About Work Station Equipment

Manual Flap Valves Automatic Flap Valves

Fume Arms and Suspension Arrangements

An extraction system is sized for only those outlets which are to be used simultaneously. Th is is in order to maximize effi ciency and minimize the size of the central unit. It must be possible to open and close all outlets. Th is could be via manual shutter and fl ap valves or automatically on demand. Th e Flexpipe can be used for fume extraction, high fl exibility and small diameter allow it to be placed very close to the fume source.

Overhead suspension arrangements such as swing-arms and hose reels can increase the usefulness of the system, increase ergonomics and minimise potential trip hazards from hose left on the fl oor.When large volumes of material are to be introduced into the system, stainless fl oor funnels can be used from which the material is then extracted.

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Work Station Equipment8

8

Cutter 108 has been developed for cutting plastic, paper and card-boardstrips and similar materials.Th e unit is connected to a f108 tubing system and will cut all material in the transport fl ow into 2–15 cm sized pieces. A rotor with three knives work against one stationary knife. Th e knives should be seviced at least twice a year at normal operation 8 hours a day. Depending on amount and type of material the knives should be sharpened and adjusted (500–5000 operation hours). Th e tubing system before and after the Cutter should consist of straight pipes. Because of safety reasons the inlet and outlet pipes should each be at least one metre long. At installation and service the safety considerations should allways be followed.Part No 7357

Exchange rotor Cutter 108 Part No 40677

Cutter 108

TECHNICAL DATA

Weight 19 kg

In-/outlet Ø108

Motor power 0.75 kW

50 Hz 60 HzRotation speed 2800 rpm 3400 rpm

Voltage 220–240/ 254–277/

360–415 440–480

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Work Station Equipment 8

447201

8455

Flap valve 50/76 with microswitch.

dmax

/D A Control Finish Part No

38/50 mm X38 --- peened aluminum 3230

38/50 mm X38 micro-switch peened aluminum 8439

38/50 mm X38 --- white enamel 3231

38/50 mm X38 micro-switch white enamel 8453

Accessories

Part No 3219 Installation set with straight joint

Part No 3218 Installation set with 90o joint

Installation Examples

Wall outlets are available with two fi nishes; peened aluminum or white enamel.

Flap Valves

Flap Valves with micro-switch and attached lead

Part No 8455 Flap valve 50/76 (X50 connection)with micro-switch c/w 3 m lead and terminal box.

Part No 447201 Handle to upper valve.

Wall OutletsFor removable connection of the suction hose. Th e suction hose must be equipped with a connecting sleeve. Installed in the wall with an installation kit, these provide a fi nished, fl ush mounted outlet valve. Th e valve body with spring loaded fl ap is installed after the wall is fi nished. On systems with on demand start-stop, the wall outlet should be equipped with a micro-switch. Th is will give a start-stop signal for vacuum producer control.

For removable connection of the suction hose to the tubing system. Th e spring loaded fl ap is opened manually and the hose cuff is inserted into the valve body. On systems with on demand start-stop, the fl ap valve should be equipped with a micro-switch. Th is will give a start-stop signal for vacuum producer control.

dmax

/D A Microswitch Part No

38/50 mm X38 No 3232

38/50 mm X38 Yes 8454

50/50 mm X50 No 3070

50/50 mm X50 Yes 8433

50/76 mm X50 No 3006

50/76 mm X50 Yes 8272

76/76 mm X76 No 3237

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Work Station Equipment8

8

G3G2½

Ø 76 Ø 76

U

D

B

C

Dimensions, Installation

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/G A Cover Part No

50mm/G21/2 X50 stainless steel 3239

76mm/G3 X76 stainless steel 3238

TECHNICAL DATA Part No Max point load Max total load

3238 180 kg 360 kg

3239 180 kg 360 kg

Accessories

Clean Room Wall and Floor OutletTh e outlet can be used in ”clean room environments”. For removable connection of the suction hose. Th e spring loaded cover is fl ush with the fl oor and can be opened with a special tool, see below. Th e fl oor outlet’s connection to the tubing system is a standard NPT 2 ½”/ 3” thread. Connection is prepared then screwed in when the fl oor covering is installed.

