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Assembly instructions for your CVMAX or CV1800 Compliance Training Australia Pty Ltd 157 McKenzie Street, Dayboro Qld 4521 Ph: 0412 734 982 Web: clearvueoz.com.au

New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

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Page 1: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Assembly instructions

for your

CVMAX or CV1800

Compliance Training Australia Pty Ltd

157 McKenzie Street, Dayboro Qld 4521

Ph: 0412 734 982 Web: clearvueoz.com.au

Page 2: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)
Page 3: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Table of Contents

Required items............................................................................................... 3

Tools ............................................................................................................ 1

General Items ................................................................................................ 1

Installation time ............................................................................................. 1

Getting to know your cyclone ........................................................................ 2

Specifications................................................................................................. 2

Unpacking the components .............................................................................. 3

Impeller housing carton (66mm x 61mm x 25mm) ............................................ 3

The cyclone body carton (51mm x 51mm x 132mm) ......................................... 5

The motor carton (31mm x 42mm x 36mm) ..................................................... 7

The VFD carton (27mm x 35mm x 25mm) ........................................................ 7

Assembly Instructions ................................................................................. 10

Step 1: Check the proposed placement ............................................................. 9

Step 2: Build and mount the Wall Bracket ......................................................... 9

Step 3: Assemble the motor mounting components .......................................... 13

Step 4: Prepare and mount impeller to the motor ............................................. 16

Step 5: Hang the motor and impeller assembly ................................................ 21

Step 6a: Assemble and fix the impeller housing if no filters ............................... 21

Step 6b: Assemble and fix the impeller housing if using filters ........................... 23

Step 7: Attach the impeller housing to the cyclone body ................................... 27

Step 8 Install the intake transition .................................................................. 29

Step 9: Assemble filters ................................................................................ 31

Step 10: Clean out box ................................................................................. 31

Step 11: Connect filter stack to cyclone ......................................................... 33

Step 12: Install collection bin ........................................................................ 33

© Compliance Training Australia Pty Ltd 2014

Page 4: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 1

Required items

Tools

9/16” spanner

7/16” spanner

3/32” Hex key

Screw driver

Drill

Drill bits

Spirit level

Ladder

Tape measure or long rule

General Items

Rubbish bin or other container capable of being made airtight

Timber and fastenings for wall bracket

Duct tape or caulk

Installation time

Assembly and installation of your Clearvue Cyclone should take between 4 and 6

hours with two people.

Installing ducting varies enormously depending on your workshop size, the number

of machines and the complications of the duct routing scheme.

Page 5: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 2

Getting to know your cyclone

*Items are not included and may be purchased separately.

Specifications

Item Description

CV1800 Footprint: 600mm x 600mm or 600mm x 1050mm if using filters,

Maximum air flow through 6” (150mm) pipe 1442 CFM

CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters,

Maximum air flow through 8” (200mm) pipe 1935 CFM

Teco Motor 3 Phase 3 KW 2 pole Monarch series

Impeller Backward Inclined Material Handling Impeller complete with taper lock

bushing. 406mm diameter for CVMAX, 381mm diameter for CV1800

Blower Housing 3/4” MDF Board Top and Bottom with 1/8” clear PETG plastic wrapper

Page 6: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 3

Unpacking the components

The Cyclone will be delivered to you in several cartons.

A standard configuration unit will consist of 3 cartons.

If you have ordered a VFD (Variable Frequency Device) this will be in a separate

carton.

If you have ordered filters these will be in two additional cartons.

You may have ordered accessories such as Blast Gates or Flexible hose. Such items

are usually able to be packed in one of the standard boxes to save freight.

Impeller housing carton

(66mm x 61mm x 25mm)

Contents:

Impeller housing includes:

the motor plate

6 x motor plate locking plates

the impeller complete with taperlock

the cyclone mounting plate

If filters were ordered the 900 transition for the outlet to the filters will be in this

box.

Unpacking tips

We advise you to open one end of the box and remove the flat box containing the

cyclone mounting plate before lifting the box onto a bench.

The impeller is held inside the housing assembly by a transit bolt through the

centre and a piece of MDF. This piece is disposable once unpacked.

If you remove the 6 motor plate locking plates the motor plate will then be free.

Remove it and dispose of the packing inside the housing. Remove the transit screw

and carefully lift the impeller out of the housing.

