Dynaset HPW-DUST User manual

1 April 2014 JLe
HPW-DUST HIGH PRESSURE SUPPRESSION SYSTEMS
HPW-DUST
HIGH PRESSURE DUST SUPPRESSION SYSTEMS
OPERATING INSTRUCTIONS
Dynaset HPW Dust high pressure suppression system is based on HPW-pump and is specially designed to
prevent dust emissions at crushing, pulverizing, demolition or to any process of dusting materials. HPW dust high
pressure suppression system can be used effectively applications like quarries, recycling and waste management,
material handling etc.
Dynaset wide HPW pump series produce needed water pressure and flow to different dust suppression application.
High pressure water mist is spayed via dust suppression nozzles round the dust particles. The weight of the water
bounded dust particles increases multiply that makes them fall down. Low water consumption is achieved by tiny
water mist that do not irrigate machine and surroundings wet. Various applicable forms of high power jets are
available, turbo jets or dousing umbrella for area suppression, falling debris etc.
Dynaset HPW Dust high pressure Suppression system is easy to install to any machine and is fully controlled
from cabin.
The system has next benefits:
- Extremely low water consumption, no need for large reservoir.
- Microscopic water binds dust particles effectively.
- No mud forming on machinery surface.
- Good visibility, clean and better breathing air.
- Saves health care expenses.
DRAFT

2
1. SAFETY PRECAUTIONS AND WARNING STICKERS 3
2. GENERAL 4
3. HPW-DUST BOUBLE BASIC COMPONENTS 5-6
4. A HYDRAULIC ACTUATOR VALVE KIT 7-8
5. CONTROL WIRING IN DUST SUPPRESSION SYSTEM 8
5.1 Dust suppression system with dual water circuit 8-9
6. INSTALLATION TO DIFFERENT HYDRAULIC SYSTEMS 9-11
6.1 Open centre hydraulic system with variable displacement pump 10
6.1.1 Dust suppression system with a dual water circuit 10
6.1.2 Dust suppression system with a single water circuit 10
6.2 Close centre hydraulic system with variable displacement pump 11
6.2.1 Dust suppression system with a dual water circuit 11
6.2.2 Dust suppression system with a single water circuit 11
7. INSTALLING COMPONENTS 12-13
8. NOZZLE SPRAY ANGLE THEORETICAL COVERAGE 14
9. HYDRAULIC ACTUATOR VALVE INSTALLATION 14
10. OPERATION 15
11. PUMPING FLUIDS 15
12. HYDRAULIC FLUIDS 15
13. MAINTENANCE 16
14. PRODUCT DISPOSAL 16
15. MANUFACTURER’S LIMITED WARRANTY 17
16. DECLARATION OF CONFORMITY 18
17. NOTES 19
TABLE OF CONTENTS
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Operating with DYNASET HPW dust high pressure suppression system, user has to conform to all safety
regulations concerning pressurized equipment. Hydraulic circuit has a highpressure over 220 bar.
EQUIPMENT TECHNICAL CONDITION HAS TO PAID SPECIAL ATTENTION TO.
In order to avoid accidents all operators and maintenance personnel must act in compliance with the laws,
regulations and recommendations the high pressure hydraulics, electricity and work safety issued by local
authorities.
EXTERME CLEANLINESS MUST BE MAINTAINED WHEN CARRYING OUT ANY DISSASSEMBLING OR
REPAIR OF HPW UNIT AND HYDRAULIC SYSTEM. THIS IS CRUCIAL TO ENSURE SAFE, RELIABLE AND
LONG-LIFE OPERATION OF THE EQUIPMENT.
The pressure in hydraulic fluid circuit is considerably high and hydraulic system has to maintain regularly.
Especially couplings, valves and hoses have to be tight and clean as well as kept under constant observation.
Check and fix possible leakages of pressure and hot blowouts immediately avoiding user and bystander injuries.
In order to exclude possible accidents, it is not allowed to clean or inspect HPW unit when hydraulic fluid circuit
is pressurized. Prior to any cleaning, inspection and service hydraulic system of your carrier machine must be
stopped and all hydraulic fluid circuits depressurized.
