Learn how to setup, use, and maintain the WeldStation EVO by Clean Air Industries.
Page 1 of 83
T ABLE OF C ONTENTS
TABLE OF CONTENTS .......................................................................................................................................... 2
SHIPPING RECEIVING, AND INSPECTION ............................................................................................................. 5
R ECEIVING AND I NSPECTION .............................................................................................................................................5
B EFORE I NSTALLATION B EGINS ..........................................................................................................................................6
WELDSTATION DESCRIPTION.............................................................................................................................. 7
FEATURES AND SPECIFICATIONS......................................................................................................................... 8
G ENERAL F EATURES ........................................................................................................................................................8
B LOWER / M OTOR S PECIFICATIONS ...................................................................................................................................9
U NIT W EIGHT ................................................................................................................................................................9
INSTALLATION ..................................................................................................................................................10
G ENERAL I NSTALLATION G UIDELINES ................................................................................................................................10
T OOLS N EEDED FOR I NSTALLATION ...................................................................................................................................11
Required Tools: ....................................................................................................................................................11
Optional / Recommended Tools: .........................................................................................................................12
S INGLE U NIT P ARTS L IST ................................................................................................................................................14
D UAL U NIT P ARTS L IST ..................................................................................................................................................16
W ARNINGS AND L ABELS .................................................................................................................................................18
M OVING THE W ELD S TATION M AIN U NIT ..........................................................................................................................19
B RINGING THE M AIN U NIT U PRIGHT , N O L IFTING T OOL .......................................................................................................21
B RINGING THE M AIN U NIT U PRIGHT , W ITH L IFTING T OOL ...................................................................................................23
M OVING THE S ECONDARY B OOTHS ..................................................................................................................................25
I NSTALLING THE F LAT G ASKET ON THE U NIT .......................................................................................................................26
I NSTALLING THE F LAT G ASKET ON THE COVER P LATES ..........................................................................................................27
I NSTALLING THE C OVER P LATES .......................................................................................................................................28
A TTACHING THE S ECONDARY B OOTH ................................................................................................................................29
R EMOVING THE I NTERNAL P ANEL B AFFLES .........................................................................................................................31
I NSTALLING THE I NTERNAL P ANEL B AFFLES ........................................................................................................................32
I NSTALLING THE I NTAKE S PARK B AFFLES ............................................................................................................................33
Page 2 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
R EMOVING THE T ABLE S LIDES .........................................................................................................................................35
I NSTALLING THE T ABLE S LIDES AND T ABLES ........................................................................................................................36
I NSTALLING THE L EVER H ANDLES .....................................................................................................................................38
I NSTALLING THE H OLE P LUGS ..........................................................................................................................................39
AIR AND ELECTRICAL CONNECTION DIAGRAMS .................................................................................................40
COMPRESSED AIR CONNECTION........................................................................................................................42
A IR R EGULATOR ...........................................................................................................................................................42
A IR F ILTER ...................................................................................................................................................................42
D RY A IR ......................................................................................................................................................................43
S HUT O FF V ALVE ..........................................................................................................................................................43
ELECTRICAL CONNECTIONS................................................................................................................................44
C ONNECTING THE S ECONDARY B OOTH L IGHT ( S ) .................................................................................................................46
P OWER D ISCONNECT S WITCH / E MERGENCY S HUT O FF S WITCH ............................................................................................48
M ODE S ELECTOR S WITCH ...............................................................................................................................................49
I NTERLOCK A CTIVATE .....................................................................................................................................................50
I NTERLOCK D EACTIVATE .................................................................................................................................................50
L IGHT S WITCH ..............................................................................................................................................................51
B REAKERS ...................................................................................................................................................................51
K EY L ATCH ..................................................................................................................................................................52
WELDSTATION EVO FEATURES ..........................................................................................................................53
S OFT S TART .................................................................................................................................................................53
P RESSURE T RACKING .....................................................................................................................................................53
TM ...........................................................................................................................................................53
E CONOMIZER
