Ever wonder what happens if you don't clean your cyclone?

[Wade Lippman]

I was drum sanding large panels and noticed there was some dust on them! I pulled the hose off and found the suction wasn't normal; I figured it was time to clean the filters. Only the filter cleaner wouldn't even turn.

The drums (Oneida Portable... two cyclones, two drums) were full. On one the drum and the hose going to the cyclone were full; on the other the entire cyclone and filter were full.

It took me an hour to clean up, but then she worked like nothing ever happened.

Well, I emptied them just before starting the new project; now I know their capacity is 60bf of jointing, planing, and sanding.

[Jim Becker]

Yup....been there, done that. Overfilling the bin and the resulting "impacted" filter is a "no fun" moment...

[Jeff Wright]

I've got you both beat. I overfilled my Oneida drum twice in two days! Didn't think I was doing that much woodworking, but the clogged filter told me otherwise.

[bob cohen]

first time I did that, I said never again. Too bad I wasn't listening

[Robert Payne]

Well guys, you need to implement Alan Schaffter's Bin Sensor on your cyclones! Alan posted this thread recently that refers to his electric eye based sensor that he built more than a year ago for his shop-built cyclone (links in the thread above).

I bought a ClearVue CV1800 cyclone and have adapted Alan's idea into a version that incorporates a 110V remote controlled outlet to feed power through a small relay's normally closed contacts to a 230V/30Amp contactor relay that handles the 5HP motor power. I use the same basic circuit from Alan's system and use the signal from the electric eye to energize the small relay, shutting down the cyclone and turning on an indicator lamp in my shop telling me the bin is full (my cyclone is in a tall crawl space under my shop). Here a circuit diagram of my system.

...and a photo of the 6"x6"x4" junction box with the relays.

... and finally, a picture of a mockup board showing the 7W candelabra in the upper handy box and the photoelectric eye in the side of the lower one.
These are placed either side of a starter collar on top of the bin below the cyclone. The parts are readily available (photo eye is for a dusk-to-dawn control for a yard light for <$13 from either of the BORGs), and all parts totaled less than $50 + the 30A contactor. The service switch bypasses the electric eye while you empty the bin so any light hitting the electric eye won't start the DC again in case you forgot to hit the Off button on the remote control. Because of a second or so response time in the electric eye circuitry, false shutoffs are minimal. Alan also recommends adding a tube 6" or so into the bin so the sensor is activated before it is totally filled.

[Todd Crow]

I also implemented Alan Schaffter's Bin Sensor on my cyclone. I tried a different photeye with limited sucess. Seems some of the photoeye sensors have a delay built into them. Once I bought the Summit Lighting CP688 photoeye (Lowes part #70551) it worked awesome!

I took a piece of 2x4 and cut a curve in it to conform to the flex between the cyclone and dust bin. Drilled a hole in the center of the board and attached the sensor through the board. I cut a 6" hose clap in half and attached it to the board and clamped that onto the flex.



You need good light for the sensor to think it is daytime.



I bought a strobe on Ebay for $45 that I plug the output of the sensor into. So when the dust bin get full and the dust starts filling the flex the dust will block the light and the sensor will power the strobe. I might have to put a horn on as well, I will try this first.

[Wade Lippman]

I also implemented Alan Schaffter's Bin Sensor on my cyclone. I tried a different photeye with limited sucess. Seems some of the photoeye sensors have a delay built into them. Once I bought the Summit Lighting CP688 photoeye (Lowes part #70551) it worked awesome!

I took a piece of 2x4 and cut a curve in it to conform to the flex between the cyclone and dust bin. Drilled a hole in the center of the board and attached the sensor through the board. I cut a 6" hose clap in half and attached it to the board and clamped that onto the flex.

Okay, a project for next week! Thanks.

[John Thompson]

I had it happen once when planing poplar down for drawers. Noticed that the flow decreased. The cyclone was full and the double filters were full as the chips had no place to go as has been stated. Took over 3 hours to clean it with compressed air and neglected long enough or often enough can fry the motor.