Wear appropriate clothing and safety equipment such as goggles, ear and eye protection, safety shoes at all
times when operating with the HPW dust high pressure suppression system. Beware of warm oily machinery
parts.
Operators and maintenance personnel must always comply with local safety regulations and precautions in order
to close out the possibility of damages and accidents.
All installation and service hydraulic and electric equipment must be performing experienced personnel only.
Preventing freezing nozzles, water circuit and pipeline. Draining and air flushing have to perform before ambient
temperature reaches 0°C (32°F) or lower.
SAFETY PRECATIONS
WARNING STICKERS
Dynaset dispatch department includes one (1) warning sticker bag per one (1) main product.
Product recipient is obligated to fix determinate warning sticker to Dynaset product.
Attach sticker to visible and appropriate place or close to Dynaset product where it’s easily seen.
Before attaching sticker, clean surface with solvent detergent.
READ OPERATING INSTRUCTIONS. BEWARE OF HIGH PRESSURE KEEP FROM FREEZING. USE EAR PROTECTOR AND
SPLATTERS. GLOGGLES.
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GENERAL
HWP High Pressure Dust Suppression system forms microscopic water
mist which means low water consumption and low costs. Mist-like
atomized water binds even the smallest dust particles and makes them
heavier to falling down in a controlled manner. Dust suppression system
avoid soiling of surroundings, inhibits mud sagging keeping the working
area almost dry.
The compact hydraulic operated high pressure pump is easily mounted
onto the machine.
HPW pump is controlled by electric ON/OFF valve on machinery cabin.
Hydraulic valve kit controls the water pressure with pressure reducer
and the oil flow limiter. Pressure reducer and solenoid valve to
appropriate application control nozzles water flow. Pressure compensated
oil flow-limiter controls the biggest running speed of the HPW-pump.
Excavator fitted Dynaset HPW-Dust suppression system are dual power
stage type. Continuous basic dust suppression is supplement with a
high power mode, which is used as frequently as necessary to suppress
dust created during demolition by fallen debris by bulk-loaded dump on
a truck’s platform etc.
Technically dual stage power output is implemented in two different
ways:
1. In a Dual Water Circuit (DWC), both basic and high power
levels use individual high-pressure nozzle pairs. The high power
dust suppression is switched on by activating separate water
solenoid valve.
High power suppression nozzles can be the first time coarsely
pre-aimed to an assumed dust source according to task demand
and conditions. Exact aiming is done after the experiment.
2. In a Single Water Circuit (SWC), the same nozzle pair is for
both basic and high power dust suppression, using two separate
hydraulic flows – one for each power level of dust suppression.
Prior to switching on the dust suppression, operator have to aim the
attachment with dust suppression nozzles to a dust source.
Front loader’s bucket or mobile crusher’s feed hopper and conveyors
can be equipped with dust suppression-nozzle pipe(s) of a single
water circuit mode continuous mode, dust suppression system
HPW200 Dust.
Nozzles: 8 x
(1,6 lpm 120°)
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HPW-DUST HIGH PRESSURE SUPPRESSION SYSTEMS

HPW-DUST DOUBLE BASIC COMPONENTS
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DUAL WATER CIRCUIT SYSTEM (DWC) components ready for installation and for instantly use, including
following components:
HPW-PUMP 1., PRESSURE REDUCING VALVE 2.2, FLOW LIMITING VALVE 2.3 and SOLENOID VALVE 2.4.
(spraying On) In OC-hydraulic systems, HPW-pump is operated under constant hydraulic pressure. The output
water flow and eventually hydraulic flow is rated by the size of installed water nozzles.
The flow limiting valve is adjusted at factory to the throughput required by high power dust suppression.
