Defender Downdraft Table Series User & Maintenance Manual

Learn how to setup, manage, and maintain your Defender Downdraft Table by Clean Air Industries.

DEFENDER Downdraft Table Series User & Maintenance Manual

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TABLE OF CONTENTS

TABLE OF CONTENTS.............................................................................................................................................. 2

(1) SHIPPING RECEIVING, AND INSPECTION ........................................................................................................... 3

(1.1) R ECEIVING AND I NSPECTION .....................................................................................................................................4

(2) BEFORE INSTALLATION BEGINS......................................................................................................................... 4

(3) SAFETY INFORMATION ..................................................................................................................................... 5

(4) DOWNDRAFT TABLE DESCRIPTION ................................................................................................... .. .............. 6

(5) FEATURES AND SPECIFICATIONS ....................................................................................................................... 7

(5.1) G ENERAL F EATURES ................................................................................................................................................7

(5.2) B LOWER / M OTOR S PECIFICATIONS ...........................................................................................................................7

(5.3) U NIT W EIGHT ........................................................................................................................................................7

(5.4) U NIT S PECIFICATION T ABLE ......................................................................................................................................8

(6) INSTALLATION .................................................................................................................................................. 9

(6.1) G ENERAL I NSTALLATION G UIDELINES ..........................................................................................................................9

(7) WARNINGS AND LABELS ................................................................................................................................. 11

(8) EXTINGUISHING A FIRE IN THE MACHINE........................................................................................................ 12

(9) ELECTRICAL CONNECTIONS ............................................................................................................................. 13

(9.1) P OWER D ISCONNECT S WITCH / E MERGENCY S HUT O FF S WITCH ....................................................................................13

(9.2) B REAKERS ...........................................................................................................................................................15

(9.3) D OUBLE P USH B UTTON .........................................................................................................................................16

(9.4) K EY L ATCH ..........................................................................................................................................................16

(10) PLC PROGRAM ............................................................................................................................................. 17

(11) BLOWER ROTATION ...................................................................................................................................... 18

(12) OPERATING PROCEDURES............................................................................................................................. 19

(13) MAINTENANCE ............................................................................................................................................. 20

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.................................................................................................................................................................................20

(13.1) C LEANING THE I NTAKE S PARK B AFFLES ....................................................................................................................20

(13.2) R EMOVING THE I NTAKE S PARK B AFFLES ..................................................................................................................21

(13.3) C ARTRIDGE F ILTER M AINTENANCE .........................................................................................................................22

(13.3.1) Filter Features.........................................................................................................................................22

(13.3.2) Filter Maintenance .................................................................................................................................22

(13.3.3) How to Determine the Filter Change Interval.........................................................................................22

(13.3.4) How to replace filters .............................................................................................................................23

(14) Troubleshooting ...........................................................................................................................................26

APPENDIX A: DIMENSIONAL DRAWINGS ............................................................................................................. 28

APPENDIX B: EXPLODED VIEWS ........................................................................................................................... 29

APPENDIX C: WIRING DIAGRAMS (OCT 2023) ..................................................................................................... 30

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(1)SHIPPING RECEIVING, AND INSPECTION

(1.1) R ECEIVING AND I NSPECTION

Congratulations on the purchase of your new Clean Air Industries Defender Down d raft Table System!

• Upon receipt of your new Down d raft Table, 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 Industries ’ Defender Down d raft Table units are shipped via freight and generally arrive on a flatbed trailer. Generally, the units are partially crated, laid down, and shipped

whole.

• 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.

(2) BEFORE INSTALLATION BEGINS

• Adequate electrical and compressed air must be connected to the Down d raft Table. These connections are defined in “Electrical Connections” and "Compressed Air Connections"

sections of this manual.

• Using a wrench, rotate the leveling feet to extend them their current position.

• When servicing or cleaning the machine, make sure the unit is OFF. It is also recommended

to wear protective respiratory equipment and safety glasses.

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(3) SAFETY INFORMATION

Recommended Use

Operating the Defender Downdraft Table for applications other than those recommended may lead

to an increased risk of fires in the filter chamber.

To minimize the potential for filter fires and create a safer operating environment, it is imperative

that operators equip the Defender Downdraft Table with the accompanying gravel tray during

applications known to produce sparks, including but not limited to, welding and grinding activities.