Page 7: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 4

Impeller housing assembly, Motor plate

& Impeller with taperlock

Cyclone mounting plate

Page 8: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 5

The cyclone body carton

(51mm x 51mm x 132mm)

Contents:

The cyclone body.

Short section of flexible hose with clips to connect to the collection bin (bin not

included).

Clear inlet transition to join up with collection duct.

Clear straight outlet transition used where no filters are specified. Machines

purchased with filters will have a 90o transition included.

Hardware components include:

8 x rubber grommets

4 x ½ Pan Head screws (intake chute)

6 x 1 5/8” Blower Housing Screws

4 x 1 ¼” Transition Screws

8 x ¼ x 20 Lock Washers

28 x ¼ x 20 Flat Washers

24 x ¼ x 20 Nuts

4 x ¼ x 20 x 7” Threaded rods

4 x ¼ x 20 x 1 ½ Hex bolts (transition bolts)

Unpacking tips

We advise you to open the top of the carton and remove the loose items setting

them aside for later.

Depending on how tall you are, you may need to lie the carton down before

removing the cyclone body. Remove the cardboard spacer that is fitted around the

narrow end of the cyclone. (This is actually the base of the cyclone but is at the top

of the carton since the cyclone is packed upside down for stability.)

Carefully slide the cyclone body from the carton. It is best to leave it upside down

for now.

Page 9: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 6

Page 10: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 7

The motor carton

(31mm x 42mm x 36mm)

Contents:

The motor

4 x M12 x 50mm High tension Bolts

4 x M12 Lock washers

4 x M12 Flat washers.

1 x motor shaft key

Unpacking tips

We advise you to move the motor carton with care as it is heavy – 29 kilos.

Remove the packet containing the four bolts nuts and washers. These will be used

to fix the motor to the cyclone mounting plate.

Remove the motor key also contained in the bolt package if it has not already been

fitted. Keep this safe as you will need it when you mount the impeller.

The VFD carton

(27mm x 35mm x 25mm)

This carton contains the Variable Frequency Unit and the manufacturer’s instruction

book. This book is a little daunting as it contains all the information that an

electrical/electronic engineer could possibly need to use the device with any type of

application. It also contains details for all the models that the company make.

If your order includes a VFD, in an envelope at the back of this manual is a

Clearvueoz manual specifically for the VFD when used with one of our cyclones. We

have developed this publication to assist you in programming and using your VFD

with your ClearVue Cyclone.

Please remember that the Law in Australia requires that these types of devices

ONLY BE INSTALLED BY LICENSED ELECTRICIANS.

Page 11: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 8

Page 12: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 9

Assembly Instructions

Step 1: Check the proposed placement

Prepare the site where you will be installing your cyclone. If there are any space or

placement issues, please contact our office so we can assist you.

It is a good idea to mark out where the various components will go and make sure

there are no obstructions like wiring or pipes.

Remember that sharp bends in ducting constricts airflow and reduces the efficiency

of the unit. Try to locate the unit taking into account the following:

Minimise the duct runs

The possibility of a separate sound insulated space

Close to suitable power supply

Easy access to outside if filters not being used

Strong structure to mount to.

Step 2: Build and mount the Wall Bracket

Cut the bracket components

Instruction Size for CV1800 Size for CVMAX

Cut 2 vertical pieces from 50mm x 100mm timber

245mm long 245mm long

Cut 2 horizontal pieces from 50mm x 100mm timber

460mm long 510mm long

Cut 1 Bracket back from 19mm plywood

310mm x 660mm 310mm x 660mm

Cut 2 bracket sides from

19mm plywood

241mm x 495mm 241mm x 546mm

Page 13: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 10

Page 14: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 11

Join the vertical and horizontal pieces

Using two #12 x 65mm or longer screws, join the vertical (shorter) pieces to the

horizontal (longer) pieces by driving the screws through the vertical member into

the end grain of the horizontal member.

You now have two L shaped brackets. Pencil mark these as LH and RH

Attach the two side pieces

Taking the LH bracket glue one side onto the LH side. Reinforce the join using 4 x

40mm screws on the vertical piece and 6 x 40mm screws on the horizontal piece.

Taking the RH bracket, glue one side onto the RH side. Reinforce the join using 4 x

40mm screws on the vertical piece and 6 x 40mm screws on the horizontal piece.

Attach the back plate

Take the back plate and line up the LH bracket so the side is flush with the LH edge

of the board, and the top of the vertical piece is flush with the top of the back

plate. Glue the two parts together and reinforce the joint with 6 x 60mm screws

from the back of the back plate into the vertical piece. Then do the same on the

right side making sure the side is flush with the right side of the back plate and the

top of the vertical piece is flush with the top.

