Trion AIR BOSS 60 User's Manual
Contents
1.2. WAWIXYN 303 ONY 54 09 58055384 BILM 804 AHOIOV3 124102 154 09 8 93 69 W3ISAS WO GG 804 OVIH TVOLN3A XV 1Y Z 54 09 6 9 06 2831545 WO OF 2 91 04 Qv3H WILAJA 1v ALOVdYO 1 409 06 n Gy 14 Qv3H ISd 34nSS38d 14405 wo ss NO O W9 9 5905 W3ISAS 13943130 MODEL6O LF4 44 AB gt NOLLIS 500488 HS 09 BOON t A8 29 641 1 5810 34 09 11008 22 582410 AS 27 9NUO3NNOOH3INI 230V3H p NOIL AB e SOLON M 430334 13983130 RA Y 20 9 23384 OL 1237805 38 1 SIN3NOdNOO ONY 31VM HSVM TW 1531034 21 09 1300W ON Nv3HISdn 31815504 SW 35070 SY NIVA OLNI 143953139 LOAPNI 21 NDNININ 1004 33d 24015 18
3. MDDEL6O LF3 0C T 1 WIC 7 006 4 001 TEE 00 Lj 1 NIC 8 C8 539995 3 00 06 09 T3IDW 40 WOIdAL NAUHS NISVE 069 3715 951 3NIT NIVNO WAWININ 804 002 928 2 NINO OLLVW3HOS ONIdId 01 83438 1103 WOOT HLIA 394080099 NI NIVNG ANNTd M i 82 34 RELON 4 1 49 01 06822 07801 00 00 6 00 00 60 09 00 dD 601 07492 2216 00 8 00 5 00 00 80 09 ea dD 26 01062 098 009 00 6 00 00 0 09 dD 78 5676 8 0025 00 00 90 09 2 WIC 7 7 ma d9 19 1995 0099 00 00 6 00 00 lt 0 09 5 dD 66 8 1861 1886 oorp 00 5 00 00 0 09 3 101 01 05822 07807 0099 00 5 005 00 609 09 Le dD v6 07 92 22 6 0 0025 00 00 809 09 d 6 01062 098 0090 00 5 00 00 09 09 6626 BT S 00 00 6 00 00 909 09 i dD 86 1995 0099 00 00 5 00 00 609 09 006 dD 8 561 1826 0099 00 6 00 00 709 09
4. ONIZIN IG MI VIIIN nn LO ECTOR WIRE RED VOI TACE VULIAG ATION ATION MANIFOLD DRIVE NO MOTORS RE REVERSIBLE MANIFOLD ROTATE C THE C PROPER IONIZING COLLECTING FIGURE 146 94 CA NO FACTORY WIRED AND MARKED AS MANIFOLD DR MOT M U Ls j OR ROTA MANIFOLD DRIVE NNECTION RE CO n NIZER 0 9 lt 901931105 5 N N N N N N N N N N N N N N N N N N N N N N N N SPA os N N N N N N N N N N N N N N N N N N N N N N N N N N o24 o M gt Jt Cete C cy Cy 2 2 NLA JR 1 Xd 22 7 7 A 4
5. 2 1 oH io QD 804 MOT 01 05 3414 TW 11 JN 30334 143953130 NL YN ON NOISE 2 ay E s DIET AU 0 NMOHS INSW3YINOIY 3855384 2310 335 58 40 A8 ONY MOTA M0 ddid AldeS 821 8 375 01 AB Add AS NIWA 09 10001 0 JAWA 00 05 NIVA ALWIXONd NI 0317901 38 01 ONIWYNO 081 A8 44 SNJHIO 48 SIHL NO NMOHS M3IN3AdHd MINIS Lo 54 001 0 391 38055384 34165354 S3AWA SIN3NOdWOO ddid T 6 Q3TWISNI SI 09 1300 HOIHM NI WALSAS ONTNvH SW IHL 30 38055344 2115 TYNNGINI 01 NNDTOO 831 8 214405 AGIAONd ISAW 8 1 310N 325 A8 a h 345534 5 Salvii 1 83 10 A8 FIAVISNPAY 1 3983130 9 3085 eh 023 028 78 02 47 35055349 HIM 80 OL 5 ZION 325 58240 A8 0310141534 LON SI N3lVM OS 30 08 38 Aldd S W3lvi WOM 1 ONidld 1 304405 ONY Q3HSvM ONE LINN 3H 01 31815509 Sv 35010 SV 031201 38 100 5 10H 7321042 HSVM 1910133 IYON v 804 0351 38 3 001 NIN Y3LYM 10H O3ON3WWOO3 SI S S31QNIN 31049 5 A8 NOILO3S 149 3lYM ATdILINN S31049 HSVM W H3HIO N03 SINSASMINDFY 3443130 O CC 31049 HSVM 135 8012 4 0258 01936 Yad 310AO Mdd SINGWGNIDO3M
6. 3 9 amp amp 4 5 4B 8 G 8 8 2 lt lt 8 5 48 8 8 8 48 8 6 lt 8 o o 6 9 2 8 o 5 90 m m 78 ms e e e 2 0 G 1 2 o o D 8 8 D 48 lt 8 8 8 g 6 g ME o o 5 0 as E em as 9 amp e e 5 2 0 n 5 o o o 8 48 8 48 8 65 48 o o i o amp 8 amp oo o oe o 5 E 55 e 8 e 9 amp o 5 9 5 By 8 lt 8 8 4B 8 8 8 8 8 8 amp 8 48 o o Fn 4 4 aw 0 0 D Q o o o
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8. WIG 340191415 1909905 1133 0071 pyr dui SPE HAU IS SE hb Ch 1 1 50340 AB SUSHLO Ag 3000 3000 55333 55333 1 NIN 0082 MO S79 9 SUBHLO A8 yNOMLODG Su a 009 3180 404 VI JaN JAS NOILOJS INNO JION LO XXX 09 13000 MODEL60O LF1 1 FIGUR LO 51112 14 Z 3004 UON S1130 144 OML THO 44 Z 3NO 13 8 40 811 SVH 10 807 0 51113 14 30 8 SIN Q3VONVIS TWNINON 14 14 532 JNO 010 NMOHS LIN IM LIN 9 13000 LI JENAN N Sd VNINON V SVONVIS 44141 HOV3 404 NIXVIN 03991003 H 3AVS IV 1133 HOV 1149 dGAVONVIS OMI 1431 SMOIOM 30 3 30 NOIO3NNOO 304 jO NI 3 1 30 305 S3NIWS3130 1431 80 1 H 1133 14 3 091412 3 001456 7 ASSY 01314 09 130011 10 409 09 0 5 SWM 179144 LO XX 09 501104 SV ASSY 13 NI 073 19 ONVH ll MOHS LHOISH NI 99139 LIN 10 38 1 34 IVNINO 1139 40 0
9. u Pages 11 14 SECTION IV REFERENCE Illustrations and Drawings Figure 1 Single Unit Outline Figure 1A Dimensional and Specification Data Figure 2 Exploded View of Single Section unit Figure 3 Recommended Foundation and Drain Basin Design Figure 4 NOT USED 4 442554 1 4 4114251 514 42 2 114244 42 454411342 Figure 5 Structural Framework Assembly Figure 6 Cell Arrangement and Bus Bar Connections Figure 6A Diagram of Bus Bar Connections Figure 6B Diagram of Bus Bar Connections Figure 7 Model 60 Cell Assembly Figure 8 Model 60 Air Baffle Figure 8A Diagram of Air Arrangement Figure 9 NOT USED zii iie Figure 10 NOT USED 5 Figure 11 Control Schematic Supplied with specific unit configuration Figure 12 Field Wiring Supplied with specific unit configuration Figure 13 Access Door Electrical Interlock Arrangement Figure 14A High Voltage Cell Termination
10. S34n1v34 HIGIM TV 51130 0 0 4 3dAl 14341003 21540 14000 HSVM 1335 S310N 1 01314 404 JNO ODEL60 LF1 2 58 8595 0 59 98001 07501 8 8 0 60 09 581 GL ve 66 1666 8 8 0 80 09 581 5602 GLEE 91 18 5018 828 0 0 09 58 5 94 e GLEE 6107 8248 0 90 09 581 59 SL 2 66 0064 848 0 402 09 58 090 GLEE 6 1810 8708 0 70 09 58 Orle B GLEE 15650 07201 v6 95 0 609 09 581 5 84 SIVE C6 1006 7695 0 809 09 58 0194 9 99 9118 5018 7696 0 09 09 58 OLE 6 5 5 61 0 96 0 909 09 58 0704 GLEE 2266 0065 7696 0 409 09 581 8421 4 5 6 1810 7696 0 709 09 58 60 2 2 GLIC 5650 07501 901 0 606 09 581 5874 B 5 YE CO 1266 9015 0 806 09 581 SGCC 6116 91 18 5018 901 0 0 09 58 000 C 6116 6104 9010 0 906 09 58 08 5116 2 66 0066 90712 0 G06 09 m 581 555 5116 6 8197 901 0 705 09 58 5044 GLIC 5650 050 6 50 0 60809 oc 58 5602 6116 66 14646 6 50 0 807 09 z 58 Sv8 6 5 91 18 5018 61050 0 07 09 581 079 5 COL 6107 6 50 0 907 09 58 097 G 5 1