Failure to operate the machine with the accompanying gravel tray increases the risk of filter fires

that can lead to bodily harm, potential smoke hazards within your facility, irreparable damage to

your Defender Downdraft Table, and operational down time.

Utilization of this Defender Downdraft Table should strictly adhere to the range of recommended

applications specified below. Please be aware that any deviation from the recommended uses

constitutes a misuse of the equipment. Your adherence to these guidelines is crucial in

maintaining a safe and effective work setting.

Recommended Applications

Welding Grinding Soldering Deburring Polishing

• • • • •

WARNING: Do not use Defender Downdraft Tables for the collection of combustible or explosive

dust.

Defender Ducted (motorless) Downdraft Tables can be used for the collection of combustible and/or

explosive dust ONLY if connected to a Wet Dust Collector. Please refer to NFPA and local guidelines

for the safe handling of combustible dust.

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(4) DOWNDRAFT TABLE DESCRIPTION

DISCLAMER: The Clean Air Industries Down d raft Table is designed to accumulate harmful welding and grinding byproducts, and provide clean air to any Industrial, educational, or workshop environment. The Down d raft Table should not be used with

highly combustible materials or explosive materials or particles.

The Clean Air Industries Defender Down d raft Table consists of:

Heavy Duty Steel Construction

•

Motor / Blower System

•

Spark Baffle and Metal Mesh Filter

•

High Quality Cartridge Filters

•

Reverse pulse cleaning

•

Silencer

•

Optional Hood, Divider, and Gravel Tray

•

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(5)FEATURES AND SPECIFICATIONS

(5.1) G ENERAL F EATURES

• Filter element design: 12.75" OD x 24 ⅝” long, flame retardant

Silencing: Built-in Acoustical Lining

•

• Heavy Steel Construction and Powder-Coat Paint Finish

• Motor Contactor and Overload; On / Off Push Button with Center Light; Disconnect Switch

• Metal Mesh spark baffles and Reverse Flow TM spark baffles, and quantity varies depending

on unit size.

• (Optional) After Filter HEPA 24x24 (2,4,6), Hood, Divider, and Gravel Tray

(5.2) B LOWER / M OTOR S PECIFICATIONS

• Backward Incline, Air Foil High Efficiency Plug type Blower(s)

• 3600-RPM NEMA MG-1; 230-460 V/60/3 (std.)

(5.3) U NIT W EIGHT

The weight of the Defender Down d raft Table 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. Additional options may increase weights.

Model

Approx. Weight (lbs.)

3x4 DDT

1175LBS

6x4 DDT

1775LBS

9x4 DDT

2100LBS

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(5.4) U NIT S PECIFICATION T ABLE

Defender Down d raft Table

Model Qty.

Qty.

Total Filter

Unit Dimension (in)

Table

True

Flow

Noise

Filters

Valves

Motors

Height

Face Velocity

Area (sq. ft.)

(Width x Depth x

(CFM)

(dB)

(FPM)

(in)

Height)

@5ft

63.65”x 48 ”x79.375”

3x4

430.6

350

4200

DDT

100.25”x 48 ”x79.375” 37

6x4

861.2

270

6480

DDT

146.62”x 48 ”x79.375” 37

9x4

1291.8

250

9000

DDT

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(6) INSTALLATION

• The Clean Air Industries Defender Downdraft Tables are very easy to install and operate. Move the unit to a desired location by using a forklift. Connect the electrical connection and

the compressed air connection (70-90psi).

• To Power ON the unit, locate the ON/OFF switch at the front of the unit,

• On units with electrical panel, turning the red knob will activate the electrical panel; pressing

the green start button will run the unit, pressing the red stop button will stop the unit.

• To Power the LED light (Hood option only), plug lights into their own 110V outlet. Press the

ON/OFF switch located on the side of the LED light

(6.1) G ENERAL I NSTALLATION G UIDELINES

Clean Air Industries Defender Downdraft Table units are shipped via freight and arrive on a flatbed trailer. The main units are fully crated, on a pallet, and are shipped standing up. Use a forklift truck,

driven by a qualified individual, to remove the crate / pallet from the truck. Occasionally, fork

extensions are helpful. Forklift lifting locations are labeled at the front of the unit with “Lift Here”

stickers ( shown below)

. 3ft

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6ft

9ft

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(7)WARNINGS AND LABELS

HIGH VOLTAGE: The voltage of the Downdraft Table 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.

