bolts are inserted, tighten them.
Lastly, insert the filters back into the chambers. Using your filter clamp tool, push the bolts on
the filter rails back up. This will lock the filters back into place.
SPRAY NOZZLE SYSTEM (OPTIONAL)
In certain situations, a Spray Nozzle System must be installed to ensure that the ZeroMist works as
intended. This system is generally needed when the unit is taking in warmer or dryer air, which causes
the mist captured within the filters to evaporate before being able to drip back down. As a result the
Spray Nozzle System sends out spurts of coolant, water, or mixtures to keep the filters moist. This
system is generally on a relay timer, and can be changed to spray more frequently or at longer intervals
based on customer needs. To adjust the relay timer, turn the dial on the timer. This system comes pre-
installed inside of the unit. The consumer must provide and attach a coolant line, or water line with a
solenoid valve based on needs.
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DRAINAGE PUMP (OPTIONAL)
If you purchased a Drainage Pump, it will come pre-assembled inside of a pump sump box. When
ordered, we generally send extension legs with the pump sump box. After you have located the extension
legs, bolts and nuts, proceed to install the pump sump box.
Lift the ZeroMist into the air with a forklift truck and lifting chains.
Attach the extension legs to the unit using 3
/ 8 ” bolts .
Next, adjust the float on the pump to your desired
level. The float controls when the pump turns on and
off. Generally the float is set in our factory before
shipping. However this is not always the case. To
ensure the float is properly set, make sure the float
cable is secured by the clamp at the desired level on
the pump with approximately 4 inches of cable
between the clamp and float.
After the float is set, install a line from the drain hole to the pump.
Now install discharge piping provided by the consumer. It is recommended that discharge piping
be at least 1” diameter, and kept as short as possible. Using piping too narrow will restrict flow
and strain the motor, and keeping the discharge piping short reduces pipe friction.
When piping keep in mind this pump has a 37 feet head, meaning no more than 37 vertical feet
can occur from the pump to the discharge area.
To avoid any air returning into the unit through the drainage pipe outlet, it should be equipped
with a drain trap. This should always have at least 150 mm high column of oil.
Lastly, connect a 110 volt power supply for the pump.
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CALIBRATING PRESSURE GAUGES
The Differential Pressure Gauges are located just above each filter chamber. They read the pressure in
air as it moves between filters. As filters become dirty the amount of pressure needed to move air
through them becomes greater, increasing the pressure drop. Thus, it is important to accurately
calibrate and monitor these gauges to know when a replacement filter is needed.
Calibrating the gauges:
First you must remove the clear protective lens
from the gauge. To do this, firmly press your
palm against the face of the glass, and twist
counter-clockwise.
Now locate the zero-adjustment screw
located behind the face of the white scale. Look
for the word “zero” in small print on the bottom
left side of the scale; just behind this is the black
zero-adjustment screw. Using the 1.5 mm Allen
Wrench, adjust the pointer to “0”.
For each Pressure Gauge, repeat the above
steps as needed.
Note: For information on knowing when to change filters based off of pressure readings,
proceed to “Filter Maintenance”.
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MOUNTING
Now that everything has been installed, you are ready to mount your unit at its desired location.
There are a few things to take into consideration before mounting down the unit.
Ensure filter doors have room to be opened and easily accessed.
Ensure power supply is coming into the unit with no kinks. If a pump was purchased, make sure
you have a nearby 110 volt power supply.
Ensure duct work can be easily installed out of the desired side of the unit.
Ensure a proper drainage has been set up. If a pump was purchased, make sure you have a
clear path back to the machine tool sump.
To mount the unit in concrete, mark the holes onto the ground where you want it to sit. Next, move the
unit out of the way with a forklift and lifting chains. Now that you can easily access your marked holes,
drill out the holes and insert concrete anchors provided by the consumer. Move the unit back onto the
anchors, and bolt it down.
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ELECTRICAL CONNECTION DIAGRAMS
Clean Air Industries ZeroMist units can be set up to operate on various power sources. Before mounting the electric panel in your desired location, look at the following electrical charts to determine power
required. Any damage incurred from improper electrical power connection will void the warranty of the
ZeroMist.
