TABLE OF CONTENTS · [email protected] Year established: 1990 PlymoVent Worldwide – we are there...

1Visit us on internet at: www.plymovent.com

TABLE OF CONTENTSPlymoVent Worldwide with references .........................................2 - 3

IT’S YOUR HEALTH Limit Values ............................................................................. 4 TLV information on the internet ................................................... 5

PROCESSES FOR COOLANT MIST/SMOKE CAPTURE AND FILTRATION Metal working fluids ............................................................6 - 9 Machining processes ....................................................... 10 - 11 Machine enclosure / System design ................................... 12 - 13 PlymoVent filtration processes ........................................... 14 - 15

PLYMOVENT COOLANT MIST/SMOKE FILTERS Quick guide ..................................................................... 16 - 17 MistEliminator General overview ............................................................. 18 - 19 The technology – general information ...................................... 20 Self-draining filter cassette technology .......................................21 Bag filter technology / Application options ............................... 22 Technical Data .................................................................23 - 24 Case study ............................................................................ 25 MistWizard™ General overview ............................................................26 - 27 Technology .............................................................................28 Application options ............................................................... 29 Technical Data ....................................................................... 30 Case study .............................................................................31 EFO General overview .................................................................. 32 Technology ............................................................................ 33 Technical Data ....................................................................... 34 Case study ............................................................................ 35

FANS AND INTELLIGENT CONTROL EQUIPMENT Quick guide ........................................................................... 36 Fans ................................................................................... 37 - 41 Intelligent Control Equipment ................................................. 42 - 45

AT SOURCE CAPTURE Quick guide ........................................................................... 46 Extraction Arms General overview ............................................................ 47 - 49 Technical Data ....................................................................... 50 Fixed Hoods General overview ....................................................................51 Technical Data ........................................................................51

SYSTEM AND DESIGN System and design .......................................................... 52 - 53 Pressure loss .................................................................. 54 - 55 Maintenance and Service ....................................................... 56

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Visit us on internet at: www.plymovent.com Visit us on internet at: www.plymovent.com

We have helped many customers just like youFor over two decades PlymoVent has been satisfying the needs of customers just like you. Listed below are some worldwide well known companies that have been concerned about the effects of hazardous coolant mist/smoke within the work shop. They have all installed PlymoVent systems to protect their largest asset – their employees. Thanks to this they have also substantially increased their profitability.

Some of our references

PlymoVent AB - Factory P.O. Box 527 SE-921 28 Lycksele, Sweden Tel: +46 950 57 67 00 Fax: +46 950 57 67 90 [email protected] Year established: 1976

All our offices have the experience and know-how to supply a complete solution for a very profitable, clean and healthy work environment. For over 25 years we have provided the most effective, and in the long run, most economical solution to any problem our customers may have.We are happy to share our professional knowledge, from analysis and design to supply, installation and commissio-ning – all included in a value for money package.Welcome to PlymoVent.

PlymoVent is a global company with subsidiaries and distributors in over 45 countries

PlymoVent GmbH Heideweg 24 D-53604 Bad Honnef, Germany Tel: +49 2224 97 300 Fax: +49 2224 89 [email protected] Year established: 1986

PlymoVent Ltd Marley Way, Southam Road Banbury, OX16 2RA, England Tel: +44 1295 25 93 11 Fax: +44 1295 27 17 50 [email protected] Year established: 1978

PlymoVent SA B.P. 30, Zone Industrielle de Mavault F-86170 Neuville de Poitou, France Tel: +33 549 51 55 88 Fax: +33 549 51 59 33 [email protected] Year established: 1991

PlymoVent AB - Sales office Industrigatan 26, Tangenten 2 SE-212 14 Malmö, Sweden Tel: +46 40 30 31 30 Fax: +46 40 30 31 40 [email protected] Year established: 1979

PlymoVent Inc 12 - 2400 Aerowood Dr. Mississauga, ON. L4W 2S7, Canada Tel: +1 905 564 4748 Fax: +1 905 564 4609 [email protected] Year established: 1990

PlymoVent Worldwide – we are there for you

PlymoVent Corp. 115 Melrich Road Cranbury, N.J. 08512, USA Tel: +1 609 395 3500 Fax: +1 609 655 0919 [email protected] Year established: 1989

PlymoVent DistributorsArgentinaAustraliaAustriaBelgiumBrazilCzech RepublicChileChinaColombiaDenmarkEgyptEstoniaFinland GreeceHongkongHungary IcelandIrelandItalyJapanKenyaKoreaLebanonLithuaniaMalaysiaMaltaMexicoNetherlandsNorwayPoland Portugal Russia - Moscow - Novosibirsk - St.PetersburgSaudi Arabia SingaporeSloveniaSouth Africa Spain Switzerland Taiwan Turkey

ABB Coiltech, SwedenAC Grinding Machine & Tool, CanadaAcedes Gear Tools Ltd, EnglandAcome, FranceAdvanced Mold & Die, CanadaAlcatel Kabel, GermanyAlcoa, HungaryAlstom Power, PolandAlstom Power, SwedenAluPro Norwat AS, NorwayAnchor Cap & Closure, CanadaArlamatic, FranceArzon Ltd, CanadaAssa AB, SwedenAta Gears OY, FinlandAtlas Copco Secoroc, SwedenAtlas Tube, CanadaAutomotive Precision Components, EnglandBaxter Mfg , USABBA Nonwovens Canada LtdBedestone Ltd, EnglandBenteler, GermanyBiggeman, GermanyBWE Ltd, EnglandBoeing Aerospace, USABoge, GermanyBombardier - Downsview, CanadaBorg Warner, USABOSH Jihlava, Czech RepublicBPW Raba, HungaryBrockhaus, GermanyBürkert, FranceBruker, FranceBrüning & Drissner, GermanyBulten, SwedenBygg og Ventilasjon AS, NorwayCables Pirelli, FranceCamas Building Materials Ltd, EnglandCanada Brick, CanadaCarillo Industries, USACaterpillar Ltd, EnglandCaterpillar, FranceCaterpiller, GermanyCeodeux Metatec, FranceCermip, FranceCesa, FranceCezus Framatome, FranceCMD, FranceCollege Tool & Die, CanadaColoplast A/S, DenmarkComau, FranceCommonwealth Steel Co, AustraliaConté, FranceCorrect Tool, CanadaCorvilla OY, FinlandCross Huller Ltd, EnglandCummins Engines, EnglandDaimler Chrysler, USADavidsen CNC A/S, DenmarkDECO Automotive, CanadaDefence Research Agency, EnglandDeha, GermanyDelphi Automotive, USADesi Hamburg, GermanyDrault Décolletage, FranceDrouin, FranceDupont CanadaEaton, France

Eaton Transmissions, EnglandEaton Transmissions, PolandEgelhof, FranceEibach, GermanyElement Six AB, SwedenEmitec, GermanyErasteel, FranceExir, HungaryExpress Transformers Ltd, EnglandFairchild Simmond, FranceFavique, FranceFB Kedjor, SwedenFederal Mogul, FranceFedida, FranceFilterwerke Hengst, GermanyFinntorpets Mekaniska, SwedenFlebu Bergen AS, NorwayFlex-n-Gate, CanadaFobe Produktion AB, SwedenFonderie Atelier du Bélier, FranceFord Components Mfg, EnglandFord Motor Co, USAFormer, FranceFrank Mohn Flatøy AS, NorwayFrance Transfo, FranceFrödinge Mejeri, SwedenGaggenau, FranceGBM Rivet & Fasteners Inc, CanadaGEC Marconi ltd, EnglandGEMA Punching BV, HollandGeneral Electric, USAGeneral Motors, FranceGKN Sintermetals, GermanyGKN Westland, EnglandGMR Maskiner A/S, DenmarkGraninge, SwedenGunther Tools, FranceGurtec, GermanyG W King Ltd, EnglandHallberg Sekrom, SwedenHallmark Cards, USAHanso Technologies, CanadaHeatrae Sadia Ltd, EnglandHellsten Mekaniska, SwedenHeritage Hardwoods, USAHermes Métal, FranceHeyco Products, USAHispano Suiza, FranceHolmatro Industrial Equipment, HollandHonda UK, EnglandHuth, GermanyHydro Aluminium A/S, DenmarkIGS, GermanyIMI Norgren, EnglandIng. Bjørn Sønju, NorwayIngersoll Rand, USAIntertractor, GermanyIrish Electricity Supply Board, IrelandIsaac Ltd, EnglandITW Construction, DenmarkJ & S Precision Produts, USAJallut, FranceJE Pedersen Maskinfabrik, DenmarkJohnson Crushers, USAKantahl, PolandKantahl, SwedenKC Production A/S, DenmarkKennametal, USA

Kienle + Spiess, HungaryKingsbury CanadaKMX Technologie, FranceKone OY, FinlandKongsberg Automotive, NorwayKongsberg Defence & Aero, NorwayKongsberg Næringspark, NorwayKrupp, GermanyKüpper, GermanyKvisgaards Maskinfabrik A/S, DenmarkKværner Mesna AS, NorwayLasert Tool, SwedenLemken, GermanyLes Emballages Winpak, CanadaLeybold, FranceLift-Rite, CanadaLinread Ltd, EnglandLU, FranceLugand Acier, FranceMachinefabriek van Aalst, HollandMalichaut, FranceManurhin, FranceMartsila NSD Norway AS, NorwayMéca 21, FranceMeca Précis, FranceMéca Téno, FranceMecachrome, FranceMecamachine, FranceMeincke A/S, DenmarkMIBA Slovakia, Slovak RepublicMichelin Tyres Ltd, EnglandMikromekanikk AS, NorwayMMC, FranceMohawk Europa Ltd, IrelandMotelec, FranceNabisco Ltd, CanadaNational Power plc, EnglandNSK Bearings Ltd, EnglandOBO-Bettermann, GermanyOetiker Ltd, CanadaOne Steel (BHP), AustraliaOpel, GermanyOttawa Fibers, CanadaOxford Suspensions, CanadaOxford University, EnglandPart Nuclear Powerplant, HungaryPCI, FrancePegard, BelgiumPharmaserve, GermanyPirkan Avartajat OY, FinlandPJ Wallbank Mfg, CanadaPlastirémo, FrancePlastone OY, FinlandPlatestahl, GermanyPowergen, EnglandPPM, HungaryPrecision Interconnect, USAPrinz, GermanyRaba, HungaryRAHM Ind Inc, CanadaRazors Edge Sharpening Service, USARecord Tools Ltd, EnglandRedditch Gears Ltd, EnglandRegulator AS, NorwayRenault F1, EnglandRenk, GermanyRHP Bearings Ltd, EnglandRichter Gedeon, Hungary