Th e fl oor valves must be installed so that the tubing system carries the stress or so that the valve’s body ( A ) is installed on a level sub-surface. Floor outlets can be specially ordered with micro-switches.

Valve dim. Part No

B C D

G21/2 40378 7443+7428 40201

G3 40377 7442+7428 40201

Floor outlets are available with stainless steel or brass covers.

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Work Station Equipment 8

Wall mounting

Hol

e in

wal

l ∅

85

and

∅ 1

04 m

m

Joint (optional)

Inductive sensor (optional)

Anchor plateWall mounting plate

Anchor plate

For wooden and raised fl oors

Anchor plate

Wall and Floor Outlet , Clean Room X38/50Th e wall and fl oor outlet is designed to meet the requirement for clean room application. Th e valve body is antistatic and made of pre-stressed polypropylene. Th e exposed surfaces of the valve are brushed stainless steel.

Th e outlet is made for both wall and fl oor mounting.

Cover wall mounting plate and spring replacement are possible without removing and replacing the valve body.

Low profi le for mounting even in thin wall partitions.

Outlet optionally equipped with inductive sensor for auto start - stop.

Select cleaning accessories Ø 32 or 38 mm.

Part No 322501Part No 84059 with sensor

For poured concrete fl oor

Accessories Description Part No Wall mounting plate high 42783

Rubberbend 90° Ø 50 2043

Straight joint 2044

Anchor plate 42264

Connector cleanroom 38 outlet 42292

O-ring 49,5 * 3 shore 50 nitril 40451

Hol

e

untingAnchor

Jo(o

(option

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Work Station Equipment8

8

Solenoid Valve Part No. V

8088 24 V AC

8054 230 V

8026 24 V DC

Manual Shutter Valves

Electrical Shutter ValveWhen a shutter needs to be electrically controlled, use an automatic shutter valve, as above, in combination with a solenoid valve as shown here.

Electrically driven shutter valves can be built for special applications. Note that the speed of the gate will be much slower for an electrical shutter than for a standard shutter.

Manual shutter valves are used for stationary machine connection or in cases where a permanent hose connection is desired. By pulling the handle the valve opens. On systems with on demand start-stop, the shutter valve should be equipped with a micro-switch. Th is will give a start-stop signal for vacuum producer control.

Shutter Valve AutoTh e shutter valve has a stainless steel gate actuated by a pneumatic cylinder. For applications on work stations and in the tubing system. With intermittent start-stop, a pressure switch is installed using a ”T” fi tting in the compressed air supply. Th is provides an electrical start-stop signal to the vacuum producer. For valve position sensing, cylinder switches are optional available

D Part No

Ø 50 mm 805308

Ø 76 mm 804408

Ø 108 mm 808404

Ø 160 mm 825404

Ø 200 mm*/ 807500

Ø 250 mm*/ 807800

*/ Note! Shutter Valve φ200 and φ250 only for clean air

and to single step fans (10 kPa max).

D Control Part No

Ø 50 mm --- 805201

Ø 50 mm micro-switch 809101

Ø 76 mm --- 804300

Ø 76 mm micro-switch 809200

Ø 108 mm --- 808300

Ø 160 mm --- 8254

Ø 200 mm*/ --- 8017

Ø 250 mm*/ --- 8016

*/ Note! Shutter Valve Ø 200 and Ø 250 only for clean air.

