ENVIROSYSTEMS AIRWALL MD Manual

AIRWALL® DUST COLLECTION SYSTEM
INSTALLATION, OPERATION, MAINTENANCE
AND REPLACEMENT PARTS MANUAL
PUBLICATION NO. UM-AW-0211
Copyrig t 2011
ENVIROSYSTEMS, LLC
2555 N Coyote Dr. Suite 118
Tucson, AZ 85745
[phone]
[phone]
SM

Copyrig t 2011 by Envirosystems Manufacturing, LLC
All rig ts reserved, including those of translation. No part of this publication may be
reproduced, stored in a retrieval system or transmitted in any form or by any means,
electronic, mechanical, photocopying, recording or otherwise, without the prior written
permission of Envirosystems Manufacturing, LLC, 2 N. Coyote Dr., Suite 118,
Tucson, Arizona 8 74 .
TRADEMARK ACKNOWLEDGMENTS
Envirosystems Manufacturing, LLC acknowledges the following companies and their
trademarks that are used in this manual. Since the trademark information was derived
from several sources, we cannot guarantee their accuracy.
Photohelic is a registered trademark of Dwyer Instruments, Inc.
AirWall and Envirosystems are registered trademarks of Envirosystems Manufacturing,
LLC..
Information in this manual is subject to change without notice.
IMPORTANT NOTICE
T is proprietary user's manual was prepared by Envirosystems
Manufacturing, LLC (ES) for t e exclusive use by its customers. T e
recommendations contained erein are based on proven tec niques
and also on test data believed to be reliable. It is intended t at t is
manual be used by personnel aving specialized training in
accordance wit currently accepted practice and normal operating
conditions. Variations in environment, c anges in operating
procedures or extrapolation of data may cause unsatisfactory
results. Since ES as no control over t e conditions of service, it
expressly disclaims responsibility for t e results obtained or for any
consequential or incidental damages of any kind incurred.

TABLE OF CONTENTS
TRADEMARK ACKNOWLEDGEMENTS . . . . . i
TABLES OF CONTENTS. . . . . . . . ii
LIST OF ILLUSTRATIONS/TABLES . . . . . . iii
SAFETY SUMMARY . . . . . . . . S-1
SAFETY PRECAUTIONS . . . . . . . S-1
GENERAL SAFETY INSTRUCTIONS AND CONSIDERATIONS . S-1
PERSONAL SAFETY . . . . . . . S-1
WORK AREA SAFETY . . . . . . . S-3
LIFTING AND CARRYING SAFETY . . . . . S-3
SETUP AND OPERATION SAFETY . . . . . S-4
MAINTENANCE SAFETY . . . . . . . S-
DESCRIPTION AND SPECIFICATIONS
INTRODUCTION . . . . . . . . D-1
SYSTEM DESCRIPTION . . . . . . . D-1
FILTER CLEANING . . . . . . . . D-2
AIRWALL PRODUCT SPECIFICATIONS . . . . D-
INSTALLATION
GENERAL INFORMATION . . . . . . I-1
UNCRATING AND INSPECTION . . . . . . I-1
POSITIONING FOR ASSEMBLY . . . . . . I-1
ELECTRICAL CONNECTIONS . . . . . . I-3
FILTER CLEANING SYSTEMS . . . . . . I-3
Integrated Control Panel . . . . . I-4
PNEUMATIC CONTROL CONNECTIONS . . . . I-
COMPRESSED AIR CONNECTION . . . . . I-
INSTALLING FILTER CARTRIDGES . . . . . I-6
INITIAL START UP PROCEDURE . . . . . I-7
Checking Fan Rotation . . . . . . I-7
Adjusting Photohelic Gage And Switch,
On-Demand Cleaning Option . . . . . I-8
CCB Installation (IF APPLICABLE)
GENERAL INFORMATION . . . . . . 2-1
ASSEMBLING THE CCB . . . . . . 2-1
ASSEMBLING THE AIRWALL UNIT . . . . . 2-4