The sensors look good, but for $5.00 purchase a blast gate and either cut a hole about 3/4 way up the drum on the side.. or cut a hole in the lid. Seal it with silcone.. If you have any suction through the gate door as it is not exactly an air-tight device, just use some duct tape to seal it competely. Duct tape is easy-on.. easy off.

At that point you either open the side gate or lid gate and shine a flash-light in. I do it every 15-20 minutes when planing as it it doesn't take long with those fine shavings. And... I have not and do not anticipate any problem with over-fill after I stupidly stepped over the log without looking and the "Rattler" bite me.

I realize it isn't high-tech.. but it works fine for me...

Sarge..

[JayStPeter]

First time I did it, my son came down and hit the remote control right after I had removed the bin and filter. While it did get the packed in material out of the cyclone body and outlet, I don't recommend it as the best way to go.

[Jim Becker]

At the present time, I just have a window in the top of my bin..which works great as long as I remember to actually look at it!!

[Bob Wingard]

I got REALLY lucky on this one .. .. picked up a surplus BINDICATOR. It is the "tuning-fork" style, and has 4 sets of contacts in it .. 2 N/C & 2 N/O. When the bin fills up, all contacts change state, so it turns ON a 110v strobe light, and 20 sec. later, it drops power to the motor relay, stopping the blower. Haven't got the entire Clear-Vue setup just yet, but the electronics are wired and ready to go.

[Alan Schaffter]

Thanks to Rob and Todd for posting pics of my design. My shop is above my garage and the cyclone at garage level. I overfilled my bag (cyclone is a push-through so no bin) too many times, so after looking at the options available, including Sugi's design on Bill Pentz's site and the expensive sychronous motor based unit sold by Oneida, I decided I would attempt what had not worked previously for others- an optical high dust alarm.

After a short amount of experimentation, I luckily discovered a few things- replacement dusk to dawn photo eyes are readily available and relatively inexpensive, they are simple in design, have a 110V output (to power a light/alarm), and WILL work to detect a high dust situation but most importantly, need a supplemental light source and must be mounted where the cyclonic air flow keeps the sensor and light source free from dust until a high dust situation blocks the path.

My original installation is still working perfectly after more than a year!! It is connected slightly differently than Rob's due to differences in our control wiring, but it is also wired so it shuts off the DC in a high dust condition. Since I use a bag and don't have a dust bin, I mounted the sensor and light at bottom of the cyclone cone. Though it works with a bright enough supplemental light source through the flex that connects most cyclones to the drum, I think it is better to mount it to a section of duct that has been added to the bin- both for light transmission issues and to control the level of dust in your bin (see sketch below).

I have tried to interest ClearVue, Grizzly, and Oneida in my design, but while ClearVue and Oneida have shown some interest, it has not gone anywhere yet.

Here are some pics of my original setup, a portable version I made for a friend, and the sketch of my recommended installation method.

Photo eye available at most big box stores:


Sensor mounted on my cyclone during testing: (nice Bondo job? )


Light source:


Basic circuit sketch and mounting recommendation:


Portable, self-contained high dust alarm:

[John Thompson]

I have a feeling Jim, that will be all you will ever need. As far as not looking to check... I have my serious doubts as to that from the through-ness of your post along with the content. You can fool some the of the people some of the time.. but............

BTW.. very clever little device. Did you purchase it or just make it? I do believe one could take a square piece of wood.. cut a squre hole and recess the bottom a standard piece of plexi-glass would sit it would work as the metal.

Field expendeincy rules the day and saves a few dollars for anniversary gifts to boot....

Sarge..

[Louis Rucci]

What a timely post. I have ClearVue and will definietly incorporate this in my system.

Many thanks

[Bob Rufener]

My grandmother, who immigrated here from Switzerland, would have said: verstopft