V Part No

76 EL 230 804411

108 EL 230 808407

160 EL 230 825407

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Work Station Equipment 8

8020

P

8 0 4 7

Pneumatic Tool Pneumatic Tool + man

Electric Tool Electric Tool + man

Stationary Machine Stationary Machine, 2

Accessories Shutter Valve Auto and El

Manual, intermittentstart/stop

Connection Schematic

Installed on pneumatic cylinders to supply electrical signals for start-stop control of vacuum producer. Gives signal when valve is opened.Part No 8047 Pressure Switch

Required for installation of the 8047 Pressure Switch.Part No 8152 T Fitting

For manual actuation of auto shutters. Part No 8040 Manual Switch

Actuates an auto shutter when installed in compressed air supply to a pneumatic tool. Controls on demand extraction. 8020 should be supported by compressed air according to PNEUROP 6611 CLASS 3. CA supply must be clean and dry, 90 PSI recommended.Part No 8020 Flow Valve

A separate solenoid is used for example, on stationary machines and in connection with a manual switch. Th e solenoid is connected pneumatically to the auto shutter. Generally installed in control panel of the subject machine.Part No 8026 Solenoid 24 V DCPart No 8054 Solenoid 230 V ACPart No 8088 Solenoid 24 V AC 50/60 Hz

Auto-start control is used for on demand extraction for electric tools ( max 8 amps on subject tool). Th e auto-start current sensor closes a relay to give solenoid actuation of an auto shutter.Part No 8196 Auto-start 230 vac

Accessories continued on the next page

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Work Station Equipment8

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4942

8001 8002

Welding Welding + man

Connection Schematic

AccessoriesPart No 4942 Silencer Ø 100 300/200

Used for automatic control of extraction in induction welding applications. Striking an arc will cause the current sensor to close a relay. In turn the relay causes solenoid actuation of an auto shutter. Th is control must be supplied with 24 V AC, 0,5 A.Part No 8168 Welding Auto-startwith current sensor

Supply transformer for 8168 Welding Auto-startPart No 8029 Transformer 230/24 V AC 4 A

Th e vacuum relief valve bleeds in air at the pre-set relief level and can be installed at the outermost point on a tubing system. Th e valve will introduce transport air into the system when the pressure in the system exceeds the setting of the vacuum relief valve.Part No 8001 Vacuum Relief Valve ø76Part No 8002 Vacuum Relief Valve ø108

Vacuum Relief Valve

Accessories Shutter Valve Auto and El

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Work Station Equipment 8

Connection Schematic Extraction Arms

AutoMan

ø76

Dimensions, Extraction Arm

Fume Extraction Arm

Extraction arm for welding fume etc. Th is articulated arm is easily adjusted to the correct working position. Th e hood is equipped with a 24 V 50 W halogen work lamp and dual switches for lamp and Shutter Valve El control. Th e 76 mm Extraction arm should always be installed with 1 m of 76 mm hose between the arm and tubing system.ø76 Part No 590102

TECHNICAL DATA Qnom

Δpnom

Ø76 400 m3/h 3 kPa

In high pressure systems, the extraction arms may require a restrictive plate

to compensate pressure for suitable air fl ow.

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Work Station Equipment8

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5726

5725

7331/7332

7330/7308

kPa Δp

2,5

2,0

1,5

1,0

0,5

00 100 200 300 400 500

Q

m3/h

ø50

ø76

5725

5726

Swingarm for Flexpipe

Mounting alternatives

Dimensions

Pressure Loss Swingarm

Q

m3/h

kPa Δp

2,5

2,0

1,5

1,0

0,5

00 100 200 300 400 500

ø50

ø76

Pressure Loss Flexpipe

In high pressure systems, the fl expipe may require a restrictive plate to compensate pressure for suitable air fl ow.

Th e Flexpipe reach can be increased with swingarm installation. Th e swingarm length is easily adjusted by either cutting the horizontal tube or by replacing it with a longer tube from the standard tubing system, max. 3 m for Ø 50 and max. 4 m for Ø 76. Th e swingarm may be equipped with suction hose but should not be loaded with anymore than the weight of the hose itself.Ø 50 Part No 5725

Ø 76 Part No 5726

FlexpipeDustcontrol’s Flexpipe is a type of extraction arm for source extrac-tion of welding fume, chemical vapors, wood dust, etc. Th e fl expipe is a fl exible hose that can be placed in practically any ori entation desired.Diameter of the Flexpipe is small and it can be used very close to the source without disturbing the work. Extraction is very eff ective.