Mount bracket assembly to wall

The top of the bracket assembly should be at least 2400 above the floor which

allows a collection bin 710mm high. If you have a taller bin you will need to

increase the height of the bracket assembly by the height above 710mm.

If you cannot get the required height see addendum A at the back of this manual.

Use at least 8 #12 x 75mm screws and drive these into studs or solid supports.

These screws take the entire weight of the machine – it does not rest on the bin.

Page 15: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 12

Wall Bracket assembled

RH side panel

Back panel

Page 16: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 13

Step 3: Assemble the motor mounting components

Assemble the threaded rods and attach to motor plate

There are four threaded rods which are used to suspend the blower housing below

the motor. The components you need are:

The round motor plate

4 x threaded rods

12 x flat washers

12 x nuts

4 x rubber grommets

4 x lm lock washers

Thread the components onto each rod in this order :

a. 1 x washer followed by 1 x rubber grommet. The washer should

be approximately 100 mm from the one end of the rod. This end

will be the top end when you fit the rod to the motor plate later.

b. 2 x nuts up to the washer but do not tighten the lock washer

yet. These lock nuts can be tightened later to compress the

rubber grommets,

c. 1 x nut only up about 15mm,

d. 1 x lock washer up to the nut,

e. 1 x flat washer up to the lock washer,

f. Repeat steps a. to e. for the remaining 3 rods.

You should now have 4 threaded rods set out as shown opposite.

Place the motor plate onto a work surface with the T-nuts facing down. Insert the

threaded rods into each of the holes in the motor plate making sure that the flat

washer and lock washer remain in place.

Thread the rods in until they are almost flush with the base of the motor plate.

Page 17: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 14

¼” Threaded rods

¼” Flat washers

¼” Nuts

Rubber grommets

¼” Lock washers

Assembled rod before fitting to motor board

Motor plate with threaded rods

Page 18: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 15

Join the cyclone mounting plate and the motor plate

The cyclone mounting plate is the large blue MDF board with reinforcing bars on

each long side. These reinforcing bars must face upwards when the cyclone

mounting plate and the motor plate are joined. They will also face the ceiling once

the installation is complete.

Keeping the reinforcing bars facing upwards, lower the cyclone mounting plate on

to the threaded rods.

Thread the components onto each rod in this order :

1 x flat washer should rest flat on top of the cyclone mounting plate,

1 x rubber grommet,

1 x flat washer,

2 x nuts up to the washer, tighten the lock nuts so they are snug

against the flat washer but do not cause the grommets to bulge.

NOTE

After the cyclone is hung and fully assembled this pair of nuts will be used to level

the unit. The bottom nuts will be used to compress the bottom rubber grommets.

Prepare the motor

Stand the motor up so the shaft is pointing upwards.

Check that the half round key that is the standard fitting for the Teco motor has

been removed. This key will not fit into the bearing on the impeller. If not removed,

use a hammer and screw driver to remove it and discard.

Check that the electric box has been fitted so it will clear the cut out in the cyclone

mounting plate. If not, remove the screws and remove the lid. You will then be able

to unscrew the box from the motor and re-fasten once you have turned it through

900.

Invert the cyclone mounting plate and motor plate assembly and lower over the

motor. Install the 4 motor bolts using a flat washer and a lock washer on each bolt.

Tighten the bolts securely.

Page 19: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 16

order of components above Cyclone mounting plate

Cyclone mounting plate

Complete assembly

Motor showing wire outlet aligned correctly and correct motor key fitted

Page 20: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 17

Step 4: Prepare and mount impeller to the motor

The impeller can be installed onto the motor either before or after the motor

assembly has been hung in the bracket. The following table shows the pros and

cons of each method.

When to install Pros Cons

Before It is easier to join the

impeller to the motor.

Increases the weight of the

motor assembly when hanging it

in bracket.

We recommend at least 2 people

to hang the completed

assembly.

After

Hanging the motor unit will

be easier but may still

need 2 people.

It is more difficult to mount the

impeller as it is hard to hold its

weight and work from

underneath against gravity.

This document concentrates on mounting the impeller before hanging the motor

assembly.

Prepare to use the impeller taperlock

The impeller is mounted onto the motor shaft using a Maska tapered bush. This

ensures that the impeller remains centred and firmly attached.

