Trion 73 Series Operation manual

CUSTOM PACKAGED
ELECTRONIC
AIR CLEANERS
Model 73 Series Units
with
Integral Washing System
INSTALLATION
OPERATION
SERVICE
For Model Numbers
Electrostatic Precipitators for
Commercial & Industrial
Applications
TRION INC.
101 McNeill Road
Sanford, NC 27330
[phone]
Fax: [phone]
MANUAL PART NO. 147417-001 11/94

TABLE OF CONTENTS
SECTION I DESIGN
For The System Design Engineer Page
1. General Description................................................................................................................... 1
2. System Design and Layout........................................................................................................ 1
SECTION II INSTALLATION
For The Installing Contractor
1. Unpack and Inspect ................................................................................................................... 2
2. Position Air Cleaner Cabinet..................................................................................................... 2
3. Connect Adjoining Ductwork .................................................................................................... 2
4. Mount Detergent System........................................................................................................... 2
5. Connect Drain............................................................................................................................. 2
6. Connect Wash Water Supply..................................................................................................... 2
7. Mount Power Pack(s) and Control ............................................................................................ 2
8. Complete Wiring
A. High Voltage Wiring................................................................................................................ 3
B. Primary Wiring........................................................................................................................ 3
9. Checkout for System Start-up................................................................................................... 3
SECTION III OPERATION
For The Maintenance Engineer
1. Introduction and Principle of Operation................................................................................... 3
2. General Description................................................................................................................... 3
3. Initial Start-up............................................................................................................................. 4
4. Wash Control and Detergent System Settings......................................................................... 5
5. Routine Maintenance................................................................................................................. 5
6. Periodic Maintenance ................................................................................................................ 6
7. Trouble Shooting ....................................................................................................................... 6
8. Spare Parts................................................................................................................................. 7
9. Trouble Reference Chart............................................................................................................ 8
SECTION IV REFERENCE
Illustrations and Drawings
Figure 1 General Component Arrangement........................................................ 9
Figure 2 High Voltage Lead Terminal Connections ......................................... 10
Figure 3 Power Pack Outline .........................................................Not Numbered
Figure 4 Multi-Cam Timer...............................................................Not Numbered
Unit Outline......................................................................Not Numbered
Control Outline.................................................................Not Numbered
Detergent System Outline...............................................Not Numbered
Piping Schematic.............................................................Not Numbered
Field Wiring Diagram.......................................................Not Numbered
Control Schematic & Sequence of Operation................Not Numbered

1
SECTION I DESIGN
FOR THE SYSTEM DESIGN ENGINEER
1. General Description
The standard major components supplied with each unit
for installation are as follows:
The Electronic Air Cleaner
The Power Pack
The Control
The Detergent System
A Wash Water Line Strainer, Solenoid Valve and
Vacuum Breaker
The Electronic Air Cleaner contains the ionizing-collecting
cells (collecting elements), wash manifolds—located to
the front and rear of each tier of cells—and metal mesh
pre-filters and after-filters. Perforated plate or
impingement type mist suppressors, in lieu of the metal
pre-filters, are options when specified.
Gasketed access doors located on one end of the cabinet,
90 degrees to the direction of the airflow, provide entry for
removal of the cells and filters. The location of the access
doors, wash manifold drive motors and manifold header
pipes may be specified as “right” or “left” handed. The
hand designation is determined by standing in the
ductwork on the air entering side of the unit so the airflow
strikes your back.
The Power Pack(s), providing the necessary high voltage
for the ionizing-collecting cells, is furnished in a NEMA 12
enclosure and is designed for remote mounting. The
distance between the pack and unit must be determined
as the interconnecting high voltage leads are furnished to
the specified length. Consult factory for distances greater
than 150 ft. Cables are not to be spliced at any point along
their length.
The Control, which operates the washing cycle, is also
furnished in a NEMA 12 enclosure designed for remote
mounting, and is a central junction for the primary wiring.
The Detergent System is furnished as a completely
assembled unit to be piped directly to the wash water
supply, into the wash manifold headers.
The Strainer, Solenoid Valve and Vacuum Breaker are to
be installed in the wash water headers.
2. System Design and Layout
The arrangement of the supplied components and the
general layout of the system will vary according to
application, adjoining equipment and available space.