Part No. 7330 7308 7331 7332

Inner Diameter ø 50 ø 50 ø 76 ø 76

Tubing System

Connection joint ø 50 joint ø 50 joint ø 76 joint ø 76

Length 700 mm 1 m 700 m 1 m

Air Flow 80–200 m3/h 80–200 m3/h 200–450 m3/h 200–450 m3/h

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Work Station Equipment 8

5740

Special

kPa Δp

3

2

1

00 100 200 300 400

Q

m3/h

864,53,52,5

Swingarms

Dimensions Mounting Alternatives

Swingarms are used to increase the working envelope without increasing hose lengths. Optionally, tools can be suspended from the swingarm.Part No 5720 2.5 mPart No 5721 3.5 mPart No 5722 4.5 mPart No 5723 6 mPart No 5724 8 m

AccessoriesTh e suspension track is installed on the inner link of the swingarm.Part No 5740 Linear Suspension Track

Pressure Loss Swingarm

Part No 5720 + 5740

Part No 5721 + 5740

Part No 5722 + 5740

Part No 5723 + 5740

Part No 5724 + 5740

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Hose Reel Th e Dustcontrol hose reel for 38 and 32 mm hose can be used with all available 38 mm accessories. Th e hose reel mechanism is equipped with a latch mechanism allow-ing the user to take out as much hose as required and then retracting it onto the reel for storage. Vacuum through the reel is controlled by a combi nation of pneumatic switch and automatic shutter valve. Th e tubing system opens automatically when the hose is withdrawn from the reel. Th e hose reel is supplied with an articulating mounting bracket.Part No 7397 Hose Reel 32 mm, complete

Part No 7305 Hose Reel 38 mm, complete

TECHNICAL DATA 32 mm 38 mm

Hose Part No/length 2005/10 m 2038/7.5 m

Connection diameter Ø 50 Ø 50

Copressed air supply min 5 bar (75 psi) min 5 bar (75 psi)

For specifi c information about the hoses - Material properties Hoses (page 144).

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Work Station Equipment 8

4149 7148

6098

7150

6005

6610

6616

Part No Description Connection (Ø) (in/mm)

4149 Suction nozzle 2”/50

6005 Universal nozzle 1.5”/38

6098 Tubular nozzle 1.5”/38

6610 Universal nozzle 1.5”/38

6616 Universal nozzle Ø 50 2”/50

7148 Funnel shaped nozzle Ø 50 2”/50

7150 Magnetic holder for 7148, 4149 2”/50

TECHNICAL DATA

Part No Qnom Δpnom

4149 150 cfm/250 m3/h 6.4inwg/1.6 kPa

6005 90 cfm/150 m3/h 6.4inwg/1.6 kPa

6098 90 cfm/150 m3/h 15.2 inwg/3.8 kPa

6010 90 cfm/150 m3/h 6.4inwg/1.6 kPa

6616 250 m3/h 6.4inwg/1.6 kPa

7148 150 cfm/250 m3/h 6.4inwg/1.6 kPa

9060 90 cfm/150 m3/h 10.8 inwg/2.7 kPa

Welding Accessories/Extraction Nozzles

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Work Station Equipment8

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About Control SystemsTh e control system is used for the starting and stopping of the vacuum producer, turbo pump or high pressure fan. Th ey also control fi lter cleaning and give condition indications. In the system control panels, additional functions can be built in by selecting options.Control systems must be installed by a certifi ed electrician. Th e control panels conform to electrical protection class IP 54 (IC529). Manufacturing standards conform to EN60204 (IEC204-1), VDE0113A2/381, DIN 57113A2. Main fuses and working disconnects are not included in the control panels..

System Control PanelsSelect confi guration of system control panel by optional additional digits.