Opposite is a copy of the MASKA leaflet.

The Maska taperlock is supplied loosely fitted to the impeller and needs to be

removed before proceeding any further.

You will see that there are 6 holes in the taperlock. 3 are plain and three are

threaded. The plain holes are used to hold the two parts of the taperlock together.

These are the holes into which the bolts are lightly fixed when delivered. The other

three holes are used if you need to remove the taperlock from the motor shaft.

To do that, take the bolts out of the plain holes and insert them into the threaded

holes. Tighten progressively until the top part detaches from the impeller part.

Page 21: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 18

MASKA leaflet

Page 22: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 19

Position the impeller

1. Stand the motor, motor plate and cyclone mounting board with the

motor shaft facing upwards.

2. Take the motor shaft key and insert it into the keyway on the shaft. It

should be a tight fit.

3. When shipped, the impeller is temporarily fastened into the housing by

a MDF shipping plate. If you have not already done so, remove this

plate and discard together with any other packing.

4. Lift the impeller out of the housing.

5. Remove the shaft part of the taperlock as described in the “Prepare to

use the impeller” section.

6. Place the impeller over the motor shaft.

7. Place the shaft part of the taperlock over the motor shaft and align the

plain holes in the taperlock with the threaded holes in the impeller part

of the taperlock.

8. Insert the 3 bolts through the larger holes in the shaft part into the

threaded holes in the impeller part.

9. Lift the impeller so that the top of the taperlock is flush with the tip of

the motor shaft.

10. Tighten the bolts in a circular fashion round the taperlock. Continue

until they are all tight.

As you tighten, you will find that the impeller is drawn towards the

motor. When you get back to the first bolt, it will be loose until you have

been round the circle sufficient times.

When completely tight, there should be at least a 7mm gap between the

impeller and the mounting plate bolt head. If there is, loosen the bolts

and re-start with the top of the taperlock just past the tip of the shaft.

The required torque is 5 ft/lbs – 2.27 kg/f.

11. Tighten the setscrew against the key.

Page 23: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 20

Page 24: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 21

Step 5: Hang the motor and impeller assembly

For this part of the assembly process you will almost certainly need

assistance!

Turn the motor and impeller assembly over so that the impeller faces downwards.

Lift the assembly and slide the cyclone mounting board onto the wall bracket you

fastened earlier.

Before you operate the cyclone you will need to fasten the cyclone mounting board

to the brackets. Do not do this yet as some minor adjustment may be needed as

you fit the rest of the cyclone parts.

Step 6a: Assemble and fix the impeller housing if no filters

Follow these instructions if you are not using filters otherwise ignore this section

and go to “Step 6b Assemble and fix the impeller housing if using filters”

Attach the straight transition to the Impeller Housing

Loosen the front 4 bolts on the impeller housing and ease it slightly open.

Place the two wooden pieces supplied onto the housing and re-tighten the bolts.

Place the straight transition square end over the opening and line up the bolt holes.

Place a flat washer on a bolt and then insert from the inside so that the bolt head

remains inside and the nut will go on the outside.

Thread onto the bolt a flat washer followed by a lock washer then a nut and tighten

gently.

Repeat the process for the other three bolts.

Apply silicone sealant to all 4 sides of the transition.

It is important to completely seal these joints – if not, fine dust may escape and

pollute your work place before being exhausted outside. The air being exhausted is

moving very fast.

Proceed now to page 28 - section 7: Attach the impeller housing to the

cyclone body.

Page 25: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 22

Motor and impeller on bracket

US motor shown

1

2

3

4

Sequence of assembly straight transition

Page 26: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 23

Step 6b: Assemble and fix the impeller housing if using filters

Assemble right angle transition

The transition is supplied as a flat pack consisting of:

1 x round base plate

2 x grooved side pieces

1 x short clear panel

1 x longer clear panel.

Insert the clear panels into the grooves on the two side pieces.

Insert the assembly you have just created into the slot in the round base plate.

Drill 4 small pilot holes into the round base plate to line up with the base of the two

side pieces.

Attach the assembly to the base plate using the four screws provided. Take care

not to split the side pieces.

Apply silicone sealant to the junction of the clear panels and the side pieces.

Apply silicone sealant to the junction of the side pieces, clear pieces and the round

base plate.

It is important to completely seal these joints – if not, fine dust may escape and

pollute your work place before reaching the filters. The air being exhausted is

moving very fast.

