NSGV CYCLONE Series User manual

NSGV SERIES “CYCLONE” DUST COLLECTOR
I, O & M MANUAL
Standard Equipment Includes:
- Cyclone Assembly
- Base Assembly
- Inlet Assembly
- Power Pack
- Surge Hopper
- Cabinet Base
- Double-Drum Base
- Hopper Base
Optional Equipment Includes:
- Attenuator
- Exhaust Accessories
- Filter Bag(s)
- Filter Bag Enclosure
- Explosion Relief Panels
National System of Garage Ventilation
714 N. Church St. / P.O. Box 1186
Decatur, IL 62525
[phone] / [phone] / (fax)[phone]
NSGV.com [email protected]

NSGV SERIES “CYCLONE” DUST COLLECTOR
I, O & M MANUAL
RECEIVING
Upon receipt of shipment, check to make sure that all items listed on the packing slip are present and in good condition. If there is any damage
or shortage, note this information on the delivery receipt from the shipping company. It is the responsibility of the recipient to report any damage
or shortages to the shipping company and file any pertinent claims. This should be done immediately to insure the possibility of reimbursement.
INSTALLATION
Lifting: Use equipment with sufficient capacity. NSGV publishes typical weights and the Bill-of-Lading or freight bill weights usually are
accurate. Make sure to error on the side of caution. Do not drop, dent, or twist equipment. Caution: Avoid overhead electrical lines.
Foundation: Provide a proper foundation (or, if hung, an overhead support) designed for the weight of the equipment, its weight, wind,
snow loads, and the captured material. Consult experts in this field when figuring the needed support pad or hanger. Responsibility for a proper
support pad or hanger structure falls solely on the end user.
Location: Locate the collector as close as possible to the source of the contaminants. If the dust is explosive, See Explosion
Supplement.
Guys, Braces – Anti-Toppling, Wind, and Earthquake: Equipment over 6 feet tall mounted outdoors or 8 feet tall mounted indoors must be
guyed to the earth or braced to the building walls or its support steel to prevent over-turning. Note: Make sure the wall can support the added
weight if the collector would topple. Most units, particularly Hopper styles, are inherently top heavy and great care must be used when
installing them. Details on particular types are given in there unique erection instructions. If your site is an earthquake zone, get the local
applicable code before erecting the unit. This will define loads and in many cases, allows load reduction when earthquake and wind acts
simultaneously. Connections must be adequately located and properly installed.
Setting the Unit in Place: Small indoor box-like collectors can be set directly on the floor on soft rubber pads. If the unit rocks, shim as
necessary. Collectors with legs or floor anchors must be anchored or bolted to the foundation. Shim as necessary. All field-assembled joints
must be caulked airtight. Straighten any bent flanges. Wipe any mating surfaces clean then use a proper caulk that has a temperature rating
exceeding the operating temperatures expected. Acrylic latex caulk is excellent for temperatures up to 130º.
Outdoor Installation: Clear any provided drain holes and attach the air outlet weather snoot. If you operate the blower or leave doors
off of the enclosure and introduce water into the filter bags they will be ruined. (See “Filter Clean” Page 3)
DUCTING
Proper duct sizing from the contaminate source(s) to the collector and exhaust ducts are an absolute necessity. Keep duct runs as short as
possible and use the least amount of elbows as is practical. A complete selection of pipe, fittings, nozzles and duct sizing is available from
NSGV. Contact your local NSGV Representative or send a simple sketch of your requirements to NSGV.
Individual machines may be isolated with blastgates. If all gates are closed, the collector suction may collapse the ducting. SOME INTAKES
MUST ALWAYS BE OPEN. Certain systems, including those handling explosive dust(s) must NOT use blastgates.
FIRE
It is possible to set this equipment on fire. Do not allow smoking, burning, etc, nearby. Many contaminants including dusts, liquids, or most filters
will burn. Fire may only be introduced into the system via an external source. All NSGV filters are naturally fire-resistant or are treated with
special flame-retardant chemicals so they will not ignite unless exposed to a continuous ignition source. The following are some simple
guidelines to follow:
1. Never mix buffing and grinding operations in the same collector.
2. Never put steel dust into a collector containing aluminum dust.
3. Never put dust from an operation that produces sparks into a collector.
4. Never capture magnesium or titanium dust into any NSGV collector.
1
National System of Garage Ventilation
714 N. Church St. / P.O. Box 1186
Decatur, IL 62525
[phone] / [phone] / (fax)[phone]
NSGV.com [email protected]

