Appearing Interchangeable; Learn More About their Differences
There are two different Electronic Precipitator Cells (ESP Cells) available for use in Mann & Hummel Tri-Mist mist collectors. The Tri-Mist 850-G2, Tri-Mist 1000, Tri-Mist 1000XL, Tri-Mist 1400 and the Cool Blaster Mist Control all accept the same electronic cells; the 806R03-0163K cell and the 806R03-0163CK.
In the Tri-Mist oil and coolant mist collection systems, the electronic cells form the essential core of the air filtration process. Whether installed in a small specialty machining cell or a high volume 24/7 production environment, the performance of the electronic cells directly impact air quality, equipment cleanliness, and overall system efficiency. Air cleanliness improves the factory environment and can improve employee productivity. A properly functioning mist extractor is key to accomplishing this goal. Among commonly specified replacement electronic cells, two nearly identical model numbers sometimes create confusion: the 806R03-0163K and the 806R03-0163CK.
While these part numbers appear interchangeable at first glance and indeed the cells themselves are, the distinction between them reflects an important difference in the service of each of these cells.
The original cell, the 806R03-0163K is the electronic cell used in most applications. The 806R03-0163CK ceramic cell is a newer version and is constructed using ceramic insulators as opposed to the poly insulators used in the original cell. The ceramic cell was introduced after a search for an improved ESP cell better suited to some of the more challenging applications. Testing has indicated that in some applications the ceramic cell may well be the better choice. This is particularly true in coolant applications.
Core Function
Both the 806R03-0163 and the 806R03-0163CK are electrostatic precipitator cells designed to remove airborne oil and coolant mist from the air. They function on the principle of ionization.
Airborne particles pass through the ionization phase. Here they proceed through the charging phase and then through the collection phase where they are collected on the collector plates. The collected fluid drains back to the machine tool or other collection point. Debris collected on the collection plates is removed during periodic preventative maintenance.
From a basic design and performance standpoint, the 806R03-0163K and the 806R03-0163CK are fundamentally the same. Where they differ is in the design of the ionizing wire and the materials used in the insulator. As illustrated, the ionizing wires for the 806R03-0163K utilize an eyelet design for mounting on the ESP cell. The 806R03-0163CK uses a spring and hook design. The two are not interchangeable. The 806R03-0163CK insulator is a ceramic material as opposed to the poly material used in the 806R03-0163K cell. Testing has indicated that the ceramic insulator offers increased reliability. In addition, the contact board used in the 806R03-0163CK is more durable resulting in increased longevity.
Both of these ESP cells are fully washable and compatible with all of the Tri-Mist Mist collectors as well as the Cool Blaster Mist Control mist collectors. There is no inherent difference in filtration efficiency, airflow capacity, or electrical operation between the two models.
Eyelet Wire End
806R03-0198
Spring & Hook
806R03-0198C1
Common Failure Modes
Even these high quality cells will fail or underperform if periodic cleaning and maintenance is neglected. Some of the typical issues that may be encountered include:
- Arcing – a snapping sound which is usually caused by debris, moisture or damaged collector plates
- Loss of efficiency – which is often due to a heavy buildup on the collector plates or broken ionizing wires.
- Indicator Faults – System indicator faults generally are caused by dirty or shorted cells or a power supply failure. The more common of the two will be an issue with the cells.
Maintenance
Regardless of which version of these two electronic cells is used, the effectiveness of an electronic cell is far more dependent on maintenance practices than on the part number of the cell. Unlike disposable filters, electronic cells are designed to be cleaned and reused. If they are not cleaned and subjected to a routine maintenance schedule, their effectiveness will suffer accordingly.
When properly cleaned and maintained, they will provide many years of reliable service.
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