Connect the main power line into the top of the power disconnect. Then run wires from the motor(s) into
the outgoing side of the VFD. Lastly, run wires from the pressure sensor into the electric panel. (See
wiring diagrams for more information)
The incoming power is connected to the electrical panel.
First make the ground connection into the grounding terminal block.
The incoming power wires must be terminated on the incoming sides of the power disconnect
switch. (L1, L2, L3)
Primary branch circuit protection must be provided by the end user. The breaker must have J-
Class Fast Acting Fuses.
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P OWER D ISCONNECT S WITCH / E MERGENCY S HUT O FF S WITCH
This switch controls the main power to the ZeroMist.
When the switch is in the “0” or “OFF” position,
the main power to the unit is disconnected.
When in the “1” or “ON” position, main power
is reaching the unit and it can be started.
This switch also provides a means to lock out
the switch using a padlock, thus preventing
accidental power up.
This is an interlocking disconnect; meaning, the door to the electrical box will not open if the
switch is in the “ON” position.
When the dial is in:
“0” position – all main power to the unit is
OFF
“1” position – the unit is powered up and
ready for operation, the unit is ON
CAUTION: Prior to performing maintenance, always use a meter to confirm the power source is
locked out.
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STARTUP / SHUTDOWN PROCEDURES
The ZeroMist has two different operational modes, Auto and Local.
If this is your first time starting your ZeroMist, turn the Power Disconnect Switch to “1” or “ON”.
To determine what mode your ZeroMist is in, locate the panel for the unit. On the outside door of the
panel you will see the VFD Display Screen. In the top left corner of the screen, you will see its current
mode.
To change the mode, locate the button that says “REM / LOC”. This button will toggle between the two
modes.
It is recommended to operate the unit in REMOTE mode.
To start: Power on the unit, and set it to “LOC” mode. Next, Locate and press the “Stop” button on the
VFD display screen. Lastly, set the unit to “REM”.
To stop: Set the unit to “LOC” mode, and press stop.
To manually operate the speed, set the unit to “LOC” and then press “Start”. Next use the up and down
arrow keys to adjust the Hertz.
Note: The blower will start immediately, but may take a minute or two to reach full speed. Also keep in
mind when shutting down in any way, the blower will not stop immediately and could take several
minutes to fully stop. The unit can be turned off quickly by turning the Power Disconnect Switch to
“0” or “OFF”, but is only recom mended in emergency situations, or when a F.S.S. System is not
used.
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BLOWER ROTATION
If blower rotation is incorrect, the unit will suffer a significant performance loss as well as an increase in
noise level. Make sure the blower is rotating properly. When the power is properly connected, the blower
will rotate counter-clockwise when viewed from above. To check blower rotation you will need two
people. After testing startup procedures, have one person stand next to the electric panel ready to start
the unit in LOC mode. Have the second person climb a ladder and look down into the motor housing
through the exhaust, and locate the blower. When the second person has a clear visual on the blower,
and an understanding of which way the blower should turn, you are ready to start the rotation test. Have
the first person press “Start” on the VFD Display Panel c ount to “4”, then press “Stop”. If the blower is
rotating the wrong direction, swap any two of the incoming power leads.
PLEASE NOTE: IT IS VERY IMPORTANT TO VIEW THE ROTATION FROM THE EXHAUST OF
THE ZEROMIST!
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MAINTENANCE
F ILTER M AINTENANCE
The Stage 1 Coalescing Filters can be cleaned or replaced when reaching a pressure drop of 2.5 in
WC. These filters can be washed in a hot water based detergent solution no warmer than 60°C, or in
a chamber washer. Rinse by flushing the solution from the clean side of the filter. Do not rinse with
high pressure, it will damage the filter. Let the filter completely dry before inserting it back into the
unit. After a few washes, the filter will expire and need to be replaced.
The Stage 2 Coalescing Filter needs to be replaced when reaching a pressure drop of 2.5 in the WC.
The Stage 3 HEPA Filter needs to be replaced when reaching a maximum drop of 3.6 in the WC, or
after one year of use due to bacteria hazards.
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Filter Maintenance Log Sheet Filter Type Inspection Method
Inspection Date Result / Reading Unit Performance at time of Inspection
Action Taken
Stage 1 Stage 2 Stage 3 Pre-filter
WC Reading WC Reading WC Reading
Visual
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