Benetech Clean Sweep AC Instruction Manual

2245 Sequoia Drive, Suite 300 l Aurora, IL 60506
l Ph 630.844.1300 l www.benetechusa.com
Clean Sweep AC
Installation & Maintenance Manual

Page 2
TABLE OF CONTENTS
SECTION DESCRIPTION
1System Precaution
2Theory of Operation
3Installation
A. Nozzles
B. Receiver Tank
C. Electrical
4Operations
A. Overview
B. Operation
C. Adjustments
5Maintenance
A. Troubleshooting Guide
B. Nozzle Repair
6Installation Photos

Page 3
1.0 SYSTEM PRECAUTION:
Clean Sweep operate at 80 - 100 PSI pressure. Place appropriate safety signage on all access
doors where CLEAN SWEEP are installed. DO NOT inspect CLEAN SWEEP nozzles
when operating. Always shut off and tag out CLEAN SWEEP prior to entering or
inspecting chutes or bins whereCLEAN SWEEP are installed.
CAUTION: Never visually inspect chutes when CLEAN
SWEEP are firing. Always turn off and tag out CLEAN
SWEEP System prior to chuteinspection or entry

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2.0 THEORY OF OPERATION
The Pneumatic Accumulation Control System (CLEAN SWEEP) works on the principle
that compressed air can be utilized to remove buildups of wet, sticky material from the
walls of bulk solids handling system chutes, bins and hoppers. Compressed air (80 to
100 psig)has been proven to exert enough energy to remove large accumulations of build
up on chute walls. CLEAN SWEEP does this without interfering with normal material
handling processand operations. Loss of material flow due to pluggage is virtually
eliminated in areas where CLEAN SWEEP nozzles are correctly positioned.
A standard CLEAN SWEEP System consists of properly positioned CLEAN SWEEP
nozzles, air operated solenoids, compressed air reservoir tank, high pressure hose/fittings
and controls (Figure#1). A blast of compressed air is delivered sequentially to each
nozzle through a quick- opening/quick-closing air operated diaphragm valve. Each
nozzle directs compressed airin a 360°pattern along the surface of the chutework for a
radial distance of approximately two to three feet. The air blast dislodges and breaks up
a layer of materialbuildup, which is then carried away by gravity or other material
flowing through the chute or bin.
All CLEAN SWEEP valve bodies are mounted flush to a chute/bin surface with (only)
the hardened steel valve nozzle head extending into the material stream. When activated,
the valve nozzle head extends into the material stream (approximately 1/8”). A blast of
high pressure air is directed along the chute or bin wall and up to a 3’ radius is cleaned.
The valve nozzle head then retracts back to its original position through spring loading.
The system will continue to cycle through all nozzles until the buildup is removed
(adjustabledepending on material conditions).
A complete CLEAN SWEEP System includes the following:
Nozzle Assembly - Includes limited travel hardened steel nozzles with high
pressure hose, hose fittings, solenoid valves, pilot actuators, flanged clamp
brackets, mounting (weld) plates with mounting bolts,.
Tank Air Supply Assembly - Includes 30 – 60 gallon ASME certified
accumulator tank with pressure gauge, auto tank drain, pressure switch and
moisture trap.
Control System Assembly - Includes NEMA 4X control panel with timer
card(s), panel switches and indicator lights for automatic and manual operation.

Page 5
3.0 INSTALLATION
If your CLEAN SWEEP System will NOT be installed by Benetech personnel, or you
have chosento expand the CLEAN SWEEP System yourself, installing/expanding your
CLEAN SWEEP System can be completed per the following instructions:
A. CLEAN SWEEP Installation
1. Determining where to locate CLEAN SWEEP nozzles:
CLEAN SWEEP nozzles should be located at the area where material first
starts to build up. From this initial point, additional CLEAN SWEEP should
be installed in an upward direction throughout the pluggage areas. Typical
areas are; dog legs, in Clean Sweep zones, bin to hopper transition, hopper
corners, slide areas, hopper ledges, corner transitions, in Clean Sweep points,
chute discharge etc. Nozzles are typically located approximately 3’ apart. It is
recommended that personnel responsiblefor clearing and cleaning pluggage
be consulted to determine area of initial buildup.
2. After nozzle locations have been selected (technical assistance provided by
your Benetech sales or service representative is recommended), a 3” diameter
hole is cut through the chute or hopper wall and lining. If the chute or hopper
wall contains two (2) or more linings and there is a gap between liners, it is
recommended that the gaps be filled in. CLEAN SWEEP nozzles have been
installed successfully in a variety of chute and hopper wall materials
including; ceramics, stainless steel and chromium carbide.
3. The square “mounting plate” (Item 1 Figure 3) is welded to the outside of the
chute or hopper wall. The 3” diameter hole in the “mounting plate” and the
hole in the chute or hopper wall MUST line up.
4. Bolt the flanged “clamp bracket” (Item 2 Figure 3) to the mounting plate, use
only two (2) bolts (finger tight) at this time.
5. Tighten the set screw located in the “clamp bracket” this will spread the clamp
apart to accept the valve body (Item 8 Figure 3).
6. Insert the “valve body” assembly (Item 3 Figure 3) into the “clamp bracket”
until the outer edge of the valve body is flush with the internal wall surface.
Loosen the set screw. Tighten both 3/8” hex head bolts (approximately 50
ft./lb.) to hold the valve body assembly in place. NOTE: Limited travel
hardened steel nozzles are pre-set, do not adjust valve stem nut.
7. Tighten the set screw.