Ring Mekanikk AS, NorwayRobin Mold, CanadaROL Gaskets, CanadaRoll Royce Engine - Bergen AS, NorwayRottefella, NorwayRyka Blow Molds Ltd, CanadaSaab, SwedenSamson Agro A/S, DenmarkSandco Automotice, CanadaSandvik-Tamrock OY, FinlandSasic, FranceSchlafhorst, GermanySchunk, GermanyShanghai Hitachi El. Appl. Co. Ltd, ChinaShanghai Mitsubishi Elevator Co. Ltd, ChinaShanghai SDS, ChinaSintertech, FranceSNFA Bearings, EnglandSlide-Master div. of Magna, CanadaSpécitube, FranceSPSG, HungarySSAB Oxelösund, SwedenStahlwerk Ergste Westig, GermanyStandard Metal, GermanySteinbach, GermanyStryker, GermanySønderborg Værktøjsfabrik A/S, DenmarkTabco Auto Brake, CanadaTechni-Scie D.M., CanadaTenneco Automotive, USATeräs-Astra OY, FinlandTexor AB, SwedenThermi Lyon, FranceThyssen Fügetechnik, GermanyThyssen Marathon CanadaTOS Varnsdorf, Czech RepublicToyota Motor Manufacturing, CanadaTrane Company, USATréfil Europe, FranceTridimus, FranceTriefus, FranceTubest, FranceUnika Værktøj A/S, DenmarkVattenfall, SwedenVAW, HungaryVernet Behringer, FranceVerrault Navigation Inc, CanadaVest-Consult AS, NorwayViessmann, GermanyVisteon, USAVitroCom, USAVolkswagen AG, GermanyVolvo Aero Norge AS, NorwayVolvo Powertrain, SwedenVolvo PV, SwedenWartsila NSD Norway AS, NorwayWellman International Ltd, IrelandWest Heights Manufacturing, CanadaWestfalia, FranceWielpütz, GermanyWilliams Fluidair Corp, CanadaWilson Tool, EnglandWinter, GermanyWorthington Cylinder, CanadaYork Metal Spinning, CanadaZircotube, FranceÖrnalp AB, SwedenÖrnsköldsviks Mekaniska Verkstad, Sweden

4 5Visit us on internet at: www.plymovent.com Visit us on internet at: www.plymovent.com

For more information on hazards and Threshold Limit Values of coolant mist/smoke, visit one of the many health regulatory agency websites listed below:

Great Britain

UK Section of European Agency for Safety and Health at Workwww.uk.osha.ei.int

Health and Safety Executivewww.hse.gov.uk

USA

American Conference of Govern-mental Industrial Hygienists, Incwww.acgih.org

American Industrial Hygiene Associationwww.aiha.org

National Safety and Healthwww.cdc.gov/niosh

Occupational Safety & Health Associationwww.osha.gov

Europe/EU

European Agency for Safety and Health at Workwww.europe.osha.eu.int

Germany

Bundesanstalt für Arbeitsschutz & Arbeitsmedizinwww.baua.de

Berufsgenossenschaftliches Institut für Arbeitssicherheitwww.bia.de

Sweden

National Institute for Working Lifewww.niwl.se

National Board for A Safe Work Environmentwww.av.se

Canada

Canadian Center for Occupational Health and Safetywww.ccohs.ca

Australia

National Occupational Health and Safety Commissionwww.nohsc.gov.au

Norway

Statens Arbeidsmiljoinstituttwww.stami.no

Finland

Social- och hälsovårds-ministerietwww.vn.fi/vn

Denmark

Arbeidstilsynetwww.arbeidstilsynet.no

Arbejdsmiljøinstituttetwww.ami.dk

It’s your health!

Threshold Limit Value (TLV)Every country has its own TLV value that will set the standard of the indoor air quality in the plant. The TLV values in the field of coolant mist/smoke are given in mg/m3. The measurement is always taken in or near the breathing zone of the operator. This means that the TLV value will give information about how much coolant mist/smoke is acceptable for the operator to inhale.

Corporate Limit ValueIn many countries the legislations are not up to the industrial standard or only recommendations. There-fore many multinational companies are setting their own hygienic limit value in own Global Production Standards. The reason for doing this is to make sure that air quality is kept at the best possible level, making sure that production can follow the quality standards in every country where the company is active.

Short Term Value (STV)The STV is an accepted short term exposure to the contaminant. Normally for periods not exceeding 15 minutes and repeated maximum 4 times per day with at least 60 minutes between each exposure. Most countries also have regulations for STV but they are not as well known as the TLV values.

Why you need machine coolant emission capture system

Indoor air qualityEnvironmental Protection Agency studies of human exposure to air pollutants indicate that indoor levels of pollutants may be 2-5 times, and occasionally more than 100 times, higher than outdoor levels. These levels of indoor air pollutants may be of particular concern because most people spend about 90% of their time indoors. A clean air environment improves productivity and reduces sick-leave.

Outdoor air qualityIn most countries certain legislation exists on the discharge of polluted air to the outside of the building. When it comes to coolant mist/smoke, a government permission for higher concentration might be required. Besides the government restriction other factors are important:

• Possible roof contamination. The mist will nor-mally stay very close to the exit point and stick to the roof, giving maintenance costs.

• In industrial areas it might not stay on your roof, instead it will bother the neighbourhood.

• In many industries exhaust air will pass through a heat recovery system. Mist in that system means higher maintenance and lower efficiency.

It’s about reducing operators exposure to harmful machine coolant contaminates.

Air quality

Exposure limits

PlymoVent reserves the right to make design and technical changes.

PortugalDirecção Geral do Ambiente

www.diramb.gov.pt


Processes for coolant mist/smoke capt ure and filtrationMetal working fluids

The metal working fluid – The major concern for both health and system design.

Metal working fluids are used to cool and lubricate the machining activity, prolong the life of the tool, carry away debris and protect the surfaces of the work pieces. The metal working fluid is a complex mix-ture, which may contain oil, additives such as biocides and rust inhibitors etc. as well as contaminants like metal fines, tramp oil and bacteria. Occupational respiratory illness due to exposure to metal working fluids includes respiratory irritation, bronchitis, pneumonia, pneumonitis and extrinsic asthma.

Straight oil / Petroleum based oil / Mineral oilA non-diluted mineral based oil, excellent for low speed operations, requiring high surface finish. Heats up quickly and will easily create mist.

Coolant mist/AerosolDuring machining, mist is produced by the interaction of the fluid with the moving parts. When liquid hits fastmoving parts, it is thrown back and dispersed as fine droplets.Important for the generation of mists are:• Higher speed of tool = higher generation of

mist• The volume, rate and point of delivery of

metal working fluid to the cutting edge.

Coolant smokeIf metal working fluids become excessively hot they may start to ”burn” and degrade. During machining of metal parts reaching a high tem-perature, such as grinding procedures, smoke may be visible.

Vapour / Gas phaseThe gaseous state of any liquid is formed as molecules leave (evaporate from) the surface of the liquid (like rainwater drying from road surface). The evaporation increases with low boiling point of the liquid and increased tem-perature of the fluid. In waterbased emulsion the evaporation will increase the humidity in the plant.

Common hazards

• Exposure to endotoxin

• Carcionogenicity

• Allergy reaction

Vegetable oil / Biodegradable natural oilBased on renewable raw materials, always developed with the eco-cycle in mind. Often mentioned as the environmentally sustainable alternative.

Common hazards

Some type of fungi (moulds) can grow in syn-thetic or semi-synthetic fluids.

In vegetable oil and some water based emul-sion (see page 8) there is a risk for bacteria growth in the system. Often this is controlled by Biocide, but not to 100%. Surviving bacte-ria can quickly re-establish.

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Synthetic based oils / Synthetic fluidContains no mineral oil and has a high water content. Offers good corrosion control with better cooling capacity than other fluids. Use range; from normal to heavy applications.

Common hazards

The use of synthetic cutting fluids has recently become questionable, due to discovery of diethanol nitroamine, a suspected cancirogen, as a product from the reaction of amones with nitrites. Besides this, synthetic oils also develop the same hazards as for water based emulsion.

The metal working fluid and the filtration system

The constant development of the metal working fluids often creates new problems in the filtra-tion system. The PlymoVent MistEliminator (see pages 18-25) is easy to re-configure to handle any type of coolant, which minimizes the risk of making the wrong investment.

The mist generated from the different coolants is always a combination of machining proc-ess, coolant type and fluid rate. The same coolant can in various applications generate heavy or light mist, depending on how opti-mized the process is.

Material Safety Data Sheet (MSDS)

The Material Safety Data Sheets (MSDS) for coolants and biocides used at the plant should be obtained and evaluated for the best PlymoVent option as well as:

• Effect on human exposure

• Discharge to atmosphere permits

• Flash point, flammability and combustibility. This is especially important when using the electrostatic filtration system. PlymoVent does not recommend using this technology with coolants with low flame point, explo-sion risk or water miscible with less than 5% water.

Provide the MSDS to your PlymoVent repre-sentative for best possible advice.

Waterbased emulsions / Soluable oil concentrateNormally a mix between oil, water and other emulsifiers to create specific features. A typi-cal mixture is 90-95% water. Offers good cooling and lubrication capacity.

Common hazards

• Carcionogenicity

• Legionnairies disease

• Microbiological contaminationAlso please note that electrostatic technology is not suitable for:• coolants with low flame point or explosion risk• emulsions with less than 5% water

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Processes for coolant mist/smoke capt ure and filtration

Coolant mist/smoke generation guideType of coolant Smoke Mist

Straight cutting oils 70 % 30 %Water based emulsion 10 % 90 %Synthetic based oils 30 % 70 %Vegetable oil 20 % 80 %

For more specific guidelines, please contact your PlymoVent representative.


Common types of machining processes

Mixing wet & dryToday some machine tools can run both wet and dry operations. This means that it is important to have filtration units with high filtration area to collect the dust but still with draining capability when running the machine with a coolant, see page 22.

High speed machiningHigher speed means more need for coolant and more mist. Higher temperature also means more fine mist and smoke. PlymoVent self draining technology is the perfect choice (see page 21).

Before selecting the filtration system, it is important to make a careful study of the machining process.

This is important for a good result regarding both capture and filtration. Here is a list of common machining operations, generating coolant mist and smoke:

• Computer Numeric Controlled – CNC Machine centers

• Grinders – OD Grinders – ID Grinders – Surface grinders – Rotary grinders

• Tool Cutters – Grinders – Form grinders – Broaching, hobbing – Sawing

• Electronic Discharge Machines (EDM)

For applications not mentioned in the list, please consult your PlymoVent representative for detailed advice regarding filtration systems.

A few comments on the selection of the optimal solution:

Control signal outputAlmost all machines have control signal outputs. Information about these outputs means that we can control the start/stop of the filtration system on, for instance, the movement of the spider. Read more on pages 44-45.

Mechanical filtration suitable for grinding processesIn grinding, small metal particles will be a part of the mist. The best way of handling this is by using PlymoVent self draining technology, see page 21. PlymoVent never recommend the use of electrostatic technology with grinding applications.




Central filtration systemTo have all filters for the machine hall in one place, will give low maintenance costs and low invest-ment cost for the total system. It is also easy to install a heat recovery system. It will however also give some disadvantages, like costly ducting, and is not flexible for changes in production layout. It also requires more engineering during the instal-lation and a closer cooperation with filter supplier and ventilation contractor.

Filtration system for production cellThis means that one filtration system serves a designated group of machines. This is well suited for plants with variable machine utilisation times in individual production cells.

Filtration unit, directly fitted in machine enclosure The coolant recovery system with easy installation, without need for ducting or floor space. The per-fect choice when the filter must follow the tooling machine. In case of high degree filtration efficiency the maintenance cost can be high but in plants with low density on machinery it is a perfect alternative. More information about the PlymoVent MistWizard, go to page 26-31.