S LEEP F UNCTION ..........................................................................................................................................................53
R EDUCED M AINTENANCE ...............................................................................................................................................53
R EDUCED N OISE ...........................................................................................................................................................54
SYSTEM CONTROLLER .......................................................................................................................................55
F ILTER C LEANING C ONTROLS ...........................................................................................................................................56
A UTO M ODE : ..............................................................................................................................................................57
M ANUAL M ODE : T IMED ................................................................................................................................................57
M ANUAL M ODE : C OUNT ...............................................................................................................................................58
Page 3 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
M ANUAL M ODE : V TEST .................................................................................................................................................58
O PTION M ODE : S HUT D OWN P LS #..................................................................................................................................58
O PTION M ODE : S HUTDWN DEL P .....................................................................................................................................58
O PTION M ODE : R UN P LS DEL P .......................................................................................................................................58
O PTION M ODE : A LARM DEL P .........................................................................................................................................59
O PTION M ODE : S LEEP T IME ...........................................................................................................................................59
O PTION D EFAULTS ........................................................................................................................................................60
S CREENLESS HMI: ........................................................................................................................................................61
Main Screen .........................................................................................................................................................62
Settings Screen ..................................................................................................................................................... 63
BLOWER ROTATION ..........................................................................................................................................64
STARTUP PROCEDURES .....................................................................................................................................65
SHUTDOWN PROCEDURES ................................................................................................................................65
MAINTENANCE .................................................................................................................................................66
B ASIC M AINTENANCE ....................................................................................................................................................66
C LEANING THE I NTAKE S PARK B AFFLES ..............................................................................................................................67
R EMOVING THE I NTAKE S PARK B AFFLES ............................................................................................................................68
C LEANING THE I NTAKE A REA ...........................................................................................................................................69
C ARTRIDGE F ILTER M AINTENANCE ...................................................................................................................................70
Filter Features ......................................................................................................................................................70
Filter Maintenance ............................................................................................................................................... 70
Where to Start .....................................................................................................................................................71
How to Determine the Filter Change Interval ......................................................................................................71
What determines the maximum acceptable pressure differential reading? .......................................................73
How to replace filters...........................................................................................................................................74
APPENDIX A: FILTER MAINTENANCE LOG SHEET ................................................................................................77
APPENDIX B: DIMENSIONAL DRAWINGS............................................................................................................78
APPENDIX C: EXPLODED VIEWS .........................................................................................................................80
APPENDIX D: WIRING DIAGRAMS (DECEMBER 2019+) ......................................................................................82
Page 4 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
S HIPPING R ECEIVING , AND I NSPECTION
R ECEIVING AND I NSPECTION
Congratulations on the purchase of your new Clean Air Industries WeldStation EVO System!
Upon receipt of the WeldStation, remove
the master packing list from the unit and
reconcile it with the total shipment.
Report any discrepancies to Clean Air Industries as soon as possible.
Clean Air America’s WeldStation units are
shipped via freight and generally arrive on
a flat bed trailer. The main units are
partially crated, on a pallet, and are
shipped lying on their sides. The
secondary booths are partially crated and
shipped upright.
Remove the packaging from the unit; 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 been incurred
during shipping. If damage is found,
report it to the shipping company and Clean Air Industries immediately.
Weld tables and spark baffles are
packaged and shipped inside the booth
area of the main unit or secondary booth.
Page 5 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
The Reverse Flow TM and Metal
Mesh spark Baffles require being
shipped separately.
Accessories may be packaged and
shipped on a separate pallet
depending on the order. In some
cases these parts may be
packaged inside the booth area of
the main unit or secondary booth.
A bolt package is included for each
unit and booth combination. This
bolt package includes lever
handles for the filter doors only of
the main unit and flat gasket for the
entire WeldStation assembly. It is
taped to the table slides inside the
unit or booth.
B EFORE I NSTALLATION B EGINS
Prior to using your WeldStation, it must be fully assembled and placed in its final operating
location.
Adequate electrical and compressed air must also be connected to the WeldStation. These
connections are defined in “Electrical Connections” and "Compressed Air Connections"
sections of this manual.
During installation, always be careful. The WeldStation is a top heavy unit and may require
experienced personal to move and set up.
Page 6 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
W ELD S TATION D ESCRIPTION
DISCLAMER: The Clean Air Industries WeldStation is designed to accumulate smoke
residue / particles and other by-products of the
manufacturing process. The nature of these
accumulations may be flammable. Operating the
WeldStation with these materials could result in a fire
inside the unit. The WeldStation is not recommended
for use with highly combustible materials or explosive
materials or particles.