11. o 1 1 1 2 He I 7 1 1 55 gt 5 1 1 91 3 Sd el 9 Il Sd cl II Sc 01 3 6 Sd 6 Ol Sd Ol 6 Sd 8 Sd BL 8 Sd BBLS 9 Sd 5654 9 3 G Sd 9 3 G Sd y Sd y 9 Sd y Sd 9 Sd 2 9 51 2 154 2 154 60 80 E 404 90L E poe 1 1 1 1 T lll i od Lil _ _ ____ l r n UM x Lee dene TT ZEE B 1 L les a i _ 1361 3 Sd vl 9 El Sd 2131 Sd cl Sc 03 6 Ol 6 Sd Ol 6 Sd 85 8 3 Sd BBLS 9555 9 3 G Sd 9 3 G Sd VRE y Sd y Sd 231 24144 231 Sd 10 7 20 J ava 508 4 4 1 gt SNULLO AN
12. 9 3495 Qv3H Nyd Oc v 1 3SvMOMNVH 9NLLNDON HIM MOIVIQISNI OL 44008415 XI44V ON3 ONVH JHL 40 39NV1i WV34ISNMOO JHL NO 0319007 05909 034 NO 310H ZIS 4400 3HZINOI 9NO1 NOILISOd 9001 9 1 9 M3NOS 0 1 3uvMONVH JAYS ONY 3lvid ONI 1 98 40 39845405 IHL NO NOLISOd ONIdd HS NOUS 3300NYIS W3ZINOI 9801 34008415 M3ZINOI GNI ONVH LHI 31901 ONY NOLNYO 10841132 3AOW3M 8 20830015 ATENSSSY 1123 301931100 83ZINOI 40 305 815 00 3lVid Ni 0 33008715 301931100 LYOHS 3400 15 801931100 180HS 504 ONidd HS 3400 15 Y3ZINOI INOI 1504 9NIddlHS 3300415 a U37INOI INOT uve PE o AIRFLOW lt _ lt AOV S 2 CM Mu NOLO3NNOO S3ZINOI MOIVIDSNI 038 355 JOVLIOA NJZINOI MODEL6O LF 7 JEL 60 AIR BAFFLE ARRANGEMENT AIR BAFFLE NOTCHED TO FIT MOTOR SUPPORT PE
13. Field Assembled ELECTRONIC AIR CLEANER AIR BOSS Model 60 Series without Integral Washing System INSTALLATION e OPERATION e SERVICE For Model Numbers 60 01 Electrostatic Precipitators for Commercial amp Industrial Applications air RIO Systems A FEDDERS ENGINEERED PRODUCTS COMPANY 101 McNeill Road Sanford NC 27330 919 775 2201 Fax 919 774 8771 800 884 0002 www trioninc com MANUAL Form 61 01478 Sept 01 5 SECTION I DESIGN For The System Design Engineer 1 General Description a 2 System Design and Floor Layout 3 Q td r installat ONS u YS r Sua aa h us For The Installing Contractor O YO ODN SECTION OPERATION AND SERVICE For The Maintenance Engineer 1 Introduction and Principle of Operation 2 General aes ahs Ean na eonte i 3 Initial StartUp ec renere an IA aa SA e ees 4 Routine Maintenance e 5 Periodic Maintenance u u u u u u u 6 TrOUDISSH OOUING oo LLL 7 Spare 8 Troubleshooting Reference Charrl
14. 5 011235 30 HANAN A8 Yad 5 31545 TWLOL 3NINE3130 OL 149 Q31NRON 38 ISAN 102 FATWA 008305 Z SIN3W38In038 3002 SNIBN ld 1183 4 3ONNGNOOOV Q3TIVISNI NV 3dAL 38065284 SDODNIINOO 34 100 5 32 30 SIH WNIVHIS ONY NOLOSNNOO 830334 1N3983130 JHL 1084 WvasiSdn 1319201 38 ISAW N31N3A3Hd MOTXOYE JHL L S3ION 002 63 AG SWS YSE 9 811 00 60 09 x 002 63 5 51 9 26 5 601 00 80 09 00 43 vv SW 9 4 d9 46 00 0 09 002 d9 07 5 282 d9 78 00 90 09 222 067 d9 C SWO 100 d9 9 00 60 09 05 d9 87 513 LLY d9 66 00 70 09 002 d9 8v 515 06 101 00 609 09 00 43 GY 513 084 63 v6 00 809 09 002 d9 SW LEZ d9 6 00 09 09 05 d9 S 515 912 99 cL 00 909 09 05 d9 87 513 v d9 86 00 509 09 05 d9 SID 06 d9 06 00 09 09 002 d9 07 5 52 d9 78 00 505 09 05 d9 LT SW 720 d9 8 00 805 09 05 99 51 9 86 d9 99 00 06 09 05 03 64 51 9 08 d9 09 00 905 09 05 d9 SN d9 8b 00 505 09 05 99 0 51 9 90 99 27 00 705 09 05 93 SWI 102 d9 9 00 60 09 06 99 07 51 9 98 d9 69 00 80 09 05 d9 5 5 9 66 63 G 00 07 09 067 99 Z SWI d 8b 00 90 09 62 193 8 SN vl 99 8 00 507 09 Sc d9 9 5 3 00 d9 76 00 707 09 Sc 63 V SWO CL 99 v6 00 0v 09 05 99 vc SID 06 d9 06 00 606 09 067 99 Z SID 17 d9 Lb 00 80 09 60 d9 6 51 9 00 d9 0 00 0 09 Sc 99 51 9 80 99 9 00 90 09
15. 6 66 00865 6 50 060709 58 4 6 GLC volv 8 7 61 SO 0 707 09 58 0 0 6116 00 2 8892 61 50 0 07 09 58 SLL S 59501 0v 0L 1 67 0 602 09 58 4 6 5 CO 1666 LE 6 0 80 09 58 527 5216 9118 018 i 6L 0 70 09 58 4 6 6116 COL 6107 15 67 090509 58 Sel 5 55 0069 ig 6 0 406 09 581 666 5 voly 187 i 6 0 70 09 IH9I3M LINN dad 74 034 ON 1300N jIVAIXONddV SMOWd 3 111 445 ON 0153 1 5 0 09 13008 MODEL60 LF2 3 HIV JO NOIL23UI0 IN3WJdONVMV QNVH 1331 00 0 09 13GON NOILO3S 319NIS FIGURE 2 34 lt 7139 9N11231109 5NIZINOI 91 332 1135 9 11231102 9NIZINOI 91 ANII 3AIHO NIVW PL NUI 9NILO3NNOO 401 t SQ104INVN HSVM 21 59 45 8 ON3 Q10 3INYW 11 1804405 0103INVWN OL 30 38 Q10JINVN LHOddNS 30 38 A18W3SSv 1 7 3AIHO 01031 18044085 317193331 5319NY ONINIVL3S 518404405 1139 31vI03WH31NI 401 AHOINdn INVES 1 3WvuJ 1331 3WVHJ 35 8 5 51394 30 121 2530 oe 17 NISVd 9 NITLVONDL 4 30 NDIL333IQ IN3N3ONVSBV Id 1921441 33
16. 6 Connect Drain Connect a drain line to the pipe coupling in the cabinet drain basin in accordance with the governing plumbing codes The drain line must be sealed with a trap or other means to prevent air by pass If a trap is used it should hold sufficient water column to overcome the System air pressure and to assure that loss of liquid from evaporation between cleaning periods will not break the seal The drain line should not be smaller than the drainpipe coupling or it will otherwise restrict the flow of water 7 Mount Controller The Controller should be mounted at eye level and located as close to the air cleaner as practical It must be mounted indoors out of the weather unless supplied with a weatherproof cabinet Allow sufficient space in front of the access door s for service Refer to appropriate Control Remote PWM Box Outline Drawing for mounting hole layout and dimensions 8 Complete Wiring A High Voltage Wiring WARNING EXERCISE ALL THE NORMAL PRECAUTIONS WHEN WORKING WITH HIGH VOLTAGE AND COMPLY WITH NEC AND ALL APPROPRIATE LOCAL CODES The high voltage wiring consists of interconnecting the ionizing collecting cells into banks with bus bars then wiring each bank of interconnected cells to its corresponding power supply with the high voltage cable NOTE IT IS IMPORTANT TO WIRE EACH BANK OF CELLS TO ITS CORRESPONDING POWER SUPPLY AS EACH POWER SUPPLY IS MARKED WITH A SPECIFIC OPERATING RA
