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Line 89: − + + − + − + − + − + − + − + − + − + − + − Shark Guard blade guard for SawStop $173+ − 7 pieces of 8"x10' DWV PVC pipe $80 + − http://www.menards.com/main/plumbing/rough-plumbing/pipe-tubing-fittings/pipes/pvc-pipes/schedule-40-cellular-core-pvc-dwv-pipe-8x20/p-1729923-c-8571.htm − 6" flexible PVC hose 25' $92 http://wynnenv.com/products-page/woodworking_hose/pvc-hose/ − miscellaneous mounting hardware (all thread rod, beam clamps, hose clamps) $200+ − 14 8" pipe hangers $16.31+ − − Caulk (for PVC pipe) $80+ − electrical (wire, conduit, circuit breaker, switches, relay) $150+ − 4" ports + − 6" ports − − Total $4546 Line 124:
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Wood Shop Dust Collection (view source)
Revision as of 19:34, 8 February 2015
, 19:34, 8 February 2015→Down Drops: add link to sawstop modification
==Sponsor==
== Sponsor ==
Matt Triano (Officially)
==History==
== History ==
*2014-xx-xx - Discussion open on member list
* 2014-05-22 - Discussion open on member list
*2014-xx-xx - Announced
* 2014-05-27 - Announced
*2014-xx-xx - Vote
* 2014-06-02 - Vote
==Background==
== Background ==
The proposal is to buy a cyclone style wood 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) catches only the large particles and distribute the smallest, most dangerous, particles through the shop. Some of the woodworking tools, e.g. drill press & bandsaw, have no provisions for dust collection.
The proposal is to buy a cyclone style wood 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) catches only the large particles and distribute the smallest, most dangerous, particles through the shop. Some of the woodworking tools, e.g. drill press & bandsaw, have no provisions for dust collection.
== Health Hazards of Wood Dust ==
== 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.
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.
== Do we produce enough dust for it to be a problem? ==
A single ripping cut with a thin kerf blade of 5/4 oak plank 8' long will create 10 grams of <15 micron dust. If distributed evenly throughout the shop, this would create a dust concentration of 9.1 mg/m**3, much greater than the ACGIH hardwood limit of 1.0 mg/m**3. In addition, fine dust is difficult to remove. When it finally settles, sweeping causes much of the dust to again become airborne. Vacuuming is only effective when using a fine filter. So the fine dust tends to accumulate, bringing the airborne dust levels higher and higher.
Calculation: https://docs.google.com/spreadsheets/d/18togRk2AZD1RfjSE-m5PjONLy_UOMeJCfzvsSp8gQTg/edit?usp=sharing
10% of dust (by volume) generated by sawing oak consists of particles smaller than 15.1 microns.
http://annhyg.oxfordjournals.org/content/44/6/455.full.pdf
Approximately 1/3 of this is < 10 micron.
This is an interesting graph showing the distribution of particle sizes created by various woodworking operations.
http://en.wikipedia.org/wiki/File:Particle_size_distribution_of_hardwood_dust.jpg
== Particle Monitoring ==
== Particle Monitoring ==
== Goals ==
== Goals ==
*Achieve better air quality inside the shop than outside.
* Achieve better air quality inside the shop than outside.
*Meet ACGIH air flow recommendations for each woodworking machine (400-1000 CFM). http://billpentz.com/woodworking/Cyclone/dc_basics.cfm#CFMRequirementsTable
* Meet ACGIH air flow recommendations for each woodworking machine (400-1000 CFM). http://billpentz.com/woodworking/Cyclone/dc_basics.cfm#CFMRequirementsTable
*4000 FPM air flow in ducting.
* 4000 FPM air flow in ducting.
*Meet American Conference of Governmental Industrial Hygienists (ACGIH) Threshold Limit Value (TLV) of 1 mg/m**3 Time Weighted Average (TWA).
* Meet American Conference of Governmental Industrial Hygienists (ACGIH) Threshold Limit Value (TLV) of 1 mg/m**3 Time Weighted Average (TWA).
== Dust Collector ==
== Dust Collector ==
== Ducting ==
== Ducting ==
6" PVC sewer & drain pipe for drops
6" PVC solid core sewer & drain pipe for drops
8" PVC sewer & drain pipe for main lines
8" PVC solid core sewer & drain pipe for main lines
== Down Drops ==
== 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:
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
* 8x8x6 DWV PVC Wye fitting (the last drop on the main could use a 8"45 & 8" to 6" reducer instead of a wye. this would probably be cheaper the wye plus a cap.)
*6" 45 elbow
* 6" 45 elbow
*approximately 5' of 6" PVC pipe
* approximately 5' of 6" PVC pipe
*6" blast gate
* 6" blast gate
*short length of 6" flexible hose (length dependent on machine).
* short length of 6" flexible hose (length dependent on machine).
*switch (wireless or wired) to control the collector motor near the blast gate.
* switch (wireless or wired) to control the collector motor near the blast gate.
down drops:
*SawStop table saw
* SawStop table saw (consider this mod: http://www.sawmillcreek.org/showthread.php?72133-Changed-Sawstop-DC-port-to-6-inch)
*ShopBot CNC router
* ShopBot CNC router
*Delta 14" bandsaw
* Delta 14" bandsaw, router table
*jointer
* jointer, drill press
* planer, sanders, miter saw
*router table
== Automating this stuff ==
== 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.
