TABLE OF CONTENTS 1, INTRODUCTION 2. MACHINE DESCRIPTION, SPECIFICATIONS AND NOMENCLATURE 3, SITE SELECTION AND PREPARATION AND UNLOADING INSTRUCTIONS 4. MANOMETER TEST STATION 5. LUGHT SOURCE ASSEMBLY 6 CONNECTING UTILITIES TO THE MACHINE (COMPRESSED AIR AND ELECTRICAL POWER). 7. MACHINE START-UP PROCEDURES 8, SAFETY PRECAUTIONS 9, PREVENTIVE MAINTENANCE PROCEDURES 10. LUBRICATION REQUIREMENTS 11. TROUBLE SHOOTING GUIDE Sonic Dry Clean is « registered trademark of Sonic Dry Clean, Inc. The information and patented ‘drawings contained in this manual are the property of and proprietary to Sonic Dry Clean, Inc. ‘and cannot be reproduce without exoressed written consent of Sonic Dry Clean, Ine. ‘Copytight 2005INTRODUCTION CONGRATULATIONS! : You have just purchased the patented Sonic Dry Clean Air Filter Cleaning System that is designed to automatically clean large heavy duty air filters that are found on large diesel vehicles both on-road and off- road units, in co-generation plants, dust collectors and powder coating operations. Because SDC-5 Cleaning Machine is totally automatic there is very little the operator has to do except familiarize him or herself with the function of the control panel switches and ensure that there is power and sufficient compressed air available to the machine in order for it to operate as designed. This instruction manual has been divided into various sections from site selection {o trouble shooting, and specific areas of reference can easily be found in the Table of Contents. Should there be any reason that you require any additional information or technical assistance you can reach our Service Department at 800/732- 4622 in US or 760/787-0510 Monday through Friday from 7 AM to 4 PM Pacific Coast Time. Or you can visit our website at www,sonicdryclean.com for update Product Support. Please read the manual completely before any installation or start-up procedures are attempted in order to familiarize yourself with not only the SDC-5 Machine and the ancillary components of the cleaning process but fo determine proper site selection and unloading precautions after the Machine has been received. Taking the time to read this Manual first will expedite Installation and reduce the chance of an error in properly locating the System.MACHINE FEATURES DESCRIPTION & NOMENCLATURE Machine Specifications / Requirements Specifications: Air: 120 to 150 psi clean dry air; 140 cfm recommend - 175 F maximum. Power: All Electrical Requirements we pre-wired at factory to meet customer's electrical requirements. The following is range of electrical options the SDC System can be converted to in the field. Please contact Sonic Dry Clean regarding these changes prior to converting to avoid any voiding the Manufacturers Warranty. SDC-5 Machine: 208-240v, 50/60hz, 1 phase SDC Dust Collector: 208-460v, 50/60hz, 3 phase SDC Manometer Table: 110-240v, 50/60hz, 1phase SDC Inspection Station: 110-240v, 50/60hz, 1phase Total Cycle Time: Approximately five minutes average cleaning time. SDC-5 is equipped with adjustable digital timer to allow for cleaning time adjustments. External dimensions: SDC-5 Machine Height (including feet): 90" Width (Including blower) 51" Depth: 25"SDC Manometer Table Height (including feet): Width (Including blower): Depth: SDC Light Souce Height (including feet): Width (Including blower): Depth: Weight: SDC-5 Machine 800 Ibs SDC Manometer Table 250 Ibs SDC Inspection Station 75 Ibs 36" 24" 36" 40" 18" 40"Features/Description/Nomenclature Sonic Dry Clean Air Filter Cleaning Machine SDC-5 OPERATOR MANUAL Descriptions - the Standard SDC-5 Cleaning Machine is capable of cleaning air filters in the following size range: Height: 8 to 32 inches Outside diameter: 6 to 19 inches Inside diameter: 3.5 to 12 inches Safety Caution: Do not attempt to operate Machine before reading and understanding installation and operation instructions. Functions: (Refer to Figure 1) 1. Control Power ON/OFF - Provides power fo the controls 2. Power ON - Indicates power on. 3. Gyele Start - Starts the operation and the light indicates the cycle is in process. 4, E-STOP - In case of emergency push this button and it will stop the cycle. 5. Sonic Dry Clean, OUTSIDE / INSIDE - Corresponds to the configuration (air flow thru the air filter): OUTSIDE cleans the outside of the air filters. INSIDE cleans the inside of the air filter 6. Cycle Count - Indicates the number of completed cycles. 7. Elapsed Time - Indicates the time the machine has been operated, 8. Digital Cycle Timer: allows for adjustment in cleaning cycle time. Circuit Breakers: 8. 4 Amp (GB1) — Controls, | AMP 9. 5 Amp (CBS) - Cleaner Lifler Motor, 5 AMP 10. 