17. 8 o 5 0 E am am SEE FIGURE 8 FOR FIGURE 8A TYPICAL ILLUSTRATION MODEL60 LF8 2 MOTOR MOUNTING PLATE ACTUALLY WELDEO INTO PLACE AS SHOWN ON AIR LEAVING SIDE REFERENCE A MANIFOLD DRIVE MOTOR ASSEMBLY DRIVE MOTOR ROTATION n MOTOR MOUNTING c 2 PLATE REFERENCE A gt MANIFOLD 9 2 A 297 Qu a 22 c MANIFOLD SN END SUPPORT AIR MAIN FLOW DRIVE MANIFOLD MANIFOLD MAJOR WASH HEADER COMPONENTS SUPPORT NOTE 1 TYPICAL 3 CELL HIGH LEFT HAND UNIT 2 ILLUSTRATION COVERS COMPONENTS ON AIR ENTERING SIDE ONLY AIR LEAVING SIDE COMPONENTS ARE IDENTICAL AND IN REVERSE OF THOSE SHOWN FIGURE 9 MODEL60 1F9 27 ii Tm RVR CAVE UA TU 6 HEAD CAP SCREW x WASHER D D HEX HEAD scnew BUSHING 3500 AM CALOR Cope WHITE Ow G19 MANIFOLD DRIVE LINKAGE MANIFOLD CONNECTING ARM TOP MANIFOLO Hex HEAD LINK AGE FUNT WASHER BUSHING x h FLAT WASHER HEX NUT MANIFOLD CONNECTING ARM MARLEOLD LINKAGE GONMEGDON MANIPOLDS EXCEPT MANIFOLD MANIFOLD DRIVE MOTOR AND LINKAGE ASSY FIGURE 10 MODEL60 LF10 28 Model 60 Control Schematic THIS PAGE INTENTIONALLY LEFT BLANK DE
18. CONNECTOR 28 np MODEL6O LF6 1 lg em pes A D aaa P 3 8 3 JJNNDIO ave gt 4 09 I 1139 2 EL60 LF M URE 6A FIG 3 o M i IM 2 ___ ll 1 ____ nd _ _ _ _ G _
19. Sc d9 Y SWO 48 d9 66 00 606 09 Sc 63 SWI SL d9 GC 00 v0 09 6 8 110 135 NOILO3S 834 1235 834 54 8 ON 13008 325 IN3NOdWOO 31949 439 12 9 Yad 1235 Ydd NOLLO3S 70 034 1 943130 003 831 8 70 034 831 4 LINN 3181 19 Side Panel H Intermediate Cel Supports Caulk or Grout to Seal Air Flow SECURING 8ASE FRAME Stud Must Be Below Channel STRUCTURAL FRAMEWORK ASSEMBLY Washer Steel Anchoring Dog 1 4 Thick ry dui Concrete Drain Basin 2 2 Le 4902 Te 252 2232 MU MON S 2 Anchoring Stud s s FIGURE 5 MODEL6O LF5 20 4 CELL ARRANGEM MODE ENI amp BUS BAR IONZER H Y WIRE RED W BLK TRACER IONZER BUS BAR 1 CONNECTOR 1 1 BUS BARS v ONIZING COLLECTING CELL 41 NOTES 1 BUS BAR CONNECTIONS ARE MADE ON THE AIR LEAVING SIDE OF ONIZING COLLECTING CELLS AS SHOWN 2 USE SEPARATE CONDUIT FOR EACH IONIZER amp COLLECTOR H V WIRE 3 ALWAYS USE CONTINUOUS LENGTH OF WIRE DO NOT SPLICE WIRE 4 SEE FIGURE 6A amp 6B FOR EACH UNIT PICTORIAL FIGURE 6 21 60 XXX 00 amp 01 PWM POWER SUPPLY 1 7 PWM POWER SUPPLY 2 7 PWM POWER SUPPLY 5 a COLLECTOR WIRE RED COLLECTOR BUS BAR
20. each duct access door 2 Duct Door Electrical Interlock and Pilot Lights Two are furnished as standard Outside each duct access door and adjacent to the electrical interlocks 3 Duct Lights Two are furnished as standard On air entering side and on air leaving side of air cleaner on the inside of the ductwork 4 Disconnect Switch and Pilot Lights Four are furnished as standard Two on Inside Two on Outside of each access door at most convenient location near the door Those located inside are wired in series with the electrical interlocks and used as a safety measure to control the primary power to the high voltage power supplies from inside the duct Those located outside control the duct lights Grounding An earth ground must be provided to the Model 60 cabinet and control All ground connections must be in contact with bare metal and securely affixed Ground conductor size and connection means will be in accordance with all applicable electrical code standards 9 Check Out for System Start up When the installation has been completed assure that the equipment is ready for start up by checking the following A Ensure all construction debris is removed from the ionizing collecting cells drain basin and ductwork B The line from the Trion drain basin is clear and completely connected to its point of termination C Supply line power is available and electrical wiring
21. ionizing collecting cell tier in height Other than the basic hand tools it is advantageous to have a volt ohm milliammeter with a 20 KVDC high voltage probe These instruments are standard catalog items by several manufactures B Secondary Short Circuit The most common outage is a short in the secondary circuit and is best located through the process of elimination Symptoms are a flickering indicating light accompanied by an arcing noise in the ionizing collecting cell s or an indicating light that is not glowing A flickering light with an arcing noise is an indication of a high resistance short circuit and a light that is not glowing is an indication of a dead short A light that is not glowing can also be an indication of an open circuit in the primary circuit Refer to the paragraph on open circuits The short may be in the power supply the high voltage cables or the ionizing collecting cell s To isolate the short to any one of these three components proceed as follows WARNING When safety interlock switches are closed do not come in contact with high voltage components The operating output from the high voltage power supply s is 12 600 VDC and 6 MA to 11 0 MA When the power supply s is de energized there Is 20 second delay for the voltage to decay Always short from ground to a point of high voltage with a well Insulated jumper wire or an insulated handled screwdriver to bleed off any remaining residual cha
22. is completed to the following components Controller Electrical Interlocks lonizing Collecting Cells The System Fan Duct Lights Indicating Lights and Switches Qi E oo SECTION Ill OPERATION amp SERVICE WARNING RISK OF ELECTRIC SHOCK These servicing instructions are for use by qualified personnel only To reduce the risk of electric shock do not perform any servicing other than that contained in the operating instructions unless you are qualified to do so FOR THE MAINTENANCE ENGINEER 1 Introduction and Principle of Operation The Trion electronic air cleaner is technically known as an electrostatic precipitator In this type of equipment all airborne particles even of microscopic size are electrically charged positively as they pass through a high voltage ionizer These charged particles are then attracted and adhere to a series of parallel collecting plates which form the negative elements of an electrostatic field The ionizer consists of charged stainless steel spiked blades spaced between grounded electrodes The collecting section consists of parallel plates arranged so that each alternate plate is charged while the intermediate plates are electrically grounded Periodically depending on the type and concentration of contamination in the air the contaminate is washed from the plates by manually cleaning the cells while in place or removing them from the unit and then cleaning Two majo