However, there are several basic factors pertaining to all
installations that must be considered:
To maintain the selected cleaning efficiency, it is important
to assure that the total air volume (capacity if CFM) is
uniformly distributed across the entire face area of the
unit. The metal mesh filters, perforated plate or mist
suppressors, provide some resistance to effect even air
distribution. However, since most air ducts are designed
to handle air velocities greater than the rated velocity of
the air cleaner, it is necessary to properly transition any
attached ducting. If possible, a contraction ratio of 1 in 3
(approximately 20) should be maintained. If space
prohibits, turning vanes, air baffles or other means may be
utilized. Ducting –where attached to the cabinet collars –
should be gasketed, caulked or otherwise made
watertight.
When there is a danger of rain, snow or trash being drawn
into the system with outside air, the make-up air intake
should be protected with rain louvers, hooding and
hardware cloth to prevent the rain, snow or trash from
entering the electronic air cleaner.
Contaminants to be collected –such as oils in vaporous
state –must be condensed into particulate form prior to
entering the ionizing-collecting cells in order to maintain
the anticipated efficiency. Gases, vapors or any non-
particulate cannot be precipitated and will therefore pass
through the air cleaner. Any condensing that takes place
downstream form the air cleaner defeats the purpose. By
the same token, heavy concentrations of water vapor, or
other matter that becomes highly conductive when
condensed, must be prevented from entering and/or
condensing in the collecting elements to prevent electrical
arc over and shorting.
Factory designed access to all electrically charged high
voltage components contain electrical interlocks for the
safety of operating personnel. Any additional access that
may be provided in the system, where there is access to
high voltage, must be equipped with such interlocks.
Interlocks are readily available from the factory.
Waterwash drain lines from the cabinet drain basin should
be trapped or otherwise sealed against the system
pressure. Wash water to the unit must meet the volume
required for the specific unit involved, and between 35
PSIG Min. –50 PSIG Max. at full flow to provide proper
spray patterns from the wash nozzles.
Each installation varies according to needs, but normally
the power pack(s) and control are located near the air
cleaner. Ideal mounting height is at eye level for ease in
reading the instrumentation, and to facilitate service.
For ease in maintenance and component removal,
adequate space must be provided in front of all access
doors, motors, pump and accessory equipment. Special
consideration should be given in this respect for
installations where the unit is suspended overhead.
Catwalks or platforms should be provided.
Refer to Figure 1, Section IV, Page 9. Contact the local
Trion Sales Office or the factory if questions arise, or any
additional information is required.

2
SECTION II INSTALLATION
FOR THE INSTALLING CONTRACTOR
1. Unpack and Inspect
At the time the unit is received, all shipping containers and
their contents should be examined for damage. Any
damage occurring in shipment must be immediately
reported to the carrier, an inspection report completed and
a claim filed at the receiving point.
The unit cabinet is shipped completely assembled and,
where size permits, the ionizing-collecting cells are
shipped inside the cabinet. On large units, the upper tier
of cells may be shopped in separate containers. The
power supply, control, detergent feeder and any separate
accessories are shipped in the containers as noted on the
packing list.
2. Position Air Cleaner Cabinet
To reduce weight for ease in handling, remove the pre-
filters, after-filters and the ionizing-collecting cells from the
cabinet, and place them safely aside. Position the cabinet
in the designated location giving consideration to the
following points:
A. Provide sufficient clearance in front of the access
doors for ionizing-collecting cell and mechanical filter
removal.
B. Level the cabinet to assure proper drainage from the
drain pan.
C. Unless specific design features have been
prearranged, the direction of airflow through the
cabinet may be either from the right or the left. When
the ionizing-collecting cells are reinstalled, the
directional arrows on the cell end plates must concur
with airflow through the cabinet. If mist suppressors
have been specified, they are to be installed on the air
entering side of the unit.
After the cabinet has been properly located, it may be
secured into place at the predrilled factory mounting pads
either by bolting or welding.
3. Connect Adjoining Duct Work
Depending on the application, the installation plan may or
may not call for adjoining ductwork on the air entering
and/or air leaving sides of the cabinet.
When adjoining ducting is to be installed, the bottom of
the horizontal duct runs should be relatively flat and
sloped toward the cabinet drain pan for an 18inch length.