10 Amp - Main Power SupplySDC-5 CONTROL PANELSITE SELECTION & PREPARATION Sonic Dry Clean System Set up & Assembly Instructions Site Preparation & Location: An ideal location is generally in a “comer” of a building or at least where the equipment can be placed alongside an outside wall. As compared to being placed in the "middle" of a room In order to properly install the Sonic Dry Clean System you will need approximately 100 square feet (25' long x 4" wide) of clean, firm, level floor space. In addition, you will need to supply the equipment with two outlets of compressed air (one outlet is %" pipe, recommended air pressure is 120 psi @140 cfm minimum constant air pressure/volume) as well as the required electrical power. Access and availability to these utility requirements should also be factored in the site selection process. Generally a minimum 40 Hp screw type compressor will meet these air pressure and flow requirements. Clean, dry, oil free and cooled air will provide for the best operation of the equipment. It is advisable that an accumulator (reservoir) of at least 200-gallon capacity with an automatic drain valve be installed after the compressor and before the SDG equipment. It would also be advisable to provide an inline desiccant dryer after the accumulator fo remove the last remaining water droplets from the air prior to entering the equipment. NOTE: In severe humid locations it may be necessary fo install an air refrigeration unit to clean and dry the compressed air. Once the necessary utilities (compressed air and electrical power) have been brought to the area where the equipment is to be located the installation of the equipment can commence.SDC-3RS System with Optional Torit Dust Collector and One Piece Manometer and Finishing BoothLoading / Un-crating Equipment Carefully unload SDC Machine and unpack the system from wooden shipping crate. Hook a chain or cable to the eyebolts located on top of the SDC Machine. Using a forklift, carefully lift the SOC Machine to the upright position and set the SDC Machine on the ground. Next, using the forks on the forklift, carefully pickup the SDC Machine from the bottom and install all five of the leveling feet. The feet are packaged in a plastic bag stored inside the cleaning chamber. Use the forklift to move the SDC Machine to the desired location setting it down carefully. Once the SDC Machine is in place use a wrench to level the SDC Machine. NOTE: SDC Machine will not slide once leveling feet are installed,MANOMETER TEST STATION Installation Instructions Manometer Installation: Choose a location for the Manometer Table comes pre assembled at the factory for easy installation. The Manometer Table needs to be located in a convenient location to the rest of the SDC System. Recommend location is to the left SDC machine. a) The Manometer table is prewired from factory for either 110v or 220v as specified from customer. For 220 volt installation, customer to supply electrical plug. ‘See Picture for clarification SDC MANOMETER TABLELight Source Inspection Station SDC Light Source is prewired from factory for either 11 0v or 220v. If wired for 220v customer to supply electrical plug. SDC LIGHT SOURCECONNECTING UTILITIES TO SDC-5 MACHINE Assembly & Installation Instructions For Connecting Ut Connecting Air to the SDC Machine for Initial Set Up: WARNING: = SDC-5 Machine will not clean properly if the recommended air pressure (120 psi at 140 cfm) is not kept constant. Run at least a 3/4" inside diameter airline to the SDC Machine location, Then follow these steps: a) Connect 3/4" airline fo the outside of the SDC Machine, installation of a water separator is recommended. NOTE: For a distance greater than 20 feet consult a compressor specialist for size of line needed to maintain cfm ‘SDC-5 UTILITIES CONNECTION LOCATIONS: 12b) Turn on air to SDC Machine ¢) Open lower door on SDC Machine. d) Locate upper oil filled 0-30 psi gauge. Adjust readings on gauge to read around 17-20 psi. Tuming the knob located directly below the gauge can make adjustment. NOTE: This gauge controls how hard the filter is going to be clamped down to the base plate. e) CLAMP PRESSURE REGULATOR AND GAUGE f] Locate lower 0-200 psi gauge. Adjust readings on gauge to read ‘around 90 psi. Turning the knob located directly next to the gauge can make adjustments. 