23. located indoors and still be reasonably close to the main cabinet If located outdoors with the cabinet it must be weather protected Contact the local Trion Sales Office or the factory if questions arise or any additional information 15 required SECTION II INSTALLATION FOR THE INSTALLING CONTRACTOR 1 Unpack and Inspect At the time the unit is received all shipping containers and their contents should be examined for damage Any damage occurring in shipment must be immediately reported to the carrier an inspection report completed and a claim filed at the receiving point The number of shipping containers included in the shipment is dependent upon the unit size and type When packaging the material for shipment consideration is given to grouping the components into the installation categories in which they will be used The packing list included with shipment identifies the various items to a specific box number In general the grouping is as follows A Framework B lonizing Collecting Cells C Controller with Power Supplies D Accessories For the protection of the components it recommended that those materials not immediately needed for installation be stored in the container in which they are received in a safe dry and clean location This is particularly true with the ionizing collecting cells which may be damaged when not properly handled 2 Assemble Framework The base frame two sides and top ar
24. or collector section of a given cell as follows 1 First determine if the short is in the ionizing section or the collecting section by connecting each high voltage lead to its respective section one at a time and energizing the power pack The lead not connected must be supported away from any point of contact The short symptoms will still exist for the section in which the short is located If the trouble causing the short is bridging both sections then the short will be indicated in both sections when they are individually connected 2 When the short is isolated to a cell tier remove all the cells within the tier and visually check the sections indicated to contain the short a If the short is in the ionizer section look for a broken or defective insulator b If the short is in the collector section look for a large piece of foreign material bridging the collector plates or a defective insulator c If the short is indicated to be in both sections it will probably be a foreign object bridging the air gap between the ionizer and the collector c Open Circuits Although open circuits can occur in the secondary they usually take place in the primary If the unit contains only one power supply and the indicating light does not glow the outage is probably one of the following 1 Supply line power to the control disconnected Reconnect 2 Open access door interlock in control of electronic air cleaner Be sure
25. through the air cleaner Any condensing that takes place downstream from the air cleaner defeats the purpose By the same token heavy concentrations of water vapor or other matter that becomes highly conductive when condensed must be prevented from entering and or condensing in the collecting elements to prevent electrical arc over and shorting SAFETY NOTE Factory designed access to all electrically charged high voltage components contain electrical interlocks for the safety of operating personnel Any additional access that may be provided in the system where there is access to high voltage must be equipped with such interlocks Interlocks are readily available from the factory A foundation and drain basin design must be provided to carry off the wash water used to clean the ionizing collecting cells It is suggested that a new concrete basin be poured prior to the scheduled shipment of the hardware Refer to Figure 3 Recommended Foundation and Drain Basin Layout Drawing Serious consideration should be given to any deviation the suggested design which would result in improper drainage leakage air bypass and mounting addition to the governing plumbing codes the following points should be considered the construction of the basin A Drain lines must be of adequate size to carry off the required amount of detergent wash water used Refer to the piping schematic drawing Figure 4 B Drain line
26. use in ventilation systems and non caustic as 95 of the ionizing collecting cells are constructed of aluminum special high voltage insulation and gasket seals C Electrical Operation The Air Boss controller Optional contains a digital LED display for kilovolt and milliampere readings The milliammeter should be observed on a routine basis to be sure that it is reading within the prescribed operating range as marked on the data plate For those units containing a voltmeter the collector voltage should be between 6 and 7 and the ionizer between 12 5 and 13 5 KV The ATS controller and remote PWM box both have LED indicating lights to show power to the PWM power supplies Flickering or failed LED s indicate electrical arcing and or power failure 5 Periodic Maintenance A Controller Every 12 Months The inside of the controller cabinet should be examined for accumulated dirt and dust If required the components should be cleaned using a good brand of electrical contact cleaner All terminal connections should be checked for securement and tightened or reworked as required B lonizing Collecting Cell Every 6 to 12 Months Remove and inspect the ionizing collecting cells for excessive dirt accumulations Manually clean as required in a soak tank commercial car wash or with a pressure hose or pressure cleaner using a low pressure setting At this time particular care should be taken in cleaning each of the insula