System designMachine enclosures

Open machines An open machine can be enclosed as a retro fit. This can create an efficient system. However the retrofit is expensive and complicated. It requires detailed knowledge of the machine and the process to suc-ceed with this task. In most cases it is more cost efficient to fit at source extractions arms directly to, or close to the machine. These can easily be positioned above the work piece to collect the mist, and when changing the work piece it can be removed to allow for easy change. See more about PlymoVent at source extraction arms on pages 46-51.

Enclosed machinesThe enclosure to a machine is the best way to have 100% capture. Important to note is that the main purpose of the coolant mist/smoke collection system is to keep the enclosure under negative pressure. Just enough to prevent mist from spreading; only the airborne light mist should be captured by the exhaust system. Used coolant and chips should stay inside the enclosure. See more about System Design on pages 52-53.

When exists - Enclosures will control airborne contaminants that are generated by the machining process.

A central system or a single machine fitted with a compact mist collector




Centrifugal mechanical filtration with filter membranePlymoVent Filtration processes

6-step mechanical filtration with self draining filter cassettes

6-step filtering process with an efficient 3 step pre-separation that will take care of 80% of the mist. Two self draining filter cas-settes will coalesce and collect

medium and fine particles. The remaining filtration takes place in the HEPA filter with 99,97% filtration down to 0,3µ. For more information, see page 21.

Excellent draining also in 24 hours operation When smaller droplets coalesce into bigger droplets, these will drain back due to gravity, against the air stream.

Superior filter lifeThe self draining cassettes have a high efficiency, up to 95% of particles down to 0,3 µm. They make sure that particles are stopped before they reach the final filter stage, the HEPA Filter.

5-step mechanical filtration with bag filter

5-step filtering process with an efficient 3 step pre-separation that will take care of 80% of the mist. A large area bagfilter removes the remaining mid-sized particles.

The remaining filtration takes place in the HEPA filter with 99,97% filtration down to 0,3µ. For more information, see page 22.

The bag filter is perfect for...The bag filter is especially suitable for applications with lower concen-tration of mist. In processes mixing wet and dry machining this is the best alternative. The bag filter is the perfect choice in applications where it is neces-sary to clean the complete workshop area from light mist, where at source capture is impossible. It has a high air volume capacity and will give a cost efficient solution, still with long filter life.

Upgrade your filterShould you start with a light application; the bag filter is an economical solution. When you start with a 2nd or 3rd shift, or the intensity of pro-cess increases, you can easily upgrade your filter.

The centrifugal inlet combined with filter membrane give this technology high separation effi-ciency.

It is designed to be fitted directly on the machine enclosure, with-out need for ducting or floor space. For more information, see page 28.

MistWizard™ is an integrated part of the machine tool. The supply of MistWizard™ is often a partnership between PlymoVent and the machine tool manufac-turer where the scope is to supply the machine tool including an effective collector for removing coolant mist from the atmosphere and returning recovered coolant back to the machine tool.

Electrostatic filtrationAn efficient 3 step pre-separation will remove 80% of the mist. Electrostatic filtration steps with ionizing cells where remain-ing particles are charged with 12 000 V where they are effi-ciently attracted to the negatively charged collector plates of the collection cell.

Combination of mechanical and electrostatic filtration, especially suited for rough applications like coolant mist and smoke. For more information, see page 33.

Electrostatic filtration requires a minimum of service. All filter elements can be washed and this is easily carried out by own personnel. This means that filter elements can be re-used year after year, without the cost for buying replacements.

Service interval and filter life

The PlymoVent ambition is to make a long term com-mitment for complete satisfaction.

Service and filter life will vary with applications and the composition of mist will decide the load on the filter:

• High concentration of liquid

• Liquid combined with solid particles

• Solid particles and low amount of liquid

The PlymoVent representative will be happy to assist you and give more information about service inter-val and filter life in your application, together with our filter life policies for the respective market.

General guidelines, valid for a typical application with CNC machines, water based emulsion and approximate 16 working hours per day:

• Mechanical filtration with self draining filter cassettes: 12 - 36 months

• Mechanical filtration with bag filter: 6 - 12 months

• Centrifugal mechanical filtration with filter membrane: 6 - 18 months

• Electrostatic filtration between cleaning the cells: 30 - 90 days

Please note that these are only guidelines. In many applications the performance goes way beyond these guidelines.

These standard configurations cover most applications but it is not all, take a closer look at pages 18-20 for more information on how you can adapt to changes in machine tool processes.




Coolant mist/smoke filter quick guideA quick guide to your choice of the optimal filtration system

ME-31 ME-32 ME-41 ME-42 MW-2 EFO

Air qualityRe-Circulation >99,97% X X Re-Circulation >94% X X X Non Re-circulation X X X X X X

Non Re-circulation heat recovery system X X X X X X Type of metal working fluid Water Emulsion 1 1 1 1 1 3Straight cutting / Biodegr. Oil 2 2 1 1 2 1Synthetic oil 3 2 1 1 3 2 Type of mist/smoke Coolant mist / aerosol 1 1 1 1 1 1Coolant smoke 2 2 1 1 2 1Coolant mist / smoke 2 2 1 1 2 1 Machining process CNC machines 1 1 1 1 1 1Grinding 2 2 1 1 2 3Electronic Discharge (EDM) 1 1 1 1 3 3Tool cutters excl. grinders 1 1 1 1 1 2High speed machining 2 2 1 1 3 1Mixing wet and dry 1 1 3 3 3 (2*) 3 System Design Central filtration system X X X X XFiltration unit directly fitted on machine enclosure X Filtration system for production cell X X X X X

Major Benefits of PlymoVent Filtration Processes

ME-31 ME-32 ME-41 ME-42 MW-2 EFO

Filtration efficiencyPre-filter, min. 40% DOP 0.3 X X X X XPre-filter with centrifugal filtration X Unit efficiency 95% DOP 0.3 X X n/aUnit efficiency 99.97% DOP 0.3 X X n/a

Unit efficiency Ashrae 95%, F9 EuroVent DOP 0.3 X n/a PlymoVent filter technology benefits Filter change not necessary XLow cost replacement media X X High grade filter media X X Pre-filtration washable X X X X X XMain filter step washable X X X XExpandable X X X XPossible to reconfigure system X X X XModular filter system X X X XFilter life indicator X X X X X Optional inlet – 3 sides X X X XOptional carbon after filter X X X X

Coolant recovery directly back to process X Optional accessories for easy installation X X X X X X

Centrifugal mechanical filtration with

filter membrane

EFO

Electrostatic filtration

MW-2

6-step mechanical filtration with self

draining filter cassettes

5-step mechanical filtration with

bag filter

ME-41, ME-42ME-31, ME-32

Optimal solution 1 - 3, 1 = first choice

*washable

n/a = not applicable


ME-31 ME-32 ME-41 ME-42 MW-2 EFO-3002 EFO-5002

< 250 Pa/1.0” wg X X< 500 Pa/2.0” wg X< 1000 Pa/4.0” wg X X X < 1500 Pa/6.0” wg X Air volume m3/h 3000 3000 2000 2000 500 1500 3000 CFM 1750 1750 1175 1175 295 880 1765

Operational pressure drop over the unit


MistEliminatorThe new ”One For All” Mechanical Coolant Filter

• Adapts to changes in machine tool processes

• Easy to reconfigure to handle any type of coolant

• Expandable, just add one more module

• Minimizes your risk of making the wrong investment

• The safest decision you will ever make...

• ...and it runs 24 hours a day, seven days a week

One filter for all applications, today and tomorrow

No leakage with PlymoVent Original SealsWith our 25 years of experience, we know the importance of having a 100% sealed system. The PlymoVent MistEliminator is designed to ensure that captured coolant mist/smoke travel through all filtration stages. No coolant mist/smoke pooling in the housing, since the filter cassettes are locked downwards, forcing the air to go straight through the filter media, where it should be.

Filter status indicator Indicates when to change filters.Also information about filter type and item number.

PlymoVent MistEliminator – Flexible and Expandable

Change the filterIf the application changes you can easily insert a different media into the same cabinet.

3 optional inlets Right, left or back – flexibility when connecting to duct work.

Add one extra filtration step– extra pre-filter for extreme con-centrations.

Rebuild / extend the filterwhen changes in production take place.

Easy assembly at siteThe filter can be assembled with only one tool. This enables instal-lation in areas where large units are difficult to place.

Unique modular assembly The unique mo-dular assembly (patent pending) and special bolts will make sure that instal-lation is easy and at the same time has the same stability as a one piece unit.

Unit FinishIn coolant hand-ling, the corro-sion resistance is important for all material that comes into contact with the liquid. The MistEliminator is built in corrosion resistant galvanized steel treated with baked epoxy powder coat finish which resists harsh industrial environments. In particular the inside of the filter will withstand corrosion attacks from the coolant used.

The concept


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6-step filtering processStep 6 HEPA filter: The remaining filtration takes place

in the HEPA filter, with 99.97% filtration of par-ticles down to 0,3 µm.

Step 5 24 m2/258.3 ft2 Self draining cassette filter: Coalesces mist into droplets and collects fine particles.

Step 4 16 m2/172.2 ft2 Self draining cassette filter: Coalesces mist into droplets and collects medium sized particles.

Step 3 Pre-filter: With aluminium mesh to screen out large particles.

Step 2 Hydro filter: A labyrinth trap to separate droplets and coalesce mist into droplets.

Step 1 Pre-separator: Inlet chamber with baffle air-knife distributes the air and prevents large particulates from entering the filter.

The technologyMistEliminator with self draining coalescing cassettes

Polluted mist

Polluted mist

Clean Fresh Air

The unit with outstanding filter life – several years.

5-step filtration without HEPA filter is available as option.

MistEliminator – Mix and Match for tailor made solutions

The “One for All” mechanical coolant filter adapts to changes and is easy to reconfigure.

Mix and match to suit specific processes. We can make a filter to suit your specific process, ask your PlymoVent representative. In the following pages you will find two standard configurations that are the most common solu-tions today. Check www.plymovent.com for the latest options.

All MistEliminator configurations can be supplied with the Plymo-Vent HEPA filter in H12 filter class according EN 1822 standards. The HEPA filter removes 99.97% of particulates down to 0,3 µm. The clean air is returned to the premises directly. The H12 filter class guarantees high separation efficiency, which does not deteriorate even over long periods of operation.

Three major advantages• Excellent draining also in 24 hours operation When a droplet coalesces to bigger droplets, these will drain back due to gravity, meaning they will drain against the air stream. Every cassette has a 4 stage separation and is perfect for continuous operation, with short or no stops at all. Contact PlymoVent for correct guidelines.

In coolant mist and smoke filtration the main task for the filtration unit is to capture, collect and then drain the coolant back to the process. The filter media has

to allow airborne droplets to combine/coalesce to form bigger droplets. These bigger droplets will drain back due to gravity.

Often in machining industry, some of the coolants in combina-tion with the process will create unpleasant odours. In order to allow re-circulation of air, this needs to be removed.

The PlymoVent MistEliminator can be supplied with a carbon filter cassette suitable for removing odours and vapours from organic gases, solvents, welding, solder-ing and ozone.