Example

System Control Panel 86 ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤Standard (IP54, painted cabinet) 861 ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤1 pump 8611 ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤18.5 kW 86119 ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤400 V, 50 Hz 861196 ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤Solenoid valves 24 V AC 861196 1 ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤Filter cleaning S 32000: After stop and man 861196 15 ⎣⎤ ⎣⎤ ⎣⎤ ⎣⎤Airlock control 160 861196 151 ⎣⎤ ⎣⎤ ⎣⎤Clean out/Flush valves 2 pcs. 861196 1512 ⎣⎤ ⎣⎤Electronic clock/External signal: No 861196 15120 ⎣⎤Lighting + power point 230V 6A in cabinet 861196 151202

System control panels are always delivered with

• Main switch• All condition indications and manoeuvres on display at front• PLC-control• Motor circuit breaker• Function for start and stop of pump/fan with soft start • Pulse control for fi lter cleaning• Start from external signal, prepared for intermittent run (10 min

stop delay)• Manual start on display• Timers for fi lter cleaning and intermittent run can be altered on

display• Connection of thermal protection (pumps of 11 kW and more)• Condition indications and alarms on display• Start on demand for lag pumps/fans (panels for 2 and 3 vacuum

producers)• Signal for shutter valve shutting at start (fans)

All condition indications and manoeuvres on display at front of system control cabinet.

Dimensions (base confi guration)

Measure Height Width Depth

1 pump/fan 2.5–11 kW 600 380 210

1 pump/fan 15–22 kW 700 500 250

1 pump/fan 30–37 kW 800 600 250

2 pump/fan 2.5–11 kW 800 600 250

2 pump/fan 15–22 kW 760 760 300

2 pump/fan 30–37 kW 1000 800 300

3 pump/fan 2.5–11 kW 1000 800 300

3 pump/fan 15–22 kW 1200 800 300

3 pump/fan 30–37 kW 1200 1000 300

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Control Systems 9

Control Systems for USA/Canada

System Control Panels

Base System Control panels are confi gured with;

• Lockable Main disconnect• Fusing on main feed and control fusing• LED Indicators• Pilot Devices for Operation• Direct magnetic motor starter• Motor overload protection • Pulse control for fi lter cleaning• PLC Control• Connection for Turbo pump Th ermal KLIXON• NEMA 12 Enclosure

Dustcontrol maintains a policy of active development for controls and control systems and recognizes that there are more ”special control” confi gurations available than basic. Th e basic panel confi guration above is the minimum required for the basic operation of an extraction system. When your requirements, or the requirements of the system, become more complex, we will be there. We can customize a control solution for you, from basic to complex multiple system architectures and everything in-between.

Some examples of options available:

• Reduced Voltage StartersSometimes referred to as a soft-start. Th ese devices are pre-progammed to give a gradual application of voltage as a motor starts. Th ey usually slow the motor start to 5 or 10 seconds and reduce the current in-rush to the motor. Th is results in less stress on electrical and mechanical parts and contributes to enhanced reliability of motors, starter components, overloads and the vacuum producer. Let us show you the benefi ts.

• Variable Frequency DrivesCommonly referred to as VFD’s or drives. Th ese devices allow us to program and control the behavior of the motor. Th e available parameters in a VFD let us, not only soft start your vacuum producer, but provide a whole range of operational parameters to make your system smarter. VFD’s can be demand controlled by a PLC to provide vacuum production on demand. Ramp up when the system usage requires it and idle back to save you energy when system utilization is low. As well as the enhanced control, VFD’s provide an un-paralleled degree of feedback for trouble shooting and power quality diagnostics

Dustcontrol USA supplied electrical control panels are UL listed and bear the serialized UL mark listing.

Dustcontrol Canada supplied electrical control pa-nels are CSA approved and bear the CSA mark.

• Touch ScreensTouch Screens can be added to a system control to give the operator more input/output capability. A standard black and white screen can be used to replace indicator lamps and pilot devices and is easily justifi ed on a cost basis. Larger and higher resolution color screens let us program more enhanced feedback for the user and allow the user access to parameters that would not be available from PB’s and indicator lamps. Access to diff erent parameters can be password protected, supervisors can adjust fi lter cleaning directly, for example.

• SensorsDustcontrol can use many diff erent types of sensors in the extraction system to inform the control and operators of diff ering system conditions.