27. Figure 14B USED eo tere iocur Figure 15 High Voltage Lead Termination at Power Supply Unpack and eerte Attach Adjoining Ductwork n Install lonizing Collecting Cells Install Air By Pass 1 UN uam ces usen Complete corre uunc RR Y Udd High Voltage WIN B Primary Wiring ennu ste ence E 5 E Len 9 Check Out For System Start Up J l u u SECTION DESIGN FOR THE SYSTEM DESIGN ENGINEER 1 General Description Model 60 equipment consists of factory assembled components to be built up in the field into a completed unit Depending on the system requirements the installation may consist of a single unit or a multi section unit A multi section unit is simply two or more single units placed side by side The factory assembled components are designed to be mounted on a field prepared pad in the form of a drain basin typically constructed of poured concrete The standard major components supplied with each unit for installati
28. N A IBN SSV 133 09 GON NOILOANNOD 801931100 AIHW3SSV 39VLI0A 401231102 21719 ONS 1417 AIRFLOW THO HOV3 X04 SINIOd NOLO3NNOO SNA 398110 NO TW 1132 HOW N03 3JOQNVIS 537101 9NOT JHL NO S SV8 ATEWISSV STZINOI IHL 30 NOUO3NNOO JHL 03 9 4715 1V3d34 7190 HOVI NO 03131900 38 SINIOd NOI23NNOO SY8 39 0 TW TNA NMOO 51883558 TON OG 44000015 JHL OINI CNY WNINSSL 2 Suya 1 ATBW3SSY MGMOS FHL ONY 3825 OVIH Nyd 3 1 30 JHL 3HHSYM 830 NOLISOd 34008815 JHL 30 ON3 370H 030 98 1 JHL N3 0 S uv8 9 AGWGSSV 301997109 IHL NOUS TvNINH3L 0 09 ONY ONWOB IHL 3150990 3300NvIS 801231102 1MOHS HOW 40 QN3 JHL H3HSVM 2 1 7 M3NOS QV3H Nyd OZ v 1 JYYMGYVH SHL SY8 ONY 1 1130 180607 ON NOINL 33 AW3MISNHOG LNIOd 1130 HOV3 NO 4400 5 801271100 ONY N37INOI 3H1 GATWISN N3HM 3iv1d 1130 NO MOTH 8 SHL 310N 09 1300 NI 51130 TWISNI 34 14 ON3 ONYH 143 3 1 NO dHOONVIS 501231102 130 JHL 804 20820035 JHL 1V3433 4315 NOUS O3AVS
29. NGE AND SIZED FOR A GIVEN BANK OF CELLS Refer to Figure 6A or 6B and select the appropriate unit model Interconnect the cells with the bus bars as shown When fully connected the cells will be grouped into banks as indicated by the letters A and Next wire the interconnected cell banks to their corresponding power supplies with the high voltage cable provided Depending on the size of the unit there may be from 3 to 14 PWM Power Supplies NOTE Each high voltage cable should be run in a separate conduit and must not be spliced at any point between the power supply and the cell termination Use the blue cable for the ionizer and the black cable for the collector plates At the cell termination the outer jacket of insulation should carefully be stripped back from the inner layer of insulation a distance of four 4 inches to prevent tracking Normally the high voltage cable entrance should be made from the top of the ductwork If the installation demands entrance from some other point the conduit should be sealed where it terminated at the duct to prevent moisture from entering the conduit during the washing operation At the power pack termination be sure the blue ionizer cable is connected to the terminal marked IONIZER and the black collector cable is connected to the terminal marked COLLECTOR B Primary Wiring 1 Duct Door Electrical Interlocks Two are furnished as standard Outside
30. OPERATING OUTPUT FROM THE POWER SUPPLY IS 15 000 VDC AND 5 5 MA to 11 0 MA WHEN IN PARALLEL IF SAFETY SWITCHES ARE CLOSED AND CIRCUIT IS ENERGIZED DO NOT TOUCH HIGH VOLTAGE WHEN THE CIRCUIT IS DE ENERGIZED ALWAYS BLEED OFF REMAINING STATIC CHARGE WITH AN INSULATED HANDLED SCREW DRIVER BY SHORTING to GROUND THE POINTS OF HIGH VOLTAGE DC POTENTIAL WARNING Risk of Electrical Shock The servicing Instructions are for use by qualified personnel only To reduce the risk of electric shock do not perform any servicing other than that contained in the service instructions unless you are qualified to do so A Introduction This section troubleshooting provides description of potential malfunctions their cause location and correction A Trouble Reference Chart listing the most probable causes and corrections follows the general text The electronic air cleaner is the unit within the system that has the highest efficiency collection rating and is also the one with the highest potential for malfunction When a malfunction does occur the outage is usually found in the electrical secondary circuit in the ionizing collecting cell s Indicating lights are installed in the face panel of the control to monitor the electrical operation of each power supply and the ionizing collecting cell s they energize The quantity of power supplies per unit is dependent upon unit size with one or two power supplies for each
31. R 5 ION SEE NOTE 3 MOTOR SUPPOR FRAM TOP FRONT EJ KG D AIR BAFFLE AIR BAFFLE 1 35 4 A 1 3 N X Y N Y 1 1 1 1 1 I 1 1 1 N 1 1 AN x AW NTE NAPA y y N RAM IDNIZER COLLECTOR CEL BOTTOM FRONT G IUNIZER COLLECTOR CE TYPICAL ILLUSTRATIONS 557 NDTES AIR BAFFLES ARE INSTALLED ONLY ON AIR ENTERING SIDE OF UNIT AS SHOWN AIR BAFFLES AR ETTER CODED SE CORRESPONDING MODEL AND FOLLOW DIAGRAM 3 UNIT WIL BE LEFT DR RIGHT HAND AS SPECIFIED LEFT HAND IS SHOWN USE LE SOLID O FUR LEFT HAND UNITS USE ETTER CODING IN BROKEN CIRCLE FOR RIGHT IAND UNITS 4 SEE FIGURE 8A FIGURE Co 8 MODEL60 LF8 26 MODEL 60 AIR BAFFLE ARRANGEMENT e eT 8 ED T Q
