Dyna-Fog CYCLONE ULTRA 2734 User manual

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DYNA-FOG
CYCLONE ULTRA
Ultra-Low Volume Sprayer
MODEL 27 4 & 27 6
OPERATION AND MAINTENANCE
MANUAL
®
TM

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INDEX
Page No
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PRINCIPLES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FLUIDS SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MAJOR COMPONENTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
GENERAL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
OUSING ORIENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FLOW RATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ELECTRICAL SC EMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ROTARY FAN REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPARE PARTS FOR T E MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
EXPLODED DIAGRAM PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PARTS LIST, METERING VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . 18
NOISE LEVEL COMPARISON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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SAFETY PRECAUTIONS
WARNING
READ AND UNDERSTAND THESE SAFETY PRECAUTIONS BEFORE
OPERATING MACHINE. FAILURE TO PROPERLY FOLLOW THESE
PRECAUTIONS MAY LEAD TO A FIRE, EXPOSION OR ELECTRIC SHOCK
HAZARD.
1. ELECTRIC POWER. This machine uses electrical power at common
commercially available voltages. When directly contacted, such voltages are
hazardous to human life. All precautions commonly applicable to the use of the
electric power general are applicable to the use of this machine. This machine is
designed to operate from three wire power systems where one of the wires is a
safety ground. Do not disconnect the safety ground or use extension cords or
“cheater” plugs to connect this machine to a two-wire system. This defeats the
purpose of the safety ground and may result in a hazardous electrical shock
condition.
When making repairs on the machine, use a work area or bench that is dry and not
electrically conductive. Dry natural wood and plastics are generally non-conductive
at the working voltages of this machine. Metals are usually conductive. Do not
probe inside the machine.
Extension cords must be properly sized and rated for the voltage, current and
length of an individual cord. Consult the nameplate current and voltage rating of
your machine and the marked rating of the extension cord. A single extension cord
only should be used. When two or more extension cord are placed in series, the
rated current carrying capacities of the cords may no longer be valid If an extension
cord gets warm to the touch, discontinue its use and obtain a cord with a higher
current rate. Improper extension cords are not only hazardous, but may result in
poor machine performance due to excessive voltage drop. Finally, since the
machine uses oil-based formulation, the extension cord should be rated as oil
resistant.
2. FORMULATIONS. Many formulations are combustible; that is, they all
can be caused to burn. This is true of even high flash point or “no” flash point
formulation (fine particle dust in a grain mill has “no” flash point). A combustible
liquid vapor can more easily be ignited because it more readily form a uniform
mixture with the air, which contains the Oxygen needed for combustion. owever,
fine particles of combustible liquids or solid suspended in the air very closely
spaced are capable of propagating flame from one to another once an ignition
starts. A good analogy is the grain mill explosion. Although the fine particle dust in a
grain mill has “no” flashpoint, the phenomena of the grain mill explosion are an all
too common occurrence.
Where a high flash point or “no” flash point liquid formulation will ignite far less
readily than a low flash point liquid and for this reason is strongly advocated. The

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higher or “no” flash point formulation can ignite if the proper conditions exist. These
conditions are basically two: 1. A sufficiently volume of liquid in the form of fine
particles suspended in the air; and 2. A sufficiently high-energy source of ignition.
3. AEROSOL CONCENTRATION. It has been fully established that an
acceptable level of liquid in the atmosphere is one gallon per 50,000 cubic feet (2.7
Liter per 1,000 cubic meters). There is a safety margin of at least 5 to 1 in this
figure. To avoid danger of fire or explosion in a closed space, the enclosed volume,
spray time and required formulation volume must be carefully calculated.
4. AEROSOL IGNITION. If a combustible atmosphere is established or a
combustible deposit is laid down, a source of ignition may cause a fire. Sources of
ignition can be gas or oil pilot lights or sparks from electrical controls. Therefore, it
is strongly recommended that all such sources be eliminated by extinguishing all
pilot lights and turning off all unnecessary electric power. To avoid danger of fire or
explosion in an enclosed space, the enclosed volume fogging time and required
formulation volume should be carefully calculated.
PROPER AND IMPROPER USE.
The following rules apply to the operation of this machine:
Read the entire manual before operating the machine and pay particular attention
to all CAUTIONS and WARNINGS.
Store formulation in its original labeled container.
Use an extension cord which is properly rated for voltage, current and length and
which is free from nicks, cracks and other signs of prior abuse. For lengths up to
100 feet (30.5 meters) cord No. 12AWG wire are usually adequate.
Replace damaged or worn electric cord immediately.
Turn the flow valve CLOCKWISE to the OFF position after each spray application
while the motor is still operating to allow clearing of the lines. This will also prevent
a siphon effect if the unit is ever accidentally knocked over with the valve remaining
open.
Always comply with any requirements for protective clothing, goggles, gloves, facial
masks or respirator required by the formulation label.
DO