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. https://wiki.pumpingstationone.org/File:Blast_gate_back.svg https://wiki.pumpingstationone.org/File:Blast_gate_front.svg
== Wood Working Machine Collection Strategies ==
== Wood Working Machine Collection Strategies ==
* ShopBot Router - A dust skirt with port is included with the machine. We will need to provide a flexible hose and support. Probably a transition from 6" down to the skirt port. Size of the port is unknown at this point.
* ShopBot Router - A dust skirt with port is included with the machine. We will need to provide a flexible hose and support. Probably a transition from 6" down to the skirt port. Size of the port is unknown at this point.
* 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
* 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
* Jointer = currently has a port approximately 4" in diameter. It appears that we an install a 6" port without difficulty and with no permanent changes to the jointer.
* Mitre saw = this tool throws a lot of dust at high speed and is one of the more difficult tools to collect dust effectively. Definitely needs a shroud.
* Mitre saw = this tool throws a lot of dust at high speed and is one of the more difficult tools to collect dust effectively. Definitely needs a shroud.
* 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
* Delta 14" Bandsaw = Add a 4" port to a new lower wheel cover (make out of wood?) This is Ed's saw and we don't want to permanently modify the existing cover). 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)
* Belt/disk sander (probably needs a shroud for the belt, or just a better sander)
* Planer (could probably use side shrouds)
* Planer (could probably use side shrouds)
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.
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 ==
== Bill of Materials & Budget ==
See spreadsheet for cost details: https://docs.google.com/spreadsheets/d/1DEpszf0J_o_FLTqVH8XopYjlOpG-GloZYVA1FlCf_E8/edit?usp=sharing
Clearvue CVMAX 3 phase with nano filters $2070, shipping $180
Clearvue CVMAX 3 phase with nano filters
Filter clean out box $80
Filter clean out box
round fiber drum $50
round fiber drum (at the base of the cyclone. stores chips & coarse dust)
Dylos DC1100-PRO-PC air quality monitor $290
Dylos DC1100-PRO-PC air quality monitor
For each down drop (7 total):
For each down drop (5 total):
*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/
* 8x8x6 45 DWV PVC wye https://www.plumbersstock.com/product/10258/8inx8inx6in-pvc-sdr35-wye/ (verify this supplier before relying on it.) alternative: 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|1&pl=1¤tURL=%3FNs%3Dp_product_qty_sales_dollar%7C1&facetInfo=
* 6" 45 DWV PVC elbow $8 each http://www.lowes.com/pd_1824-676-6P03_4294765362__?productId=3452924&Ns=p_product_qty_sales_dollar|1&pl=1¤tURL=%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¤tURL=%3FNtt%3Ddwv%2Bpvc%2Bpipe&facetInfo=
* 5' 6" DWV PVC solid core pipe http://www.menards.com/main/plumbing/rough-plumbing/pipe-tubing-fittings/pipe/pvc-pipes/schedule-40-solid-core-pipe-6x10/p-1729943-c-8571.htm
*6" blast gate $15 http://www.clearvuecyclones.com/supporting-products/38-blast-gate-6.html
* 6" blast gate
* 3' 6" flexible tubing.
Shark Guard blade guard for SawStop
7 pieces of 8"x10' DWV PVC solid core pipe
6" flexible PVC hose 25' $92 http://wynnenv.com/products-page/woodworking_hose/pvc-hose/
http://www.grainger.com/product/4HXW7?gclid=CJ7Sr82Yhr4CFUVgMgodtGAAYw&cm_mmc=PPC:GooglePLA-_-Plumbing-_-Pipe%20and%20Tubing-_-4HXW7&ci_src=17588969&ci_sku=4HXW7&ef_id=U1-dgQAAANr@lgZv:20140429171233:s
miscellaneous mounting hardware (all thread rod, beam clamps, hose clamps)
Caulk (for PVC pipe)
electrical (wire, conduit, circuit breaker, switches, relay)
Operating cost estimate:
Operating cost estimate:
== Installation ==
== 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 work may take longer than 90 days to complete for all the machines. Because of this, the spending authorization for the ducting and accessories will be extended.
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 work may take longer than 90 days to complete for all the machines. Because of this, the spending authorization for the ducting and accessories will be extended.
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.
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.
For planning purposes: the current woodshop is approximately 34' x 21'. Ceiling is 14'.
For planning purposes: the current woodshop is approximately 34' x 21'. Ceiling is 14'.
==Electrical Requirements==
== Electrical Requirements ==
3 phase 230v, 12 amps. The collector motor will be switched through a relay controlled by a low voltage switches near each blast gate.
3 phase 230v, 12 amps. The collector motor will be switched through a relay controlled by a low voltage switches near each blast gate.
== Dust Collection Links ==
== Dust Collection Links ==
http://sandwichtechskis.com/ski-builders-shop.htm
http://sandwichtechskis.com/ski-builders-shop.htm
==Language==
Overview of wood dust and collection:
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.
http://www.fwwa.org.au/Art005_WoodDust_c1.pdf
== Language ==
Authorize the board to spend up to $4854 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.
== Receipts ==
[https://rt.pumpingstationone.org/Ticket/Display.html?id=925]
[https://rt.pumpingstationone.org/Ticket/Display.html?id=694]
==Receipts==
[https://rt.pumpingstationone.org/Ticket/Display.html?id=1000]