32. TAILED SCHEMATIC DRAWINGS WILL BE PROVIDED BASED ON THE SIZE AND CONFIGURATION OF YOUR UNIT ORDERED FIGURE 11 Model 60 Field Wiring THIS PAGE INTENTIONALLY LEFT BLANK DETAILED FIELD WIRING DRAWINGS WILL BE PROVIDED BASED ON THE SIZE AND CONFIGURATION OF YOUR UNIT ORDERED FIGURE 12 ATBN3SSV 1 00182 201 ONILNNOW 1 1000 00005 008 72 00817 WOldAL 5 0 187 019201 3108 NNHO ALJAS 0006 005 00887 00002 WOleAL S310H ONILNNON 215 NOIIV9O1 310H NMNO SYJ 8000 S 9 ATgW3SSV LEON 2 138 NWHO 1185 WOWLONA 5000 583009 1 WOUIO313 A000 553239 0006 005 9 013931 00007 Dy 000071 00007 OWL WAISAL S310H 9NIINDON ZLE yYOMLONG 93101519 ONISNOH 09 1300 MOO I83INI 414 4000 553 VIVI j L60 LF1 MOD FIGURE 15 IONIZER WIRE K TRACER LONG STA CONDUIT VOLTAGE VU v PAN HEAD MACHINE SCREW SHEET METAL HOUSING CONDUIT
33. all access doors are properly closed and secured 3 Blown in line fuse Replace Power Supply 4 Outage in the power supply Look for charred or burned components or a loose wiring connection Replace power supply or reconnect wiring 5 Defective indicating light Replace light d Malfunctions other than short or open circuits Refer to troubleshooting reference chart in this section 7 Spare Parts Recommended spare part quantities are usually based on the unit size and the amount of units per installation For specific recommendations consult the Trion factory or nearest Sales Office Consideration however should be given to stocking the following components DESCRIPTION QTY PWM Power Supply Cell Insulators LED Part Numbers are not listed as they are subject to change Always state Unit Model and Serial Numbers when ordering parts Troubleshooting Reference Chart PROBLEM SYMPTOM PROBABLE CAUSE LOCATION REASON CORRECTION Indicating Light Not Glowing Short Circuit lonizing Section of Cell om Dirty insulator s Clean Defective insulator s Replace Foreign Object Between lonizing Bar and Ground electrode Remove Collecting Section of Cell Dirty insulator s Clean Defective insulator s Replace Foreign Material Bridging Plates Remove Bent Plates Straighten or Replace High Voltage Leads Bon Disconnected High Voltage Lead Co
34. e match marked on the air entering side of the air cleaner at the factory prior to shipment See Figure 5 A Position the base frame on the drain basin Make sure it is located with the marking BOTTOM FRONT on the air entering side The anchoring studs in the drain basin should be located on the inside of the frame channels and the entire frame should be level Shim as necessary B Secure the base as illustrated It is important that the studs do not protrude above the base frame channel Cut top of studs if necessary Each anchor should be treated to prevent rust C Attach the side and top panels match marking where the pieces join on the air entering side A to A B to B etc The required fasteners are packaged and marked for the framework D After the outside frame structure is complete position and secure the intermediate cell supports The side to receive the air bypass strips marked FRONT should be positioned toward the air entering side 3 Attach Adjoining Ductwork Depending on the application the installation plan may or may not call for adjoining ductwork on the air entering and or air leaving sides of the cabinet When adjoining ducting is to be installed attach to the flanges on the air entering and air leaving sides of the unit Maintain structural squareness during attachment The seam should be made air and watertight by caulking or gasketing The seam between the concrete drain basin and the metal
35. loor Layout The arrangement of the supplied components and the general layout of the system will vary according to application adjoining equipment and available space However there are several basic factors pertaining to all installations that must be considered To maintain the selected cleaning efficiency it is important to assure that the total air volume capacity in CFM is uniformly distributed across the entire face area of the unit However since most air ducts are designed to handle air velocities greater than the rated velocity of the air cleaner it is necessary to properly transition any attached ducting If possible a contraction ratio of 1 in 3 approximately 20 should be maintained If space prohibits turning vanes air baffles or other means may be utilized Ducting where attached to the sheet metal panels should be gasketed caulked or otherwise made water and airtight When there is a danger of rain snow or debris being drawn into the system with outside air the make up air intake should be protected with rain louvers hooding and hardware cloth to prevent the rain snow or debris from entering the electronic air cleaner Contaminants to be collected such as oils in vaporous state must be condensed into particulate form prior to entering the ionizing collecting cells in order to maintain the anticipated efficiency Gases vapors or any non particulate cannot be precipitated and will therefore pass
36. nstruction or other sources in the cell s and should subside quickly If the arcing is continuous and does not subside recheck the routing of the high voltage leads between the power supply s and the cell s Refer to the field wiring diagram The ionizer lead must be connected to the ionizer and the collector lead to the collector Routine Maintenance Washing Frequency The frequency that the collected dirt is to be washed from the unit depends upon the type and amount of dirt in the air to be cleaned Dirt which is greasy in nature tends to harden after collection and should be washed away often Likewise units operating under extremely heavy dirt loads should be washed more often as a large build up of collected material will have a tendency to blow off if permitted to remain on the collecting elements for long periods of time In that the type and amount of dirt varies geographically and from one location to another in any given area it is recommended to start operation with a washing frequency of at least once a month This schedule may then be altered as needed after visual examinations of the collected material contained on the ionizing collecting cells Detergent Effective washing is dependent upon detergent The detergent as supplied by Trion Inc is formulated specifically for electronic air cleaners substitutes are used they must be approved by Trion so as to not void the warranty They should be safe for