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Ensure that formulation is applied only in strict compliance with the formulation label
as well as local State and Federal regulations.
Do not Spray flammable liquids near open flame or other source of ignition.
Do not Use a machine that is broken or damaged in any way.
Do not Alter the machine by adding or removing parts.
Do not Restrict the motor blower inlet area.
Do not Tamper with the output nozzle.
Do not Allow the machine to operate unattended.
Do not Apply more than one gallon of formulation per 50,000 cubic feet (2.7 Liters
per 1,000 cubic meters) enclosed space. Exceeding this concentration is both
hazardous and wasteful.
DO NOT
WARNING
The US Occupational Safety and Health Administration
(OSHA) recommends that hearing protection be used when
noise levels exceed 85 decibals (dba). See noise level chart
on page 19 of this manual.

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SPECIFICATIONS
The Cyclone™ Ultra machine is an electric “Cold Fog” ULV that utilizes a rugged
anodized aluminum nozzle and a high performance blower.
This device is intended for applications of both Oil Based (following necessary
precautions) and Water Based chemical treatments.
The body and tank are made of high-density chemical resistant polyethylene. The
applicator is useful for dispensing most chemicals which are labeled for aerosol or
mist applications such a disinfectants, deodorizers, germicides, insecticides, etc., in
locations such hospitals, schools, nursing homes, greenhouses, stables,
warehouses, homes, and farm buildings. The particle sizes generated range from 7
to 30 microns VMD, obtained using water. Machine output and particle size are
dependent upon the viscosity of the liquid being dispensed.
Cyclone™ Ultra model 2734, 110-130 VAC
Cyclone™
Ultra model 2736, 210-250 VAC
This machine is one of the world’s finest hand held ULV/Mist generator built to
precision standards. With reasonable care and maintenance, this efficient
equipment will provide many hours of service. For best result, this ULV generator
must be operated and maintained in compliance with these instructions.
MOTORIZED BLOWER:
MODEL 2734 MODEL 2736
Continuous Duty
110-130 VOLTS AC
6.85 AMPS
50/60 Z
20,000 RPM
107 CFM (6.42 m
3
/min) Max
Continuous Duty
210-250 VOLTS AC
3.4 AMPS
50/60 Z
22,000 RPM
109 CFM (6.54 m
3
/min) Max

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PRINCIPLES OF OPERATION
The machine consists of a motor/blower assembly, blower housing, a nozzle,
formulation tank, tank neck filter, metering valve, check valve and shutoff valve
(solenoid or manual, depending of the model). The various components are identified in
the fluid systems diagram and major components diagram.
The blower is a two-stage centrifugal compressor driven by a universal motor operating
at a speed of 20,000 rpm. The blower moves a large amount of air through the nozzle
system. The flexible hose is located between the nozzle and the blower housing to allow
easy orientation of the nozzle to direct the spray into hard to reach areas. The nozzle
has six (6) stationary fins, which direct the air to create a swirling effect of the air mass
as it leaves the nozzle. In the center of this exiting swirling air, a liquid supply spout tube
injects formulation. The formulation is sheared into tiny aerosol droplets and dispersed
into the atmosphere.
The liquid is delivered to the liquid spout by a combination of positive and negative
pressures. A negative pressure is generated in the nozzle by the exiting air mass and a
positive pressure is generated inside the blower housing and sampled to pressurize the
formulation tank. The positive pressure minimizes the effect of the variation of the flow
rate due to the difference in the static head of the liquid when the nozzle is at higher or
lower position.
The rate of flow is controlled by a metering valve located at the left side of the tank.
Generally, the sizes of the output droplets increase with increasing flow rates and with
increasing viscosity of the liquid being dispensed.
The check valve allows the airflow from the blower housing to the tank, and avoid any
return of pressurized air/vapor or liquid to the blower housing.
The vented tank cap in combination with the air coming from the blower housing, allow
a medium positive pressure inside the formulation tank when the machine is in
operation, and equalize the tank pressure to the atmospheric pressure in relatively short
period of time, when the machine is turn off.