ELECTRICAL CONNECTIONS . . . . . . 2-
TIMER CONTROL BOARD . . . . . . 2-7
COMPRESSED AIR CONNECTION . . . . . 2-9
INSTALLING LIGHTING FIXTURES . . . . . 2-11
SEALING CCB BEAMS AND SUPPORTS . . . . 2-12
ELECTRICAL SCHEMATIC . . . . . . 2-13
OPERATION
OPERATION PROCEDURE . . . . . . O-1
FILTER CLEANING OPERATION. . . . . O-1
INTEGRATED CONTROL PANEL . . . . . O-2
DUST COLLECTION DRAWERS . . . . . . O-3
MOISTURE ACCUMULATION . . . . . . O-4
CHANGING FILTER CARTRIDGES . . . . . O-4
DUST COLLECTION DRAWERS . . . . . . O-4
FAN MOTOR LUBRICATION . . . . . . O-
TROUBLESHOOTING . . . . . . . O-
REPLACEMENT PARTS
ORDERING REPLACEMENT PARTS . . . . . R-1
REPLACEMENT PARTS LISTING . . . . . R-1
AIRWALL 60 THROUGH AIRWALL 100 MD’S. . . R-1
AIRWALL 100 THROUGH AIRWALL 160 HD’S. . R-2
LIST OF DRAWINGS INCLUDED WITH MANUAL
AirWall Model MD
AirWall Model HD
PULSE SYSTEM WIRING DCT (D Size)

SAFETY PRECAUTIONS
These safety precautions have been prepared to assist the operator in practicing good
shop safety procedures.
These safety precautions are to be used as a guide and supplement to all other safety
precautions and warnings in:
a. all other manuals pertaining to machines, controls and auxiliary
equipment.
b. local, plant and shop safety rules and codes.
c. federal and state safety laws and regulations.
See the latest edition of the OCCUPATIONAL SAFETY AND HEALTH STANDARDS,
available from the DEPARTMENT OF LABOR, WASHINGTON, D.C.
__________________________________________________________
WARNING
Read all t e Safety Precautions in t is c apter before operating t e
equipment. Failure to follow t is precaution may result in severe
bodily injury.
__________________________________________________________
GENERAL SAFETY INSTRUCTIONS AND CONSIDERATIONS
Machine owners and operating personnel must be aware that constant, day-to-day
safety practices are a vital part of their job. Accident prevention must be one of the
principal objectives of the job regardless of what activity is involved.
Know and respect your machinery. Read and practice the prescribed safety and
checking procedures. Make sure that everyone who works for, with or near you fully
understands, and, more importantly, complies with the following safety precautions and
procedures.
PERSONAL SAFETY
Avoid sudden movement, loud noises and horse-play. Distractions may result in unsafe
conditions for those working near equipment. Equipment can and will cause
extensive damage and/or injury if the practice of horse-play is not totally prohibited.

Observe and follow safety instructions such as NO SMOKING, HIGH VOLTAGE and
DANGER in your working area.
Accidents can occur that result in serious injury to you or others due to clothing and
other articles becoming entangled or in contact with revolving parts, levers and
electrical equipment.
a. Do not wear neckties, scarves or loose-fitting clothing.
b. Do not wear jewelry such as bracelets, watches, rings or necklaces.
Use safety protective equipment. An OSHA-NIOSH approved respirator must be worn
at all times while blasting, changing filter cartridges, emptying dust collection drawers,
and when handling media that contains free levels of silica and toxic material that are in
excess of those allowed by applicable OSHA, USEPA, ACGIH or NIOSH regulations
and recommendations. Wear clean, approved eye or face protection. Keep your
protective equipment in good condition. Wear sturdy safety-toe shoes with slip-proof
soles.
The following chart lists the permissible noise level exposures for hourly duration.
Permissible Noise Exposures
Duration per Sound Level dBa
Day, Hour Slow response A Scale
8 90
6 92
4 9
3 97
2 100
1 10
1/2 110
1/4 or less 11
Make sure the hearing protection is in good working order and replace as necessary.
Wear hearing protection whenever you are in a noisy environment, such as a media
blasting area, and when equipment is in operation. Noise from a blasting operation can
exceed 120 dBa. See WARNING next page.
__________________________________________________________