The Clean Air Industries WeldStation consists of:
WeldStation Housing
Motor / Blower System
Four Cartridge Filters
Online Automatic Pulse Filter Cleaning System
The “dirty air” inlet is located inside the booth at the back of the booth portion. Metal Mesh spark baffles and Reverse Flow TM spark baffles protect the inlet. T he “clean air” outlet is located on the top
of the unit above the motor access panel. The optional silencers or exhaust deflectors may be
installed on the outlet end. A large opening door provides easy access to the internal cartridge filter,
and bolt on access panels allow access to the motor compartment and valve compartment for
maintenance.
Page 7 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
F EATURES AND S PECIFICATIONS
G ENERAL F EATURES
Patented Down-Flow Air Cleaning Technology
Filter Element Design: 12.75" OD x 26" Long, Flame Retardant, 100% Cellulose
(4) Filters for a total area of 904 sq. ft.
Silencing: Built-in Acoustical Lining
Heavy Steel Construction and Powder-Coat Paint Finish
Pulse Air Reservoir; (2) 1" Valves; 1" Compressed Air Connection
1.0 ft 3 Valve Pulse at 70 - 90 psi
Clean Air AutoPulse TM Controller: A Programmable Pulse Controller with Filter Differential
Readout; Manual Mode Options
Motor Contactor and Overload; On / Off Push Button with Center Light; Disconnect Switch
(2) 24" x 24" x 2" Metal Mesh spark baffles and (2) 24" x 24" x 2" Reverse Flow TM spark
baffles for each unit and each booth
Customizable Filters
65 dB Noise level on OSHA scale with clean filters
77 dB Noise level on OSHA scale with dirty filters
Soft Starting to avoid initial amperage spikes
Pressure tracking to maximize airflow for filter loading
Economizer TM for automatic start and stopping of the motor / blower based on demand
Sleep Mode to reduce energy usage and maintain blower rotation during intermittent
operations
Managed blower and airflow speed for reduced dust impaction and better cleaning cycles
Built- in 12” Riser
Page 8 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
B LOWER / M OTOR S PECIFICATIONS
Backward Incline, Air Foil High Efficiency Plug type Blower(s)
Single Phase 115, 208, or 230 Volts
3 Phase 208, 230, or 460 Volts
3450RPM
3600-RPM NEMA MG-1; 230-460 V/60/3 (std.)
U NIT W EIGHT
The weight of the WeldStation unit can vary depending on the configuration, application, and
accessories purchased. This is due to the wide selection of motors, blowers, filters, and accessories Clean Air Industries has to offer. Please see the following chart for approximate weights.
Page 9 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
I NSTALLATION
The WeldStation requires some minor assembly.
A standard unit will come with an exhaust cover pre-installed.
The unit and a booth are integrated into a single machine referred to as the 'main unit'.
A secondary booth can be attached to the main unit and creating a "Dual WeldStation". If no
secondary booth is used, then the main unit is referred to as a "Single WeldStation".
See the 'WeldStation Accessories User Manual' for accessory assembly instructions.
G ENERAL I NSTALLATION G UIDELINES
Clean Air America’s WeldStation units are shipped via freight and generally arrive on a flat bed trailer.
The main units are partially crated, on a pallet, and are shipped lying on their sides. The secondary
booths are partially crates and shipped upright. Use a fork lift truck, driven by a qualified individual, to
remove the crate / pallet from the truck. Occasionally, fork extensions are helpful.
Once the WeldStation unit is inside the facility, ready to be uncrated, please proceed
cautiously. Banding straps and plastic wrap must be removed.
WeldStation units are heavy and tend to
be top heavy. The motor and the majority
of the metal are located at the top of the
unit. Please see the "Unit Weight" section
for proper weights.
There are (4) steel plate eyelets vertical at
the top of unit. These are the lifting lugs.
There are (9) floor mounting holes on the
bottom flange of the unit
Page 10 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
T OOLS N EEDED FOR I NSTALLATION
The Following tool lists are given as a general outline. Additional tools may be used or substituted
based on availability. The required tool list is given as a bare minimum required to assembling a
WeldStation. Powered tools are recommended.