As a result, any wash water splash back occurring during
the washing operation will run back into the drain pan.
Duct securement to the collar may be completed using the
predrilled flange. The seam should be made air and
watertight by caulking or gasketing.
When the blower is installed downstream from the Trion
cabinet, the ducting between the cabinet and the blower
will be under negative pressure and should also be made
air tight to prevent the infiltration of contaminated air.
After the ductwork has been installed, clear remaining
material or debris of installation from inside ducts and
bottom of cabinet, then re-install both the mechanical
filters and the ionizing-collecting cells.
NOTE: Follow the directional arrows located on the cell
end plates. The side of each cell containing the spiked
ionizer blades must be located on the air entering side of
the cabinet. Also, mist suppressors when specified must
be located on the air entering side of the cabinet.
4. Mount Detergent System
Refer to Detergent Outline Drawing. The detergent system
should be located as close to the unit as practical in a
level position. Service space must be provided for
periodical manual filling of the detergent tank, and to gain
access to the pump and motor assembly. When
positioned, the assembly may be secured into place at the
predrilled factory mounting pads, either b bolting or
welding.
5. Connect Drain
Connect a drain line to the pipe coupling provided in the
cabinet drain basin in accordance with the governing
plumbing codes. The drain line must be sealed with a trap
or other means to prevent air by pass. If a trap is used, it
should hold sufficient water to overcome the system air
pressure and to assure that loss of liquid from evaporation
between cleaning periods will not break the seal. The
drain line should not be smaller than the drainpipe
coupling, or it will otherwise restrict the flow of water.
6. Connect Water Wash Supply
The items furnished to be included in the wash water
supply are a strainer, an electrically operated valve, a
vacuum breaker and a detergent system. Refer to the
Piping Schematic.
Unless otherwise specified, the water wash supply should
be hot (125F minimum) at the volume specified for the
given unit, and at a full flow pressure between 35 and 50
PSIG.
Although not required, a pressure gage and a manual
service valve are recommended as shown in the diagram.
The components should be located within the system to
provide for service access.
7. Mount Power Pack(s) and Control
The Power Pack should be mounted at eye level and
located as close to the air cleaner as practical. For units
requiring two or more power packs, the packs are
normally mounted side by side. Allow sufficient space in
front of the access door(s) for service. Refer to Power
Pack Outline Drawing for mounting hole layout and
dimensions.
Although not necessary, it is advantageous for
convenience in operation to locate the Control near the
Power Pack(s). The Control should also be mounted at
eye level with adequate space provided for service. Refer
to Control Outline Drawing for mounting hole layout and
dimensions.

3
8. Complete Wiring
A. High Voltage Wiring
CAUTION:
EXERCISE ALL THE NORMAL PRECAUTIONS WHEN
WORKING WITH HIGH VOLTAGE.
The high voltage wiring entails interconnecting the
power pack(s) to the ionizing-collecting cell(s). All the
wiring in the cabinet between the cells has been
completed at the factory.
Refer to the Field Wiring Diagram. Two high voltage
leads, one blue for the ionizer and one black for the
collector, are factory furnished. Each lead is to be
run in separate conduit and must be of continuous
run (do not splice) between the power pack and
ionizing-collecting cell terminals. Knockouts are
provided on the top of the air cleaner cabinet for
conduit securement.
B. Primary Wiring
The Wash Control is the main distribution point for all
primary wiring. The various electrical components
involved are connected to and powered from the
control. Note that the hot line of the 115-volt supply
must be connected in series through all of the access
door electrical interlock switches before entering the
power pack(s). (The power pack(s) interlock is factory
wired.) These interlocks are safety switches that
prevent access to the charged high voltage
components without first turning “OFF” the high
voltage by interrupting the primary power source.
Refer to the Field Wiring Diagram.
9. Check Out for System Start-up
When the installation has been completed, assure that the
equipment is ready for start-up by checking the following:
A. All construction debris is removed from the ionizing-
collecting cells, drain basin and ductwork.
B. The inside of the Power Pack(s), Control and
Detergent Tank is clear of any foreign materials.
C. The drain line from the Trion drain basin is clear and
completely connected to its point of termination.
D. All piping is completed to the manifold headers and
wash water is available.