High Efficiency Particulate Arrestor (HEPA)

Carbon after filter to remove vapours and odours

• Minimum of pressure required A low pressurer reduces fan power and saves energy. It provides for excellent draining in combi-nation with high efficiency, but needs no extra fan power.

• Superior filter lifeThe self draining cassettes have a high efficiency, up to 95% of particles down to 0,3 µm. This will make sure that particles are stopped before they reach the final filter stage, the HEPA filter. The total life span of the unit depends on how much of the coolant mist/smoke is captured before it reaches the final filter stage (HEPA) since this will only collect particles.See page 15 for more information on filter life.

MistEliminator with selfdraining cas-sette and 3-step pre-filter for air volume up to 1000 m3/h / 590 CFM.


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MistEliminator with bagfilter

For applications mixing wet and dry, or light applications.

The bag filter is traditionally used to collect coolant mist and smoke. It is especially suitable for appli-cations with lower concentration of mist. The combination between low concentration and large filter area, make this the most econo-mical choice. The bag filter is the perfect choice in applications where it is necessary to clean the complete workshop area from light mist

4-step filtration without HEPA filter is available as option.

5-step filtering processStep 5 HEPA filter: The remaining filtration takes place in

the HEPA filter, with 99.97% filtration of particles down to 0,3 µm.

Step 4 Bag filter: Removes the remaining mid-sized partic-les. The large filter area results in high performance, extreme efficiency and minimal maintenance.

Step 3 Pre-filter: With aluminium mesh to screen out large particles.

Step 2 Hydro filter: A labyrinth trap to separate droplets and coalesce mist into droplets.

Step 1 Pre-separator: Inlet chamber with baffle air-knife distributes the air and prevents large particulates from entering the filter.

The technology

Polluted mist

Polluted mist

Clean Fresh Air

Application options

MistEliminator connected to central fan in machine hall

At source extraction arm system connected to MistEliminator

MistEliminator connected to large machine Pl

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and where at source capture is impossible. It has a high air volume capacity and will give a cost efficient solution, still with long filter life. Should you start with a light application; the bag filter is an economical solution. When you extend to a 2nd or 3rd shift, or the intensity of process increases, you can easily upgrade your filter unit – see previous page.

Flexible and Expandable

TECHNICAL DATA

MistEliminator with self-draining filter cassette

Product no: ME-42 ME-41Filtration steps: No. 1 – 6 (see page 21) No. 1 – 5 (see page 21)

Air volume: 2000 m3/h / 1175 CFM 2000 m3/h / 1175 CFM

Unit weight: 117 kg / 257 lbs 92 kg / 203 lbs

Unit dimensions: 1798 x 675 x 695 mm / 1402 x 675 x 695 mm /

70.8 x 26.6 x 27.4” 55.2 x 26.6 x 27.4”

Inlet dimension: 250 mm / 10 inch 250 mm / 10 inch

Initial filter pressure over filter: 300 Pa / 1.2” wg 200 Pa / 0.8” wg

Final filter pressure over filter: 1500 Pa / 6.0” wg 1300 Pa / 5.2” wg

Housing material: Galvanized steel Galvanized steel

Housing finish: Epoxy powder coat Epoxy powder coat

Max. negative pressure: 4000 Pa / 16” wg 4000 Pa / 16” wg

Oil drain container: 10 litre / 2.6 gal 10 litre / 2.6 gal

Indicator, Manometer: 0–2000 Pa / 0–8” wg 0–2000 Pa / 0–8” wg

Unit efficiency: DOP 99,97 0,3 µ DOP >90% DOP 0,3 µ

MistEliminator with bag filter

Product no: ME-32 ME-31Filtration steps: No. 1 – 5 (see page 22) No. 1 – 4 (see page 22)

Air volume: 3000 m3/h / 1765 CFM 3000 m3/h / 1765 CFM

Unit weight: 115 kg / 253 lbs 90 kg / 198 lbs

Unit dimensions: 1998 x 675 x 695 mm / 1603 x 675 x 695 mm /

78.7 x 26.6 x 27.4” 63.1 x 26.6 x 27.4”

Inlet dimension: 250 mm / 10 inch 250 mm / 10 inch

Initial filter pressue: 150 Pa / 0.6” wg 50 Pa / 0.2” wg

Final filter pressure: 1000 Pa / 4.0” wg 500 Pa / 2.0” wg

Housing material: Galvanized steel Galvanized steel

Housing finish: Epoxy powder coat Epoxy powder coat

Max. negative pressure: 4000 Pa / 16” wg 4000 Pa / 16” wg

Oil drain container: 10 litre / 2.6 gal 10 litre / 2.6 gal

Indicator, Manometer: 0–2000 Pa / 0–8” wg 0–2000 Pa / 0–8” wg

Unit efficiency: DOP 99,97 0,3 µ 95% Ashrae/F9 Eurovent

MistEliminator ME-426-step filtration with self draining coalescing cassette.

MistEliminator ME-325-step filtration with bag filter.


TECHNICAL DATA – Component parts

Complete media modules

Accessories

ME-600-INL: Inlet module, complete with impinger and aluminium pre-filter

BFME-31-95: Bag filter 95 %, Glass fibre 11.2 m2/121 ft2

OC-1: Self draining coalescing cassette, 16 m2/172.2 ft2

OC-2: Self draining coalescing cassette, 24 m2/258.3 ft2

HFME-3: HEPA filter 99.97%, Glass fibre 22 m2/237 ft2

CFM: Carbon filter, Activated carbon: 25 kg/55.1 lbs. BET 1000 m2/g Pressure loss: 200-400 Pa/ 0.8-1.6”wg Air volume: 1200-2500 m3/h/ 700-1470 CFM

FF-WALL: Wallbracket, set of two pieces

FF-TOP-OUT: Top cover

Filter adapter plates

FF-DUCT-250: for 250 mm/10” duct outlet

FF-FANS-S: for fans 1300-2100

FF-FANS-B: for fans 3000-4700

FF-FEET: Rubber feet, set of four units

FF-OILCONT: Oil drain container, 10 litre /2.6 gal

FTL-1: Filter Twin Link. Join two units together

CFD-250: Constant flow damper, 250 mm/10”

CFD-315: Constant flow damper, 315 mm/12.4”

MistEliminatorCase Study – GKN Sintermetals, Bonn, Germany

CustomerGKN Sintermetals, Bonn, GermanyYear of installation: 2001/2002

Background / problemGKN Sinter Metals is the world’s leading producer of powder metal (P/M) components. Powder metal-lurgy is today one of the preferred technologies in the manufacture of metal components. When the tooling department expanded they needed a new Local Exhaust Ventilation (LEV) and filtration system. The process included both dry and wet filtration

Case Study – ASSA Abloy, Lycksele, Sweden

systems, but in this case we only show our solution for coolant mist filtration. The machine tools were a mix of both grinding, turning, milling erosion and hardening. Scope: • LEV from all working places with flexible at source extraction arms• LEV from a couple of enclosed machines• Energy efficient system with Intelligent Process Ventilation

SolutionA total of 33 units of Miniman extraction arms used on open machines and a number of enclosed machines connected to the central duct. 3 Mist Eliminator with bags, built as a central system, was selected for the filtration coolant mist and smoke. A central fan and a DCV controller was used as a pressure controlled system to ensure lower energy costs and lower noise levels.

PlymoVent Equipment supplied7 pcs MMH 100 26 pcs MMH 753 pcs ME-3 MistEliminator 1 pc fan 37 kW 1 pc DCV ControllerTotal air volume; 12000 m3/h / 7000 CFM

CustomerASSA Abloy, Lycksele, SwedenYear of installation: April 2002Application: CNC milling machine with oilbased cooling agent

Background / problemThe company installed a MistEliminator in 1999 with bag filter technology. When an increase of the inten-sity in production took place, the bags could not handle the heavy coolant mist/smoke. The concen-tration was above 150 mg/m2 with 2 shifts a day. The ME-3 filter bags had to be replaced once every month, including the HEPA. This gave high maintenance and production down time.

SolutionFortunately PlymoVent was just in the process of deve- loping a new filter technology: the self draining tech-nology. This was the right solution for ASSA Abloy and they agreed to install one filter as a BETA instal-lation. Today ASSA Abloy is very satisfied, especially

with the fact that PlymoVent supported them in find- ing a solution to their problem with the bag filter unit. Today it is standard to upgrade your filter. ASSA Abloy got return on investment due to savings in cost for filter replacement.

PlymoVent Equipment supplied1 pc ME-42 MistEliminator with encased fan.Draining: 1 litre / dayEstimated service interval for filter stages 4/5/6: 18 monthsFiltration efficiency: 99,97 at DOP 0,3µ

ME-1000-M: Media module, complete with Bag filter (BFME-31-95)

ME-OC-1-M: Media module, complete with Self draining coalescing cassette (OC-1)

ME-OC-2-M: Media module, complete with Self draining coalescing cassette (OC-2)

ME-HF-M: Media module, com-plete with HEPA filter 99.97% (HFME-3)

CFM-M: Media module, complete with Carbon filter (CFM)

Replacement filters for media module

Complete inlet module Replacement filters for inlet module

FF-RACK: Leg stand

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IMP-MODUL: Hydro filter

PF-INL-AL: Pre-filter, aluminium


MistWizard™

The coolant recovery system

PlymoVent MistWizard™ is the perfect solution for single machine tool applica-tions.

MistWizard™ is designed to be fitted directly onto the machine enclosure, with no need for ducting or floor space. The perfect solution in machining workshops with need for an easy, practical and compact system. The air will be cleaned directly at the machine tool – this means low installation costs!

MistWizard™ is an integrated part of the machine tool. The supply of MistWizard™ is often a partner-ship between PlymoVent and the machine tool manu-facturer. The purpose is to supply the machine tool including an effective collector for removing coolant mist from the atmosphere and returning recovered coolant back to the machine tool.

LocSeal™ is an integrated filter sealing system that places the filter seal out of reach for the air stream. This prevents them from being attacked by coolant that leads to filter by-pass and coolant breakthrough.

This PlymoVent patented filter draw lock design guarantees 100% sealing and makes filter mainte-nance clean and easy as 1, 2, 3.

LocSeal™ Mechanical AdvantagePlymoVent incorporates the only 100% filter seal in the coolant filter industry.

Step 1: Open the LocSeal™ clamp.

Step 2: Remove the filter element and replace with new or spare when filter life indicator reaches final pressure.

Step 3: Close the LocSeal™ clamp.

Filter life indicator

Filter life indicator

Direct fitted with standard PlymoVent fanIt is easy to install the MistWizard™ with a fan. The fan mounting kit is directly fitted to the stan-dard unit and allows for easy installation. The fan will easily slide to the side for filter change.

MistWizard™ – ceiling mount with PA-110 stanchion

MistWizard™ – Floor mounted with PA-220 stanchion, MW-INL and drain loop

MistWizard™ – wall mounted with MW-INL inlet and drain loop

Easy installation with PlymoVent accessories The MistWizard™ is provided with a range of acces-sories to allow easy and fast installation, without need for special adapters, brackets etc. It will make sure that the installation can be suited to fit local conditions and requirements. Study the complete list on page 30 and do not hesitate to consult the PlymoVent representative for detailed advice regarding the installation.


Indication for filter replacement.


AquaSpin™ inletMistWizard™ starts its filtrating process with a revolutionary patent pending inlet. The AquaSpin™ inlet will capture and return more coolant to your machine than most units will collect.