Required Tools:
5 / 32 " Allen Wrench
(2) 7 /
(1)
16 " Box Head Wrenches
(1) Fork Lift Truck
(1) Utility Knife
(1) Set of Lifting Chains
(1) Set of Ratchet Straps
(1) Small Flat Head Screwdriver [for Electrical Connections]
(2) 9 /
16 " Box Head Wrenches
Page 11 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
Optional / Recommended Tools:
(1) Ratchet
(1) Air Ratchet
(1) Cordless Drill
(1) 7 /
5 /
7 / 16 " Drive Socket
16 " Socket Bit
(1)
32 " Allen Bit
(1)
(1) 9 /
9 / 16 " Drive Socket
16 " Socket Bit
(1) Flashlight
(1)
Page 12 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
(1) Set of Fork Extensions
(1) Fork Lifting Tool
Page 13 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
S INGLE U NIT P ARTS L IST
The following parts are shipped with each WeldStation Single (no secondary booth). Colors of some
parts may very if a custom color was ordered. Please confirm that all parts have been shipped before
(30) 1/4" - 20 x 1.0" black socket head cap screw
(30) 1/4" Black Flat Washers
(30) 1/4" Black Lock Washers
(1) Flat Gasket, 25' each [May arrive in 50' rolls]
(42) 1/4" Black Nuts
(3) Locking Hole Plugs
(2) Black Lever Handles
(1) Electrical Box Key
(2) 3/8" Lock Nuts
beginning assembly.
Page 14 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
(2) Internal Panel Baffles [pre- installed]
(2) Table Slides [pre-installed]
(1) Welding Table
(2) Reverse Flow TM Spark Baffles
(2) Metal Mesh Spark Baffles
(3) 19" x 27" Plenum Cover Plates
Page 15 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
D UAL U NIT P ARTS L IST
The following parts are shipped with each WeldStation Dual (one secondary booth attached to main
unit). Colors of some parts may very if a custom color was ordered. Please confirm that all parts have
been shipped before beginning assembly.
(50) 1/4" - 20 x 1.0" black socket head cap screw
(50) 1/4" Black Flat Washers
(50) 1/4" Black Lock Washers
(50) 1/4" Black Nuts
(4) Locking Hole Plugs
(1) 25' Roll of Flat Gasket
(2) Black Lever Handles
(1) Electrical Box Key
(2) 3/8" Lock Nuts
Page 16 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
(2) Internal Panel Spark Baffles if the secondary booth is 5' or 6' wide, (3) Internal Panel Spark Baffles if the secondary booth is 3' or 4' wide [pre- installed]
(4) Table Slides [pre-installed]
(2) Welding Table
TM Spark Baffles if the secondary
(2) Reverse Flow
(4) Metal Mesh Spark Baffles if the secondary booth is 5' or 6' wide, (3) Metal Mesh Spark Baffles if the secondary booth is 3' or 4' wide
booth is 5' or 6' wide, (3) Reverse Flow TM Spark Baffles if the secondary booth is 3' or 4' wide
(4) 19" x 27" Plenum Cover Plates
Page 17 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
W ARNINGS AND L ABELS
HIGH VOLTAGE: The voltage of the WeldStation 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
Page 18 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
M OVING THE W ELD S TATION M AIN U NIT
There are various ways to move the WeldStation main unit.
If the WeldStation unit has NOT been
uncrated or is still on the pallet, then it can
easily be moved by using a fork lift truck.
Place the forks under the pallet's main
beams and simply lift the unit. Keep in
mind, the motor end (top) of the unit is
heavier and forks may need to be shifted
toward the motor end.
If the WeldStation unit has been uncrated,
then it can easily be moved by using a fork
lift truck. Attach the lifting chains or cables
to the fork head ache bar. Attach the other
end of the lifting chains or cables to the
lifting lugs. The top of the unit can then be
lifted using the fork lift truck. Place a
wooden '2 x 4 underneath the raised end
of the unit. This wood piece will create a
gap allowing the forks to be slid under the
unit. Make sure not to scratch or damage
the unit.