E. Supply line power is available and electrical wiring is
completed to the following components:
1. Control
2. Solenoid Valve
3. Detergent Pump Motors
4. Manifold Drive Motors
5. Electrical Interlocks
6. Power Packs
7. Ionizing-Collecting Cells
8. The System Fan
F. NOTE: Do Not put the Initial supply of detergent
into the detergent tank. This is to be done after
volume settings are made at start-up.
SECTION III OPERATION
FOR THE MAINTENANCE ENGINEER
1. Introduction and Principle of Operation
The TrionElectronic Air Cleaner is technically known as
an electrostatic precipitator. In this type of equipment, all
airborne particles, even of microscopic size, are
electrically charged (positively) as they pass through a
high voltage ionizer. These charge particles are then
attracted and adhere to a series of parallel collecting
plates, which form the negative elements of an
electrostatic field.
The ionizer consists of charged stainless steel spiked
blades spaced between grounded electrodes. The
collecting section consists of parallels plates arranged so
that each alternate plate is charged while the interleaving
plates are electrically grounded.
Periodically, depending on the type and concentration of
contamination in the air, the contaminate is washed from
the plated by the integrally constructed water wash
system.
Three major functional components comprise the air
cleaner:
(1) Ionizing-Collecting Cells to ionize and collect airborne
particulate matter.
(2) Power Pack to supply high voltage direct current to
the ionizing-collecting cells.
(3) Control operated washer to automatically wash away
the collected contaminate.
Normally, systems are designed for collection efficiencies
in the range of 90 percent or more. Collecting a
contaminate at these efficiencies, especially when there
are high concentrations can result in large accumulations
in a relatively short period. Therefore, maintenance must
encompass two areas; the operation of the equipment for
efficient collection and the systematic removal of the
collected contaminate.
2. General Description
The Ionizing-Collecting Cells (contaminate collecting
elements) are housed in the cabinet on slide rails. They
can be removed from the cabinet as required, through the
end access door, by sliding them out like drawers. On
multi-cell units, all of the electrical connections between
cells in a given tier are automatically made through spring
connectors. On the access end, the high voltage leads
from the power pack and the connections from cell tier to
cell tier on multi-tier units are made with cables. When
installing cells into the cabinet, observe the directional
arrows on the cell end plates. The side of the cell
containing the spiked ionzer blades always must be
located on the air entering side.
Both the air entering and air leaving side of the cabinet
contain either metal mesh filters or perforated plate,
whichever was specified. These items act as trash
screens, provide some resistance for even air distribution,

4
and help contain splash back from the integral water wash
system.
The Power Pack(s) convert the 115 volt, 60HZ, single
phase AC supply to the high voltage DC needed to power
the ionizing-collecting cells. Potential of 13 KVDC are
required for the ionizer sections and 6.5 KVDC for the
collector sections of the cells. The high voltage leads
between the power pack(s) and the ionizing-collecting
cells are color-coded: blue for the ionizer and black for the
collector. The power pack is all solid state and arranged
so that individual components or complete assemblies can
be easily replaced when required.
The integral wash system consists of a series of spray
nozzles soldered into oscillating water wash manifolds.
The manifolds are located in the front and rear of each cell
tier. They are oscillated through straight drive linkage
powered by fractional HP motors. A Detergent System is
also incorporated into the wash system. The amount of
detergent used for washing is readily adjustable, and that
amount is dependent upon the type and amount of
collected contaminate.
The washing operation is cycled periodically, and again
the frequency is dependent on the type and amount of
contaminate collected. The events in a wash cycle are:
(A) Power Pack(s) and System Blower “OFF”
(B) Washer and Detergent “ON”
(C) Washer and Detergent “OFF”
(D) Pause for Detergent to react
(E) Washer “ON” (without detergent for rinse)
(F) Washer “OFF”
(G) Blower “ON” for forced dry
(H) Power Pack(s) “ON”
The time span for all of the events is adjustable.
3. Initial Start-up
A. Inspect the inside of the adjoining ductwork and Trion
cabinet to be sure it is clean and free of any debris or
construction materials. Especially note the opening in
the drain basin for any restrictions. The ducting,
where secured to the cabinet collars, should be
sealed water tight either with gasketing or caulking.
B. Inspect the ionizing-collecting cells to see that al of
the ionizing blades are intact, that no large pieces of
foreign material are lodged between the plates, and
that the cells are properly installed in the cabinet with
the spiked ionizing blades located on the air entering
side.
