Donaldson BOFA DustPRO 100 User manual

V2 Jan 16
DustPRO 100
USER MANUAL

Contents
01
02
Overview of your DP100 Unit (front)
Overview of your DP100 Unit (back)
1
01
Unpacking and unit placement
3
01
02
Fume capture methods
Connecting to power supply
03
Optional added features
4
01
Turning extractor on
5
01
02
Important safety notes
Safety labels
2
01
02
Cleaning the unit
Filter replacement
6
01
Consumable spares & filter disposal
7
01
DustPRO 100 specifications
8

Overview
Company branding
Main isolation
switch
Lockable castors
Filter retaining
plate
Bag filter
Door catches
01
1

Overview
Mains inlet
Air outlet/motor
cooling
Air outlet
Air inlet
02
1

Safety Instructions
Important safety notes
Concerning symbols used on the extraction unit and referred
to within this manual.
Danger
Refers to an immediately impending danger. If the danger is
not avoided, it could result in death or severe (crippling)
injury. Please consult the manual when this symbol is
displayed.
Warning
Refers to a possibly dangerous situation. If not avoided it
could result in death or severe injury. Please consult the
manual when this symbol is displayed.
Caution
Refers to a possibly harmful situation. If not avoided,
damage could be caused to the product or something in its
environment.
Important (Refer to manual)
Refers to handling tip and other particularly useful
information. This does not signify a dangerous or harmful
situation. Refer to manual when this symbol is displayed.
Electrical Safety
The DP100 has been designed to meet the safety
requirements of the Low Voltage Directive 2006/95/EC
(previously numbered 73/23/EEC)
Warning
When working with the pump/motor housing open, Live
230/115 volt mains components are accessible. Ensure that
the rules and regulations for work on live components are
always observed.
Important
To reduce the risk of fire, electric shock or injury:
1. Always isolate the system from the mains power
supply before removing the pump/motor access
panel.
2. Use only as described in this manual.
3. Connect the system to a properly grounded outlet.
Dangers to eyes, breathing and skin
Once used, the filter within the DP100 system may contain a
mixture of particulates, some of which may be sub-micron
size. When the used filters are moved it may agitate some of
this particulate, which could get into the breathing zone and
eyes of the operative. Additionally, depending on the
materials being used, the particulate may be an irritant to
the skin.
This unit should not be used on processes with sparks of
flammable materials or with explosive dusts and gases,
without implementation of additional precautions.
Caution: When changing used filters always wear a mask,
safety shoes, goggles and gloves.
BOFA Technical Service
If problems arises with your DP100 unit please contact us:
•Visit our website at www.bofa.co.uk for on-line help.
•Or contact the helpline on [phone],
Mon-Fri, 9am-5pm.
Email: [email protected].uk
Serial Number
For future reference, fill in your system details in the space
provided. The serial number is on the rating label located on
the side/rear of the unit.
Serial Number:
01
2

Safety Instructions
Warning and Information labels
The following listing details labels used on your DP100
extraction unit.
Goggles, Gloves & Mask Label
Location: Filter
Meaning: Goggles, Gloves and Masks should be worn while
handling used filters.
Do Not Cover Label
Location: Rear panel above Motor Cooling
Meaning: Do not cover any louvers or holes adjacent to the
label.
Electrical Danger
Location: Rear Panel
Meaning: Removal of panels with this label attached will
allow access to potentially live components.
Warning Label
Location: Door Panel
Meaning: Power should be isolated before the panel with
this label attached is opened/ removed.
Serial Number Label
Location: Next to mains inlet.
Meaning: This label contains a variety of information about
the extraction unit, including.
•Company name, Address & Contact number
•Extractor model
•Unit serial number
•Operating voltage range
•Maximum current load
•Operating frequency
•Year of Manufacture
•Relevant approval markings/ logos
PLEASE NOTE: If the equipment is used in a manner not
specified by the manufacturer, the protection provided by
the equipment maybe compromised.
Fire Risk Warning
In the very rare event that a burning ember or spark is
drawn into the fume extraction unit, it may be possible that
the filters will ignite.
Whilst any resultant fire would typically be retained within
the fume extraction unit, the damage to the extractor could
be significant. It is therefore essential to minimise the
possibility of this occurring by undertaking an appropriate
Risk assessment to determine:-
a). Whether additional fire protection equipment should be
installed.
b). Appropriate maintenance procedures to prevent the risk
of build-up of debris which could potentially combust.
This unit should not be used on processes where sparks
could occur, with explosive dusts and gases, or with
particulates which can be pyrophoric (can spontaneously
ignite), without implementation of additional precautions
It is essential that nozzles or other extraction/ fume capture
devices and hoses/pipework are cleaned regularly to prevent
the build-up of potentially ignitable debris
02
2