WARNING
Wear earing protection w enever you are in a noisy environment,
suc as a blasting area, and w en equipment is operating. Failure to
follow t is precaution may result in severe bodily injury.
__________________________________________________________
WORK AREA SAFETY
Keep your work area clean. Dirty work areas with such hazards as oil, debris or water
on the floor may cause someone to fall to the floor, into the machine or onto other
objects, resulting in severe bodily injury.
Make sure your work area is free of hazardous obstructions and be aware of protruding
equipment components.
Return tools and similar equipment to their proper storage place immediately after use.
Keep work benches neat, orderly and clean.
Report unsafe working conditions to your supervisor or safety department. Worn or
broken flooring, ladders and handrails, unstable or slippery platforms or scaffolds must
be repaired before use. Do not use skids, stock, media drums or boxes as makeshift
climbing aides.
LIFTING AND CARRYING SAFETY
Contact supervision if you have any questions or are not sure about the proper
procedures for lifting and carrying.
Before lifting or carrying an object, determine the weight and size by referring to such
things as tags, shipping data, labels and marked information or manuals.
Use power hoists or other mechanical lifting and carrying equipment for heavy, bulky or
hard-to-handle objects. Use hookup methods recommended by your safety department.
Know and use the signals for safely directing a crane operator. See WARNING next
page.
If in doubt as to the size or type of lifting equipment, method or procedure for lifting,
contact Envirosystems Manufacturing, LLC before proceeding to lift the equipment or its
components.

___________________________________________________________
WARNING
Never place any part of your body under a suspended load or move a
suspended load over any part of anot er person's body. Before
lifting, be certain t at you ave a safe location for depositing t e
load. Never work on a component w ile it is anging from a crane or
ot er lifting mec anism. Failure to follow t is precaution may result
in severe bodily injury or deat .
___________________________________________________________
Always inspect slings, chains, hoists and other lifting devices prior to use. Do not use
lifting devices, which are defective or questionable. Never use lifting devices, which
have been painted as the paint, can hide stress or fatigue cracks.
Never exceed the safety rated capacity of cranes, eyebolts, hoists, slings or other lifting
equipment. Follow standards and instructions applicable to any lifting equipment used.
SETUP AND OPERATION SAFETY
Do not set up or operate any machine until you read and understand all safety
instructions.
Assign only qualified, fully trained personnel, instructed in safety and all machine
functions, to operate any equipment.
Operators must carefully read, understand and fully comply with all machine-mounted
warning and instruction plates. Do not paint over, alter or deface these plates. Replace
all plates, which become illegible
Do not operate machinery with safety guards, shields, barriers, covers or other
protective devices disconnected, removed or out of place. Interlocks are provided for
various units. Do not remove or bypass them.
Never lean on a machine or reach over or through a machine. You may become caught
between moving elements or you may accidentally activate start buttons or
similar devices.
Be attentive during operation. Excessive vibration, unusual sounds, etc. can indicate
problems requiring your immediate attention.
System power must be off if the equipment is left unattended. Shut off power to a
machine when you leave the operating area or at the end of your work period. Never
leave the machine running unattended. Make sure system power is off before cleaning

any machinery.
Working space around electrical equipment must be clear of obstructions. Provide
adequate illumination to allow for proper operation.
MAINTENANCE SAFETY
Do not perform maintenance on this machine until you read and understand all the
safety instructions. Assign only qualified service or maintenance personnel to perform
maintenance and repair work on this machine. Consult the maintenance sections in this
manual before starting any service or repair work. When in doubt, contact
Envirosystems Manufacturing, LLC, Tucson, Arizona.
Before removing or opening any electrical enclosure, cover, plate, or door, make sure
the main disconnect switch is in the OFF position. Post a sign at the disconnect switch
indicating that maintenance work is being performed. Working space around electrical
equipment must be clear of obstructions. Provide adequate lighting to allow for proper
operation and maintenance.
Before working on electrical circuits, turn the main disconnect switch OFF and lock it.
When removing electrical equipment, place numbered or labeled tags on those wires
not marked. If wiring is replaced, make sure it is of the same type, length, and size and
has the same load carrying capacity. An electrical technician must analyze the electrical
system to determine the possible use of power retaining devices such as capacitors.
Such power retaining devices must be disconnected, discharged, or made safe before
maintenance is performed.
Unless expressly stated in applicable Envirosystems Manufacturing, LLC
documentation or by an Envirosystems Manufacturing, LLC representative, do NOT
work with electrical power "ON". If such statement or advice exists, working with
electrical power "ON" should be performed by an Envirosystems Manufacturing, LLC
representative. The user must determine that any other person performing work with
electrical power "ON" is trained and technically qualified. See DANGER: HIGH
VOLTAGE next page.
__________________________________________________________
DANGER: HIGH VOLTAGE
Before working on any electrical circuits, turn t e mac ine main
disconnect switc "OFF" and lock it.
Unless expressly stated in applicable Envirosystems Manufacturing,
LLC documentation or by an Envirosystems Manufacturing, LLC
representative, do NOT work wit electrical power "ON".