Page 27: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 24

1

2

3

4

Construction of right angle transition

Page 28: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 25

Attach the transition to the impeller housing

Important Do not remove the white piece of wood located in the impeller

housing. This piece operates as a sound damper as the blades pass by the opening

of the impeller housing.

Loosen the front 4 bolts on the impeller housing and ease it slightly open.

Slip the transition into the impeller housing.

Re-tighten the front 4 bolts clamping the transition in place.

Ensure the transition is square and level where it meets the housing, and drill

through the holes in the side pieces.

Place a flat washer on a bolt and then insert from the inside so that the bolt head

remains inside and the nut will go on the outside. It is fiddly to fit the bolt from

inside but causes less turbulence and interruption to airflow.

Thread onto the bolt a flat washer followed by a lock washer then a nut and tighten

gently.

Repeat the process for the other three bolts.

Apply silicone sealant to all 4 sides of the transition.

It is important to completely seal these joints – if not, fine dust may escape and

pollute your work place before being exhausted through the filters. The air being

exhausted is moving very fast.

Instructions for assembling and attaching the filters is dealt with later in

this manual at Step 9 onwards. Please continue with Steps 7 and 8.

Page 29: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

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Page 26

Page 30: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 27

Step 7: Attach the impeller housing to the cyclone body

You need to decide where the intake and outlet transitions should face. You can

rotate the impeller housing to achieve the desired outlet position. You can orientate

the cyclone body to set the intake transition at the required position.

Before progressing further you will need to prepare a support for the cyclone body.

We recommend that you use a bin or strong box to stabilise the body whilst you fix

the housing to it. You will then need a temporary support while you join the

impeller housing to the motor assembly. It is often possible to create this by

placing a board over the bin you have already used.

If you want to seal all the seams in the impeller housing it is easier to do this now

using silicone sealer.

Check the desired position of the exhaust transition.

Place the cyclone body into a container to stabilise it while fixing the impeller

housing.

Check where the inlet transition needs to face to make connecting ducting easy and

as smooth as possible.

Attach the cyclone body to the impeller housing using the 6 x 1&5/8” screws

provided. DO NOT OVERTIGHTEN THE SCREWS or you could crack the cyclone

body.

Remove the cyclone body with the impeller housing attached and support it under

the hanging motor and impeller assembly. Using packing pieces, lift the cyclone

body until the impeller is in place inside the impeller housing.

Install the 6 locking plates on the impeller housing. At this stage, leave them

slightly loose in case you need to move the unit whilst completing the installation.

Note: the motor plate may not sit flush with the top of the impeller housing - this is

normal.

Use a spirit level to make sure that the cyclone is level. Adjust the nuts on the

threaded rods to level if necessary.

Page 31: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 28

Page 32: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 29

Step 8 Install the intake transition

It may be easier to rotate the cyclone body for better access.

Slide the intake transition into the hole in the cyclone body.

Attach the transition with the 4 #6 x 3/8” screws provided.

Seal the joins of the transition with silicone sealant.

Rotate the cyclone body into its permanent position and firmly tighten the 6 x

locking plates on the top of the impeller housing.

Re-check the cyclone body is level and re-adjust if needed.

Secure the cyclone mounting board into the wall bracket using either 35 mm

screws or suitable bolts.

Pre-drill the holes to avoid any spitting.

Page 33: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 30

You may see a small black

grommet near the intake. This serves to

prevent dust from collecting in the

dead space inside the cyclone body.

Page 34: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 31

Step 9: Assemble filters

Stack one filter on top of the other.

Apply a thin bead of silicone on the outside of the join between the two filters

Take the band clamp supplied and assemble if needed. The two flanges are held

together with a bolt.

Place a flat washer on the bolt and insert it through the flanges.

On the outside of the second flange thread a flat washer then a lock washer.

Loosely fit the wing nut supplied.

Slide the band clamp to cover the join in the two filters and tighten lightly using the

wing nut.

Step 10: Clean out box

If you are using filters you need a clean out box at the bottom of the filter stack.

This enables you to collect any small quantities of dust which may come from the

filters when they are cleaned.

To clean the filters gently vibrate the filter stack. This should not be necessary very

often and will depend on the type of work you do and how often you use the

system.

Clearvueoz offer a custom made clean out box as an accessory. Alternatively you

can make your own.

There are only a few requirements for the clean out box:

It should be at least 36 cm square or round.

It must be airtight except through the filter inlet.