• Proximity Sensors - monitor levels in silos.• Ultrasonic sensors - monitor fi lling levels in containers.• Temperature sensors - monitor motor, pump and exhaust temp.• Flow sensors - control velocity and fl ow rate.• CT Coil - montior current demand on a vacuum producer.• Inductive Position Sensors - feedback on an object’s position

• Network Ready Architecture: we can program the PLC to be network ready and have access to the World Wide Web. Web access ads a whole range of possibilities; remote monitoring, remote diagnostics and software upgrades over the web.

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Control Systems9

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System Control Panel

Starter

Starter for manual or microswitch start

Part No 8117, 2.5 kW, 400 V

Part No 8119, 2.5 kW, 230 V

Part No 8132 Starter for microswitch or manual start and function for automatic fi lter cleaning.

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Control Systems 9

DC Green System

Lower power consumption•

No micro switches•

Higher peak performance•

Optimum suction performance •

at all times

Increased lifetime of the va-•

cuum system

Why not reduce your carbon footprint and at the same time cut your costs?

DC 11-Module with DC Greensystem

Dustcontrol´s patented DC Green System is a system for the control of vacuum producers that helps to save energy. Th e DC Green System together with our vacuum producers (radial blowers and turbo pumps), can potentially off er you an energy saving with existing or new Dustcontrol vacuum producers of between 40 and 90 percent.

Depending on the number of open outlets, the RPM of the vacuum producer is optimized by the DC Green System, generating just as much vacuum as needed. By using a sophisticated on-demand control with a frequency converter, the maximum performance is also increased compared to a normal system. When no outlets are open the vacuum producer automatically switches to a saving mode. Th is eliminates the need for electrical microswitches at each work station.

Depending on individual cases and the current market price of electricity; payback time for the purchase of the DC Green System is generally between 1-5 years. In summary, lower energy consumption contributes to economic savings, less environmental impact and an increased life span of the equipment.

Your Dustcontrol contact can calculate the estimated saving in your case.

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Control Systems9

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Dustcontrol DC Green System™

Traditional Vacuum System

Part of total working hours

Number of users

Part of total working hours

Number of users

104

Control Systems 9

DC Green System for 1 turbopump

Part No 87 1 1 4 E 1 3 0 0 0 0D

C G

reen

Sys

tem

Cat

egor

y

Vac

uum

Pro

duce

r

Pow

er

Ele

ctric

al S

uppl

y

Vol

tage

Sol

enoi

d V

alve

s

Filte

r Cle

anin

gD

isch

arge

Shu

tter v

alve

s

El.

Clo

ck/E

xter

nal s

igna

Ext

ras

CATEGORY FILTER CLEANING1 Standard 1 S11/21000: After stop, man and during run 3

S32000: After stop, man and during run 6VACUUM PRODUCER S34000: After stop, man and during run 9

1 pump 1DISCHARGE

No 0POWER Airlock 160 1

11 kW 6 Airlock >160 215 kW 8 Discharge valve 318,5 kW P-pump 9 Auger Compactor 422 kW P-pump A30 kW P-pump B SHUTTER VALVES18,5 kW S-pump D No 022 kW S-pump E Clean out valve 1 pcs. 130 kW S-pump F Clean out valves 2 pcs. 2

Clean out valves 3 pcs. 3ELECTRICAL SUPPLY Clean out valves 4 pcs. 4

380-480V, 50/60 Hz E Shutting off valvel (filter unit) 5

VOLTAGE SOLENOID VALVES ELECTRONIC CLOCK/EXTERNAL SIGNAL24 VAC (Standard) 1 No 024 VDC 2 Electronic clock weekly, external 1110 VAC 3 Electronic clock weekly, internal PLC (RTS) 2230 VAC 4 External alarm signal 3

External operation signal - pump/fun runningt 4External switch - start requirement 5

EXTRASNo 0Power point 230V 6A in cabinet 1Lighting + power point 230V 6A in cabinet 22 pressure sensors 33 pressure sensors 44 pressure sensors 5

Selections, DC Green System

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Control Systems9

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