Dust collector for small woodworking shop, using Oneida cyclone - Jim Yehle

Oneida Air Systems offers excellent cyclone dust collection systems, and a free design service. I called them to get a recommended size, given the number and type of machinery in my shop.

Oneida order #1

Quantity Item Description Unit Price Extended

1 XXK020111 2HP SYSTEM 1PH NEW *NO FILTER $699 $699

1 FXK010239 PLENUM CART KIT 1.5/2HP NW 39"
INCLUDES 1 FILTER $195 $195

1 MSS600000 KIT DRUM FIBER 55 GAL 9" INLET $63.36 $63.36

TOTAL
$1156.36

Quantity	Item	Description	Unit Price	Extended
1	XXK020111	2HP SYSTEM 1PH NEW *NO FILTER	$699	$699
1	FXK010239	PLENUM CART KIT 1.5/2HP NW 39" INCLUDES 1 FILTER	$195	$195
1	MSS600000	KIT DRUM FIBER 55 GAL 9" INLET	$63.36	$63.36
		TOTAL		$1156.36

Oneida order #2

Quantity Item Description Unit Price Extended

1 ATC000000 ATC4-0 5 BLADE HAND CRIMPER $32.94 $32.94

5 DEA900500 5" LARGE RAD 90° ADJ ELBOW $9.30 $46.50

10 DEA900600 6" LARGE RAD 90° ADJ ELBOW $10.14 $101.40

1 DEA900700 7" LARGE RAD 90° ADJ ELBOW $11.58 $11.58

2 DGA040000 4" DIA ALUMINUM BLAST GATE $14.46 $28.92

3 DGA050000 5" DIA ALUMINUM BLAST GATE $19.14 $57.42

2 DGA060000 6" DIA ALUMINUM BLAST GATE $21.78 $43.56

5' DHF030000 3" DIA FLEX HOSE $19.40/5' $19.40

10' DHF040000 4" DIA FLEX HOSE $20.95/5' $41.90

10' DHF050000 5" DIA FLEX HOSE $22.50/5' $45.00

2 DPT260524 5" DIA X 24" LONG 26GA PIPE $4.01 $8.02

3 DPT260560 5" DIA X 60" LONG 26GA PIPE $10.99 $32.97

2 DPT260624 6" DIA X 24" LONG 26GA PIPE $4.11 $8.22

6 DPT260660 6" DIA X 60" LONG 26GA PIPE $11.18 $67.08

1 DPT260724 7" DIA X 24" LONG 26GA PIPE $5.46 $5.46

1 DQK040000 4" QUICK CONNECT SET $21.60 $21.60

1 DRL040212 REDUCER 4 TO 2.5 INCH $7.86 $7.86

1 DRL050400 REDUCER 5 TO 4 INCH $8.64 $8.64

1 DWS060303 6X3X3 45° WYE JOINT $26.04 $26.04

1 DWS050504 5X5X4 45° WYE JOINT $22.80 $22.80

1 DWS060404 6X4X4 45° WYE JOINT $26.04 $26.04

1 DWS060505 6X5X5 45° WYE JOINT $26.04 $26.04

1 DWS060604 6X6X4 45° WYE JOINT $26.04 $26.04

1 DWS060605 6X6X5 45° WYE JOINT $26.04 $26.04

1 DWS070606 7X6X6 45° WYE JOINT $27.24 $27.24

1 DWS060606 6X6X6 45° WYE JOINT $26.04 $26.04

TOTAL
$794.75

Notes:
Hand crimper seen at Home Depot for $19
Hose clamps from Home Depot for about $1 each
Blast gates from Oneida don't work smoothly, and the inlet/outlet diameters are way under. I prefer the Taiwanese model available from several sources; my 4" gate came from Woodcraft for $10, but that's the only size available.
The pipe diameter on Oneida's aluminum blast gates was much smaller than the pipes to which they mate. I filled the gap with cork bicycle handlebar tape. It compresses, is self-adhesive and tapered, and is the right thickness so that one wrap was just about right. (Cinelli is, of course, the best.)
Oneida suggests putting a stub of pipe after the blast gate, ostensibly to make it easier to attach the flex hose. Hogwash.
The quick connect set sucks. Buy one from Woodworker's Supply (Fazlok, 4" only, in clear plastic) for $16.