If the WeldStation unit is uncrated and
upright, then the unit can still be moved
with a fork lift truck. Place the forks under
the unit portion of the main WeldStation
unit. Card board or rubber padding can be
placed on the forks to prevent scratching
of the unit. Make sure the forks are on
both side of the light(s) / cables to prevent
damaging the lights. Do NOT place the
forks under the lights. Do NOT let the
forks enter the intake at the back of the
booth area. The WeldStation unit is top heavy and must be prevented from falling backwards
Page 19 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
during movement. It is recommended
that the top of the unit is bound to the
mast of the fork lift truck during
movement. This can be done by
wrapping a strap around the unit and
mast. Another method is to attach a
chain or cable between the mast and
the lifting lugs.
Page 20 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
B RINGING THE M AIN U NIT U PRIGHT , N O L IFTING T OOL
NOTE:
Please be sure the chain
hoist, come along, or
chain/cable, is rated for
that amount of weight to
be lifted.
Properly sized chain or cable can be
attached to header bar on a fork lift
truck. The chain or cable can then be
connected to the lifting lugs of the
unit. The forklift truck can then be
used to lift and move the unit.
Other methods include attaching a
chain hoist or come along, or both to
the eyelets provided at the top of the
unit.
When the unit is being lifted, the
bottom of the unit may shift. If
possible, brace the bottom of the
unit to prevent slipping.
A '2 x 4' brace is fastened to the front
floor flanges of the booth. This is used
during shipment to prevent the
collapse of the booth side walls. This
'2 x 4' should be kept in place while
bringing the unit upright to prevent
damage.
SLOWLY hoist the unit up, supporting
it whenever and wherever possible.
DO NOT let the unit slam suddenly
when bringing the unit into the upright
position. This can cause damage to the unit.
Page 21 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
If risers are being used, then attach the
risers before bringing the unit upright. See
the WeldStation Accessories user manual
for additional instructions.
Please proceed cautiously.
Page 22 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
B RINGING THE M AIN U NIT U PRIGHT , W ITH L IFTING T OOL
NOTE:
Please be sure the chain
hoist, come along, or
chain/cable, is rated for that
amount of weight to be
lifted.
Properly sized chain or cable can be
attached to a lifting tool on a fork lift truck.
The chain or cable can then be connected
to the lifting lugs of the unit. The forklift
truck can then be used to lift and raise the
unit.
Other methods include attaching a chain
hoist or come along, or both to the eyelets
provided at the top of the unit.
When the unit is being lifted, the bottom of
the unit may shift. If possible, brace the
bottom of the unit to prevent slipping.
A '2 x 4' brace is fastened to the front floor
flanges of the booth. This used during
shipment to prevent the collapse of the
booth side walls. This '2 x 4' should be
kept in place while bringing the unit
upright to prevent damage.
SLOWLY hoist the unit up, supporting it
whenever and wherever possible.
DO NOT let the unit slam suddenly when
bringing the unit into the upright position.
This can cause damage to the unit.
If risers are being used, then attach the
risers before bringing the unit upright. See
Page 23 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
the WeldStation Accessories user
manual for additional instructions.
Please proceed cautiously.
Page 24 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
M OVING THE S ECONDARY B OOTHS
If the secondary or slave booth has NOT
been uncrated, then it can easily be
moved by using a fork lift truck. Place the
forks under the pallet's main beams and
simply lift the unit. Make sure to lift the
booths from the side of the pallet.
If the secondary or slave booth has been
uncrated, then the booth can still be
moved with a fork lift truck. Place the
forks under the bottom of the intake panel
of the booth. Card board or rubber
padding can be placed on the forks to
prevent scratching of the unit. Do NOT
place the forks under the lights. Do NOT
let the forks enter the intake at the back of
the booth.
Page 25 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
I NSTALLING THE F LAT G ASKET ON THE U NIT
Flat Gasket must be places around the outside of the plenum
opening before assembly. This should only be done around the
opening being mated to the secondary booth.
The flat gasket must be cut to length from the roll.
For each opening, the following pieces should be cut (2) 19" long,
and (2) 25" Long.
The 19" long pieces are placed above and below
the opening. These will cover all (3) bolt holes above the opening
and all (3) bolt holes below the opening.
The 25" long pieces are placed on the sides of the
opening. These gasket pieces will be between the upper and lower
gasket pieces and will cover the (2) bolt holes on each side of the
opening.