13Connecting Electrical Power to the SDC Machine WARNING: The SDC-5 Machine requires a power supply of 208-240 volts, 50/é0hz, 10 Amps of Single phase power. Any other form of power will permanently damage the Machine and void the warranty. A qualified electrician should perform electrical power installation. The recommended power cord is & 10/3 SO Cord. NOTE: Make sure power is off while handling power lines. Connect 10/3 SO cord to the male receptacle supplied with the SDC Machine. Insert the male receptacle into the female receptacle located on the bottom left hand side of the SDC-3 Machine. ‘Once the male receptacle has been secured; tum on the you are now ready to turn on the MAIN POWER SWITCH LOCATED ON THE FRONT OF THE SDC MACHINE. SDC-5 CONTROL PANEL 14MACHINE START-UP PROCEDURES Machine Start-Up Procedures Starting up SDC Machine: 1. Tum the POWER ON switch to the ON position. 2. Open upper door on SDC Machine. 3. Determine if the cylindrical air filter element is inside/out or outside/in dirty. NOTE: If ditt is on the outside of the air filter element (air flow is from outside inward) the filter is outside dirty. If dirt is on the inside of the air fiter (air flow is from the inside to the outside) then the filter is inside dirty. 4, Tum on manometer table and place the dirty air filter element over the opening on top of the manometer table. 5. Tum on the manometer table and take the readings from the gauge. NOTE: Not al air filter elements will read the same. 4, Tum off manometer table 7. Place air filter elements in SDC Machine with the opening of the air filter down on the base plate of the SDC Machine. NOTE: Make sure the filter is level on the bose plate. 8. Close door. NOTE: SDC Machine will not run unless door is completely closed and secured. 9. Switch the INSIDE/OUTSIDE switch to the proper position. 10. Press the CYCLE START button on the SDC Machine. 11. Once cycle is complete open the upper door on the SDC Machine and remove the air filter element. 12, Place air filter element on manometer. 15Continued: 13.Tum on manometer and take reading. 14, Tum off manometer. 15.Place air filter element on the wheels located inside the hood of the finishing booth. 16. Take finishing wand firmly in hand and proceed to blow off dust collected at the end caps of the air filter element. 17. Place air filter element on light bar located in dark room 18.Slep on foot pedal switch fo activate light bar. WARNING: Light bar consists of a 750-watt halogen bulb which runs hot and is extremely bright fo the naked eye. Only step on foot pedal switch if filter is covering the light, 19.Slowly rotate cir filter element on light bar looking at filter media. NOTE: Holes in the air filter media will shine through like bright stars. 20. Check the filter to ensure the gasket is glued down properly to the filter. If not, re-adhere gasket to filter with a strong gasket glue. Check for manufacturer filter defects such as media not glued to end caps or not glued in inseam. 21. Repeat 2 thru 23. 16SAFETY PRECAUTIONS Safety Precautions DURING INSTALLATION: 1. Install the feet and level the machine on a solid cement floor. 2. Connect cir and power to the Machine. See specifications for requirements. SAFETY CAUTION: Machine must be grounded! Insure that the power meets local electrical codes or the N.E.C.. Failure to ground Machine properly may cause serious injury to personnel. 1. If not using the supplied SDC Dust Collector make sure that vacuum ports outlet to an approved collection system. SAFETY CAUTION: Do not operate Machine with an open vacuum outlet! High velocity airborne particles may cause serious injury to personnel. 1. Open the lower door by loosening the two thumb screws and verity that the main air regulator located on the inside bottom of the Machine is set at 90 psi. If adjustment is necessary, pull slightly on knob to unlock, Push in to lock affer adjustment. 2. Verify that the clamp air regulator located on the inside middle of the Machine is set at 18 to 20 psi. If adjustment is necessary, push knob to unlock, pull slightly fo re-lock after adjustment. 3. Close the lower door and fasten the two thumbscrews. 17During Machine Operati 1. Tum the Main Power ON. SAFETY CAUTION: Machine operates at 75-80 dba! Appropriate ear protection should be worn, Extended exposure to high sound levels —_may result in hearing damage. 2. Set item 5, selector switch to OUTSIDE position if the filter is an outside-in filter. If the filter is an inside out, set the selector to INSIDE position. 3. Open the upper door and place a filter on the chuck, aligned as vertical as possible. Cleaning efficiency is best with a centered filler. Close the upper door and secure handle latch. SAFETY CAUTION: Filters not centered properly will result in unbalanced loads. _In extreme cases, the filter may come off, causing damage to filter or injury to operator! 4. Press the CYCLE START button. NOTE: The cycle will not start unless: + E-STOP is released * Both doors are shut 5. At the end of the cycle, when the white cycle indicator light tums off, open the upper door and remove the filter. 