NSGV SERIES “CYCLONE” DUST COLLECTOR
I, O & M MANUAL
NOISE
Any air-moving device creates noise. NSGV can provide special designs and features which provide greater noise reduction than most.
Generally the collectors are quieter than the machines they serve. If maximized quietness is required, tailor made Noise Absorbers are available
from NSGV. If Noise Absorbers were purchased, they must be in place before operation of the Cyclone. If Noise Absorbers were not purchased
originally, they may be retrofitted to the Cyclone, usually without a huge inconvenience. Contact your local NSGV Representative or NSGV
directly.
Noise Absorbers: If provided, all noise absorbers bolt or sheet metal screw into position. Caulk all the joints if gaskets are not supplied.
Provide external support when the absorber is cantilevered from the collector. Respect any flow arrows.
Cyclone Collectors: Noise absorbers attach between the blower and after-filter with provided transitions. Position any enlargements as shown.
Other Collectors: Attach absorbers directly to the blower outlet. Center the long dimension. The short dimension (width) of the absorber is
almost always wider than the blower it serves. Position this as shown, aligning one side of the noise absorber with the drive side of the blower.
Noise
After
Filter
Correct
Cyclone Plan Views
Blower
Rotation
Wrong
Correctly
Aligned Motor
Wheel
Blower
Aligned
Incorrectly
Flow
Flow
Other Collectors Sections
ELECTRICAL
Independently ground this equipment with at least #0 bare copper conductor to a buried grounding rod or a grounded water pipe system.
Grounding to the building steel is not sufficient. All connections must be made correctly. This is necessary to protect personnel and to help
protect against explosions and/or fires. If the motor starter (by others) is remote, install “Emergency Stop” buttons near the operator(s).
Almost every NSGV collector has an integral blower. Many collectors also have electrically driven filter shakers. Proper wiring by a qualified
electrician skilled in industrial wiring must be provided. Full voltage magnetic starters should be provided for each motor (provided by others).
All electrical work should be done by a licensed electrician and in accordance with all local and state codes.
All NSGV motors are outside the air stream which simplifies the wiring. Follow the wiring diagram on the motor and verify rotation by turning
wheel hand and visually checking as the motor coasts to a stop.
Blower Rotation: Unless otherwise marked, the rotation is clockwise when viewed from the drive side. The wrong rotation produces airflow in
the correct direction but only produces about half f the airflow.
Changing Rotation: For Single-Phase motors see motor wiring diagram. For Three-Phase motors interchange any two power leads.
2
National System of Garage Ventilation
714 N. Church St. / P.O. Box 1186
Decatur, IL 62525
[phone] / [phone] / (fax)[phone]
NSGV.com [email protected]

NSGV SERIES “CYCLONE” DUST COLLECTOR
I, O & M MANUAL
AFTER FILTER MODULE ASSEMBLY
There are four “modules” to the upper Inlet Plenum of the After Filter. They are to be bolted together by matching the internal holes on the
flanges. Orient the plenums as shown below. NOTE: CAULK ALL FLANGES PRIOR TO BOLTING TOGETHER.
Closed Edge Typical
Closed Edge Typical
Closed Edge Typical
Air Inlet From Blower Outlet
No Filter
Collar On
This Module
Front View
Top View
Open
Bolt
Bolt
BoltBolt
3
National System of Garage Ventilation
714 N. Church St. / P.O. Box 1186
Decatur, IL 62525
[phone] / [phone] / (fax)[phone]
NSGV.com [email protected]

NSGV SERIES “CYCLONE” DUST COLLECTOR
I, O & M MANUAL
ERECTION PROCEDURES
With the Cyclone in place, and after the After Filter upper modules have been assembled on the floor, assemble the Noise Attenuator with
respective transitions. This can be done on the floor and hoisted into position or you may assemble the transitions in steps off of the blower,
temporarily supporting each piece that is added. After completing this assembly procedure, hoist and temporarily support the After Filter module
assembly previously assembled. The After Filter assembly may now be bolted to the Noise Attenuator assembly. The assembly should look as
shown below.
NOTE: CAULK ALL FLANGES BEFORE BOLTING TOGETHER IN EACH STEP.
After Filter
Module Plenum Transition
Large Noise
Attenuator and Blower
Cyclone Body
AIRFLOW
4
National System of Garage Ventilation
714 N. Church St. / P.O. Box 1186
Decatur, IL 62525
[phone] / [phone] / (fax)[phone]
NSGV.com [email protected]