The (4) gasket pieces must be placed centered
over the bolt pattern.
Once all four flat gasket pieces are placed, there
should be no gap between the gaskets.
Once all four flat gasket pieces are placed, then
punch a hole into the gasket at each bolt hole to allow a bolt to
pass through. Be careful not to damage the gasket.
Page 26 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
I NSTALLING THE F LAT G ASKET ON THE COVER P LATES
Flat Gasket must be places around the outside of all the cover plates before assembly onto the unit.
The flat gasket must be cut to length from the roll. For
each opening, the following pieces should be cut (2) 19" long, and (2)
25" Long.
The 19" long pieces are placed along the top and
bottom short sides of the cover plate. These will cover all (3) bolt holes
above the opening and all (3) bolt holes below the opening.
The 25" long pieces are placed on the long sides of the
cover plate. These gasket pieces will be between the upper and lower
gasket pieces and will cover the (2) bolt holes on each side of the
opening.
The (4) gasket pieces must be placed centered over
the bolt pattern.
Once all four flat gasket pieces are placed, there
should be no gap between the gaskets.
Once all four flat gasket pieces are placed, then punch
a hole into the gasket at each bolt hole to allow a bolt to pass through.
Be careful not to damage the gasket.
Page 27 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
I NSTALLING THE C OVER P LATES
Any intake plenum opening not used for connecting the main unit to the secondary booth must be
covered using one of the plenum cover plates.
It may be necessary to install the cover plates before setting the units in the final location.
Obstructions such as walls or other WeldStations may prevent or hinder access.
Flat Gasket must be installed on the main unit and booths before the cover plates can be
installed.
Align the cover plate blocking the intake plenum opening so that the bolt holes are aligned.
Fasten the cover plate to the main unit or booth using (10) 1/4" - 20 x 1.0" black socket head
cap screw, (20) black 1/4" flat washers, (10) black 1/4" lock washers, and (10) black 1/4"-20
nuts. The screw heads should be on the outside of the unit.
For most installations, it will be necessary to remove the internal baffle plates to install the
cover plates.
Page 28 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
A TTACHING THE S ECONDARY B OOTH
The WeldStation main unit can have a
secondary welding booth attached for added
welding stations. This booth can be attached
to either side or onto the back of the booth.
This achieved by connection through the
rectangular opening with bolt patterns on the
sides and back of the unit intake plenum.
The secondary booth will have matching
openings with bolt patterns in the intake
plenum.
NOTE:
Before connecting the
main unit and
secondary booth, the
Flat Gasket must be
installed around the
connection opening.
Remove the table slides from the
adjoining booth walls. The same bolt
is used for mounting both table
slides to the common booth walls.
For easy access to the bolt holes,
remove the internal spark baffles.
Do not install of the metal mesh spark baffles and Reverse Flow TM
spark baffles until after the unit and
booth have been joined together.
Page 29 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
If the spark baffles are already
installed, remove them. See the
'Removing the Spark Baffles' section
of the user manual.
Place the main unit in the final
location. This may require bolting on
some of the cover plates before
placement due to obstructions. If
risers are being used, they must be
installed on the unit before final
placement.
Place the secondary booth next to
the main unit. This may require
bolting on some of the cover plates
before placement due to
obstructions. If risers are being
used, they must be installed on the
booth before final placement.
Slide the secondary booth into place
and align the plenum openings and
bolt hole patterns.
Each rectangular opening has a ten
hole bolt pattern. Fasten the
secondary booth to the main unit
using (10) 1/4" - 20 x 1.0" black
socket head cap screw, (20) black
1/4" flat washers, (10) black 1/4"
lock washers, and (10) black 1/4"-20
nuts.
Page 30 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
R EMOVING THE I NTERNAL P ANEL
B AFFLES
The internal spark baffles must be removed for
some WeldStation installations. Internal baffles
are located in both the main unit and secondary
booth.
1. Begin by loosening and removing the
bolts on both the left and the right side of
the baffle plate. This should allow the
baffle plate to fall free from the vertical
supports.
2. Reach into the intake opening and slide
the baffle midway to the opposite side of
the booth in front of the vertical supports.
3. Rotate the baffle so that one side begins
to twist into the back of the back of
plenum area.