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

COMPRESSED AIR: Compressed air is used in the

operation of this unit. Follow proper lock out / tag out

procedures prior to servicing the unit. This includes

draining the compressed air reservoir inside the unit.

Failing to do so can lead to injury or hearing loss. Lock

out – drain tank – do not service while pressurized.

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(8) EXTINGUISHING A FIRE IN THE MACHINE

After a fire in the Defender Downdraft Table, the machine may only be put back into operation after Clean Air Industries (CAI) or a company contracted by CAI has repaired the table.

MEANS, TOOLS, MATERIALS NEEDED:

CO2 hand-held fire extinguisher

•

Protective gloves

•

Safety Glasses

•

Protective mask

•

1. Put on protective equipment. 2. Press the EMERGENCY STOP push-button. 3. Switch off the MAIN SWITCH of the machine. 4. Remove sealing cap from the extinguisher opening. 5. Push the extinguisher nozzle completely into the extinguisher opening. 6. Release the extinguishing agent intermittently and completely into the Modular Downdraft Table 7. Insert sealing cap immediately.

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(9) ELECTRICAL CONNECTIONS

Defender Downdraft Table s runs on 208/230/460VAC power, 60Hz

The incoming power is connected to the unit at the conduit connection located on the outer side of the

motor housing on the unit.

(10) When power is brought into the Downdraft Table through the EMT Conduit fitting, it will enter the electrical box at the front/top side of the motor housing. (11) First make the ground connection into the grounding terminal block. (12) The incoming power wires must be terminated on the incoming side of the power disconnect switch / emergency shut off switch (L1, L2, L3). (13) Primary branch circuit protection must be provided by the end user. The breaker must have an IC trip rating of 30kA. Please see the following chart for recommended breaker size. (14) A wiring diagram for the Downdraft Table is provided in Appendix C. (15) The full load amperage varies depending on the unit configuration. Please see the following chart for motor and unit full load amperage ratings (FLA).

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(9.1) P OWER D ISCONNECT S WITCH / E MERGENCY S HUT O FF S WITCH

This switch controls the main power to the Downdraft Table.

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, the main

power is reaching the unit and it can be

started.

• Under normal operating conditions, the unit

will not start when the green "START" push

button is depressed if the disconnect is in

the "0" or "OFF ” position .

• This switch also provides a means to lock out the switch using a small 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 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 voltmeter to confirm the

power source is locked out.

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(9.2) B REAKERS

Multiple breakers are located in the electrical box.

•

• Breakers showing GREEN are 'safe' or tripped and will not allow

current through the breaker.

• Breakers showing RED are 'hot' and will allow current through

the breaker.

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(9.3) D OUBLE P USH B UTTON

• This switch controls the operation of the motor / blower.

• The green “START” button begins the Downdraft

Table Unit operation.

• The red “STOP” button stops the Downdraft Table

Unit operation.

• The center light will illuminate when the “Start” button is

depressed. The light will remain illuminated until the “Stop”

button is depressed.

(9.4) K EY L ATCH

• The key latch is a cam style latch that rotates clockwise to unlock

the electrical box, and counterclockwise to lock the electrical box.

• Simply insert the key into the keyhole and press down firmly

while the key is rotated.

• When closing the electrical box, the gasket will need to be

compressed. This may require additional force in closing the

electrical box.

• Keep in mind, the electrical box also has an interlocking disconnect / emergency shut off

switch. If this switch is not deactivated, the door will not open even if the key latch is

unlocked.

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(10)PLC PROGRAM

Step by Step Instructions for using PLC program:

*NOTE: Disconnect must be on for screen to turn on

1. To Scroll: Hold “B” button

2. Press + or – arrows to cycle through each valve screen.

To manually pulse valves:

1. Cycle to Valve # screen

2. Select Valve # that you would like to pulse

Press “A”

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(11)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. To check blower rotation, have a colleague

start the unit, count to '4', and then stop unit. As the fan slows, watch the rotation. When power is

properly connected, the blower will rotate counterclockwise when viewed from the motor access panel of the Downdraft Table unit. Make sure to check rotation from the motor access panel (Front of motor housing). To change the blower rotation direction, simply swap any (2)

of the incoming power leads.