NSGV SERIES “CYCLONE” DUST COLLECTOR
I, O & M MANUAL
OUTDOOR AFTER FILTER STRUCTURE AND SKIN ASSEMBLY
COMPONENT DESCRIPTIONS
1. Plenum (1 Assembly) 9. Drip Cap
2. Top Leg (2RH, 2LH) 10. Doors (1RH, 1LH)
3. Bottom Leg, 4 pcs. 11. Barrel Bolts, 2 pcs.
4. End Top Flashing, 2 pcs. 12. Shaker Assembly
5. Side Top Flashing, 2 pcs. 13. Plastic Tubing, 4 pcs.
6. Skin Side – 54” Long 14. Connecting Rod for Manual Shaker 9With nut)
7. Skin End – 54” Long 15. 2” Knob foe End of Connecting Rod
8. #10 x 1/2” Sheet Metal Screws
1
2
3
45
6
7
8
9
10
11
12
13
14 15 LOCATE & ARRANGE
CUT-OUT FOR
RETURN AIR DUCT
PER BUILDING PLANS
ASSEMBLE SHAKER
ON OPPOSITE SIDE
THAN SHOWN
FIELD DRILL & BOLT
AIR FLOW
5
National System of Garage Ventilation
714 N. Church St. / P.O. Box 1186
Decatur, IL 62525
[phone] / [phone] / (fax)[phone]
NSGV.com [email protected]

NSGV SERIES “CYCLONE” DUST COLLECTOR
I, O & M MANUAL
OUTDOOR AFTER FILTER STRUCTURE AND SKIN ASSEMBLY
1. Assemble Modular Plenum (1). Caulk, bolt, and sheet metal screw air tight. Using a 7/16” drill bit, drill (4) holes at the center punched
marks. Orient the Plenum, Noise Attenuator, and Transitions as previously shown on Page 4. Caulk and bolt flanges air tight. Lift this
assembly, caulk and bolt it to the blower outlet. TEMPORARILY SUPPORT the assembly so no undue twist or strain is placed on the
blower. A “T” of 2 x 4’s in the plenum is suggested.
2. Note that the (2’s) are Right and Left Hand. At each corner snugly bolt (2) to (1) using t he holes you pre-drilled in Step 1. The sides of
(2) are in-line and the 3” faces are at the ends of the structure. Vise-grip (3) to (2), plumb and anchor bolt (3) to pad. Then field drill
only the outer holes and bolt (3) to (2).
3. Caulk flashing (4) and slide under (1) and atop (2), leaving a 1/16” space between it and the 3” faces of (2). Sheet metal screw (8)
upward into (1). Similarly caulk and install (5) atop (2) and (4) leaving a 1/16” space between it and the narrow face of (2). Then sheet
metal screw (8) horizontally into (1). Finish tightening the 4 bolts from (1) to (2).
4. The Plenum, corner posts, and top flashing should now all be in place, anchored, caulked, and fully bolted. Remove the temporary
support used in Step 1 and the vise-grips used in Step 2.
5. Establish which end is for the Manual Shaker operator. Position (12’s) connecting bracket at that end. Make sure to avoid re-
circulating duct. (See Step 11 below)
6. Hang (12) level, at a height half-way between the bottom of the plenum (1) and the top of the drums (typical height 32”), criss-crossing
four equal lengths of plastic tubing (13). After yanking tubes taut, re-check levelness and height of (12) and then cut off and discard all
but 1” of excess tubing (13) which sticks through the collars in (12). Shove a nail or other metal rod into each tube and “bury” (12’s) set
screws through the plastic into the nail or metal rod.
7. Choose the door side and mount (9) 48” above the pad on that side. Hang doors (10) (Left Hand door overlaps Right Hand door) with
about 1/4” bottom clearance above pad. If re-circulating, apply self-stick gasket material vertically on (3), horizontally on (9) and
vertically on the seal flat of the Right Hand door. DO NOT STRETCH GASKET WHEN INSTALLING. Knife cut to fit. Push the doors
closed tightly and mark and drill (9) and the pad to accept the barrel bolts (11).
8. The enclosure should now be in place except for “skin” and the Manual Shaker. Lay up the “skin” like shingles, working from the
bottom up. Attach with sheet metal screws (8). Use 54” wide pieces (6) on the sides and 28” (54”) wide pieces on the ends, with the
screens at the very bottom. (If the unit was ordered for re-circulation, (7’) are all solid). Caulk each piece and overlap evenly as
required (minimum 2” overlap). In certain cases, you may have a surplus of panels. Discard these now.
9. MANUAL SHAKER ONLY – Field drill a 3/4” hole through (7) centered and at the proper elevation to line-up (14) and (12). Connect
(14) and (12) and screw on the 2” knob (15). Install Decal (Shaker Notice) where it will be seen.
10. If re-circulating, install the duct work as directed on the building plans. Merely cut an appropriate opening in the skin.
11. Install the filter tubes (not shown in the drawing), 55 gallon drums, and cinch strap the bottom of the filter tubes onto the drums.
12. The unit is now ready to operate. NOTE: MAKE SURE THE UNIT IS COMPLETELY WATERTIGHT.
6
National System of Garage Ventilation
714 N. Church St. / P.O. Box 1186
Decatur, IL 62525
[phone] / [phone] / (fax)[phone]
NSGV.com [email protected]