C. Check the high voltage leads to see that they are
connected to the proper terminal both at the ionizing-
collecting cells and inside the power pack. Refer to
Figure 2.
D. Be sure that the drain line from the Trion Cabinet
Drain Basin is completely connected and properly
terminated. A trap or seal of some type should be
incorporated in the line to prevent air bypass.
E. Check the water supply line to be sure water is
available and that the strainer, solenoid valve,
vacuum breaker and detergent system are properly
installed and connected. Refer to the Piping
Schematic.
F. Be sure that electrical power is available, that the
wiring is completed, and that the system blower is
ready to energize.
G. Check the multi-cam timer located in the control to be
sure it is in the home position. Refer to Figure 4.
When in the home position the No. 1 switch lever will
be bottomed out in its cam recess and the red pointer
on the graduated dial will indicate zero. If it is not in
the “home” position, loosen the two screws securing
the motor assembly and slide the assembly in the slot
provided, disengaging the gears. When the gears are
disengaged, rotate the cams by hand until the No. 1
switch lever bottoms out into the cam recess and the
graduated dial so that any of the tabs located on the
outer circumference are at least 12 hours away from
depressing the activating switch lever.
H. Be sure that all access door interlocks are closed.
I. Close system electrical supply switches, making
power available to the Trion Control and the system
blower.
J. Turn Control “ON-OFF” switch “ON”.
K. Turn Power Pack(s) circuit breaker “ON”. Electrical
arc-over within the ionizing-collecting cells may occur.
It is a normal occurrence caused by accumulated
construction dust deposits in the cells and should
soon subside with the milliammeter reading in the
prescribed range as shown on the operating range
plate. If the arc-over is continuous and does not
subside, recheck the routing of the high voltage leads
between the power pack and the cells. Refer to Figure
2. If the milliammeter does not read within the
prescribed operating range, adjust the variable lead
taps on the front of the high voltage transformer in
accordance with the instructions on the label located
on the inside of the power pack door. If constant arc-
over still occurs, or difficulty other than outlined
above, refer to the Trouble Shooting Guide in this
section, Page 8.
L. Be sure the detergent tank is clean, then fill the tank
1/8 full with clean water. Do not fill with the
detergent until start-up adjustments have been
made.
M. Set the detergent pump running time for 60 seconds
by adjusting the knob on the 1.2 to 120 second timer
inside the control. Manually initiate the control by
initiating the start button. The wash control duration is
80 minutes and will sequence the events as shown in
the Control Schematic Sequence of Operation
Diagram. When the detergent pump is energized,
note the amount that is used by observing the
reduction in the liquid level in the tank. The usage
should be approximately 1 part of detergent to 20
parts of water. The water requirements for each unit
model are listed in GPM on the Piping Schematic. To
adjust the volume output from the pump, refer to the
Detergent System Outline. The pump is a constant
displacement type and the amount of detergent forced
into the water supply to wash the unit is dependent
upon the setting of the control valve in the bypass
return line to the reservoir. The side of the translucent
reservoir is marked with volume markers. Adjust the
control valve to obtain the correct usage for the given

5
unit model, then secure the setting with the Allen
Head set screw located in the valve adjustment knob.
When the correct adjustment has been made, remove
the remaining water from the reservoir and fill the tank
with initial supply of detergent furnished.
N. When the wash control has cycled out and an initiator
time clock has been provided in the control for
automatic operation, set the clock as follows:
(a) Estimate the washing frequency desired. Normally
once per week is adequate for normal dirt loads.
(b) Each dial tab on the outer edge of the large hourly
time dial represent approximately 15 minutes.
These tabs can be tilted in and out with the
fingers.
(c) Tilt all the tabs outward.
(d) Select the time of the day the wash cycle is to be
initiated and tilt the dial tab on that time inward.
(e) Rotate the large hourly time dial counterclockwise
by hand until the correct time of day is indicated
by the triangle time arrow on the nameplate.