Studies show the Aqua-Spin™ inlet achieves a higher efficiency than most ASHRAE type filters.

AquaSpin™/Coolant-Tec filtration technology (patent pending)

This filtration technology is the newest break through in machine tool coolant collection in over a decade.

Coolant-Tec filter membraneCoolant-Tec is a low cost washable filter mem-brane that handles both coolant mist and smoke applications. This synthetic filter membrane will not compress like glass fibre filters. The Coolant-Tec inclu-des a Polyester wrap, which will protect the filter membrane and cap-ture grinding particles and dust. The PlymoVent Coolant- Tec filter maintains its efficiency even in the harshest machine tool environments.

Application optionsThe technology

Polluted mist

Clean Fresh Air

MistWizard™ direct mounted on machines – central system

MistWizard™ – machine mount

MistWizard™ – system solution MistWizard™ – wall mount, recycled

The coolant recovery system

Single or central system



TECHNICAL DATA

MistWizard™. Complete with Self-cleaning Aqua-Spin™ inlet, Polyester filter wrap and Coolant-Tec filter cartridge

Product no: MW-2Air volume: 550 m3/h / 350 CFM

Intake velocity: 14 m/s / 2800 fpm

Outlet velocity: 14 m/s / 2800 fpm

Unit weight: 13 kg / 29 lbs

Inlet dimension: 159 mm / 6.25 inch

Outlet dimension: 159 mm / 6.25 inch

WRAP-2: Polyester filter wrapper for MW-2.

MistWizard™ – Accessories

MW-OUT: 360° adjustable outlet difuser 45° angle discharge. Outlet size Ø 160 mm/6”

MW-INL: Inlet for 160 mm/6” spiral ductwork connection.

Y-branched inlet adapter for two intakt hoses. MW-Y125: Ø 125 mm/5”

Clear oil resistant polyrethan hose 998328: Ø 165 mm/6.5”

998310: Ø 127 mm/5.125”

998302: Ø 102 mm/4.125”

CART-2: Coolant-Tec cartridge filter for MW-2. Filter area 10 m2/108 ft2

Adjustable hose clamp 961466: Ø 160 mm/6.3”

961458: Ø 125 mm/5.3”

961441: Ø 100 mm/4.3”

MW-W: Mounting wall bracket

MistWizard™ – Installation material

MW-STA: Stand for elevated machine mounting. Stand elevation 150 mm/6.1”

MW-ADA: PA Stanchion mounting bracket.

Floor, ceiling or wall mounting stanschion PA-110: L=110 cm/3 ft

PA-220: L=220 cm/7 ft

MistWizard™

Case Study – Burkert, Triembach au Val, France

CustomerBurkert, Triembach au Val, France Year of installation: 2003Application: CNC machine with water based cooling agent.

Background / problemBurkert is the leading global manufac-turer of fluid control systems and compo-nents with manufacturing facility all over the world: http://www.burkert.com. The PlymoVent subsidiary in France contacted Burkert to offer our new filter

Case Study – Multi Wing, Cleveland, Ohio, USA

CustomerMulti Wing, Cleveland, Ohio, USAYear of installation: 2003

Background / problemMulti Wing America manufactures various types of industrial fan propel-lers. They have a strong concern for their employees’ comfort in the work place and wanted to reduce house-

keeping costs resulting from coolant mist/smoke spreading throughout their workshop. The type of coolant used, is water soluble with a 20 to 1 water to coolant mixture. The operation runs one 8 hr shift.

SolutionThe specific problems were solved by installing two MistWizard™ MW-2 directly to their Cincinnati Milacron vertical machining centers. Two additional MistWizards™ on floor mounted stanchions were connec-ted to the side of the machine tool via flexible hoses. By installing PlymoVent MistWizard™ they cleaned the air in the work area and have now been able to protect their employees health while reducing maintenance costs.

PlymoVent Equipment supplied4 pcs MW-2 – MistWizard™ filters with fan2 pcs PA-220 – StanchionsFiltration efficiency: 94,0% at DOP 0,3µAir volume on each machine: 1100 m3/h / 650 CFM

system; MistWizard™. Burkert had problems with coolant mist and smoke and needed a coolant recovery system that was easy to install and could improve the indoor air quality.

SolutionExtraction and filtration of coolant mist/smoke on nine CNC machines and recycling of clean air into the facilities. The MistWizards™ are installed on or next to the machines.

PlymoVent Equipment supplied9 pcs MW-2 – MistWizard™ filters with fan1 pc PA-220 – StanchionFiltration efficiency: 94,0% at DOP 0,3µ


Housing material: Galvanized steel

Housing finish: Epoxy powder coat

Indicator, Manometer: 0–1000 Pa / 0–4” wg

Fan: Not included

Unit efficiency: >94% DOP 0,3 µ

MW-FAN-KIT: Installation kit for FUA-1300 fan

FUA-1300: Fan to be mounted directly on MW-2 (to be combined with MW-FAN-KIT)

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Electrostatic filter – EFO

The unique combination of mechanical and electrostatic filtration puts PlymoVent EFO in the front line of electrostatic filtration technology, especially suited for rough applications like coolant mist and smoke.

Single or multiple EFOThe single EFO unit will be supplied with a directly fitted standard PlymoVent FUA fan. In bigger systems the EFO filter will be installed as a central unit, with multiple EFO placed centrally and ducted to each machine tool. By having multiple units service and maintenance will be easy and provide an efficient system with high air volume capability. Whatever solution you choose, the EFO gives lowest possible pressure drop which in return gives savings in energy and allows for installation in low pressure systems.

5-step filtering process

Step 5 Collection cell Step 4 Ionizing cell

Electrostatic filtration steps 4-5In stage 4, the ionizing cell, all remaining particles are charged with 12 000 V whereafter they are effi-ciently attracted to the negatively charged collector plates of the collection cell.

Step 3 Pre-filter Step 2 Hydro filterStep 1 Inlet chamber

Mechanical filtration steps 1-380% of all coolant mist/smoke particles (i.e. all in liquid form) are captured in the mechanical filtra-tion.

There’s more inside EFO than in other electrostatic mist and smoke filters.

Polluted mistPolluted mist

Clean Fresh Air

The technology

Due to the highly specific design, separating particles down to 0.005 µm, the EFO is ideal for straight cutting oil.

Filter AlarmEFO can be supplied with a special electrical incident alarm, which reacts on dis-turbance on high voltage output. This is indicated by light and sound.

Electrostatic filtration is one of the most efficient forms of filtration. It operates by placing a static charge on the mist particles and then attracts the particles to appositely charged collector plates. The PlymoVent electrostatic filters clean the air of particles from 0.005 µ up to 100 µ. This means that even the smallest and most dangerous particles are captured. Larger particles are separated in the three mechanical pre-filter stages.

Power pack

Collection cell

6 000 V

Ionizing cell 12 000 V

How efficient is the EFO?The efficiency of the filter depends on the velocity of the air through the filter i.e., the less air that passes through the filter, the higher efficiency. In coolant mist/smoke applications PlymoVent never recom-mend less than 99% efficiency.

Approximate efficiency at different air volumesEfficiency %

PlymoVent EFO m3/h m3/h m3/h m3/h

Do not use electrostatic technology of any kind in the following applications:• Coolants with low flame point or explosion risk• Emulsions with less then 5% oil• Grinding (no metal particles into the unit)

Another piece of adviceWe do not recommend electrostatic technology in 24 hours application. The filter needs to stop every day to allow the oil to drain down.

The PlymoVent EFO filter requires a minimum of service. All filter elements can be washed and this is easily carried out by own per-

sonnel. Filter elements can be re-used year after year, without cost for buying replacement filters.

For easier and faster service an extra set of collector cells are used to limit down time on the filter system.

EFO with PlymoVent FUA fan

EFOs connected tocentral system

Wall mounted EFO

Wall mount or free standingAs standard the EFO is supplied with a wall moun-ting bracket. In the accessory list, see page 34, you will find a floorstand to ensure stability of the free standing filter.

Recovery of oil back to the processThe re-covered oil drains down to an oil collection sump and can be brought back to the process from a drain plug on the bottom of the unit.Free standing EFO

The heavy duty electrostatic technology


EFO-3002 1500 1900 2300 2800

EFO-5002 3000 3500 4000 4800


TECHNICAL DATA

Electrostatic coolant mist/smoke filter – EFOComplete with impinger, pre-filter, ionizing cell, collection cell and inlet with oil collection tray and drain.

Rec. airflow Effective collector Inlet Height Width Depth Weight Prod. no: m3/h / CFM cell area, m2 / ft2 mm / inch mm / inch mm / inch mm / inch kg / lbs

EFO-3002/AL* 1500 / 880 16.4 / 176 250 / 9.8 1094 / 43 506 / 20 750 / 30 102 / 224

EFO-5002/AL* 3000 / 1765 32.8 / 353 250 / 9.8 1533 / 60 506 / 20 750 / 30 151 / 332

IMP-3000: Oil trap (impinger) for EFO-3002/AL and -5002/AL

EFO – Spareparts

* These models are equipped with a safety-monitoring device, that indicates with light and sound. In case of malfunction the filter and fan automatically stops.

FFO-3000: Pre-filter for EFO-3002/AL and -5002/AL

IOO-3000: Ionizing cell for EFO-3002/AL and -5002/AL (for EFO-5002/AL you need 2 cells. 10 ionizing wires.

EC-3000: Collection cell for EFO-3002/AL and -5002/AL (for EFO-5002/AL you need 2 cells. 83 collection plates.

EFO – Accessory

RACK-20/30: Floor rack for EFO-3002/AL

RACK-50: Floor rack for EFO-5002/AL

Case Study – Stryker, Schönkirchen, Germany

CustomerStryker, Schönkirchen, GermanyYear of installation: 2002

Background / problemStryker Trauma, a division of Stryker Corporation, develops,

manufactures and markets a wide variety of innova-tive surgical devices to treat patients with orthopae-dic trauma, specifically bone fractures. The production requires high precision, and com-ponents manufactured in CNC machines require minimal tolerances. Stryker had a problem with coolant mist and needed a solution for the local exhaust ventilation (LEV) and a coolant mist filtration system. The pro-cess included 15 CNC machines.

SolutionPlymoVent offered a complete solution including projecting, installation and start up. The delivery included a central filtration system with electrostatic filters and a central fan. The PlymoVent Demand Controlled Ventilation was also installed to ensure reduced energy costs. The exhaust air is ventilated to the outside through a heat recovery system.

PlymoVent Equipment supplied3 pcs EFO 50021 pc Central fan1 pc DCV-Controller15 pcs ASE-12 Automatic Motordriven dampers

Case Study – Volvo Personvagnar Komponenter AB, Köping, SwedenCustomerVolvo Personvagnar Komponenter AB, Köping, Sweden Year of installation: 1987-1995

Background / problemVolvo in Köping manufactures transmissions for cars. The production process pro-vides, among others, a lot of oil emulsion and cooling liquids, that have caused a bad external and internal environment.

Volvo have the following demands:• continuous 3-shift operation• high separation degree• reliability in operation• low running charges• application, mounting at machine (flexibility)

SolutionPlymoVent’s electrostatic filters are mounted direct onto the machines. The process air is extracted from the machine into the filter where the air is cleaned. The air is then transported to heat exchangers to utilize the heat generated in the process.