Page 6
8. Install the two (2) remaining bolts into the “mounting plate” and tighten all
bolts.
9. Install a 1½” all-thread nipple and air operated diaphragm valve (See Figure
2) to the back of valve body.
NOTE: Use Teflon thread sealant on all pipe fittings.
10. Install ¼” MNPT x ¼” tube 90°elbow into air operated diaphragm valve.
11. Locate the 6-gang pilot valve solenoid box(s) in an area so that the length of
¼” poly tubing from the valve box to the solenoids does not exceed five feet.
All tubing from the pilot box to solenoids should be (approximately) the
same length (±1-2’). If this cannot be accomplished, additional pilot valve
solenoid boxes should be installed.
12. Connect ¼” poly tubing from ¼” tube fitting in air operated diaphragm valve
to the 6-gang pilot valve solenoid box.
13. Locate the air accumulator tank in a suitable area (not more than 100’ from
tank to CLEAN SWEEP) that minimizes piping material and manpower.
Install supply air to the tank. Install 1 ½” pipe from the tank to the CLEAN
SWEEP area(s). NOTE: if asuitable sized accumulator tank is not being
used, (e.g.: small air compressor) insure that a pressure switch is placed in
the CLEAN SWEEP air supply line set at 60 PSI. Pressure below this set
point will deactivate CLEAN SWEEP system.
14. Connect 1½” high pressure fitting and hose from air operated diaphragm
valve to CLEAN SWEEP air header. It is recommended that shut off
valves be installedbetween the air header and CLEAN SWEEP nozzles.
(Reference installation pictures)
15. Mount control panel, connect 120 volt, 60 Hertz, 15 amp, single phase
(Figure 1 & Figure 7). Install conduit and wire from the control panel to the
pilot valve solenoid box(s)
16. Place Caution and Warning signs on all access doors where CLEAN
SWEEP areinstalled.

Page 7
4.0 OPERATIONS
A. OVERVIEW
The system is designed to maintain material flow through hoppers, bins, or chutes
using a sequential timing device to alternately fire each CLEAN SWEEP nozzle.
The system can be interlocked with a “run permissive” to ensure that the system
will only operate during times when material is present.
A selector switch allows the user to select two (2) modes of operational service;
“TIMED” and “CONTINUOUS”. During normal conditions the system can be
operated in the “TIMED” mode. In this mode nozzles fire as usual but take
“breaks” between timing cycles. This mode saves air and provides the longest
nozzle service life. If material is abnormally wet or sticky, place the selector
switch in the “CONTINUOUS” mode. In this position, nozzles fire at the same
frequency as “TIMED” but without “breaks” between cycles.
A “Clean Out” pushbutton switch activates all nozzles for one or more
(programmable) cleaning cycles regardless of whether the run permissive is made
or not.

Page 8
B. ADJUSTMENTS
The digital timer boards located inside the control panel activate the CLEAN
SWEEP nozzles in a preset sequence and interval to insure even clearing of
material. Thefiring order is usually from the discharge (lowest unit) of the chute
or hopper to the top.
There are six (6) adjustments that should be made prior to putting the
CLEAN SWEEPSystem into operation. They are defined as follows (See
Section 8, Goyen Sequential Timer for additional information):
ON Time: The duration of electric pulse sent to
operate nozzle.
OFF Time: The length of interval between the
operation of individual nozzles.
Number of Valves: The number of outputs actually being
used on the timer board.
Number of OFF’s: The number of complete firing cycles
when the clean-out is used.
Rest Time: The time the nozzles will be inactive
when the system is in “TIMED” mode.
Run Time: The time the nozzles will be active
when the system is in “TIMED” mode.