(f) The small seven spoke wheel at the lower right of
the large hourly time dial moves ahead once each
day at 2:00 a.m. Each spoke is marked with a day
of the week. Insert a knurled brass screw in all the
spokes except the spoke marked with the day the
unit is selected to wash. CAUTION: DO NOT
ATTEMPT TO INSERT SCREW IN SPOKE
WHILE IT IS POINTING TO THE LARGE
ARROW, IIF NECESSARY TURN THE SPOKE
WHEEL BY HAND. THEN INSERT THE SCREW.
(g) If later than 2:00 a.m., turn the spoked wheel by
hand until the present day of the week is opposite
the large arrow. (Between midnight and 2:00 a.m.
the setting must be made to the day just ended at
midnight.)
4. Wash Control and Detergent System Settings
The total time required for the complete wash cycle is 80
minutes. The four main events that take place during the
cycle are: Wash, Soak, Rinse and Dry. Once the Wash
Control has been initiated, either by manually pushing the
washer start button or through the means of an automatic
time clock, the time for each event is controlled by the
multi-cam timer located inside the control housing. The
time duration for each event within the 80 minute cycle is
adjustable.
In addition to the multi-cam timer settings, the detergent
cycle has two additional settings: A “fine tune” time
adjustment and a volume adjustment (ratio of detergent to
water). These adjustments enable the washing operation
to be set most effectively for the particulate type and
amount of dirt loading for a given installation. Some dirts
being more tenacious than others are more difficult to
remove and require a loner wash time or a stronger
detergent solution. Average settings have been factory set
and are outlines in the Control Schematic, sequence of
operation. Best possible setting for any given installation,
however, are best determined through experience.
Determination can be made by visually examining the
ionizing-collecting cells after the first few washings.
To change the multi-cam timer settings refer to Figure 4.
Each disc on the double disc cams is adjustable by
turning the adjusting screws located on the side of each
disc. The time between the “OFF” operation of Switch 3,
and the “ON” operation of Switch 4 is the soak time.
NOTE: Switch 3 controlling the detergent, should never be
set for less than 2 minutes (120 seconds). The detergent
time is “fine tuned” with the adjustable, 1.2 to 120 second
time delay relay, which overrides Switch 3.
To set the time for any given event except detergent,
simply turn the adjusting screws to adjust the length of the
cam recess. Open the recess to increase the time or close
the recess to decrease the time. When adjustment is
made to one of the cams the other cams, may have to be
adjusted to bring the time relationship between the cams
in proper sequence. The operation of any one event must
not overlap the operation of any other event.
To adjust the volume of detergent used within the given
time setting, loosen the knurled knob with an Allen wrench
on the control valve located in the by-pass line. Refer to
the Detergent System Outline. Turning the knob clockwise
increases the volume and counter clockwise decreases
the volume. When adjustment has been made, be sure to
retighten the set screw.
5. Routine Maintenance
A. Washing Frequency
The frequency that the collected dirt is to be washed
from the unit depends upon the type and amount of
dirt in the air to be cleaned. Dirt which is greasy in
nature tends to harden after collection and should be
washed away often. Likewise, units operating under
extremely heavy dirt loads should be washed more
often as a large build-up of collected material will have
a tendency to “blow-off” if permitted to remain on the
collecting elements for long periods of time. In that the
type and amount of dirt varies geographically (and
from one location to another in any given area) it is
recommended to start operation with a washing
frequency of at least once a week. This schedule may
then be altered as needed after visual examinations of
the collected material contained on the ionizing-
collecting cells. Daily washing is not unusual for units
operating on heavy welding fume or similar
contaminants.
B. Detergent
Effective washing is dependent upon detergent. The
detergent reservoir should be examined on a routine
basis, a minimum tank level established and never
permitted to empty. An empty tank not only means
poor washing, but can also be detrimental to the
pump. The inside of the tank should be kept clean,
free from dirt and foreign objects. The detergent, as
supplied by Trion, Inc., is formulated specifically for
Electronic Air Cleaners. If substitutes are used, they
should be safe for use in ventilation systems and non-
caustic, as 95% of the ionizing-collecting cells are
constructed of aluminum.

6
C. Electrical Operation
The front of the power pack(s) is equipped with a
milliammeter. Some models also contain a voltmeter.
The milliammeter should be observed on a routine
basis to be sure that it is reading within the prescribed
operating range as marked on the data plate. For
those units containing a voltmeter, the collector
voltage should be between 6 and 7 KV, and the
ionizer between 12.5 and 13.5 KV.