6. If there are more filters to be cleaned, repeat steps 2 thru 5. 7. If E-STOP is pushed, either door opened, or air pressure drops below 80 psi during cleaning, the cycle will stop. To lower the cleaner assembly ifit is extended up ‘© Twist the E-STOP button to release * Close both doors 18PREVENTIVE MAINTENANCE PROCEDURES Preventive Maintenance Procedures MAINTENANCE: 1. Regularly remove dust and dirt accumulations from upper compartment by brushing into air vent at bottom rear of compartment with vacuum blower on. SAFETY CAUTION: Before servicing or working on equipment or changing fuses, disconnect power source and air supply. 2. Lubricate the three grease fittings for the spindle bearings located inside the bottom door of the SDC machine every 8 hours of operation, or weekly, whichever comes first. Use molybdenum disulfide (Moly) additive, soap or lithium base grease. Three to five shots from a standard grease gun should be sufficient to lubricate the bearings, and flush dirt out. Wipe off dirt and excess grease from the grease fittings before and after lubrication. (See Figure 3) SDC-5 SPINDLE ASSEMBLY AND GREASE FITTINGS. 19LUBRICATION SCHEDULE Lubrication Procedures LUBRICATING & SERVICING SDC MACHINE: SDC-5 Machines Spindle Assembly needs to be lubricated every eight hours of use or once per day. The Operator cannot over grease the spindle assembly, just not grease it enough. Cleaning of the upper chamber is recommended every 2-3 hours or when deemed necessary in order to keep the integrity of the cleaning process at optimum efficiency. NOTE: Servicing/greasing of spindle assembly is needed for longevity of the SDC- 3RS Machine. See servicing and lubricating spindle instruction pamphlet. 20Trouble Shooting Guide Sonic Dry Clean Air Filter Cleaning Machine Model SDC-5 INTRODUCTIO! This guide will give the repair technician guidelines to aid in isolating problems. In rare cases, there may be other problems or combinations of problems, which cause symptoms not covered by this guide. In those cases, please contact the factory directly 800/732 4622 or 760/787-0510. Or visit our website for up to date Product Support at www.sonicdryclean.com The first step to take if there is a problem with the SDC-5 Machine, is to see that the machine has been installed and maintained in accordance with the Operator Manual. Check to see that the electrical power is attached and that the air supply is adequate. Make sure that the spindle has been greased. Check to see that the Dust Collection bags are not overloaded. HOW TO USE GUIDE: The guide contains a list of symptoms in the left column. The right column. indicates probable cause. There may be several possible causes for a given symptom, FOR TECHNICIANS ONLY: In this trouble shooting guide there are listed in parentheses PLC Code Numbers as an added cid to trouble shooting. These numbers correspond with LED indicator lights on the PLC. These lights can only be checked with the Control Panel door open and with Control Power on. CAUTION HAZARDOUS VOLTAGES EXIST INSIDE THE CONTROL PANEL EVEN WITH THE POWER TURNED OFF. THESE CHECKS ARE TO BE MADE ONLY BY QUALIFIED TECHNICIANS. USE EXTREME CAUTION. a1SYMPTOM No power, no lights, with Service Disconnect on. Service Disconnect will not turn power off. No power at light-check outlet. 10 Amp Main Breaker Faults Breaker CBI opens Breaker CBS opens PLC internal fuse blows SYMPTOM, Control Power switch does not tum on. Power is on & machine runs normally but green light out Cycle start does not work Power Controls PROBABLE CAUSE 10-amp breaker fault Disconnect defective Disconnect defective 1 Amp Breaker ault Check circuit breakers to further isolate problem. Refer to Controls Refer to Cleaner Refer to Controls PROBABLE CAUSE CBI is Tipped Defective lamp Detective lamp Upper or lower compartment door ajar causing safety switch to open. Ait pressure below 80 psi (403 LED not lighted) 22Cycle start does not work & green light is off. Cycle Start light is off but cycle Start switch normal E-STOP switch does not stop machine operation Cycle repeats continuously Outside/inside switch does not work, Controls Cont'd Hour meter does not count Cycle counter does not count » E-SIOP switch activated Defective door interlock switch. Defective pressure inter lock switch. PLC internal fuse blown. PLC 5 year battery dead (battery LED on) Defective cycle start switch Defective E-STOP switch (400 LED never on) CBI Tipped Defective lamp Detective switch Defective Cycle-Stort switch (400 LED always lighted) Defective switch (404 LED always/never on) Defective air nozzle valve Defective meter Ten year battery dead Defective meter Ten year battery dead 23Filter Clamp SYMPTOM PROBABLE CAUSE Clamp does not come down 1. Defective air valve SV5 at cycle start 2. Defective air cylinder (434 LED on} Clamp does not release at 1. Defective air valve SV5 end of cycle. 