NSGV SERIES “CYCLONE” DUST COLLECTOR
I, O & M MANUAL
START-UP
Before Start-Up: Spin the blower wheel by hand. Make sure that there is no rubbing. If the wheel does rub, the assembly clearance must be
restored. On most units, the blower inlet cone (funnel) is provided with oversized holes and can be adjusted radically if needed. On small and
medium cyclones, the motor feet holes have sufficient clearance or can be shimmed to provide adjustment or, if C-Faced flange mount, the
entire blower can be shifted after loosening the bolts that attach it to the top of the cyclone. NOTE: MAKE SURE TO RETIGHTEN ALL BOLTS
BEFORE OPERATION.
Start-Up Checklist:
1. Make sure power is disconnected.
2. Check all bolts, anchors, etc, to make sure they are completely tightened.
3. The blower wheel spins freely by hand.
4. All wiring is completed with no loose wires left open. Fuses or circuit breakers are sized correctly. Heaters in starters sized
for full-load motor amps should be plus 5% to 10%.
5 Inlet and Outlet ducting is in place and blastgates are open.
6. Al doors, covers, hopper slides, etc. are in place.
7. Dust drums are in place and sealed.
8. Oil mist drain traps are pre-filled with coolant.
9. Electrical shakers, if provided, are at neutral position (cyclone after filter) or bottom of stroke (fabric, smoke, fume, etc.).
Also verify the rotation is correct.
10. Make sure all personnel are clear and close the fused power switch, turning the power on.
11. Press “Emergency Stop Button” if automatic shaker timer control exists.
12. Press “Blower Start Button” which starts the unit.
OPERATION
After going through the Start-Up Check List step by step, you can apply full continuous power. After a short period of operation, 15 minutes or
so, turn off all power and check that all bolts, anchors, and other connections are all tight. It is extremely important that the blower motor and
support and all bolted connections associated with the unit be securely tightened. Re-check again after another 15 minutes of operation and
again after a few days of operation. After this, checks should be routinely made to insure the best possible performance of the unit. Shakers,
because they handle a low frequency varying load, are prone to loosening. Check shakers at least once a month.
Dust Catch: When first used, empty containers regularly. This should be done until a regular service schedule can be established so that
containers do not get over two-thirds full.
Filters and After-Filters: It is very important to clean filters often. This can be done by shaking the filters vigorously. The filters are semi
permanent and rugged providing you follow the steps listed below.
1. Shake thoroughly at least once a day or if dust load is heavy, at every break. An initial dust cake can be developed more
rapidly on light jobs by postponing the first shaking, but, once developed; shaking should be done daily thereafter.
2. Never shake filters while the unit is running. This drives the Sub-Microscopic dust particles into the fabric and will plug
the filters. This is called “blinding”.
3. Never allow moisture into the unit or allow the fingers to get wet. Never operate so the air goes below its dew point
which will cause undue humidity and condensation, creating a liquid.
7
National System of Garage Ventilation
714 N. Church St. / P.O. Box 1186
Decatur, IL 62525
[phone] / [phone] / (fax)[phone]
NSGV.com [email protected]