4. Tilt the baffle plate at a 45 degree angle
to remove it through the front intake of the
booth.
5. Repeat steps 1 through 4 with any other
baffles.
Page 31 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
I NSTALLING THE I NTERNAL P ANEL
B AFFLES
The internal spark baffles must be installed before
using the WeldStation. Internal baffles are located
in both the main unit and secondary booth.
1. Begin by tilting the baffle at about a 45
degree angle
2. Slide the baffle into the intake plenum
through the intake opening. Slide it in past
the internal baffle support.
3. Once the baffle is entirely inside the
plenum area, rotate the baffle so that it is
vertical.
4. Then slide the baffle forward in front on
the intake supports.
5. Once the baffle is vertical in front of the
supports, place it flush on the supports
and slide it up so that the bolt pattern on
the baffle is aligned with the bolt pattern
on the baffle supports.
6. Fasten the baffle to the supports inside
the plenum area using (6) 1/4" - 20 x
0.75" zinc plated hex head bolts, (6) 1/4"
zinc plated flat washers, and (6) 1/4" zinc
plated lock washers.
7. Repeat steps 1 through 6 with any other
baffles.
Page 32 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
I NSTALLING THE I NTAKE S PARK B AFFLES
All of the intake spark baffles must be installed
before using the WeldStation. These baffles are
the first defense in stopping sparks from passing
into the WeldStation. Smaller width secondary
booths will only have one spark baffle of each
type. The metal mesh spark baffles must be installed behind the Reverse Flow TM spark baffles.
1. First, carefully slide the top of the metal
mesh spark baffle upward into the top
channel of the intake at a slight angle
(approximately 10 degrees).
2. Then push the bottom of the metal mesh
spark baffle inward so that the baffle is
vertical and aligned with the bottom
channel of the intake.
3. Next slide the metal mesh spark baffle
down into the bottom channel of the
intake.
4. Slide the metal mesh filter all the way to
the right hand side of the intake. Make
sure it is seated in the bottom of the
channel and shifted so that it is flush with
the side of the intake.
5. Repeat steps 1 through 4 for the other
metal mesh spark baffle; however slide
the second baffle all the way to the left.
6. Repeat steps 1 through 4 for the (2) Reverse Flow TM spark baffles; placing first
on the right and the second on the left.
Page 33 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
NOTE:
Make sure when installing the
intake baffles that they are
installed in the correct
direction. On both the metal mesh and Reverse Flow TM
spark baffles, there are
markings to show the proper
air flow direction. The arrows
must point into the intake. Additionally, the Reverse Flow TM spark baffles must be installed so that
the baffles are horizontal.
Page 34 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
R EMOVING THE T ABLE S LIDES
Before the unit and secondary booth can be attached
together, the table slides of the adjoining walls must be
removed. The same bolt is used to hold the table slides of
Loosen and remove the (4) bolts holding the table
slide onto the side wall of the booth or unit. Retain
these bolts.
Hold onto the table slide to support it while
loosening the bolts and prevent damage due to
falling.
Page 35 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
I NSTALLING THE T ABLE S LIDES AND T ABLES
Once the unit and secondary booth are attached together,
the table slides and welding tables can be installed into
both the secondary booth and the main unit.
Place the table slide on the wall of the unit so that
the slide channels are horizontal and the channels
open to the inside of the booth.
Align the bolt hole pattern on the table slide to the
bolt hole pattern on the side wall of the booth.
Fasten the table slide to the wall of the booth
using (4) 1/4" - 20 x 1.0" black socket head cap
screws, (8) black 1/4" flat washers, (4) black 1/4"
lock washers, and (4) black 1/4"-20 nuts. The
screw heads should be on the outside of the
booth.
When a secondary booth is being attached on the
side of a main unit, (2) table slides are being
attached to a common booth wall. In this situation,
each of the (4) bolts must be used to attach both
table slides. If the table slide is being installed on
the common wall between a main unit and
secondary booth, the bolt head can be on either
side.
Once all the table slides have been attached to the
booth walls, insert the table into the channel at the
desired height.
The table simply slides into the channels of the
table slides on both sides of the booth. Make sure
the table is being inserted into the same height on
both sides of the booth so that the table is not
tilted.
Page 36 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
Once the table has been installed, it can
be moved by simply pulling the table out
and sliding it into another height channel.