If suc statement or advice exists, working wit electrical power
"ON" s ould be performed by an Envirosystems Manufacturing, LLC
representative. T e user must determine t at any ot er person
performing work wit electrical power "ON" is trained and
tec nically qualified.
Failure to follow t is precaution may result in severe bodily injury or
deat .
__________________________________________________________

INTRODUCTION
The AirWall dust scrubber is a stand-alone unit that may be installed in an existing
location or as part of a new piece of equipment. Capacities range from 10,000 to
30,000 cfm per unit for standard modules. Custom configurations can provide filtration
capacities over 100,000 CFM. Standard Specifications are listed at the end of this
chapter.
Because of the cfm capacity range, the AirWall Scrubber units can be configured to
meet required linear air flows for practically any equipment or space ventilating
requirement
SYSTEM DESCRIPTION
The AirWall Scrubber is designed with large inlet and outlet plenums, resulting in low
static pressure requirements. This allows the use of relatively low horsepower motors
and low decibel level blowers. This results in cost efficient ventilation of large, dusty
environments found in tunneling and mining operations. Incoming air passes through
the protective baffles on the front inlet where large or heavy particles are stopped to
prevent filter damage. The dust-laden air then passes through the filter medium from
the outside to the inside of the filter cartridges and out the open top of each cartridge.
This leaves the dust on the out-side surface of the cartridges. The filtered air then flows
from the cartridges into the clean-air plenum above the filter cartridges where it is pulled
out of the unit to the fan.
Options for the AirWall dust collection unit include:
1. Time delayed cleaning feature to provide automatic reverse pulsejet
cleaning of filter cartridges during non-working hours.
2. Integrated control panel including disconnect, motor starter(s), control
transformer, Photohelic gage and switch, and indicator lights. Up to four
(4) AirWall Scrubbers may be controlled from the central control panel.
3. Hoppers for use with screw or a pneumatic conveying duct to transfer dust
to a central collection point.
4. HEPA (High Efficiency Particulate Air) filter package.
Each AirWall Scrubber can provide filtration for a variety of dust or other airborne
contaminates, removing sub-micron particles at a high efficiency rate. This allows the
exhaust air to be redirected back into the workplace for exhausting though the standard
ventilation system without contamination of surrounding areas.

FILTER CLEANING
Filter cleaning is accomplished by actuating a short burst of air that blows back-ward
from the clean side of the cartridge. This dislodges the caked dust that then drops into
collection drawers or optional dust collection hoppers. Each pulse cleans two to six filter
cartridges, depending on scrubber type, leaving the remaining cartridges available to
continue filtering the ventilation air. This allows the cleaning to take place without the
need to stop the air ventilation system.
Descriptions of certain main filter cartridge cleaning system components are as follows:
1. Pulses of compressed air automatically clean the cartridges by reverse
pressurization. A preset solid state timer with digital display, controlling
both frequency and duration of the pulses, controls cleaning. A pressure
transducer monitors differential pressure across the filter section. When
the pressure differential reaches a pre-set value, the reverse pulse system
will automatically dislodge dust from the cartridges using compressed air
stored in an integral header tank inside the clean air plenum. Since the
header tank is protected from uv and moisture the service life of the
reverse components is several time longer than competitors units where
the header tank is mounted externally.
2. Timer Control Board. This solid state device controls the cleaning cycle of
the filter cartridges. When the pre set pressure differential setting has
been reached, an output signals the timer control board to start the
cleaning cycle. The timer control board then initiates a series of timed
pulses, cleaning a single row of filter cartridges with each pulse. This
sequence starts left-to-right (facing the air inlet). The length of each pulse
is adjustable from .0 to . second with the normal pulse time being 0.3
second.
A time delay between each pulse allows the air accumulator tank to
recharge for the next pulse. This delay is adjustable between 8 and 180
seconds with the normal delay for the standard system being 8 seconds.
During the cleaning cycle, the controller will pulse each set or filter
cartridges in turn until the pressure differential drops below the LOW set
point. When the LOW set point is reached, the cleaning cycle stops until
the HIGH set point is again reached.
The timer control board’s memory feature remembers which filter cartridge
set was the last one cleaned. The next cleaning cycle will start with the
next filter element in line. This feature ensures that all filter cartridges
receive the same cleaning regardless of their position in the cycle.