PLEASE NOTE: IT IS VERY IMPORTANT TO VIEW THE

ROTATION FROM THE EXHAUST OF THE Downdraft TABLE!



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(12) OPERATING PROCEDURES

• The Downdraft Table power must first be turned on by rotating the Power Disconnect / Emergency Shut Off switch to the 'ON' position.

• The unit can then be started by simply pressing the green button, on units with electrical

panel.

The blower will start immediately.

•

Reverse Pulse cleaning options

•

• To properly shutdown the Downdraft Table, simply press the red button or turn the rotary handle counterclockwise. The blower will not stop running immediately and may take a

couple minutes to fully stop.

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(13) MAINTENANCE

The Downdraft Table unit is very low maintenance. If you notice the suction is getting weaker, it may be time to replace the filters or clean out the Spark Baffle and metal mesh.

Spark Baffle

Metal Mesh

(13.1) C LEANING THE I NTAKE S PARK B AFFLES

The Reverse Flow TM spark baffles and metal mesh spark baffles are designed to inhibit and reduce

the energy of sparks. Because these bafflers and filters are the first in line concerning air flow, they

become soiled by welding smoke and need to be cleaned periodically.

How often they need to be cleaned is dependent upon the amount and type of welding performed.

Feedback, which we greatly value, indicates that filters need to be cleaned every six to twelve

months.

• It is recommended that educational/industrial facilities inspect the baffles every quarter, or

every 3 months, and clean them as needed.

• It is recommended that the baffles can be washed with a garden hose or, if carefully used, a pressure washer. Be sure they are dry before placing them back into the Downdraft Table.

• The easiest and most convenient way to clean the baffles is by first simply shaking the loose

debris from the baffles, and then spraying them with a compressed air hose.

• If the baffles are not cleaned thoroughly, they can affect the performance of the Downdraft Table, restricting of air flow and reducing the performance quality.

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• Examine the metal mesh filters at the inlet of the unit. These filters should be washed when

they become visibly dirty / contaminated.

• How often they need to be cleaned is dependent upon the amount of welding performed and

the given application.

• If they are not cleaned, they can affect the performance of the unit by reducing air flow.

• If Spark Baffle needs replacing. You can purchase replacement baffles from Smith Filters

using part number: F01327.

• If the Metal Mesh needs replacing. You can purchase replacement metal mesh’s from Smith

Filters using part number: F01771-1

(13.2) R EMOVING THE I NTAKE S PARK B AFFLES

The spark baffles must be removed for installation and cleaning.

1. First carefully remove the metal grate from the table. This will give you access to the Spark Baffle. 2. To remove the Spark Baffle, grab and lift up the Spark Baffle from the Downdraft Table, Be careful not to cut yourself when removing the Spark Baffle. 3. Removing the Spark Baffles will give you access to the Metal Mesh. Remove the Metal Mesh by grabbing and lifting it up. 4. Clean the Spark Baffles and Metal Mesh. 5. Remove the debris in the Downdraft Table as much as possible using a hand broom and dust pan, or an appropriate vacuum system.

6. Place everything back in the appropriate order

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(13.3) C ARTRIDGE F ILTER M AINTENANCE

(13.3.1) Filter Features

• Filter Dimensions: 12.75” OD x 24 ⅝” H

• 80/20 Blend Cellulose/Polyester – Optional: Nano Filters

• Pleat Construction

• Flame Retardant

• Cartridge Filters

(13.3.2) Filter Maintenance

Filters are of excellent construction and of the best quality available. The filters are preconditioned

with a unique process which has proven to be effective over time with long filter life and excellent

cleaning characteristics.

Because of all of these factors, the customer must monitor and document the system airflow readings

for a period of time. The information collected will help determine the most appropriate time to change

filters. This process will ensure that the system runs at maximum efficiency while minimizing filter

replacement costs.

The easy access system of the Defender Table helps with faster filter replacement and reduced maintenance. Replacement filter cartridges and metal mesh of all types are available from your Clean Air Industries sales representative.