The table can also be left partially
extended from the booth to allow welding
of larger objects outside the booth. When
doing so, make sure the welding does not
exceed range of the airflow for the booth.
Page 37 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
I NSTALLING THE L EVER H ANDLES
For each main unit, there are two lever handles. These
handles must be installed in the filter compartment door
for increased ease of maintenance.
Remove the bolts holding the filter door shut. The
door was bolted shut during shipping to prevent
damage to the lever handles. Make sure to keep
the 3/8" flat washers; however, the 3/8" retaining
bolts can be discarded.
The filter door may swing open allowing access to
the filter compartment.
Swing the filter door closed.
Place a 3/8" zinc flat washer on each of the lever
handles.
Place the threaded stud of the lever handles
through the holes in the filter door arms.
Screw the lock nut onto the back of the lever
handle. This will keep the lever handle attached to
the door during maintenance and prevent the loss
of hardware.
Screw the lever handle into the weld nut and
tighten the door down.
Page 38 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
I NSTALLING THE H OLE P LUGS
Once the unit is fully assembled and
operational, place all of wire track hole
plugs into the sides and back of the unit.
There is a 'T' shaped wire track built into
the bottom of the plenum. Each end of the
'T' had an exposed 1-1/2" circular
opening.
Each side of the main unit and secondary
booth has a circular opening.
The back of the main unit and secondary
booth each has a circular opening.
Simply press the open side of the plug
into the circular opening. It will lock in
place.
It may be necessary to install the hole
plugs before setting the units in the final
location. Obstructions such as walls or
other WeldStations may prevent or hinder
access.
Page 39 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
A IR AND E LECTRICAL C ONNECTION D IAGRAMS
Page 40 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
Page 41 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
C OMPRESSED A IR C ONNECTION
In order for the automatic pulse filter cleaning system to operate, the Clean Air Industries WeldStation requires a compressed air connection to be made.
The compressed air inlet is located on the top of the WeldStation in front of the exhaust
panel.
This WeldStation compressed air inlet supply is a 1” NPT male fitting.
Use a regulator to adjust the pressure to 70 to 90 PSI.
A dryer may be needed to condition the air before entering the WeldStation.
1.0 ft 3 Valve Pulse at 70 - 90 psi
5/8" Minimum compressed air supply line required; 1" Recommended
NOTE:
Do not operate the WeldStation for an extended period of time without an
appropriate compressed air supply. Doing so will greatly diminish the life
of the filter cartridges.
A IR R EGULATOR
The compressed air for the WeldStation must be regulated at 70 to 90 PSI. A Regulator is used to
allow the high-pressure air supply lines or tanks to be reduced to safe and usable pressure for pulsing
the unit. If the pressure is too low, the valves may not properly clean the filters. If the pressure is too
high, it may damage the valves.
A IR F ILTER
The compressed air for the WeldStation must be clean. Dirty air entering the system can cause
damage to pneumatic components. The air should be filtered to remove all contaminants by the
compressed air supply system prior to entering the WeldStation.
Page 42 of 83
1-866-665-1829
clean-air.com
sales@clean-air.com
Page 1 Page 2 Page 3 Page 4 Page 5 Page 6 Page 7 Page 8 Page 9 Page 10 Page 11 Page 12 Page 13 Page 14 Page 15 Page 16 Page 17 Page 18 Page 19 Page 20 Page 21 Page 22 Page 23 Page 24 Page 25 Page 26 Page 27 Page 28 Page 29 Page 30 Page 31 Page 32 Page 33 Page 34 Page 35 Page 36 Page 37 Page 38 Page 39 Page 40 Page 41 Page 42 Page 43 Page 44 Page 45 Page 46 Page 47 Page 48 Page 49 Page 50 Page 51 Page 52 Page 53 Page 54 Page 55 Page 56 Page 57 Page 58 Page 59 Page 60 Page 61 Page 62 Page 63 Page 64 Page 65 Page 66 Page 67 Page 68 Page 69 Page 70 Page 71 Page 72 Page 73 Page 74 Page 75 Page 76 Page 77 Page 78 Page 79 Page 80 Page 81 Page 82 Page 83Made with FlippingBook - professional solution for displaying marketing and sales documents online