Page 9
The first four (4) adjustments are made on the timer board. Press the select button on
the timer board. Then press the adjust button to change the value. The last
adjustments are made on the timer relay.
Step 1: Press select button on timer board. An
LED will light next to “ON Time”. This
time is generally set to 35 to 45
milliseconds. The nozzles should give
a rapid “pop” when adjusted properly
(importance of ¼” tubing lengths not
exceeding 5’ and all approximately the
same length.
Step 2: Press select until LED lights next to
“OFF Time”. The time is set in seconds,
typically 20 to 30 seconds. The time
setting will vary dependingon number
of nozzles in service, airdemand, etc.
The time should be set as long as
reasonable.
Step 3: Press select until LED lights next to
#valves. Press adjust button for number
of nozzles used on this timer board.
Step 4: Press select until LED lights “#OFF’s”.
This is usually set at 1 or 2.
There are four settings on the Crouzel
OLR1 timer located inside the control
panel.
Step 5: (1) Set the top setting on 0-60 minutes.
(2) Set the second dial “On Ttime” so
that all the nozzles fire at least one time
whenever the system is in the “Timed”
mode.
Note: The rest time should be set as long
as practical. This reduces excess air
usage and prevents premature nozzle
failure.

Page 10
Step 6:
(3) Adjust the third (lower)
thumbwheel on the timer relay to 0-60
seconds for length of active time when
in “TIMED” mode.
(4) Adjust the fourth timer to three to
four minutes. This is the amount of
time
the system will be at rest between cycles

Page 11
5.0 MAINTENANCE
A. TROUBLESHOOTING GUIDE
SYMPTOM
CAUSE
REMEDY
System does not operate in any
mode
No power to controls
Low air pressure
Timer Board Faulty
Circuit Breaker
Increase air pressure
Replace timer board
System only operates in clean-
out mode
Auto run permissive not made
Verify that equipment is running
Check permissive contact
Nozzles will not fire in TIMED
mode only
Cycle is in ‘Pause’ time
Timer Relay fault
Wait for ‘Pause’ time to end
Replace timer relay
Nozzle(s) will not stop blowing
Solenoid pilot stuck open
Solenoid diaphragm broke or
material lodged in it
Tubing from pilot to solenoid
leaking
Output bad on timer board
Repair or replace pilot valve
Repair or replace solenoid
diaphragm
Repair ¼” poly tubing
Move to spare output or replace
timer board
Nozzle(s) do not clear material
build-up
Valve body not adjusted to
proper depth
Valve head worn or missing
Solenoid valve or pilot valve not
working
No 120 Volt signal from timer
board
¼ pilot tube to long
Refer to installation guide
Repair or replace
Repair or replace
Move to spare output timer board
or replace board
Relocate pilot box to shorten
tube
NOTE: For maintenance purposes, isolation valves should be installed on the
individual CLEAN SWEEP nozzles. This will allow for one or more nozzles to
beremoved for repair without taking the entire system out of service.
CAUTION: Never visually inspect chutes when CLEAN SWEEP are firing. Always
turn offand tag out CLEAN SWEEP System prior to chute inspection or
entry.

Page 12
B. CLEAN SWEEP NOZZLE REPLACMENT
NOTE: Before performing maintenance and/or adjustment, electrical
power and compressed air supply must be turned off and
supply header must be drained of pressure. Follow
appropriate lock and tag procedures
Remove CLEAN SWEEP valve body in reverse order of
installation.Install new CLEAN SWEEP valve body per
installation instructions.
Adjust the body to achieve the proper adjustment of the valve to the chute
or wall surface by measuring the distance from the internal wall surface to
the outer portion of the clamp flange that holds the main body. Insert the
main body into the clamp flange the measured amount. If this is done
correctly, the valve head should extend 0.125 inches past the internal
chute or hopper wall. See Figure 4.

Page 13
Note air supply piping installation with block valves
CLEAN SWEEP Installed in Chute to Remove/prevent
Pluggage