6. Periodic Maintenance
A. Water Wash System –Every 6 Months
The water wash spray pattern should be checked on
each nozzle to be sure a full spray pattern is
developed. Distorted patterns are usually caused by
dirt in the nozzle orifice, which can be cleaned by
inserting a small gage soft copper wire into the orifice.
If any one manifold contains several nozzles that are
restricted, the drain plug at the idler end of the
manifold should be removed, after the nozzles have
been cleaned, and the manifold flushed with clean
water. The main supply line strainer and the strainer
in the detergent system should be checked and
cleaned. Check the wash manifold drive linkage
connections and tighten or adjust as required.
B. Power Pack(s) and Control - Every 12 Months
The inside of the Power Pack(s) and Control should
be examined for accumulated dirt and dust. If
required, the components should be cleaned using a
good brand of electrical contact cleaner. All terminal
connections should be checked for securement and
tightened or reworked as required.
C. Ionizing-Collecting Cell –Every 12 to 18 Months
Remove and inspect the ionizing-collecting cells for
excessive dirt accumulations not removed by the
integral washing system. Manually clean as required
in a soak tank, commercial car wash, or with a
pressure hose or pressure cleaner using a low
pressure setting. At this time, particular care should
be taken in cleaning each of the insulators.
D. Motors –Every 24 Months
As the operation of detergent pump motor is limited,
frequent oiling is not required. Lubricate with several
drops of SAE 10 motor oil every two years. DO NOT
OVER OIL. The manifold drive motors are factory
lubricated for life and require no oiling.
7. Troubleshooting
WARNING:
EXERCISE THE USUAL PRECAUTIONS WHEN
WORKING WITH HIGH VOLTAGE. THE MAXIMUM
OPERATING OUTPUT FROM THE POWER SUPPLY IS
18,000 VDC AND 25 MA.
IF SAFETY SWITCHES ARE CLOSED AND CIRCUIT IS
ENERGIZED, DO NOT TOUCH HIGH VOLTAGE. WHEN
THE CIRCUIT IS DE-ENERGIZED, ALWAYS BLEED
OFF REMAINING STATIC CHARGE WITH AN
INSULATED HANDLED SCREW DRIVER BY
SHORTING ACROSS CAPACITOR TERMINALS OR
GROUND AND POINTS OF HIGH VOLTAGE DC
POTENTIAL.
A. General
Outages in electrostatic precipitators occur more
frequently in the high voltage circuit rather than in the
auxiliary systems such as the controls and washer.
Other than the basic hand tools, it is advantageous to
have a standard volt/ohm milliammeter with both a 25
KVDC and 10 KVAC high voltage probe. These
instruments are standard catalog items by several
manufacturers.
B. Secondary Short Circuits
The most common outage is a short in the secondary
circuit and is best located through the process of
elimination. Normal symptoms are a high milliammeter
reading accompanied by the circuit breaker tripping
out. It may be located in the ionizing-collecting cells,
high voltage cables or the power pack. To isolate the
short circuit to any one of these three components,
proceed as follows:
1. Disconnect both high voltage leads from their
respective terminals inside the power pack and
energize the pack. If the circuit breaker remains
“on” and the milliammeter registers zero, the pack
is indicated to be normal. (The milliammeter
should register zero as the normal load, as well
as the short load, have been removed.) If the
circuit breaker continue to trip and/or the
milliammeter registers some value, the trouble is
indicated to be with the power pack. Refer to
Trouble Reference Chart in this section, Page 8.
2. Next, reconnect both high voltage leads to their
terminals at the ionizing-collecting cells and
support them free from any point of contact.
Energize the pack. If either or both leads are
defective, it will be indicated by some value
registered on the milliammeter and/or the circuit
breaker tripping out. If the leads are indicated to
be defective, one can be checked independently
from the other by disconnecting and energizing
them one at a time. When a lead is found to be
defective, replace it in its entirety. It is not
recommended to attempt a high voltage repair or
splice.
3. When both the power pack and high voltage
leads are found to be normal, the trouble is
indicated to be in the bank of ionizing-collecting
cells. The trouble can then be isolated to a tier of
cells, a single cell, or the ionizing or collector
section of a given cell as follows:
a. First determine if the short is in the ionizing
section or the collecting section by
connecting each high voltage lead to its
respective section, one at a time, and
energizing the power pack. (The lead not
connected must be supported away from any
point of contact.) The short symptoms will still
exist for the section in which the short is
located. If the trouble causing the short is
bridging both sections, then the short will be
indicated in both sections when they are
individually connected.