37. ntacting Ground Reconnect Defective Lead Insulation Breakdown Replace Entire Lead Power Supply Charred Over Heated Components Replace Power Supply Indicating Light Not Glowing Open Circuit Control Disconnected Supply Line Power Reconnect Faulty indicting Light Replace Power Supply Blown Fuse Replace Power Supply Disconnected Wire Replace Charred Over Heated Components Replace Power Supply Electronic Air Cleaner Housing Electrical Interlock Switch Not Closed Close Access Door Faulty Electrical Interlock Switch Replace Indicating Light Flickering High Resistance Short High Voltage Circuit lonizer High Voltage Lead Connected to Plate Section and Plate Lead to lonizer Reconnect Leads Loose or Disconnected High Voltage Lead Tighten or Reconnect Loose or Defective Intercell Connection on Multicell Units Tighten or Replace Foreign Object Adrift in lonizer or Plate Section of Cell Remove 10 MO INOMJ N3HII3 WON4 318VAOW3N 1130 51132 9NIIO3T102 ONIZINOI 18041 AG I I I 5 3 03 01 8 90 2 MIIA 401 e 1 I Kas Soe Der Se 252221 gt ij 9
38. on are as follows A Framework Support members complete with sheet metal panels on the top and sides to receive and locate the ionizing collecting cells B lonizing Collecting Cells The elements used to remove and collect the contaminants from the air stream C Control Power Supply Box s Located in the control enclosure and converts 115VAC to the high voltage DC required to energize the ionizing collecting cells The programmable logic controller PLC electrically sequences the washing operation The Pulse Width Modulated PWM power supplies providing the necessary high voltage for the air cleaner and the controls initiating and sequencing the wash cycle are furnished in a NEMA 12 enclosure designed for remote mounting The distance between the controller and unit must be determined as the interconnecting high voltage leads are furnished to the specified length Consult factory for distances greater than 50 ft Cables are not to be spliced at any point along their length In addition the enclosure is a central junction for the primary wiring D Accessories Electrical interlocks lights and switches for safety and monitoring Note Trion Tridex Detergent is specially formulated for use with Trion electronic air cleaners Use of other cleaners and detergents not specifically approved by Trion will cause possible failures in the unit and will void any and all warranties on our equipment 2 System Design and F
39. or construction materials Especially note the opening in the drain basin for any restrictions The ducting where secured to the cabinet collars should be sealed water tight either with gasketing or caulking Inspect the ionizing collecting cells to see that all of the ionizing blades or wires are intact that no large pieces of foreign material are lodged between the plates and that the cells are properly installed in the cabinet with the spiked ionizing blades or wires located on the air entering side C Check the high voltage leads to see that they are connected to the proper terminal both at the ionizing collecting cells and inside the controller Refer to Figure 14A Be sure that the drain lines from the Trion cabinet drain basin are completely connected and properly terminated A trap or seal of some type should be incorporated in the line to prevent air bypass Be sure that electrical power is available that the wiring is completed and that the system blower is ready to energize Be sure that all access door interlocks are closed Close the system electrical supply switches making power available to the Trion controller and the system fan Turn the controller selector switch to the ON position The blower should run if installed and the power supply s should be energized Electrical arcing within the ionizing collecting cells may occur It is a normal occurrence caused by accumulation of dusts from co
40. r functional components comprise the air cleaner 1 lonizing collecting cells to ionize and collect airborne particulate matter 2 Power supply s to supply high voltage direct current to the ionizing collecting cells Normally systems are designed for collection efficiencies in the range of 90 percent or more Collecting contaminant at these efficiencies especially when there are high concentrations can result in large accumulations in a relatively short period Therefore maintenance must encompass two areas the operation of the equipment for efficient collection and the systematic removal of the collected contaminant 2 General Description ionizing collecting cells contaminant collecting elements are housed in the cabinet on unistrut frames They can be removed from the unit as required from the backside downstream airflow side When installing cells into the cabinet observe the directional arrows on the cell end plates The side of the cell containing the spiked ionizer blades always must be located on the air entering side The Power Supply s convert the 115 volt 60HZ single phase AC supply to the high voltage DC needed to power the ionizing collecting cells Potential of 13 KVDC are reguired for the ionizer sections and 6 5 KVDC for the collector sections of the cells 3 Initial Start up A Inspect the inside of the adjoining ductwork and Trion cabinet to be sure it is clean and free of any debris
