BMS Clearvue installation

**Breezy** · 24th December 2013, 12:32 AM

Twelve months ago the Bicton Mens Shed decided that the dust collection system was not doing the job! So we started looking for a replacement Dust Collector that could replace the existing 2hp ducted arrangement and 2 single 1hp units directly connected to machines. Locally available DCs with the power to be ducted to all machines had too big a footprint to fit into the space the old DC occupied. The committee finally settled on the Clearvue Max based on reports on this forum. After sorting out how to finance the purchase we placed an order with Stephen in mid August 2013 and it was shipped beginning of September and arrived one week later. Construction started on the CV housing after checking the CVs dimensions. As BMS is only open 3 times a week for half a day it took quite a few weeks to build the housing and during that time the old canvas bags on the DC died (holes keep appearing after patching them) so we had to invest in a new filter and plastic collection bags.
As can be seen the collection bag fitment was not perfect and leaked.
Old dusty-2.jpg

The housing for the CV was built from donated materials, there are several layers of 6mm ply, felt insulation and insulation batts, covered with Colorbond sheeting.
We designed the enclosure to have a built-in exhaust baffle and use a mini wheelie bin as the dust collector. But housing construction crew didn't understand that the cyclone/collection pipe needed to be sealed, hence the strange arrangement seen here.
Clearvue enclosure.jpg Clearvue temp install-1.jpg Clearvue temp install-2.jpg Clearvue & dust collector.jpg

While we waited for some 6inch flexible ducting, we taped some solid ducting between the cyclone and the bin.
Dust collection bin lid.jpg Clearvue & dust collector connection.jpg

As can be seen from these two photos the exhaust baffle didn't work, too much back pressure, some holes were drilled into the baffle to relieve the pressure but in the end we ripped it out and are in the new year connecting some A/C ducting to reduce the exhaust noise. The overall noise from the CV is allot less than the old DC. No noise measurements have been made but it is quieter in the shed, if it were not for whistles of the leaks in the ductwork one would know the CV is running. The chipboard lid to bin is required to be a perfect seal otherwise fine dust blows out of the exhaust port. We obtained that seal by using concrete expansion joint foam glued to the underside of the lid. We will be modifying the bin to provide a view port to check on the level of dust collected and some internal bracing as the sides get sucked in by about 100mm when the CV is in operation. After the inlet ducting was completed and the cyclone bolted into its final position the enclosure was closed off.
Enclosure completed.jpg

Whilst the crew were constructing and installing the CV another crew was installing the shed ducting. I will write their progress in the next post.

**Timless Timber** · 24th December 2013, 04:39 AM

Any chance of providing the internal dimension measurements of the enclosure? (For those of us who are thinking of doing the same)?

Many thanks in advance if your able to.

**Breezy** · 24th December 2013, 06:51 PM

Originally Posted by Timless Timber

Any chance of providing the internal dimension measurements of the enclosure? (For those of us who are thinking of doing the same)?

Many thanks in advance if your able to.

From memory the outside dimensions are a bit over 900mm square. Wall thickness is about 100mm. The minimum distance between the two buildings at the gutter is 920mm and it is tight fit, you can see that the gutter is being pushed up. We are using a standard internal door, that has had extra sound insulation added to the inside face.

When the shed opens again in the new year I will measure internal dimensions.

**Breezy** · 25th December 2013, 01:07 AM

After a lot of design work on Sketchup a ducting plan was produced to keep costs down but provide an easy install path for the connection of the new machines and the replacement of the existing 4inch ducting with 6inch. Part of that plan was that the main duct would be made from 12mm MDF cut to a width of 200mm, hence two and half 2440 x 1220 sheets provided 8metres of approx 200mm square ducting. This ducting would be hung from the roof around two sides of the shed. We started with installation of the hangers.

Ducting support rods.jpg

The first section was installed with the intention of using a 45 degree joint but as we progressed it was realised that because of the slope of the roof, we would not get a strong air tight joint. So the end of the ducting was modified to allow a twisted joint as the following photos show.

Main duct install first go.jpg Main duct install-3.jpg Main duct install-4.jpg

We then got to the stage that the Clearvue and its enclosure had to be positioned in its final location so that a hole could be cut through the wall. That also meant the existing DC had to be moved, so it was brought inside and connected back up to the existing ducting which is under the floor.

Old dusty relocated-1.jpg Old dusty relocated-2.jpg
As can be seen the old dusty is a dirty machine which is why it was placed outside in the first place.

We then proceeded to cut the hole in the wall. As we were not connecting to any round ducting we did away with the Clearvue transition piece and extended the rectangular inlet through the wall and made our own transition.

Cyclone inlet.jpg Clearvue & ducting adaptor.jpg Main duct install-1.jpg
Main duct to CV-1.jpg Main duct to CV-2.jpg Temp connection to old system.jpg

As we wanted to get the old DC out of the shed as soon as possible a temporary connection to the old ducting system was made when the CV was operational. The hole in the main duct was cut where the thicknesser will be connected in the completed system, but because of the position of the old ducting the first connection attempt is sloping the wrong way for efficient operation of a ducting system. This is corrected in the next photos.

Manometer & temp connection to old system.jpg Temp connection to old system (2).jpg

It maybe noticed that VFD changes model types between the early photos. We have problems with the first unit it wouldn’t work until it was reset to factory defaults and then it would just cut out with an over current error, this was intermittent fault so Stephen kindly sent as a replacement the latest model, which has been tuned to meet BMS’s requirements. Since the last photo was taken the electrician has installed a 15amp GPO for the VFD, we had to have the sub-board upgraded to fit the extra circuit breakers.

In the new year I will cover the connection of various machines.

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