Before Installation
Packaging Removal & Unit Placement
Before installation, check the extraction unit for damage.
All packaging must be removed before the unit is connected
to the power supply.
Please read all instructions in this manual before using
this extractor.
1. Move the unit to the location where it is going to be
installed and remove the outer packaging. This unit should
be installed in a well-ventilated area.
Ensure that 500 mm space is available around any vented
panels on the extractor to ensure adequate airflow.
2. Check the bag filter is located in its correct position
before closing the door and securing the catches.
Caution
Do not block or cover the airflow and motor cooling ports on
the unit, as this severely restricts airflow and may cause
damage to the unit.
Caution
Under no circumstances should the exhaust outlet/s be
covered as this will restrict the airflow and cause
overheating.
01
3

Installation
During the machining processes which remove material,
dust is usually generated as a by-product. This dust needs to
be removed in order to prevent interference with the
performance of the machine and also to protect the health
of the operator. The Dust Pro range of units has been
developed to provide effective removal of swarf and smaller
particulates created during processes such as routing,
mechanical engraving, grinding and lathing. Dust Pro units
are compact and portable. They are of robust design, and
feature ease of use with minimal maintenance and long life.
Exposure to airborne contaminants at work, such as
inhalable and respirable dust particles, can put people’s
health at risk. Health and safety regulations require
employers to control exposure to hazardous substances in
order to prevent ill health. The use of a suitable extraction
system will enable you to conform to the Health and Safety
regulations and protect the health employees and others.
The DP100 has been designed to remove and filter fume
containing potentially hazardous particulate generated
during manufacturing processes. Such hazardous
substances are captured within a multistage filtration
system after which the cleaned air is returned to the
workplace.
Fume Capture Methods
The fume is normally captured by 1 of 3 methods.
•Flexible arm/ Nozzle
•Enclosures
•Cabinets
General Guidelines for a successful installation
•Keep duct run length to a minimum
•Avoid sharp bends / turns in the ductwork
•Avoid multiple bends / turns in the ductwork
•Use a larger diameter duct where able
•Position the capture device as close as possible to the
marking point. (if used on high speed lines, position the
capture device slightly downstream)
Flexible Arm & Nozzle Extraction (Optional Kits)
The stay put arm should be mounted as close as possible to
the marking point using the horseshoe clips. Unscrew the
push fit connector from the other side of the flexible hose.
Cut the flexible hose to suit the distance back to the
extractor connection and push onto the extractor inlet.
Purge air should be kept to a minimum, where possible, to
prevent the fume being blown away from the nozzle.
Moving products
For applications where the product to be marked is moving
past the stationary head the capture nozzle should be
positioned as close as possible to the marking area on the
side the product is moving towards.
Enclosures
The extraction hose and nozzle can be attached to the
enclosure surrounding the marking zone provided that the
extraction point is within 50-75mm of the marking point.
Cabinets
Cabinets normally have a 75mm 0r 100mm spigot for fume
extraction. For best performance use the same diameter
hose as the spigot and reduce at the extractor end if
necessary. Keep the hose run as short as possible.
01
4

Installation
Specification DP100
Dimensions: Height 540mm Depth 737mm Width 460mm
Weight: 58kg (128lbs)
Voltage: 115-230V
Frequency: 50/60Hz
Full load current: 230V:7.0A 115V: 12.0A
Power: 230V:0.8Kw 115V:0.9Kw
Capacity: 180m³h (105CFM)
Connection to Power Supply
Please follow the above specification when selecting the
power supply outlet for the extraction system, ensure the
power supply is suitable before connecting the DP50
system.
Check the Integrity of the electrical power cable, if the
supply cord is damaged the extraction unit should not be
connected to the mains. The supply cord should only be
replaced by a BOFA engineer as an electrical safety test may
be required after replacement.
The extraction unit MUST be connected to a
properly earthed outlet.
If your extraction system was ordered with any
optional extras please read section 4.03 before
the power connection is made as additional connections
may be required before power is connected to the
extractor.
Connect the power cable to an isolated electrical supply.
The mains socket should be installed near the extractor it
should be easily accessible and able to be switched On/ Off.
The cable run should be arranged so as not to create a trip
hazard.
02
4