A optional manual on/off switch is also available and, when installed,
allows the pulse system to be activated at any time, whether or not the fan
is running. This allows periodic deep cleaning of the filter cartridges and
will extend filter life. This option should be monitored when used to
prevent accumulated dust being forced backward down the dirty air inlet
and out into the workspace.
3.
Air Pressure Accumulator Tank. An air pressure accumulator tank is pro
this tank. The entire capacity is released in one (1) pulse each time one of
the diaphragm valves is opened. Some Scrubber models will have more
than one accumulator tank.
4.
Solenoid Valves. There are three (3) or five ( ) solenoid
releases a small amount of pressure, allowing a control diaphragm to
depressurize and open a 1 in. diameter valve. Each pilot solenoid is
energized in turn by the timer control board.
. Diaphragm Valves. There are three (3) or five ( ) pilot-operated dia-
phragm valves in each AirWall Scrubber. When the pilot solenoid releases
the diaphragm pressure holding the valve closed, the valve snaps open,
immediately releasing the contents of the air accumulator tank through the
opening in the valve and into a pulsejet blow pipe.
6. Pulsejet Blow Pipe. Each pulsejet blowpipe, located in the upper AirWall
frame, contains two (2) or three (3) orifices, depending on scrubber type.
These orifices are positioned above, and directed into, the opening of the
filter cartridge through the tube sheet. As the pulse of air reaches the filter
cartridge opening it travels down the entire length of the inside of the filter
cartridge, dislodging the dust from the filter cartridge.

AIRWALL SPECIFICATIONS
Model AWC 2S
Unit Dimensions
Height (Excludes Blower Height)
Inch 66
(mm) (1676)
Width
Inch 7
(mm) (1448)
Length
Inch 208
(mm) ( 283)

Filter cartridges (Standard) Spunbond 80/20
No. 20 20
Total Filter Area
Sq. Ft. 2400 6000
Air Requirements
Pulse Air Supply: 3.0 CFM @ 90 – 100 psi (6,2 – 6,9 bars)
Electrical Requirements
Pulse System: 2A@ 120 VAC, 1-Phase, 60 Hz

GENERAL INFORMATION
The AirWall dust collection unit will arrive disassembled for shipment and must be
reassembled by the customer or his agent. Unit assembly, with the exception of the
electrical and air connections, can usually be accomplished by anyone with a basic
understanding of common hand tools.
Besides a common set of hand tools, a forklift or chain-fall will be required to position
the fan and motor on top of the AirWall unit clean-air plenum.
NOTE: Envirosystems Manufacturing, LLC (ES) must rely on t e skill
and expertise of its customers and t e customer’s installation
contractor to ensure t at all electrical connections are made
correctly and air connections and regulation devices are installed
and operating properly.
UNCRATING AND INSPECTION
The AirWall unit and related components are shipped on separate skids and some of these
components may be drop shipped directly from an approved ES vendor to shorten
delivery time.
NOTE: Use extreme care w en andling t e unit and components.
Careless andling can damage delicate parts or affect alignments.
Compare the number of items received against the carrier’s Bill of lading. Inspect all
items for apparent damage. Immediately report any shortages or obvious damage to
the carrier and to ES.
NOTE: Do not return any damaged components wit out first
contacting ES.
POSITIONING FOR ASSEMBLY
1. Position the AirWall unit filter section where it will be permanently located.
2. Check all setscrews and bolts on the exhaust fan/motor assembly to make
sure they have not loosened in transit. If necessary, retighten the
setscrews and bolts.
3. Rotate the fan impeller by hand to make sure it has not shifted in transit or
been damaged during shipment.
4. Open the access door, located in the clean-air plenum, above the inlet
baffles on the front of the AirWall unit.