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b. If the unit is more than one tier of ionizing-
collecting cells high, determine which tier is
shorted by disconnecting the jumper wires
between cell tiers and proceeding as
described above. Start by disconnecting the
bottom tier of cells first and work upward.
c. When the short is isolated to one cell tier,
remove all the cells within the tier and visually
check the sections indicated to contain the
short.
(a) If the short is in the ionizer section
look for a broken or defective
insulator.
(b) If the short is in the collector section
look for a large piece of foreign
material bridging the collector plates
or a defective insulator.
(c) If the short is indicated to be in both
sections, it will probably be a foreign
object bridging the air gap between
the ionizer and the collector.
C. Open circuits
Although open circuits can occur in the secondary
circuit, they usually take place in the primary. The
common indications are “zero” milliammeter reading,
indicating light “out”, and the circuit breaker “on”. As
all access panels and doors contain electrical
interlocks, these switches should be checked first to
see that they are electrically sound and properly
closed mechanically. It is usually most expedient to
start with the power pack safety switch and work back
to the primary source of supply. Next, check the
power pack circuit breaker to be sure it is electrically
closing when the switch lever is in the circuit breaker,
check the power pack primary wire connections and
determine if power is being supplied to the high
voltage transformer. Refer to Wiring Diagram, shown
on the Power Pack Outline.
D. Problems other than Short and Open Circuits
Refer to Trouble Reference Chart in this section.
8. Spare Parts
Recommended spare part quantities are usually based on
the unit size and the amount of units per installation. For
specific recommendations, consult the Trion factory or
nearest Sales Office. Consideration, however, should be
given to stocking the following components;
DESCRIPTION QTY.
Secondary Component Board Assembly 1
Cell Insulators 6
Milliammeter 1
High Voltage Transformer 1
Part Numbers are not listed as they are subject to change.
Always state Unit Model and Serial Numbers when
ordering parts or service.

8
TROUBLE
SYMPTOM
PROBABLE
CAUSE
LOCATION
REASON - CORRECTION
Circuit breaker
tripping off and/or
excessive arcing
Short circuit
Ionizing section of cell
1. Defective insulator(s) –replace
2. Dirty insulator(s) –clean
Collecting section of
cell
1. Foreign material bridging plates –
clean
2. Defective insulator(s) –replace
3. Dirty insulator(s) –clean
4. Bent plates –straighten or replace
Power Pack
1. Defective capacitor –look for traces
of oil leakage or bulged case –dead
shorts may be indicated with ohm
meter –confirm by replacement.
2. Defective rectifier –look for obvious
defect in case. No practical field
method for positive check. Confirm
by replacement.
3. High voltage transformer. Check AC
output. Approximately 8,000 VAC
open circuit.
High voltage leads
1. Defective leads –replace
2. Ionizer lead connected to plate
section.
Interchange
High milliammeter
reading
Dirty insulators
Ionizing-Collecting
Cell
Wash unit
Bent
components in
ionizer
Ionizing-Collecting
Cell
Correct as required
Increase in
supply line
voltage
Primary input
If condition is permanent, adjust
variable taps on transformer. Refer to
wiring diagram on the inside of the
power pack access door.
Low milliammeter
Dirty ionizer
Ionizing-Collecting
Cell
Wash unit
Open rectifier
Power Pack
Confirm be replacement
Indicating light
does not glow
Circuit breaker
tripped
Power Pack
Reset circuit breaker
Electrical
interlock open
Primary Circuit
Reset each switch mechanically and/or
electrically check switch and replace if
required
No primary
power
Primary input
Check line service
Indicating light
burned out
Power Pack
Check and replace
No milliammeter
reading, circuit
breaker “on”
indicating light
glowing
Open circuit
Open or Power Pack
Ionizer high voltage lead disconnected.
Reconnect.
Open circuit
Power Pack
Disconnected lead. Check all
connections and reconnect.
Defective
milliammeter
Power Pack
Check for secondary high voltage. If
voltage is correct, replace meter.

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