Power supply:

High voltage ionizing cell: 12 000 V

High voltage collection cell: 6 000 V

Filter alarm:

• Input disturbance in high voltage output

• Output disturbance in high voltage output

• Filter function and fan will automatically stop

PlymoVent Equipment supplied100 pcs EFO-200010 pcs EFO-300020 pcs EFO-5000



Fans and Intelligent Control Equipment

A quick guide to your best choice of intelligent control equipment

A quick guide to your choice of the optimal fan TEV FUA-1300 FUA-1800 FUA-2100 FUA-3000 FUA-4700

Suitable for filterunit ME-31 / ME-32 X X XME-41 / ME-42 X X XMW-2 X X EFO-3002 X X XEFO-5002 X X X

System designDucted outlet X X X X X XDirect mount on filterunit X X X X XCentral system X

Fan Technology BenefitsEnergy efficiency * 1 2 2 2 2 2

Unit finish in epoxy powder

coat galvanized steel X Unit finish in epoxy powder

coat mild steel X X X X XNo weld fan housing X

Impeller X X X X X X

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DCV-Controller ICE-LC/MD ES-90 Motorstarter

To be used with fansTEV X n/a XFUA n/a X X

System designCentral filtration system X XFiltration unit directly fitted

in machine enclosure X XFiltration system for production cell X X

Intelligent Control Equipment BenefitsAvailable for all power supply X X X XOperate by monitoring

pressure in system XControl air volume at each

extraction point/machine cell X** X X XAdjustable after run time X X XExternal input, potential free NO X X XUL-listed control boxes available X X X X> IP54 enclosure X X X X

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High performace fansThe heart of the coolant mist/smoke collection system

Different fans for different requirements. When designing and planning a coolant mist/smoke capture system, the selection of fan is a very important decision. Many parameters need to be evaluated.

Central system fan or one fan for each unitThe best possible noise level is always achieved by installing the fan in a designated area, separated from the working space. Normally this means a central fan.

Should flexibility be important, a fan on each filter unit and re-circulation is the best choice.

Higher pressure requirementsA central fan gives the opportunity to increase the pressure normally required in a central system.

Using a DCV Controller gives the possibility to adapt to low volume when needed. The direct fit fans are designed to give a pressure suited for the application, with normal duct work and at source extraction.

The PlymoVent Fans – AMCA certified

PlymoVent is one of very few worldwide fan man-ufacturers who have tested and certified all their fans completely at AMCA (Air Movement and Control Association), the international authority on air system components.


High performance fans for Intelligent Process Ventilation


The PlymoVent Fans – The impeller

PlymoVent fan impellers are designed in high impact aluminium alloy, suited for continuous temperatures up to 80°C / 180°F.

Self cleaning PlymoVent fan impellers are suited for both general ventilation applications and process ventilation applications requiring the removal of dust, mist, smoke and fumes. The backward incline design eliminates the build up of material that would upset the balance of the fan impeller thus reducing air delivery and increasing the vibration/noise.

Self balancingThe high tech machine stamped impellers guarantee perfect balance and alignment every time.

Easy access All PlymoVent fan housings are designed for easy access to the impeller. Our design allows an installer or service technician to remove the motor and impeller wheel without removing inlet or outlet duct work or disassembling the fan housing. It provides the installer the option of separating the fan into two pieces when mounting takes place in confined locations above drop ceilings or tight access ways.

Non-sparking An extra precaution if extracting unintended gases.

The PlymoVent FUA-fans

Safety firstPlymoVent fans are provided with protective safety screens on both the inlet and outlet of the fan housing. PlymoVent protects your investment and personnel from the moving parts of the fan.

Flexible direct mount fan for PlymoVent filter systems. The standard PlymoVent fan that gives an integrated part of the installation.

Rotational outletWhen fan is fitted on top of filter house, it can be rotated to allow discharge in any direction. This reduces the cost for additional fan outlet transition.

Noise levelThe FUA fans have a high capacity and relatively low noise level. In installation near the operators working area PlymoVent recommend a silencer and/or ducted outlet.

PlymoVent reserves the right to make design and technical changes.The PlymoVent TEV-fans

High efficiency with air foil impellerPlymoVent in co-operation with an internationally recognized university, has designed the ultimate air foil fan impeller. PlymoVent has de-signed a fan impeller that maximizes air delivery at higher static pressure and in turn reduces energy consumption at the same time.

Noise levelToday it is critical to control noise pollution in the work place. Recognizing this problem, PlymoVent has produced a fan (TEV) that will operate at a lower sound power level (db) and a lower sound pressure level (dbA) than other competitive models. All PlymoVent fans have been tested by AMCA in accordance with AMCA 300 standard.

Energy SavingPlymoVent TEV fans require less kW versus air volume delivered. This does not only equate to less power consumption but also less installation cost. This allows the electrical installer to reduce the cost of installation by reducing the associated com-ponents required to run the motor.

No weld fan housingPlymoVent’s patented no-weld housing is produced with a state of the art fastening technique which

eliminates the need for metal welding which distorts metal compo-nents and destroys critical tolerances. This provides for less vibration and better fit and finish.

Unit finishBuilt in corrosion resistant galvanized steel, treated with baked epoxy powder coat finish, to resist harsh industrial environment.

Easy mount housingThe new TEV series has been designed with slotted mounting channels on all four sides for a wide vari-ety of mounting options. This eliminates the cost for suspensions or platforms.

Energy saving ventilators make a perfect match to any intelligent process ventila-tion system.

40 41

0

500

1000

1500

2000

2500

3000

3500

4000

4500

0 2000 4000 6000 8000 10000 12000

1200 2350 3500 4650 5800 6950 9250

14000

2

4

6

8

10

12

14

16

18

7,5 kW

4,0 kW

2,2 kW

0,75 kW

2,2 kW

1,1 kW

0,37 kW

0,55 kW

m3/h

Pa

* 220-240/380-420 V** 220-240 V

inchwg

CFM

0,75 kW

3.0 HP

1.5 HP

1.0 HP

0.5 HP

0.75 HP

20 HP

15 HP

10 HP

7.5 HP5 HP

3 HP

2 HP

CFM

inchwg

inchwg

CFM

* 208-230/460/575 V** 115/230 V m3/h

Pa

m3/h

Pa


Fans – 50 Hz, Conforms to CE standards

m3/h

CFM

Motor Weight Inlet size Outlet size Hou- Im- Prod. no: kW 50 Hz Voltage kg/lbs Ø mm/inch mm/inch sing peller

TEV-385-50 0,75 3-ph, 220-240/380-415 V 31/68 160/6.3 160x252/6.3x9.9

TEV-585-50 2,2 3-ph, 220-240/380-415 V 51/112 200/7.8 200x320/7.8x12.6

TEV-765-50 4,0 3-ph, 220-240/380-415 V 78/172 250/9.8 220x400/8.7x15.7

TEV-985-50 7,5 3-ph, 380-415/650-670 V 157/345 315/12.4 250x448/9.8x17.6 Alu

min

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Pow

der

pain

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teel

TEV-series fan curvePainchwg

Measurement in accordance

with SS ISO-5801.

Please consult PlymoVent technical data sheets for specific motor data. Additional voltages available upon request.

Motor 50 Hz Weight Inlet size Outlet size Hou- Im- Prod. no: kW Voltage kg/lbs Ø mm/inch mm/inch sing peller

FUA-/FS-1300 0,37 3-ph,* 12.6-15,6/27.7-34.3 160/6.3 Ø 160/6.3

FUA-/FS-1301 0,37 1-ph,** 13.2-16.2/29.0-35.6 160/6.3 Ø 160/6.3

FUA-/FS-/FUK-1800 0,55 3-ph,* 13.4-16.4/29.5-36.1 160/6.3 Ø 160/6.3

FUA-/FS-/FUK-2100 0,75 3-ph,* 16.4-19-4/36.1-42.7 160/6.3 Ø 160/6.3

FUA-/FS-/FUK-2101 0,75 1-ph,** 16.6-19.6/36.5-43.1 160/6.3 Ø 160/6.3

FUA-/FS-/FUK-3000 1,1 3-ph,* 24.0-27.0/52.8-59.4 250/9.8 142x215/5.6x8.5

FUA-/FS-/FUK-4700 2,2 3-ph,* 32.0-35.0/70.4-77.0 250/9.8 142x285/5.6x11.5

Alu

min

ium

Pow

der

pain

ted s

teel

F-series fan curve

Fans – 60 Hz, Conforms to NEMA standards

TEV-series fan curve

Motor Weight Inlet size Outlet size Hou- Im- Prod. no: HP 60 Hz Voltage kg/lbs Ø mm/inch mm/inch sing peller

TEV-359-60 2.0 3-ph, 208-230/460/575 V 36/80 200/7.87 160x252/6.3x9.92

TEV-3110-60 3.0 3-ph, 208-230/460/575 V 39/85 200/7.87 160x252/6.3x9.92

TEV-559-60 5.0 3-ph, 208-230/460/575 V 79/175 250/9.84 200x320/7.87x12.6

TEV-585-60 7.5 3-ph, 208-230/460/575 V 84/185 250/9.84 200x320/7.87x12.6

TEV-745-60 10 3-ph, 208-230/460/575 V 132/290 315/12.40 220x400/8.66x15.74

TEV-768-60 15 3-ph, 208-230/460/575 V 145/320 315/12.40 220x400/8.66x15.74

TEV-798-60 20 3-ph, 208-230/460/575 V 191/420 315/12.40 220x400/8.66x15.74

Alu

min

ium

Pow

der

pain

ted s

teel

Motor Weight Inlet size Outlet size Hou- Im- Prod. no: HP 60 Hz Voltage kg/lbs Ø mm/inch mm/inch sing peller

FUA-/FS-1300 0.5 3-ph * 18 / 40 160/6.3 Ø 160/6.3

FUA-/FS-1301 0.5 1-ph ** 18 / 40 160/6.3 Ø 160/6.3

FUA-/FS-/FUK-1800 0.75 3-ph * 19 / 42 160/6.3 Ø 160/6.3

FUA-/FS-/FUK-1801 0.75 1-ph ** 19 / 42 160/6.3 Ø 160/6.3

FUA-/FS-/FUK-2100 1.0 3-ph * 22 / 48 160/6.3 Ø 160/6.3

FUA-/FS-/FUK-2101 1.0 1-ph ** 22 / 48 160/6.3 Ø 160/6.3

FUA-/FS-/FUK-3000 1.5 3-ph * 27 / 60 250/9,8 142x215/5.6x8.5

FUA-/FS-/FUK-4700 3.0 3-ph * 43 / 95 250/9,8 142x285/5.6x11.2

Alu

min

ium

Pow

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pain

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teel

F-series fan curve

Data based on AMCA testing in accordance with AMCA

Standard 210.

Please consult PlymoVent technical data sheets for specific motor data. Additional voltages available upon request.



Intelligent Control EquipmentPlymoVent Demand Control Ventilation (DCV)

In systems where a central fan will serve a number of machine tools, the PlymoVent Demand Controlled Ventilation is the best way to ensure lower energy costs and improved indoor environment.