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FLUID SYSTEM DIAGRAM
Cyclone™ Ultra

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MAJOR COMPONENTS DIAGRAM
Cyclone™ Ultra

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GENERAL DIMENSIONS

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CYCLONE™ FLOW RATE AND DROPLET SIZE (VOLUME MEDIAN DIAMETER)
Valve
Positionin
g
2 Seconds
Formulatio
n
Droplet Size
Microns
40 Seconds
Formulation
Droplet
Size
Microns
50 Seconds
Formulatio
n
Droplet Size
Microns
LOW (*)
40 ML/MIN
1.4 OZ/MIN
8 VMD 37 ML/MIN 15 VMD 12 ML/MIN
0.4 OZ/MIN
20 VMD
MED (*)
83 ML/MIN
2.8 OZ/MIN
10 VMD 80 ML/MIN
2.7 OZ/MIN
18 VMD 48 ML/MIN
1.6 OZ/MIN
22 VMD
MAX (*)
93 ML/MIN
3.1 OZ/MIN
11 VMD 92 ML/MIN
3 OZ/MIN
20 VMD 60 ML/MIN
2 OZ/MIN
24 VMD
CAUTION: Read and follow the instructions on the formulation
manufacturer s label and in the operation manual.

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MAINTENANCE
1. Periodically clean the formulation tank using a hot water/detergent solution. Fully
open the machine valve and operate the machine for 3 to 5 minutes, flushing the
solution through the valve, lines and nozzle.
2. Examine the electrical cord for evidence of damage and replace any damaged cord
immediately.
3. After 400-500 hours of operation, carefully remove the blower assembly and
examine the brushes and the commutator bars of the blower motor. If brushes are
worn out, replace them. If commutator bars are damaged, replace Blower
Assembly.
4. If it becomes necessary to disassemble the Machine Flow Valve for cleaning, be
careful not to enlarge the metering orifice or damage the taper of the valve steam,
as this will affect the calibration of the machine.
5. Clean the Air Intake Filter after every application. If the filter gets saturated (wet and
dripping) while the machine is working, stop the machine and clean the filter.
Note: If it b com s n c ssary to op rat th machin in ar as wh r th air b com
saturat d with spray dropl ts and th s dropl ts accumulat at th blow r intak filt r,
th machin can b outfitt d with an optional “Fr sh Air Intak Hos ” P/N 62060.
To repair the blower/motor components and request spare parts, please see section
“”Rotary Fan Replacement”.

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ELECTRICAL SCHEMATICS

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ROTARY FAN REPLACEMENT
CAUTION:
Th Blow r of your machin rotat s at a high sp d (approximat ly 20,000 RPM). Th
r plac m nt of th Rotary Fan, if r quir d, should b p rform d by a c rtifi d Dyna-Fog
r pr s ntativ .
If the machine has been working in a closed room, the intake air filter gets saturated,
and liquid (chemical) is introduced to the blower. The first contact point is the center
section of the rotary fan, which could be attacked for the chemical. Then the debilitated
wall of the fan fails. As result of the broken fan, the motor increases the speed, the
airflow and the mist stops. The machine has to be shut off immediately.
The deterioration process of the fan material is accelerated if the machine is operated
without air intake filter, or if disinfectant is applied in a closed room. The Fresh Air Intake
hose P/N 62060 is recommended for those kinds of applications.
When the machine is disconnected from the power supply, remove the rear cover and
pull the motor out the plastic housing. Some cables will keep the motor close to the
housing.
TO DISASSEMBLE T E BLOWER:
1) To remove the metal end shell, add some pieces of industrial strength tape and use a
screwdriver and hammer to lightly tap as indicated in above diagram. Gently tap the
edges gradually working around the entire diameter.
2) After removing the end shell, use a 1/8” Allen Wrench and a ½” open end wrench to
loosen and remove the nut. Remove the circular section of the remaining material from
the broken fan.
3) Remove tape and proceed to remove the stationary fan by using the screwdriver and
hammer. Remove the long spacer and the rotary fan of the second stage (item 1).