HPW90 dust double, PC-SAE 1"-24V, D200105500
HPW90/150-85
2.3 FLOW LIMITING VALVE
ON / OFF -VALVE (CONTINUOUS)
2.4 SOLENOID VALVE (HIGH PRESSURE)
PRESSURE RELIEF VALVE
HPW200 dust double-DWC, D200105350
HPW200/30-45
PV-SAE
NOZZLES:
2 x 6504 (12 lpm 65°)
2 x 6502 (6,4 lpm 65°)
FILTER
ELEMENT
HAND SPRAY
PISTOL
- PUSH AND PULL
BUTTONS
- INDICATOR LAMP
- SOLENOID PLUGS
- CONTROL WIRING
HOSE
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HPW-DUST HIGH PRESSURE SUPPRESSION SYSTEMS
2.3 2.2
2.4
1.

HPW-DUST DOUBLE BASIC COMPONENTS
6
Following Hydraulic High Pressure Water Pumps (HPW) are widely used in Dynaset high-pressure dust
suppression systems:
- HPW 200/30-45 dust. 4 x 6,4 l/min nozzles.
- HPW 200/30-45 dust double. Double power spray 20/30 lpm.
- HPW 220/50-70 dust double. Double power spray 30/50 lpm.
- HPW 180/90-115 dust double. Double power spray 30/90 lpm.
- HPW 130/180-140 dust double. Double power spray 30/180 lpm.
HPW 200/30-45 HPW 130/180-140
H
8
0-
14
0
Dust suppression nozzles
installed to a nozzle pipe.
Water nozzle with required
fittings is suitable for both
continuous and intermittent
high power modes.
Nozzles left to right:
- No. 1- 4, 11002 (6,4 lpm 200bar 110º) for
intermittent high power mode.
- No. 5 and 6, 2 x R3/8" (51 lpm 70bar) for
continuous mode.
- No. 7 nozzle attaching clamp.
Water solenoid valve for occasional high-pressure
dust suppression with required fittings.
1. 2. 3. 4. 5. 6.
Water intake hose
with strainer and
claw coupling from
machinery’s
separate water tank.
High pressure spray pistol with 10m hose.
Filter to water intake (claw coupling) from
pressurized water supply, i.e. water from
hydrant, max. pressure 5 bar.
7.
MAIN PARTS HPW90 Dust double, PC-SAE 1"-24V oc. D200105500
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A HYDRAULIC ACTUATOR VALVE KIT
HYDRAULIC VALVE KIT for a DUAL WATER CIRCUIT SYSTEM (DWC) includes following components:
PRESSURE REDUCING VALVE 2.2, FLOW LIMITING VALVE 2.3 and SOLENOID VALVE 2.4.
In OC-hydraulic systems, HPW-pump is operated under constant hydraulic pressure. The output water flow and
eventually hydraulic flow is rated by the size of installed water nozzles.
The flow limiting valve is adjusted at factory to the throughput required by high power dust suppression.
Valve kit for Open centre hydraulic systems includes pressure compensator PV-SAE pos. 2.1. When installing
to close centre hydraulic system, concerned pressure compensator is not required.
2.2
Pressure reducer
7-210
Flow limiter R3/4 u s
Solenoid valve
2/2 NC
PC-SAE 3/4"
OC-HYDRAULICS 2.3
2.4
2.2
2.1
A
B
T
P
LS
P
LS
2.3
1
3
2
2.4
2.3
Control valve kit for single water circuit system (SWC).
Flow limiting
valve
On / Off -valve Solenoid-valve
HYDRAULIC VALVE KIT for SINGLE WATER CIRCUIT (SWC) SYSTEM provides two separate hydraulic flows,
one for both power level of dust suppression.
Pressure relief valve
HPW200 dust double-DWC, D200105350
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HPW-DUST HIGH PRESSURE SUPPRESSION SYSTEMS
P
T

8
HYDRAULIC VALVE KIT for SINGLE WATER CIRCUIT SYSTEM (SWC):
Valve kit includes an adjustable FLOW LIMITING VALVE 2.5 for continuous dust suppression, LS Valve with
FLOW LIMITER 2.6 for high power dust suppression (adjusted in factory), two SOLENOID VALVES 2.7 and 2.8
respectively and PRESSURE RELIEF VALVE 2.9.
By activating the solenoid valve 2.7, the
continuous dust suppression is being started.
Water flow is rated by setting of flow limiting valve
2.5, which can be re-adjusted within certain limits.