. Apply a bead of sealant around the fan inlet opening on top of the
cleaning plenum.
6. Use a forklift or chain-fall to lift the exhaust fan and motor assembly into
position on top of the filter cartridge section clean-air plenum. See
CAUTION.
CAUTION
Do not oist t e fan-motor assembly by lifting on t e fan or s aft.
Failure to follow t is instruction may cause damage to t e
fan/motor components.

7. Position the fan exhaust pointing off any one of the four sides. If the
exhaust is to be pointed off the side of the AirWall unit, the front and rear
clearance will change depending on which side the exhaust is pointed.
Align the mounting holes in the fan/motor assembly with the mounting
8. holes in the top plate of the clean-air plenum.
9. Use the 2 1/2” bolts, flat washers, and flange nuts to secure the
assembly firmly into place. Wipe away any sealant, which may have
squeezed out.
10. If HEPA (High Efficiency Particulate Air) filters have been specified, attach
them at this time. General instructions are as follows:

a. Apply sealant, or a closed-cell foam gasket material, to the
flange attachment surface on the inlet side of the safety filter
assembly. Attach the transition duct, using the duct flange
doublers provided.
b. Move the filter assembly, together with any required transition
ducting up to the rear of the AirWall unit. Align the open end of
the transition ducting with the fan exhaust duct flange. Apply
sealant or a closed-cell foam gasket material to the fan exhaust
flange-mating surface.
NOTE: In reference to Steps A and B, neit er a support platform nor
a transition duct is provided due to differences in facility installation.
c. Open the access doors.
d. Slide the pre-filters into the slots provided. Make sure the air flow
direction is correct.
e. Install the HEPA or safety filter on the back wall of the filter
stand. The gasket will seat on the metal frame. Once the filter is
in place, swing the locking bolts into position so that the locking
bolts hook on the edge of the filter corners.
f. Evenly tighten all four (4) corners to 29 in. lbs. (3,3 Nm).
g. Close the access doors. Position the positive sealing latches on
both sides of the access doors and tighten to provide a 0 percent
gasket compression.
NOTE: Refer to t e HEPA filter manufacturer’s product documen-
tation for specific information regarding your HEPA application or
installation.
ELECTRICAL CONNECTIONS
The electrical requirements for the exhaust blower motor are 208/230/460 VAC, 3-
phase, 60 Hz power. Only a qualified electrician should connect this device to an
appropriate motor starter.
NOTE: W enever possible, EECI attempts to deliver t e fan motor
wired for your specific voltage requirements. It is recommended,
owever, t at your electrician verify t e motor terminal connec-
tions to ensure proper wiring for your installation.

The electrical requirements for the Photohelic gage and switch are 120 VAC, single
phase, 60 Hz. Only a qualified electrician should make the connection of this device.
FILTER CLEANING SYSTEMS
With the standard filter cleaning system, the reverse pulse is released from the
diaphragm valve by the solenoid pilot valve, which is activated in turn by the timer
control board.
On-Demand Filter Cleaning System. A Photohelic gage and switch are used to
initiate the filter cleaning sequence. This unit is a sophisticated and sensitive device.
Therefore, any questions regarding the electrical connection of this device should be
referred to EECI at 1-800-999-0 01 before proceeding. Refer to the electrical
schematic labeled “Pulse System Wiring” provided with this manual. Do not connect
circuit test equipment to the timer control board. See CAUTION.
CAUTON
Do not connect circuit test equipment to t e timer control board. T e
use of certain types of test equipment can seriously damage t e
timer control board components. Failure to follow t is instruction
will void t e warranty.
1. EECI recommends that the timer control board be mounted next to the
AirWall unit, or within 4 to 6 ft. of the unit.
2. The common (white) lead, along with wires numbered 1 through , have
been pre-wired into the junction box located on the AirWall unit. Leads in
this junction box are numbered 1 through , with an additional common
(white) lead. Run these leads through suitable conduit into the Photohelic
control panel. Since the distance from the junction box to the Photohelic
control panel is not known for your installation, this cable is not supplied.
3. From the junction box, connect wires 1 through to terminals 1 through
on the timer control board.
4. Connect the common lead (white) from the AirWall unit to the common
terminal on the sequence controller board. These connections allow the