Quantity	Item	Description	Unit Price	Extended
1	ATC000000	ATC4-0 5 BLADE HAND CRIMPER	$32.94	$32.94
5	DEA900500	5" LARGE RAD 90° ADJ ELBOW	$9.30	$46.50
10	DEA900600	6" LARGE RAD 90° ADJ ELBOW	$10.14	$101.40
1	DEA900700	7" LARGE RAD 90° ADJ ELBOW	$11.58	$11.58
2	DGA040000	4" DIA ALUMINUM BLAST GATE	$14.46	$28.92
3	DGA050000	5" DIA ALUMINUM BLAST GATE	$19.14	$57.42
2	DGA060000	6" DIA ALUMINUM BLAST GATE	$21.78	$43.56
5'	DHF030000	3" DIA FLEX HOSE	$19.40/5'	$19.40
10'	DHF040000	4" DIA FLEX HOSE	$20.95/5'	$41.90
10'	DHF050000	5" DIA FLEX HOSE	$22.50/5'	$45.00
2	DPT260524	5" DIA X 24" LONG 26GA PIPE	$4.01	$8.02
3	DPT260560	5" DIA X 60" LONG 26GA PIPE	$10.99	$32.97
2	DPT260624	6" DIA X 24" LONG 26GA PIPE	$4.11	$8.22
6	DPT260660	6" DIA X 60" LONG 26GA PIPE	$11.18	$67.08
1	DPT260724	7" DIA X 24" LONG 26GA PIPE	$5.46	$5.46
1	DQK040000	4" QUICK CONNECT SET	$21.60	$21.60
1	DRL040212	REDUCER 4 TO 2.5 INCH	$7.86	$7.86
1	DRL050400	REDUCER 5 TO 4 INCH	$8.64	$8.64
1	DWS060303	6X3X3 45° WYE JOINT	$26.04	$26.04
1	DWS050504	5X5X4 45° WYE JOINT	$22.80	$22.80
1	DWS060404	6X4X4 45° WYE JOINT	$26.04	$26.04
1	DWS060505	6X5X5 45° WYE JOINT	$26.04	$26.04
1	DWS060604	6X6X4 45° WYE JOINT	$26.04	$26.04
1	DWS060605	6X6X5 45° WYE JOINT	$26.04	$26.04
1	DWS070606	7X6X6 45° WYE JOINT	$27.24	$27.24
1	DWS060606	6X6X6 45° WYE JOINT	$26.04	$26.04
		TOTAL		$794.75

Returned to Oneida, from order #2

Quantity	Item	Description	Unit Price	Extended
2	DEA900600	6" LARGE RAD 90° ADJ ELBOW	$10.14	$20.82
1	DGA040000	4" DIA ALUMINUM BLAST GATE	$14.46	$14.46
1	DQK040000	4" QUICK CONNECT SET	$21.60	$21.60
1	DRL050400	REDUCER 5 TO 4 INCH	$8.64	$8.64
		Subtotal		$65.52
		Restock fee, 25%		$16.38
		Total		$49.14

I didn't return extra stove pipe, because its value was less than the shipping cost.

Parts for power switch

Quantity	Catalog #	Description	Unit Price
1	Crouzet 84 137 120	SSR/cover, 4-32VDC ctrl, 50A 24-660VAC (0-cross) out	$26
1	Continental Industries HEATSK-DIN-1.6	SSR heat sink, DIN rail mountable	$15
4	Omron G2R-14 120VAC	Relay, contacts: 10A @ 250 VAC, coils: 120V AC, 6.8k ohm	ca. $6
3	any	Resistor, 6.8k ohm, 3 W	-
7	e.g. Cherry E33-50H	SPST or SPDT microswitch w/paddle	ca. $3
1	* Amperite 24DSPDTR1-120C	Time Delay relay, triggered delay-on-release, 24 VDC, 1-120 sec	$31.13 Allied Electronics
1	-	24V DC power supply	-
1	50'	20-ga 2-conductor wire	-
2'		1 x 1 Aluminum angle stock

* Alt. NCC Ametek Q3F series for a bit less ($25), but it's solid-state (1A load), which may not trigger a 240VAC SSR.
Other alternatives:

Airotronics "True Off" mode timer TGMT or TQMT (24 vdc in min.)
Brentek "Pulse Stretcher" output module: SM-IPS5-NRS-T5 (5 sec) or -T10 $40
Artisan Controls "True Delay On Break" 4386A-1-C: 24 vdc in, 8a AC out

Wiring

Mounting a microswitch to a blast gate
(Note replacement thumbscrew)
Don't do it this way, at least with blast gates from Oneida.
There's so much sideways slop that the switch won't engage.

Wiring a relay inside a chopsaw

If I were doing it again, I would use 24 VAC for signal wiring, since the transformers are cheap (doorbells or sprinkler valves) and I actually had some on hand. I would use blast gates pre-wired with microswitches which are now available from Highland Hardware and Hartville Tools, but only in the 4" size, for about $10 or $11 each. I would run three wires instead of two: one for delayed-off switches (where there is a blast-gate switch in series with a motor-switched relay) and another line for only blast-gate switches, for instant shutoff; the third conductor is common ground.