Page 14
Pilot Valve Box Location and ¼” Tube

Page 15
CLEAN SWEEP Installed in Hopper Discharge: Note location of pilot box

SAFETY VALVE
AIR SUPPLY, 80-100 PSI,
SUPPLIED BY CUSTOMER
POWER SUPPLY, 120V, 15A
SUPPLIED BY CUSTOMER
AIR TANK
PRESSURE GAUGE, 0-160 PSI
ISOLATION BALL VALVE
STEEL ASME AIR TANK, 200 PSI W.P.
OPTIONS:
30 GALLONS
60 GALLONS
80 GALLONS
2" AIR PIPING
S
SV-1
S
SV-2
S
FOR ASSEMBLY DETAILS,
SEE DWG CLEAN
SWEEP-M003
1 1/2" HYDRAULIC HOSE
2" x 1 1/2"
2" BALL VALVE
AOV
DOUBLE DIAPHRAGM
AIR VALVE
CLEAN SWEEP NOZZLE
SEE DWG CLEAN SWEEP-M002
SV-3
S
SV-4
AOV
S
SEQUENCE
BOARD
CLEAN SWEEP
CONTROL PANEL:
OPTIONS:
10 POINTS
16 POINTS
24 POINTS
SEE DWG CLEAN SWEEP-E030
SV-5
S
SV-6
S
SV-7
S
SV-8
S
SV-9
AOV
AOV
CLEAN SWEEP NOZZLE ASSEMBLIES
S
SV-10
PILOT ENCLOSURE,
EXPLOSION PROOF
OR
NON-EXPLOSION PROOF
1/4" POLY TUBING,
MAXIMUM 6' LG.
BASIC CLEAN SWEEP SYSTEM
DIAGRAMFOR REFERENCE
ONLY!
COMPRESSED AIR
PILOT AIR
CONTROL WIRING
ELECTRICAL POWER
AOV
AOV
AOV
AOV
AOV
AOV

FIGURE A1

2 "
8
1/4"
1/4" TUBE STRAIGHT
PUSH ON FITTING
DOUBLE DIAPHRAGM AIR VALVE,
93885
1 1/2" CLOSE NIPPLE,
SCH. 40, GALVANIZED
CLEAN SWEEP NOZZLE
MOUNTING PLATE
3/4-10 HEX BOLT, 1" LG.,
TIGHTEN TO 50 FT-LBS
CHUTE WALL
SPRING ADJUSTMENT NUT
1/4" POLY TUBING,
CUT TO FIT IN FIELD,
MAXIMUM 6' LG.
CLEAN SWEEP NOZZLE
BODY, ADJUST STEM WITH
SPRING
ADJUSTMENT NUT AND CLAMP
INTO CLEAN SWEEP COLLAR
GOYEN 6-GANG SOLENOID ENCLOSURE,
NEMA 7/9
1
4
3" HOLE
IN CHUTE WALL
1/4" TUBE 90°
PUSH ON FITTING
1", ADJUST SPRING
TENSION TO SET
HYDRAULIC ADAPTER,
1 1/2" NPT x JIC,
90015
THIS EDGE FLUSH WITH
INSIDE CHUTE WALL WHEN
CLAMPED INTO COLLAR
HOSE COUPLING,
1 3/8" I.D. HOSE x FEMALE JIC,
90017
CLEAN SWEEP CLAMP COLLAR
1 1/2" NIPPLE x 3" LG.,
SCH. 40, GALVANIZED
HYDRAULIC HOSE, 1 3/8" I.D.,
500 PS CUT TO FIT AND ATTACH ENDS IN FIELD
91597
2" COUPLING
150#, GALVANIZED
2" x 1 1/2" REDUCER BUSHING
HOSE COUPLING,
1 3/8" I.D. HOSE x 1 1/2" MNPT,
90016
1 1/2" BRASS BALL VALVE

CLEAN SWEEP NOZZLE ASSEMBLY
DETAILS
FOR CLEAN SWEEP NOZZLE EXPLODED VIEW AND BILL OF MATERIAL, SEE DWG
CLEAN SWEEP-M002
FIGURE A2

BILL OF MATERIAL
1
/
6MI
R 8;o
I
DESCRIPTION
I
MANUFACTURER
MODEL NUMBER
OR EQUIVALENT
1
'
1 '
CLEAN SWEEP MOUNTING PLATE ,
92590 PURCH
2
1
CLEAN SWEEP CLAMP COLLAR
90629 PURCH
3
1
CLEAN SWEEP MAIN NOZZLE BODY wNALVE GUIDE
90269 PURCH
4
1
CLEAN SWEEP VALVE STEM
93346 PURCH
5
1
CLEAN SWEEP SPRING
93324 PURCH
6 1
CLEAN SWEEP SPRING GUIDE
91523 PURCH
7 1
NYLON LOCKNUT, 9/16-18
94130 PURCH
8 1
5/16"-18 SET SCREW, 1/2" LG.
95407 PURCH
9 2
SCREW SHC 3/8"-16 x 1" Long Black Oxide ASTM A574
95408 PURCH
10 4
WASHER, LOCK-SPLIT 3/4" NOM ID ZINC PLATED
94043 PURCH
11 4
SCREW, HEX HD CAP, 3/4"-10 x 1" LG, GR 5, ZINC PLATED
I 931 50 I PURCH
6
7
5
3
10
11
8
2
4
CLEAN SWEEP NOZZLE EXPLODED
VIEW
11
10
'
'
'
'
9
10
FIGURE A3