NSGV SERIES “CYCLONE” DUST COLLECTOR
I, O & M MANUAL
MAINTENANCE
If unusual vibration or noise ever develops, shut the unit of immediately. Continued operation can cause irrevocable damage or injury.
Vibration: Most blower wheels are of welded construction and have both “hop and wobble” that is they do not turn perfectly true. But
they are carefully balanced both dynamically and statically and are factory tested before shipment. If vibration ever develops, it must be
immediately eliminated. Sticky materials or uneven buildups may occur during normal operation of blower wheels and will cause severe vibration
which must be corrected. Remove build-up by scraping with a stiff wire brush. Work through the access doors or by pulling the motor and wheel
out of the scroll. Clean both side of every blade. If this build-up is not corrected, continued operation will cause steel supports, blower scrolls,
motor mounts, etc to crack, break, and fail. This may cause personal injury or render the unit useless. If such damage has occurred, do not
operate the unit until this problem has been discussed with your local NSGV Representative or NSGV directly.
Lubrication: Since motors are not in the air stream carefully follow motor manufacturers instructions for actual exposure. Generally
grease can be added to motor bearing, pillow block, and oil added to gear reducers about every six months. This period should be shortened for
continuous duty and lengthened for intermittent duty. Grease any linkage parts and cam surfaces at the same time. It is extremely important that
grease fitting be wiped perfectly clean before using a grease gun so that no contaminants get into the bearings. DO NOT OVERFILL.
Motor/gear reducers service should only be done after contacting a local sales or service shop of the motor manufacturer. They will be able to
give details of warranty, service, and parts. When the surface is dry and clean, the new adhesive-backed gasketing sticks instantly. Cut butting
ends square and allow 1/4” extra length so the gasket is compressed when fitted.
Filter Cleaning: If shaking does not correct a fall-off in airflow, or if collected material is extremely tenacious or sticky, cloth filters may be
brushed or vacuumed. Brush only by hand, using only a soft bristled brush and only on the dirty side of the filter. If this is not sufficient, an
industrial vacuum cleaner may be used. Vacuum only the dirty side of the filter and be careful not to puncture or tear the fabric. If the filter is
extremely dirty, they can sometimes be dry-cleaned by a competent industrial dry cleaner. DO NOT LAUNDER FILTERS as this removes any
flame retardant chemicals and will shrink most filters. Minor tears can be repaired after cleaning by sewing a patch of a similar material over the
tear. If the filter’s edges, folds, or creases are worn, or if the fabric has deteriorated, or if the filter cannot be cleaned sufficiently, the filter must
be thrown away and replaced with new filters.
Gaskets: If gaskets rip, deteriorate, wear, or take a permanent set, they must be replaced. Order the total footage required and cut to
precise lengths in the field. Old gasket material and adhesive residue must be completely removed. This may be done by using paint thinner or
lacquer thinner. Use extreme caution as this is a fire hazard. Once the surface is completely cleaned and dried, the new adhesive and gasket
may be applied. Cut the beading ends square and allow 1/4” extra length so the gasket is compressed when fitted.
8
National System of Garage Ventilation
714 N. Church St. / P.O. Box 1186
Decatur, IL 62525
[phone] / [phone] / (fax)[phone]
NSGV.com [email protected]

NSGV SERIES “CYCLONE” DUST COLLECTOR
I, O, & M MANUAL
TROUBLESHOOTING
PROBLEM PROBABLE CAUSE REMEDY
Improper motor wire size Rewire using correct wire gauge as specified by national and local codes
Not wired correctly Check and correct motor wiring for supply voltage. See motor
manufacturer’s wiring diagram. Follow wiring diagram and the National
Electric Code.
Unit not wired for available voltage Correct wiring for proper supply voltage. A 10% differential is permissible.
Input circuit down Check proper supply to motor circuit on all leads.
Blower Fan &
Motor Do Not
Start
Electrical supply circuit down Check power supply circuit for proper voltage. Check for fuse or circuit
breaker fault. Replace as necessary.
Blower rotation backwards Proper blower rotation is clockwise when looking down at the blower
motor.
Incorrect motor-starter installed Check for proper motor starter and replace if necessary.
Incorrect motor heater coil installed Check and replace as necessary.
Starter or supply voltage connections
loose
Check all wiring connections for tightness. Loose connections can cause
single phasing on three-phase circuits and heater coil damage. Motor
hum or growling is an indication of this condition.
Dust storage container is leaking or 55-
gallon drum cover is loose
Check for large leaks in the storage chamber. Check the 55-gallon drum
cover gasket and that the drum cover is fastened securely.
Motor Runs Hot,
Starter Kicks
Out
Electrical circuit overload Check that the power supply circuit has sufficient power to run all
equipment.
Unit not wired for available voltage Correct wiring for proper supply voltage. A 10% differential is permissible.
Blower rotation backwards Proper blower rotation is clockwise when looking down at the blower
motor.
Dust storage container leaking or 55-
gallon drum cover is loose
Check for large leaks in the storage chamber. Check the 55-gallon drum
cover gasket and that the drum cover is fastened securely.
Large diameter branch in extended length
duct system
Install blast gate.
Improper duct or hood size Check and replace if necessary.
Fan exhaust area restricted Check blower exhaust area for obstructions. Remove material or debris.
Adjust damper flow control.
Obstruction in duct Check and remove obstructions.
Filter bags plugged Check and clean or replace if necessary.
Insufficient
Airflow
Grinding or polishing equipment in use Increase air flow to compensate for equipment that creates its own air
circulation.
9
National System of Garage Ventilation
714 N. Church St. / P.O. Box 1186
Decatur, IL 62525
[phone] / [phone] / (fax)[phone]
NSGV.com [email protected]