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4) Add the new fans positioning them as shown in below diagram, place the big washer
with the smooth outside edge against the fan material, tighten out the nut to a torque of
20 to 25 Lb-Inch, and reinstall the end shell. A thread lock product like Loctite ref. 222
(purple) is recommended prior to reinstalling the nut onto the shaft thread.
SPARE PARTS FOR THE MOTOR
ITEM
QTY
P/N
DESCRIPTION
VOLTAGE
1 1 39651-5 Rotary Fan, 4.93” O.D. 110/130 VAC
BLOWER (120 VAC)
SERVICE KIT
P/N 6 5 4
2 1 39651-5 Rotary Fan, 4.93” O.D. 110/130 VAC
3 1 39651-13 Flat Washer ANY
4 1 39651-11 Nut ANY
5 2 62309-2 Brush Mechanism 110/130 VAC
1 1 39592 Rotary Fan, 4.18” O.D. 210/250 VAC
BLOWER (120 VAC)
SERVICE KIT
P/N 6 5 4
2 1 39591 Rotary Fan, 4.72” O.D. 210/250 VAC
3 1 39651-13 Flat Washer ANY
4 1 39655-11 Nut ANY
5 2 62340-2 Brush Mechanism
210/250 VAC

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CYCLONE™ ULTRA EXPLODED DIAGRAM

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CYCLONE™ ULTRA EXPLODED PARTS LIST
ITEM
QTY P/N DESCRIPTION
1 1 62130-10 TANK, 1 GAL
2 1 62135-2 CAP AY, TANK BLK
3 1 62131-2 CLEVIS, BLOWER
4 1 45933-1 STRAIN CONNECTOR
5 1 62031-2 POWER CORD AY, 120 AY
6 1 62313 NOZZLE ASSEMBLY
7 1 80296-11 CLAMP
8 2 62343-1 EYELET, BRASS
9 2 62163 SCREW, 8-32 X 3/8, TAP
10 1 62325 INDICATOR PLATE
11 1 62316 XMAS TREE CLIP
12 1 62310 ANDLE SUPPORT
13 1 59962 GRIP
14 1 62301-54 OUSING AY
15 1 62312 TOGGLE SWITC AY
16 1 10000-13 O’RING
17 1 62309 BLOWER (115 V)
1 62340 BLOWER (230 V)
18 1 62002-1 OUSING CLOSURE
19 1 62160 SCREW, 10-16 x 1.25 S W
20 5 62161 SCREW, 10-16 x .75 T R
21 2 62309-2 MOTOR BRUS (115 V)
2 62340-1 MOTOR BRUS (230 V)
22 1 62366 GASKET, FOAM, DIE CUT
23 1 62083 WAS ER, FRICTION
24 1 62118 LOCK ANDLE, & WAS ER
25 1 62124 AIR FILTER
26 1 64956 KNOB AY., FORMULATION VLV.
27 1 39090 RETAINER, SQUARE WAS ER
28 1 62134-1 VALVE INDICATOR, METERING
29 1 62195 VALVE AY., BRASS (WIT FILTER)
30 1 62329 INJECTION TUBE AY.
31 1 10247-31-1 ORIFICE, .031 DIA.
32 1 63409 LABEL, MADE IN USA
33 1 62029-1 LABEL, CAUTION
34 1 62253 LABEL, FLOW
35 1 62151-3 LABEL, ID, CYCLONE ULTRA, 115V.
1 62151-4 LABEL, ID, CYLCONE ULTRA, 120V.
36 1 62251 LABEL, CYCLON ULTRA LOGO

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ITEM
QTY
PART NUMBER
ITEM DESCRIPTION
1 1 64956 KNOB ASSEMBLY
2 1 39090 RETAINER, SQUARE WAS ER
3 1 62134-1 VALVE INDICATOR, METERING
4 1 62195 VALVE AY., BRASS (WIT FILTER)
ITEM
QTY.
PART NUMBER
DESCRIPTION
1 1 32692-1 NUT, PACKING, BRASS
2 1 32690 WAS ER, PACKING
3 1 32691 WAS ER, BRASS
4 1 62319-1 STEM, VALVE
5 1 62180 VALVE BODY/BARB AY.
6 1 10100-110 O-RING
7 1 62227-1 TUBE, BLUE, 3/16 ID. X 5.16 OD.
8 1 80408 FILTER, LONG TAPER, 130 MICRONS
VALVE ASSEMBLY, BRASS
(P/N: 62195)
VALVE ASSEMBLY,
SPARE PARTS KIT
(P/N: 62185)

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NOISE LEVEL COMPARISON CHART
The Cyclone Ultra hand held electric aerosol applicator is a relatively quite machine, as
shown in above comparison.

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REV. 10-09
Rev. 11-4-2013