Wood Shop Dust Collection

Sponsor

TBD

History

• 2014-xx-xx - Discussion open on member list
• 2014-xx-xx - Announced
• 2014-xx-xx - Vote

Background

The proposal is to buy a cyclone style dust collection system that can bring the dust down to a safe level. The current system (Jet collector on the table saw, shop vacuums on the small machines) catch only the large particles and distribute the smallest, most dangerous, particles through the shop. Many of the woodworking tools have no provisions for dust collection.

Health Hazards of Wood Dust

Exposure to wood dust has long been associated with a variety of adverse health effects, including dermatitis, allergic respiratory effects, mucosal and nonallergic respiratory effects, and cancer. Contact with the irritant compounds in wood sap can cause dermatitis and other allergic reactions. The respiratory effects of wood dust exposure include asthma, hypersensitivity pneumonitis, and chronic bronchitis.

Particle Monitoring

The most hazardous dust particles are too small to be seen (<10 microns). To determine the effectiveness of the collection system, we will use a relatively inexpensive laser particle counter, such as: http://www.dylosproducts.com/dcproairqumo.html This will help us fine tune the collection system and tell us when there is insufficient flow due to duct blockage, excessive open gates, or dirty filters.

Goals

• Achieve better air quality inside the shop than outside.

• 1000 CFM for each machine in operation.

• 4000 FPM air flow in horizontal ducting.

• Meet American Conference of Governmental Industrial Hygienists (ACGIH) Threshold Limit Value (TLV) of 1 mg/m**3 Time Weighted Average (TWA).

Dust Collector

http://www.clearvuecyclones.com/cv-max/13-cv-max-three-phase-with-filters.html

Collector dimensions are approximately 24" x 52" x 96" tall.

5 HP motor (Leeson 132242.00 frame 184TC, 86.5% efficiency)

This dust collector will have sufficient flow with two open gates. Occasional use with three gates open is acceptable. The 'nano' filter option ($100) is recommended (Efficiency: 99.999% at .5 micron) Collector cost with nano filter is $2070.

Clearvue technical support does not recommend mixing wood and metal dust in the same collection system.

Ducting

6" PVC sewer & drain pipe for drops

http://www.lowes.com/pd_5752-1814-S/M+06006++0600_4294765358__?productId=3134721&Ns=p_product_qty_sales_dollar%7C1&pl=1&currentURL=%3FNs%3Dp_product_qty_sales_dollar%7C1&facetInfo=

8" PVC sewer & drain pipe for main lines

Down Drops

Each large machine or cluster of small machines will require a down drop from the main duct to the machine port or manifold. The drop will require:

• 8x8x6 DWV PVC Wye fitting
• 6" 45 elbow
• approximately 5' of 6" PVC pipe
• 6" blast gate
• short length of 6" flexible hose (length dependent on machine).
• switch (wireless or wired) to control the collector motor near the blast gate.

Machines with dedicated down drops:

• SawStop table saw
• ShopBot CNC router
• Delta 14" bandsaw
• jointer
• drill press

Automating this stuff

Initially, the dust collector will be turned on and off manually and the blast gates will be opened manually. After all the wood working machines are connected to the dust collector, we will work to automate the gates and collector motor - turning on a tool will activate the collector.

Wood Working Machines that need collection

• ShopBot Router
• SawStop Table saw = Initially use 6" drop to a 6" to 4" tapered transition connected directly to the stock cabinet port. 3" duct to the blade guard. Consider this blade guard: http://www.thesharkguard.com/ Monitor result and increase the cabinet port size to 6" if required. Useful discussion on dust collection for the sawstop: http://lumberjocks.com/topics/33892
• Jointer
• Mitre saw (needs a shroud built)
• Delta 14" Bandsaw = Add a 4" port to a new lower door (this is Ed's saw and we don't want to permanently modify it). http://www.highlandwoodworking.com/bandsaw-dust-control-that-works-2.aspx
• Belt/disk sander (probably needs a shroud for the belt, or just a better sander)
• Planer (could probably use side shrouds)
• CNC mini mill.
• Wood lathe (needs a shroud)
• Drill press

While all of these machines need dust/debris collection of some sort. Some of them may be better served by water buckets instead of a central dust vacuum. For instance grinders should have their exhausts feed into a bucket with water in it.

Collector Location

The dust collector will be either centrally located in the wood working area ( to minimize duct lengths) or at the back of the shop to keep it out of the way and minimize the effects of the noise. The main duct will be run overhead, most likely lying on the bottom member of the ceiling trusses.

Budget

Clearvue CVMAX 3 phase with nano filters $2070 shipping $180 Filter clean out box $80 round fiber drum $50 Dylos DC1100 air quality monitor $200

For each down drop:

• 8x8x6 45 DWV PVC wye $83 http://www.nibco.com/Fittings/Plastic-Fittings/PVC-DWV-Fittings/4810-45-Wye-H-x-H-x-H-PVC-DWV/

• 6" 45 DWV PVC elbow $8 http://www.lowes.com/pd_1824-676-6P03_4294765362__?productId=3452924&Ns=p_product_qty_sales_dollar%7C1&pl=1&currentURL=%3FNs%3Dp_product_qty_sales_dollar%7C1&facetInfo=

• 10' 6" DWV PVC pipe $23 http://www.lowes.com/pd_86806-1814-PVC+04600++0600_0__?productId=3135431&Ntt=dwv+pvc+pipe&pl=1&currentURL=%3FNtt%3Ddwv%2Bpvc%2Bpipe&facetInfo=

• 6" blast gates $15 http://www.clearvuecyclones.com/supporting-products/38-blast-gate-6.html

Shark Guard blade guard for SawStop $173

x pieces of 6"x10' DWV PVC pipe $23

y pieces of 8"x10' DWV PVC pipe

mounting hardware $200

Caulk (for PVC pipe)

4" ports 6" ports

Operating cost estimate:

3.24kw X .12$/kwh = $.39/hour

(filters last indefinitely with regular maintenance)

Installation

The installation of the dust collection system will be done by PS1 volunteers. We will target the machines that produce the most dust first (likely the CNC router and table saw). Many of our woodworking machines have inadequate provisions for dust collection and will require custom shrouds and some tinkering to make them effective. This will likely take months to complete for all the machines. Because of this, the spending authorization will be longer than the usual 90 days.

The PVC joints will be sealed with silicone caulk rather than glued, to allow for reuse of the pipe and fittings if we have a layout change.

Electrical Requirements

3 phase 240v. The collector motor will be switched through a relay controlled by a low voltage switches near each blast gate.

Dust Collection Links

http://billpentz.com/woodworking/Cyclone/index.cfm

http://sandwichtechskis.com/ski-builders-shop.htm

Language

Authorize the board to spend $xx on a dust collection system. Authorization for the dust collector expires in 90 days. Authorization for the related equipment (ducting, hardware, ports, etc) expires in 180 days.