(13.3.3) How to Determine the Filter Change Interval

• The process for determining your specific filter change interval is based on many variables.

Please feel free to establish a filter change interval that meets your application and desired

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performance results. By properly monitoring the filters you will reduce filter costs and improve

the efficiency of the units.

• Proper filter cartridge replacement is important to optimal performance of the unit.

(13.3.4) How to replace filters

NOTE:

It is important to ensure that the filter gaskets seal correctly for proper operation of the Downdraft Table. This will ensure that you do not get

particulate past the filter compartment.

1) Turn the rotary switch to OFF position and disconnect main incoming power.

2) Open the filter door. This will reveal the cartridge filters.

3) Remove and empty the dust tray located below the filters.

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4) Slide the filter out and into a bag

5) Tie the end of the bag closed.

6) Some excess dust and debris may need to be removed while the filter has been removed

from the unit. This can be done by sweeping or vacuuming the dust from the unit.

7) Slide the new filter onto the filter rails.

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8) Close and secure door.

9) Turn the rotary switch to start the motor. Some dust or debris may have fallen into the filter

ducts; this dust would then be blown out when the unit begins to run.

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(14) TROUBLESHOOTING

Problems

Possible Cause

Recommended

Course of Action

GENERAL

1. Check Power Supply

Fan does not start running.

1. No Power Supply

2. Turn on Main Switch.

Downdraft table does not

2. Main Switch Off

function.

3. Repair or replace motor

3. Motor defective

4. Replace ON/OFF Button

4. ON/OFF Button Defective

5. Check current settings and reset

5. Overload Relay Tripped

overload relay.

6. Replace overload relay

6. Overload Relay Defective

7. Close and lock both doors

7. Left and/or right door open

8. Correct wiring for proper supply

8. Unit not wired for available voltage

voltage.

ReInsufficient Flow.

1. Filter Cartridges need replacing

1.Replace both filter cartridges

Downdraft Table does not function properly.

2. Replace HEPA filter cartridge

2. Baffle filter and/or Metal Mesh dirty

2. Clean Prefilters

3. Fan Rotation Backwards

3. Proper fan rotation is counterclockwise

from the front of the unit. Re-wire if fan is

rotating clockwise

4. Access doors open or not closed tight

4. Check that all access doors are in place

and secured

Insufficient Flow.

5. Silencer exhaust area restricted

5. Check fan exhaust area for obstructions,

remove any material or debris.

Downdraft Table does not function properly.

7. Dust Tray overfilled

7. Clean out dust storage area

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8. Pulse valves leaking compressed air

8. Lock out all electrical power to the unit.

Bleed the compressed air supply. Check

for debris, valve wear, pneumatic tubing

fault. Check for solenoid leaks or damage.

If solenoid valves and/or tubing are

damaged, replace.

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APPENDIX A: DIMENSIONAL DRAWINGS

Notes concerning the dimensional drawings:

• Weights of the assemblies vary based on configuration, options, and application set up.

Please see the "Unit Weight" section for more information.

• The electrical and compressed air connections are located at the motor side of the unit.

Please see the "Air and Electrical Connections Diagram" section for more information.

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APPENDIX B: EXPLODED VIEWS

Notes concerning the exploded view drawings:

• Weights of the assemblies vary based on configuration, options, and application set up.

Please see the "Unit Weight" section for more information.

• The electrical and compressed air connections are located at the motor side of the unit.

Please see the "Air and Electrical Connections Diagram" section for more information.

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APPENDIX C: WIRING DIAGRAMS (OCT 2023)

Notes concerning the wiring diagram:

• Power is brought into the electrical box as 208/230/460VAC Three Phase

• The overload may need to be reset. The overloads have an automatic reset function, which is

turned off. If this has not been set, the overload will require being reset via the red button

marked 'Reset'.

• Wire numbers have been added to the wiring diagram to aid in both the diagnostic issues as

well as the maintenance and service issues while in the field.

• The wire numbers will be shown in small Black numbers at each end of the wire. The wires

are numbered by the 'node', meaning that several wires connecting into one point will have

the same number. Labels are placed on the terminal blocks as well as the wires.

• Multiple electrical options / accessories are available for the Downdraft Table

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