Installation
Optional added features
The DP100 can be configured to suit customer specification.
These optional extras would be discussed, arranged and
installed prior to delivery.
(If unsure what features your DP100 is equipped with
please contact the seller with the unit serial number,
(Refer to section 2for location) who will be able to advise
what specification has been supplied.
Filter blocked/System failure signal.
With this option the extraction unit will have been fitted
with a pressure transducer to monitor the condition of the
filters and to indicate the extractor is running, this signal is
available via the green and white cores of the control cable
that exits the cabinet next to the power cable or via the D-
type connector. The signal is a “volt free” contact, i.e. a
closed circuit will exist between the green and white wires
when the filter condition is good and the unit is running. This
will change to an open circuit on filter blockage or system
failure. This feature should only be used on control voltage
circuits. The signal can be connected to the laser or
alternatively to operate a beacon, siren or warning device.
Open circuit condition of this circuit will not directly stop the
extractor motor.
Remote Stop/Start feature
Enables the extraction unit to be remotely turned On / Off
via an external signal.
This feature can be configured in 3 ways
•DC Voltage input –Range 12-24VDC
•Volt free input –Open / Closed contacts
•Override –Stop / Start feature switched off
Note: Care must be taken to ensure that the system is correctly
wired in order for the extraction unit to function correctly.
DC Voltage input
This configuration requires the Black & Red cores of the
signal cable (Refer to section 1 for location) to be connected
to a known and tested DC power supply, in order to start the
extractor.
The operating voltage for this signal is between 12 &
24VDC. Only voltages within this range should be
connected. Voltages connected outside of this range may
cause irreversible damage to the internal control PCB.
Red cable = V+
Black cable = V-
When the extractor is provided with the correct DC voltage
the motor will start and maintain the set flow rate (Refer to
section 5for how to set the flow) when the DC voltage is
removed the motor will slow down and come to a stop.
The extractor will need to be turned on (See section 5 for
turning the extractor on) in order for this feature to operate.
Volt free input
This configuration requires the Black & Red cores of the
signal cable (see section 1 for location) to be connected
together, in order to start the extractor.
When the 2 cables are connected together the motor will
start and maintain the set flow rate (see section 5for how to
set the flow)
when the 2 cables are disconnected the motor will slow
down and come to a stop.
The extractor will need to be turned on (See section 5 for
turning the extractor on) in order for this feature to operate.
Override
Enables the extractor to operate fully with or without either
DC voltage input or the Volt free input.
The override feature can be toggled On / Off by a switch
mounted on the internal motor access panel (see below for
switch location)
Switch in “On” position
In this position the extractor will require a start signal (either
Voltage input or Volt free, depending on the requested
specification) to enable the motor within the extraction unit.
Switch in “Off” position
In this position the extractor motor will run without the
requirement for an external start signal. This feature is
useful for engineers carrying out works/ tests on the
extractor without the need for the auxiliary signal being
present.
03
4

Operation
Turning extraction unit On
Press the main isolation switch to the “On” position (Refer
to section 1 for switch location) by depressing the ‘I’ side of
the switch.
01
5