It needs a sealed opening to allow the contents to be extracted. We

recommend a flange with lid suitable to connect a vacuum hose to.

The height can be determined by standing your filter stack under the transition and

measuring the gap. This will then be the desired height for the box. Alternately you

can insert packing under a shorter box.

To install the clean out box simply stand the filter stack on the box and apply a thin

bead of silicone sealer around the join between the box and the filter stack.

Page 35: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 32

Filter clamp

Filter Stack

Clean out box available for

Purchase from Clearvueoz.com.au

Example home-made dust collection box

Page 36: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 33

Step 11: Connect filter stack to cyclone

Slide the filter stack with the clean out box attached under the filter transition. The

assembly should be a snug fit. If there is a gap, use packing pieces to close the

gap.

Drill pilot holes in the MDF plate at the base of the transition.

Attach the filter stack using 35mm #6 sheet metal screws.

Either cover the join with a good quality duct tape or apply a thin bead of silicone

sealant around the join.

Step 12: Install collection bin

There are many possible alternatives which you can use to act as a collection bin.

There is only one golden rule – It must be airtight!

Other considerations include

Weight of the finished item.

Ease of moving and emptying.

It must be sufficiently rigid to not collapse under the suction.

Maybe the ability to know when it is full or getting full.

Alternatives include:

A galvanised rubbish bin – you will need to modify the lid.

A heavy duty plastic bin – you will need to modify the lid.

A wheelie bin – You will need to make a new lid and check the bin is

airtight.

A steel barrel eg 44gal drum – you will need to modify the lid.

A cardboard drum – You will need to modify the lid.

Construct your own design of box – beware you do not make it too

heavy to move easily for emptying.

Page 37: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 34

Note: the photograph shows an

older filter with a square joining

plate.

Page 38: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 35

Modify or make a lid

Metal lids

The most common situation where you will need to modify a metal lid is where you

are using a metal rubbish bin or a steel drum.

You need to create a hole 150mm in diameter.

This hole will normally be in the centre of the bin but if you need to offset it due to

location challenges this is not a problem.

There are 2 simple ways to fix the short hose from the bottom of the Cyclone body

to the lid.

a. Simply cut a hole and silicone seal the hose to the lid.

b. Fasten a flange joint to the lid and slip the hose over this.

If you are using silicone sealer and no flange

Using a drawing compass or a suitable sized template, draw a circle

150mm in diameter in the location where you want the hole. (drawing-

compass is set to 75mm radius)

Inside that circle, use the same centre but only120mm in diameter.

(drawing-compass set to 60mm radius)

Using your tool of choice eg: tin snips, jigsaw or multi-purpose cutter,

cut out the smaller circle

Make a series of cuts (between 15 and 20 works best) from the edge of

the hole you have created straight out as far as the outer marked circle

Using pliers, bend the tabs you have created upwards to form support

for the inside of the hose

Place the hose provided over the tabs and seal with silicone generously

applied both inside and outside the lid

Apply a dust sealing tape around the perimeter of the lid to sit between

the lid and the bin sides.

Page 39: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 36

Lid showing tabs folded up

Hose slipped over tabs

Page 40: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

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Page 37

If you are using a pre-formed flange joint

Using a drawing-compass or a suitable sized template draw a circle

150mm in diameter in the location where you want the hole (drawing

compass is set to 75mm radius)

Using your tool of choice eg: tin snips, jigsaw or multi-purpose cutter,

cut out circle

Check that the hole you have made allows the flange to slide through –

if not, enlarge the hole slightly

Apply a generous amount of silicone sealant to the top of the flat plate

of the flange

Pass the flange through the hole and press firmly into the underside of

the lid

Apply more sealant around the lid where the flange protrudes

Place the hose provided over the insert and use one of the bridge

clamps supplied to hold it tight against the insert

Apply a dust sealing tape around the perimeter of the lid to sit between

the lid and the bin sides.

Page 41: New Assembly instructions CVMAX or CV1800 - Clearvueoz.com.au · 2015. 6. 4. · CVMAX Footprint: 600mm x 600mm or 600mm x 1050mm if using filters, Maximum air flow through 8” (200mm)

Compliance Training Australia Pty Ltd ABN: 73 12 54 698 898 157 McKenzie Street Dayboro Qld 4521 0412 734 982 www.clearvueoz.com.au [email protected]

Page 38

Inside of lid showing dust sealing tape

Example pre formed flange