Ventilation efficiency on demandThe DCV-Controller will operate your process ventila-tion by monitoring the air pressure of your system. The DCV-Controller will only run fans to meet the demand of your production and do it automatically. You will never have to oversize your air requirements or depend on staff to control your system manually. The DCV controller will run the fan on the optimal rpm for each given moment. This reduces wear and tear on the fan motor. Wear is also reduced by soft starts and stops fully controlled by the controller. To maximize the energy saving in a system, the motor driven dampers (ICE-LC/MD) should be installed on each extraction point (see page 44). In systems with enclosed machines the DCV con-troller will increase air volume when door is opened. In return the system will save energy by running less air volume during operation with closed doors. TECHNICAL DATA

Prod. no. Motor DCV-011-54 1.1 kW / 1.5 HP

DCV-022-54 2.2 kW / 3.0 HP

DCV-040-54 4.0 kW / 5.0 HP

DCV-055-54 5.5 kW / 7.5 HP

DCV-075-54 7.5 kW / 10.0 HP

DCV-110-54 11.0 kW / 15.0 HP

DCV-150-54 15.0 kW / 20.0 HP

DCV-185-54 18.5 kW / 25.0 HP

DCV-225-54 22.0 kW / 30.0 HP

DCV-300-54 30.0 kW / 40.0 HP

DCV-Controller

The world supply of energy will continue to run in short supply. Do your part to save costly energy and reduce your operating overhead by reduc-ing peak demand on electricity, reducing running time for process ventilation fans, reducing power consumption, reducing air delivery to your process by demand only operation, reducing heating and cooling costs.

Pressure transmitterThe pressure transmitter will adjust the air delivery by adjusting air volume based on duct system pressure.

High quality variable drivePlymoVent cooperates with major suppliers in vari-able drive technology, designed for installation in HVAC systems. Our suppliers have a worldwide coverage to ensure rapid support and service.

Easy to use and easy to install• Clear text parameters in your local language, no

numbered parameters• Remote programming of unit possible• Detachable remote control – can be used to pro-

gram one unit and copy the settings to another unit

• Can be stacked next to each other when using more than one unit

Rated voltage: 380-460 VEnclosure: IP 54 (IP 20 optional)EMC protection: Built in

Prod. no. RangeTG-1600 0-1600 Pa / 0-6.4” wg

TG-2500 0-2500 Pa / 0-10” wg

TG-5000 0-5000 Pa / 0-20” wg

Pressure Transmitter

Enclosure: IP 54Output signal: 4-20 mASupply voltage: 18 .. 33 VDC

Invest in the most intelligent working environment and let your savings pay for all of it

10 tooling machines in a central system with pressure transmitter, DCV-Controller, central MistEliminator filter system and a central fan.

Features BenefitsSmaller filter Lower Life Cycle Costs Less space

Less power to fan Lower Life Cycle Cost Lower noise level

Heating energy savings Lower Life Cycle Costs

Indoor air improved Increased productivity

Balanced ventilation Increased productivity Secures duct work

Investment 15%Maintenance 5%

Operation 80%

The cost of your ventilation system



PlymoVent Energy Saver – ES-90

PlymoVent ES-90 is one of the most profitable investments you can make when it comes to the control of fans in smaller systems.

PlymoVent Automatic Motordriven Damper – ICE-LC/MD

Fully automatic system to control air volume at every extraction point.

TECHNICAL DATA

Prod. no: ICE-LC

Supply: 115/230/400 VAC

External input: Potential free NO

External output: Potential free NO/NC (max 5A - 230 VAC)

Automation: Adjustable over-run time 7 sec - 6 min.

Manual override included.

The ES-90 will start the fan when operator starts the machine. When the machine is stopped, it will stop with a given after run time so that all mist/smoke will be removed before fan stops. This fully automatic system gives significant savings in energy and a lower noise level when the machine is stopped.

Perfect for systems with at source extraction arms, fixed hoods or enclosed machines with exact air volume settings at each extraction point. The ICE-LC controller will open the motordriven damper when an operator starts the machine. When the machine is stopped, the damper will close with a given delay time so that all mist/smoke will be removed before the damper closes.

Motorstarter with overload

TECHNICAL DATA

Prod. no: ES-90

Supply: 115/230/400 V

Contactor: up to 4,0 kW, must be fitted with relevant

motor overload (not included)

Output to fan: Max 420 VAC

External input: Potential free NO

External output: Potential free NO/NC (max 5A - 230 VAC)

Automation: Adjustable over-run time 7 sec - 6 min.

Manual override included.

UL-listed control boxes available, ask for separate product list.

Intelligent Control Equipment

Automatic Local Controller

Prod. no: Diameter

MD-160 160 mm / 6.25”

MD-200 200 mm / 8”

MD-250 250 mm / 10”

MD-315 315 mm / 12”

MD-400 400 mm / 16”

Motordriven Damper

5 open machines with PlymoVent Miniman arms, motordriven dampers, pressure transmitter, DCV-Controller and MistEliminator with FUA-fan.

PlymoVent offers motor starters in the range from 1.0 – 16.0 A.

Automatic Energy Saver

Standards: DIN VDE 0660, IEC 947, EN 60947 VDE, UL, cUL, SEV, SEBEC, MEEI, EZU, CE

Enclosure: IP 55

Rated operational voltage: 690 VAC

Rated operational current: 1 - 16 A acc. to setting range

Rated frequency: 40-60 Hz

Prod. no: Description

ECMSO-1.6 Motorstarter with overload 1.0-1.6 A






TECHNICAL DATA

Motorstarter with overload

DCV-Controller ICE-LC

Pressure transmitter

MistEliminator


MD

46 47

65° 65° 120° 75°


At source capture quick guide PlymoVent At Source Extraction Arms

Clear-Thru designThe PlymoVent extraction arms provide un-obstructed airflow without turbulence. Maximum ”pick-up veloc-ity” makes sure that mist and smoke is captured and transported inside the arm.

• avoid bacteria, fungus attack and other substances• easy to clean both inside and outside• low pressure drop• low noise level

• Supplied fully assembled to save expensive instal-lation time and eliminate mistakes

• Exterior easily adjustable joints for easy and smooth operation and service

• Aluminium tubes give a light and robust arm with low pressure drop

• Visible yellow colour in epoxy powder coat for health and safety friendly design for use in harsh areas

• Universal mounting bracket standard for easy installation

Why size mattersThe diameter of an arm affects air volume and pick-up velocity. The closer to the source, the smaller diameter can be used. The length of an arm determines where it can be mounted to reach the areas around the work piece. Wall or column mounted extraction arms are always preferable, being easier to position. The ability to position correctly is paramount, as is its capacity to extract efficiently. PlymoVent extraction arms have been designed to achieve all that.

Hood operationThe hood can be angled 65° to the side, 75° for-ward and 120° backwards.

The best way of reducing airborne pollutants is by capturing at source.A quick guide to your choice of the optimal at source capture product

Miniman MultiSmart® Arm Ø 75-100 mm / 3-4” Ø 125-200 mm / 5-8”

Air volume100-700 m3/h/60-420 CFM X 500-1500 m3/h/300-890 CFM X1500-2100 m3/h/890-1250 CFM X

Rec. hood distance100-300 mm/4-11.8” X 265-400 mm/10.4-15.7” X400-500 mm/15.7-19.7” X

Miniman

On open machine tool an articulated extraction arm is the best solution.

More features with PlymoVent at source extraction arms

Miniman MultiSmart® Arm

Supplied fully assembled X X

Various sizes for maximum flexibility X X

Universal mounting bracket standard X X

Clear-Thru Design X X

• No bacteria or fungus build up

• Easy to clean

• Low pressure drop

• Low noise level

PlymoVent At Source Extraction Benefits


MultiSmart® Arm

48 49

0

1

2

3

4

5

6

250

500

750

1000

1250

1500

50 100 150 200 250 300 350 400 450

85 170 255 340 425 510 595 680 765

PaInchwg

CFM

m3/h

3"/75 mm 4"/100 mm


Miniman – 75 mm/3” and 100 mm/4”

The Miniman offers full flexibility over the work area and captures mist and smoke closely at the source.

Data based on AMCA testing in accordance with AMCA Standard 500-89.

Pressure loss – AMCA flow ratings

Miniman 75 mm/3” is perfect for all types of smal-ler mist and smoke applications, where you easily can fit the hood close to the source. Miniman 100 mm/4” is the most common in mist and smoke applications and is the perfect mix between at source capacity and smooth operation. The air volume is always within machine recommen-dations and at the same time it is small enough to reach close to the source.

Features and Benefits• Available in both standing and hanging versions

for installation flexibility

• Reach above mounting height means maximum flexibility

PlymoVent At Source Extraction Arms

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.

TECHNICAL DATA

Miniman (MMS – Standing, MMH – Hanging)

Prod. no: Working radius Weight Tube/hose Rec. air volume Rec. hood distance

MMS-75-10 1.0 m / 3 ft 3.4 kg / 7.5 lbs 75 mm / 3” 100-425 m3/h / 60-250 CFM 100-120 mm / 4.0-4.7”

MMH-75-10 1.0 m / 3 ft 3.4 kg / 7.5 lbs 75 mm / 3” 100-425 m3/h / 60-250 CFM 100-120 mm / 4.0-4.7”







MM-001:

Hood, 160 mm/6.3”.

Accessories for Miniman 75 mm / 3”

MM-002:

Hood with work light

MM-003:

Slot nozzle

MM-004:

Transparent hood

MM-005:

Table bracket

D-75:

DamperTR-24/75:

Work light transformer*

Accessories for Miniman 100 mm / 4”

* included when using ES-90 or ICE-LC with the arm.

HL-20/24-100:

Halogen light kit

D-100:

Damper

PA-110:

Stanchion 110 cm / 3.6 ft

PA-220:

Stanchion 220 cm / 7.2 ft

50 51

1

2

3

4

5

6

250

500

750

1000

1250

1500

PaInchwg

300 400 500 600 700 800 900 1000 1100 1200 1300

510 680 850 1020 1190 1360 1530 1700

CFM

1870 2040 2210 m3/h

5"/125 mm 6"/160 mm 8"/200 mm


MultiSmart® Arm

Prod. no: Working radius Weight Tube/hose Rec. air volume Rec. hood distance

MSA-125-3 3 m / 10 ft 22.5 kg / 49.5 lbs 125 mm / 5” 500-850 m3/h / 300-500 CFM 265-320 mm / 10.4-12.6”






Halogen light kit

HL-20/24-125: For MSA-125-3/-4

HL-20/24-160: For MSA-160-3/-4

HL-20/24-200: For MSA-200-3/-4

Damper

D-125: For MSA-125-3/-4

D-160: For MSA-160-3/-4

D-200: For MSA-200-3/-4

SmartArmExtension from 3-4 m/10-14 ft

SAE-125-4: For MSA-125-3

SAE-160-4: For MSA-160-3

SAE-200-4: For MSA-200-3

Extension from 4-5 m / 14-17 ft

PA-110:

Stanchion 110 cm/3.6 ft. For all MSA models

Extension from 4-6 m / 14-20 ft

PA-220: Stanchion 220 cm/7.2 ft. For all MSA models


MultiSmart® Arm – 125 mm/5”, 160 mm/6.3” and 200 mm/8”

The MultiSmart® Arm is built for higher air volumes and combines smooth move-ment with outstanding stability.