41. rge 1 Disconnect both high voltage leads from their respective terminals the power supply and support them away from any point of contact 2 Energize the power supply a If the light still flickers or does not glow the trouble is indicated to be in the power supply First check the inline fuse mounted on the circuit board and replace if it is blown Second replace the power supply in its entirety b If the light glows steady with the leads disconnected the power supply is indicated to be normal NOTE It will be necessary to close the access door electrical interlock switch operated by the access door to complete the primary circuit to the power supply 3 Next reconnect both high voltage leads to their respective terminals inside the power supply and disconnect them at the ionizing collecting cell s Support them away from any point of contact and energize the power supply a If either high voltage lead is defective the light will indicate the trouble Each lead may then be checked separately by disconnecting them one at a time from their respective terminals at the power supply When a lead is found to be defective replace it in its entirety Do not repair or splice b If the light glows steady with the leads disconnected at the ionizing collecting cell s the trouble is then indicated to be in the ionizing collecting cell s The trouble can then be isolated to a single cell or the ionizing
42. s must be suitably trapped and vented to prevent line gases from entering the air handling System C The basin floor should be properly pitched and finished to prevent puddling D The cross members containing the anchoring studs to receive the air cleaner base frame must be even and level to provide a proper foundation for the metal framework base Where the installation site is not suitable for a poured concrete basin rust resistant metal pans may be used The metal should withstand the weight of service personnel in addition to the weight of the unit Each installation varies according to needs but normally the controller is located near the air cleaner Ideal mounting height is at eye level for ease in reading the instrumentation and to facilitate service For ease in maintenance and component removal adequate space 39 Minimum Required must be provided in front of all access doors motors pump and accessory equipment 3 Outdoor Installations Requirements for outdoor protection vary in accordance to climate and equipment component arrangement for the particular job The best approach for equipment protection is the construction of a heated shed or building over the installation As an alternative the installing contractor should treat the equipment as required to meet the specific needs Controller PWM Power Supplies As the controller oower supplies are designed for remote mounting they can be in many cases
43. tors WARNING DO NOT USE HIGH PRESSURE STEAM CLEANING EQUIPMENT TO CLEAN CELLS THE EXCESSIVE HEAT AND PRESSURE WILL CAUSE THE PLATES TO WARP AND IN TURN POSSIBLY CAUSE EXCESSIVE ARCING C Filter Devices Every 4 to 6 Months Hoods impingers metal mesh filters ducts and other appurtenances shall be cleaned to bare metal at frequent intervals prior to surfaces becoming heavily contaminated with grease oil or other contaminate It may be advantageous to clean readily removable items such as impingers metal mesh filters or other permanent filter devices in a soak tank with a pressure hose or pressure cleaner low setting After cleaning to bare metal components shall not be coated with powder or other substance When a cleaning service is used a certificate showing dates of inspection and or cleaning shall be maintained on the premises WARNING Flammable solvents or other flammable cleaning aids shall not be used At the start of the cleaning process electrical switches that could be accidentally activated shall be locked out Components of the fire suppression system if installed shall not be rendered inoperable during the cleaning process Care should be taken not to apply cleaning chemicals on any fusible links or other detection devices of the automatic extinguishing system 6 Troubleshooting WARNING EXERCISE THE USUAL PRECAUTIONS WHEN WORKING WITH HIGH VOLTAGE THE MAXIMUM
44. work must be caulked or grouted to form a good watertight seal When blower is installed downstream from the Trion cabinet the ducting between the cabinet and the blower will be under negative pressure and should be made air tight to prevent infiltration of contaminated air After the ductwork has been installed clear remaining material or debris from inside ducts and bottom of cabinet 4 Install lonizing Collecting Cells Before placing the ionizing collecting cells into the framework the electrical cell to bus connectors must be inserted through the holes located in the flanges of the end plates and secured into place There are two connectors per cell one short collector standoff and a long ionizer standoff Connect the bus bars and cell wiring as shown on Figure 6 6A 6B and Figure 7 NOTE Follow the directional arrows located on the cell end plates The side of each cell containing the spiked ionizer blades must be located on the air entering side of the cabinet 5 Install Air By Pass Baffles The air baffles provided are to be secured to the air entering side of the unit to block off the air gap between the frame and the top and the sides of each cell They are secured into place with the screws provided The vertical baffles for the cell ends are all rubber backed The horizontal baffles across the top of each cell are plain There are different sizes of each Refer to Figure 8 and 8A for the arrangement
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