Maintenance
Maintenance UK
It is a legal requirement, under regulation 9 of the COSHH
regulations that all local exhaust ventilation systems are
thoroughly examined and tested at least once every 14
months (typically carried out annually). The approved code
of practice recommends that a visual check should be
carried out at least once a week.
COSHH requires the annual inspection and testing to be
carried out by a competent person and specifies that
documentation results are recorded in a log.
Contact the seller for more information about inspection
and certification.
Maintenance General
User maintenance is limited to cleaning the unit and filter
replacement, only the manufacturers trained maintenance
technicians are authorised to carry out component testing
and replacement. Unauthorised work or the use of
unauthorised replacement filters may result in a potentially
dangerous situation and/or damage to the extractor unit
and will invalidate the manufacturer’s warranty.
Cleaning the unit
The powder coat finish can be cleaned with a damp cloth
and non-aggressive detergent, do not use an abrasive
cleaning product as this will damage the finish.
The cooling inlets and outlets should be cleaned once a year
to prevent build-up of dust and overheating of the unit.
Filter Information
A log of filter changes should be maintained by the user.
The filters require attention when the display shows the
configuration shown on the next page or when the extractor
no longer removes fume efficiently.
All filters are tested to BS3928. A certificate of conformity
for each filter is available on request.
It is recommended that a spare set of filters are kept on site
to avoid prolonged unit unavailability. Part numbers for
replacement filters can be found on the filters fitted in your
system.
To prevent overheating, units should not be run with a
blocked filter condition, or with dust obstruction of Inlets /
Outlets.
Fire Risk Warning
In the very rare event that a burning ember or spark is
drawn into the fume extraction unit, it may be possible that
the filters will ignite.
Whilst any resultant fire would typically be retained within
the fume extraction unit, the damage to the extractor could
be significant.
It is therefore essential to minimise the possibility of this
occurring by undertaking an appropriate Risk assessment to
determine:-
a). Whether additional fire protection equipment should be
installed.
b). Appropriate maintenance procedures to prevent the risk
of build-up of debris which could potentially combust.
This unit should not be used on processes where sparks
could occur, with explosive dusts and gases, or with
particulates which can be pyrophoric (can spontaneously
ignite), without implementation of additional precautions
It is essential that nozzles or other extraction/ fume capture
devices and hoses/pipework are cleaned regularly to prevent
the build-up of potentially ignitable debris
01
6

Maintenance
Filter Replacement
The DustPRO 100 uses one polyester bag filter. This should
be replaced when the extraction unit no longer removes
particulate effectively.
To remove and replace the filter, follow the instructions
below.
To remove and replace the combined filter follow the
procedure detailed below.
1. Isolate the electrical supply to the extractor
2. Undo the catches and open the front door.
3. Lift the bag filter out of the unit. Once removed it is
recommend that the used filters are bagged and
sealed.
4. Secure the new filter into position. The retaining
plate should sit in between the polyester bag and
the black plastic collar on the filter.
Close the door and fasten the catches.
Note: The filter MUST be fitted when the extractor is in
use.
Bag Filter
Retaining plate
02
6

Replacement Units
Consumable Spares
The DP100 contains a bag filter. See section 6for replacing
the filters.
To maintain performance it is important that the filters are
replaced with identical BOFA filters. To re-order please refer
to the Filter number printed on the filter installed in your
extraction unit.
Maintenance Protocol
Users can record changes in filter change intervals on the
table below.
Unit Serial Number:
Bag Filter
Date
Engineer
Filter disposal
The combined filter is manufactured from non-toxic
materials. Filters are not re-usable, cleaning used filters is
not recommended. The method of disposal of the used
filters depends on the material deposited on them.
For your guidance
Deposit
EWC
Listing*
Comment
Non
Hazardous
15 02 03
Can be disposed of as non-
hazardous waste.
Hazardous
15 02 02M
The type of hazard needs to
be identified and the
associated risks defined.
The thresholds for these
risks can then be compared
with the amount of material
in the filters to see if they
fall into the hazardous
category, if so, the filters
will need to be disposed of
in line with the
local/national regulations.
*European Waste Catalogue
01
7

System Specifications
Unit: DP 100
Capacity: 180 m³h (105 CFM)
Weight: 58kg (128lbs)
Motor: Centrifugal Fan
Output: 0.8Kw (0.9Kw)
Electrical supply: 115/230V
Hertz: 50/60Hz
Full Load Current: 230v: 7.0A 115v: 12.0A
Noise Level: Below 65db (at typical operating speed)
Size:
Metric
(mm)
Imperial
(inches)
Height
540
21.2
Depth
737
29.0
Width
460
18.1
Filters:
Filter Type
Construction
Efficiency
Bag Filter
20 Litre Polyester
Bag
F8 (95% @ 0.9
microns)
Environmental operating range:
Temperature: +5oC to + 40oC
Humidity: Max 80% RH up to 31oC
Max 50% RH at 40oC
01
8

Contact Information
BOFA Headquarters
19-20 Balena Close
Creekmoor industrial Estate
Poole
Dorset
BH17 7DU
UK
Phone: [phone]
BOFA Americas
303 S.Madison Street
Staunton
Illnois
62088
USA
Phone: [phone]
BOFA International GmbH
Sudring 62
D-21465
Wentorf bei Hambury
Germany
Phone: [phone]