Data based on AMCA testing in accordance with AMCA Standard 500.

Pressure loss – AMCA flow ratings

No fine tuningMultiSmart® Arm is de-signed with high quality gas springs giving one touch smoothness and it stays in place – guaran-teed. The mechanism is safety encased, to prevent squeezing accidents.

The MultiSmart® Arm is suitable when the hood needs to be further way from the source and when the arm has to be installed away from capture area.

PlymoVent At Source Extraction ArmsTECHNICAL DATA

Accessories for MultiSmart® Arm


System Design

Coolant mist and smoke will condense and coalesce in ducting. This means that sealed duct-ing always has to be used and care must be taken to slope the duct to allow draining towards the filtration unit, following the air movement. Placing the main duct close to ceiling is one way of making sure that bigger particles drain back to the machine tool.

Recommended valuesIt is important to have a low velocity and only extract the airborne light mist.Machine enclosure duct connection: 5 m/s / 1000 fpmMain duct: 12-18 m/s / 2500-3500 fpm

Flex hosesFlexible duct connections are useful in coolant mist/smoke systems but must be used with cau-tion. The function of flex hose is to isolate the vibration from the machine enclosure and the duct work. It also gives tolerance adjustment. The length of the flex hose should be limited to 0,5 m / 20”. This helps avoiding low spots with bacteria growth when hose is bending while exposed to heat and mist.

Airflow rates to be extracted from metal cutting machines depend upon the follow-ing factors:

Approximate airflow rates to be extracted from enclosed machines Duct design

Velocity in duct work is a point to consider when designing the system.

Below please find charts for determining the airflow rate at various machining processes. This is to be used for preliminary system selection and dimensioning.

• type of machine tool• type and size of machine enclosure• number and size of the openings in the machine enclosure

Approximate airflow rates extracted by coolant mist/smoke control systems from major operations at transmission production plant areas

Operation Extracted airflow rate per machine

Turning 1500 m3/h / 880 CFM

Gear cutting 2000 m3/h / 1180 CFM

Shaving 1600 m3/h / 940 CFM

Grinding 800 - 2000 m3/h / 470 - 1180 CFM

Approximate airflow rates to be extracted from metal cutting machines

Machine size Required extracted airflow rate

Smaller machines ( < 3 m3 / 106 ft3) 500 m3/h / 300 CFM x Machine Enclosure Volume

Big machines ( > 3 m3/ 106 ft3) 300 m3/h / 175 CFM x Machine Enclosure Volume

Table A6.6. Approximate airflow rates extracted by coolant mist/smoke control systems from transfer lines

Extracted airflow rate

Operation partly enclosed line totally enclosed line

Per metre/3.3 ft Per metre/3.3 ft of transfer line Per station of transfer line Per station

Milling 480-720 m3/h 1200-1600 m3/h 320-480 m3/h 800-1100 m3/h 280-425 CFM 705-940 CFM 190-280 CFM 470-650 CFM

Turning 430-650 m3/h 1200-1600 m3/h 290-440 m3/h 800-1100 m3/h 250-380 CFM 705-940 CFM 170-260 CFM 470-650 CFM

Grinding 420-630 m3/h 1100-1650 m3/h 310-470 m3/h 800-1100 m3/h 245-370 CFM 650-970 CFM 180-275 CFM 470-650 CFM

Drilling/honing 380-570 m3/h 1000-1500 m3/h 230-350 m3/h 600-900 m3/h 220-335 CFM 590-880 CFM 135-205 CFM 350-530 CFM

Threading 300-450 m3/h 1000-1500 m3/h 180-270 m3/h 600-900 m3/h 175-265 CFM 590-880 CFM 105-160 CFM 350-530 CFM

Grating 300-450 m3/h 1000-1500 m3/h 180-270 m3/h 600-900 m3/h 175-265 CFM 590-880 CFM 105-160 CFM 350-530 CFM C

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are

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Manual damperThe airflow rates extracted from each enclosure might need adjustment after machines are in place and operating. By placing a manual damper at each machine, the exact airflow rate can be set individually, just enough negative pressure to prevent mist from spreading.



Pressure lossThe importance of minimising pressure loss in your duct system

Pressure loss is the No. 1 enemy in a ventilation system. It’s no use buying the world’s best coolant mist/smoke extraction system if the pressure in your duct work is too high. To help you understand pressure loss and how to minimise the effects of it in your system, these two pages show, in a simple way, how to calculate.

The air resistance in a duct work system is mainly determined by the velocity of the air in that system. As the velocity increases, so does the resistance. This is, what we call pressure loss. The ”static pressure” in a fan indicates the volume of air the fan extracts, given a certain pressure loss. The higher the pressure loss, the less air the fan will extract. The diagram above demonstrates how the pres-sure loss (resistance) can be kept down by increas-ing the size of the ducts, to help you achieve an even velocity in the entire system.

What is pressure loss?

Ø 160 mm/6.25”Ø 250 mm/9.8”

Ø 315 mm/12.4”

1 x 1000 m3/h è 13 m/s1 x 600 CFM è 3000 fpm 2 x 1000 m3/h è 11 m/s

2 x 600 CFM è 3200 fpm 3 x 1000 m3/h è 9 m/s3 x 600 CFM è 3400 fpm

1000 m3/h / 600 CFM 1000 m3/h / 600 CFM

1000 m3/h / 600 CFM

Suggestion!In larger systems, it is usually a good idea to posi-tion the fan in the middle of the system. This gives several advantages – one is a lower pressure loss, another is that you can use smaller dimensioned duct work.

Ductdiam.

in inches

Table shows pressure loss in inches wg and air velocity in fpm at different air volumes (CFM) and different ducting dimensions in inches.

600 CFM 1200 CFM 1800 CFM 2400 CFM 3000 CFM 3600 CFM 4200 CFM 4800 CFM 5400 CFM 6000 CFM

Table shows pressure loss in Pa and air velocity in m/s at different air volumes (m3/h) and different ducting dimensions in mm.

1000 m3/h 2000 m3/h 3000 m3/h 4000 m3/h 5000 m3/h 6000 m3/h 7000 m3/h 8000 m3/h 9000 m3/h 10000 m3/h

Pa m/s Pa m/s Pa m/s Pa m/s Pa m/s Pa m/s Pa m/s Pa m/s Pa m/s Pa m/s

Ø 160 18 13 60 26Ø 200 5 9 20 18 45 26 75 35 Ø 250 2 5.5 6 11 14 18 22 22 40 28 50 34 70 39Ø 315 2 6.5 3 9 6 13 9 16 11 19 17 22 22 26 27 28 32 32Ø 400 1 7 2 9 3 11 5 12 6 15 8 17 10 18 12 22Ø 500 1 6 1 7 2 8 2 10 3 11 3 13 4 14

Ductdiam.in mm

wg wg wg wg wg wg wg wg wg wg

Ø 6” .024 3000 .094 6000Ø 8” .006 1700 .022 3400 .047 5100 Ø 10” .007 2200 .015 3300 .028 4400 .040 5500 .058 6600Ø 12” .006 2300 .011 3100 .016 3800 .023 4600 .031 5400 .038 6100 .050 6800Ø 14” .003 1700 .005 2350 .007 2800 .011 3400 .014 3900 .018 4500 .023 5000 .014 4300Ø 16” .002 1300 .002 1700 .004 2150 .005 2600 .007 3000 .009 3450 .012 3900 .005 2750Ø 20” .002 1650 .002 1900 .003 2200 .004 2400

In fpm In fpm In fpm In fpm In fpm In fpm In fpm In fpm In fpm In fpm

Pressure is measured in Pascal (Pa) / inch water gauge (wg). To calculate how many Pa / inch wg you get in a certain duct, you must know how much air passes through the duct. Air volume is measured in m3/h / CFM. On next page, you will find a pres-sure loss table and an example of the calculation.

6380

100

125

160

200

250

315

400

500

630

800

1000

1250

2

2015

10

5

Ø mm

m/s

2.5

34

56

810

1216

2025

3240

50

400

400030002000

1000

ft/min

Ø inch

100

50

105

1

0,5

0,1

0

Pa/m

50 100 500 1000 5000 10000 m3/h 21 100 210 1060 220 10600 21200 CFM

0.40.2

0.040.02

0.004

0.002

0.0004

0

inches wg/3 ft

Pressure loss in ducting

Airflow Airflow

Pressure loss at sourceWhen using at source extractors, higher negative pressure is needed to ensure the correct pick up velocity. The pressure loss for the extraction arms has to be included in the pressure loss calculation, see the charts on page 48 for Miniman and page 49 for MultiSmart® Arm.

Pressure loss over the filter unitWhen the duct design is ready and calculated, the various pressure for each of the filter units has to be added. In the technical data for each filter unit, the initial and final filter pressure levels are given.

Total pressure loss – exampleIf total air volume is 2000 m3/h / 1175 CFM, divided in a system with 3 machines.

Duct pressure loss: 300 Pa / 1.2” wg

ME-42 filter unit operational pressure: 1500 Pa / 6.0” wg

Total pressure in system: 1800 Pa / 7.2” wg

Select a PlymoVent TEV-585 / TEV-559 or a FUA-4700.

Even if the final pressure for the filter unit is 1500 Pa / 6.0” wg, it is not necessary for the fan to handle the final pressure. By accepting a

lower air volume you can extend the filter life. Lower pressure is also an early indication for the need of maintenance.PlymoVent reserves the right to make design and technical changes.

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Maintenance and ServiceAt PlymoVent, good advice is free!

Customer support and service are fundamental parts of PlymoVent’s business. To be your personal consultant is one of our most important tasks. Our experienced engineers and specialists are always available to assist you in planning and installing your system. Our idea of service involves a continuous dispersion of useful knowledge in many different forms.

Technical support and project supportThere are many questions to be answered during the planning of coolant mist/smoke connection sys-tems. Calculations of pressure loss as well as system solutions, demand time and detailed knowledge of computation models, special cases, the capacities and design of the units. The PlymoVent representative will act as your best and most reliable adviser, from planning through installation. They are also able to contribute with ideas and knowledge at the idea stage.

Follow upPlymoVent has interest in the long term performance of the system. In some cases the PlymoVent repre-sentative handles both installation and start up, but many times installation is executed by a third party supplier. The PlymoVent representative will always assist at start up to confirm that everything has been supp-lied, installed and designed according to project specifications. This way we avoid unnecessary maintenance cost and make sure that we have best possible long term performance.

Continuous informationProgress within the field of the working environment is rapid. PlymoVent is one of the companies in the forefront of this development. Hence our information about new products and solutions are making an active contribution to a better working environment.

Mounting assistanceIn case of larger and more complicated projects, the PlymoVent representative can take care of the entire, or part of, installation and start up process.

CAD supportPlymoVent has a well developed CAD system to design and describe different solutions regarding coolant mist/smoke collection systems.

Courses / EducationA comprehensive educational program, consisting of both theoretical and practical exercises, makes life easier for consultants and customers. Our engineers and specialists will be happy to visit you and carry out instructions and training.

Service agreementsAdvantageous service agreements with regular overhauling and adjusting of the installation will give savings in time and money for our customers.


TABLE OF CONTENTS · [email protected] Year established: 1990 PlymoVent Worldwide – we are there...

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