Hydraulic fluid flow Q1 is directed to the pressure
port of HPW-pump through above components
and fixed flow limiter 2.6.
The High power dust suppression is switched by activating the solenoid valve 2.8 when system’s operation
(primary hydraulic flow and secondary water flow) is rated tothe fixed flow limiter setting 2.6. Pressure relief
valve protects the equipment against damages.
2.8 2.9
2.6
2.5
Q2
Q1
2.7
Q1
Q2
P
LS
P
LS T
A HYDRAULIC ACTUATOR VALVE KIT
CONTROL WIRING IN DUST SUPPRESSION SYSTEM
HPW-PUMP’S ON-OFF SWICTH
+ 24 VDC
2 x 1,5 mm2
0 yellow
red 2.4
DUST SUPPRESSION SYSTEM WITH DUAL WATER CIRCUIT
HPW-pump is switched on by activating the
hydraulic solenoid valve 2.4. The switch is to
be located in a suitable place inside of the
machinery cabin.
ON-OFF SWITCH
OF BASIC DUST
SUPPRESSION
IN CABIN.
OC-HYDRAULICS
2.1
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HPW-pump is to be connected to hydraulic system of carrier machine, as well as to pumping fluid circuit.
HPW can be installed with no particular efforts to system based on either constant or variable displacement
hydraulic pump, as well as to closed hydraulic systems.
ATTENTION !
Check the ports of your HPW-pump and connect it to hydraulic and pumping fluid circuits according to their
markings !
If the hydraulic pressure line will be connected by accident to the return port and return line correspondingly to
the pressure port, it will not cause any harm to HPW-pump, however pump will not operate.
In order to reduce both pressure pulsation and return line oscillation, the flexible hose with textile fabric cord is
recommended to be used in return line to protect from damage low pressure units, such as oil cooler.
Prior to connecting HPW-pump to hydraulic circuit, compatibility of used equipment should be ensured.
Hydraulic pressure and flow rate produced by hydraulic circuit should meet values demanded by your HPW-pump.
Refer to the technical specifications.
2.7 2.8
0
2 1
24 VDC from the 10 A fuse
By activating either of hydraulic solenoid valves with
a rocker or other 3-pole switch, an operator directs
the hydraulic flow of chosen power mode to the
HPW-pump’s pressure port.
The switch can be located onto the dashboard or any
other user-friendly position. When the switch is in the
mid-position, both solenoid valves are disengaged
and HPW-pump stopped.
INSTALLATION TO DIFFERENT HYDRAULIC SYSTEMS
HIGH POWER WATER SOLENOID VALVE’S
BUSH-BOTTON SWITCH
+ 24 VDC
+ 24 VDC
0
0
2 x 1,5 mm2
1.3
High power dust suppression is switched on by activating
the water solenoid valve 1.3. Spring-loaded push-on
button is recommended to place on a boom’s control
stick.
CONTROL WIRING IN DUST SUPPRESSION SYSTEM
DUST SUPPRESSION SYSTEM WITH DUAL WATER CIRCUIT
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Nozzles for
continuous dust
suppression mode.
INSTALLATION TO DIFFERENT HYDRAULIC SYSTEMS
OPEN CENTRE HYDRAULIC SYSTEMS WITH VARIABLE DISPLACEMENT PUMP
DUST SUPPRESSION SYSTEM WITH A DUAL WATER CIRCUIT
High power dust
suppression nozzles.
Water solenoid valve
for high power dust
suppression.
Water supply from water
hydrant (Max. pressure 5 bar).
AN ALTERNATIVE:
Water reservoir,
intake hose, filter.
DUST SUPPRESSION SYSTEM WITH A SINGLE WATER CIRCUIT.
Dual mode high dust
suppression nozzles.
AN ALTERNATIVE:
Water reservoir,
intake hose, filter.
Water supply from water
hydrant (Max. pressure 5 bar).
High-pressure
spray gun.
High-pressure
spray gun.
PC-SAE
PC-SAE
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HPW-DUST HIGH PRESSURE SUPPRESSION SYSTEMS