2. Defective air cylinder Clamp wobbles excessively 1. Worn clamp bearing Clamp hits clamp-frame 1. Defective clamp spring during vibration cycle. Clamp jammed 1. Vroller off track Spindle SYMPTOM PROBABLE CAUSE Spindle does not tum 1. Blown 10 Amp Fuses inside CONTROL PANEL Spindle does not tum 1. Defective motor Spindle does not tun and 1. Excessive dirt in spindle AC motor hums and spindle bearings & lack of grease. Hard to tum by hand with 2. Grease seal broken or the power off worn 3. Loose or jammed cam/cam ting. 24Spindle does not tum but is easy fo turn by hand with power off. Spindle turns slow or erratically but easy to tum with power off. Spindle turns slow or erratically and hard to tum with power off. Spindle slow or erratic and hard by hand in CCW direction and easy in CW direction with power off. Spindle slow or erratic and easy to tum by hand in CCW direction and hard in CW direction with power off. Excessive play between spindle chuck & inside tube. Excessive wobble Spindle turns fast, no vibration cycle 1. Defective AC Motor 1. Defective AC Motor Excessive dirt in spindle bearing & lack of grease. Bearing grease seal broken. Dirty lower spindle fo tum bearing Worn lower spindle bearing Dirt in cam bearing Worn cam bearing Worn chuck bushing Loose or broken bolts Wom spindle tube bearings. Broken cam-stop spring Loose cam-stop pin. 25Procedure For Servicing/Cleaning Spindle Assembly 1. TURN OFF ALL POWER TO SDC MACHINE AND REMOVE 220v PLUG FROM. SDC MACHINE. 2. Prop up upper clamp frame and SECURE IT. 3. Locate and remove master link on spindle assembly chain and remove it 4, Loosen and remove three allen-head bolts from center of spindle assembly (the three bolts that hold the sprocket assembly in place). 5. Loosen and remove mushroom rub bolt from inner air nozzle’s aluminum block. 6. Pull chuck plate and inner spindle pipe out through top of machine in one entire unit 7. Once chuck plate and spindle pipe are removed, proceed to wipe excess grease off spindle. 8. Once excess grease has been wiped away from assembly, spray assembly with WD-40 or equivalent [inside assembly through top and also outside assembly). Wipe grease and WD-40 off spindle assembly. Repeat as necessary. WARNING: Do NOT use any kind of chemical degreaser on the spindle assembly. Use only lubricating oil. 9. Once spindle assembly has been degreased with WD-40, spray the inner vacuum tube with WD-40 and wipe off grease build-up on inner vacuum tube. Repeat as necessary. 10.Before reassembling of spindle assembly, the chuck plate and inner spindle pipe need to be degreased. Spray the inner spinale pipe inside and out with WD-40 (avoid spraying the chuck plate with WD-40 for it lubricates the rubber and makes the filter slip when cleaning) and wipe the excess grease and WD-40 off the inner spindle pipe. 11.To reassemble the spindle assembly, follow the procedures in reverse order starting with number 6 through 2. 12.Once reassembling is completed, grease the SDC Machine thoroughly prior to running the machine. 13.Once the Machine is running, check and re-grease it periodically. 14, Repeat servicing/cleaning if heavy cleaning occurs. 26Cleaner SYMPTOM No Cleaner lifter movement Cleaner lifter erratic or slow Cleaner travels up, tops out picking up filter. Cleaner goes down upon power-up but during cycle travels up and tops out picking up filter. Cleaner lifter does not reverse Inside nozzles do not extend Inside nozzles do not retract Inside nozzles do not blow NO OREN Pa PROBABLE CAUSE Loose or failed up or down proximity switch Blown 5 Amp Fuses Failed motor capacitor Failed lifter motor Jammed lifter motor fan Lifter relay R) (LED 437) Lifter relay SSRI or SSR2 (LED 432). Broken or slipped chain Failed relay R1 (437 LED) Failed motor capacitor V rollers off track Loose or failed down- limit proximity switch (401 LED) Loose of failed up-limit switch (402 LED) Loose or failed up-limit switch. Failed relay SSRI or SSR2 Failed down-limit proximity switch. Defective air valve Sv4 Defective air cylinder Defective air valve Sv4 Defective air cylinder Defective air valve SV1 aTOutside nozzies do not extend Outside nozzles do not retract ) Outside nozzles do not blow Nozzles out of sequence Defective air valve Sv4 Defective air valve Sv4 Defective air valve SV2 Defective outside/inside switch (404 always or never on). 28