Learn how to setup, manage, and maintain your Amtech AV AutoVent Weldcell Collector by Clean Air Industries.
OWNER’S MANUAL
Amtech AutoVent Series
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AutoVent Series
Important!!!
Due to the nature and variety of dusts/fumes/smoke, it is impossible to list all potential hazards related to dust/fume/smoke control equipment or systems. Additionally, it is impossible to list all potential hazards involved with installation/operation/servicing a dust/fume/smoke collector system. It is assumed that the installer/operator/servicer will follow ALL local, state, and national codes/laws/regulations, as well as, accepted practices by the industry. This manual serves as a guide for the installation/operation/servicing of the system. If any aspect of the installation/operation/servicing is not addressed or fully explained to the satisfaction of the installer/operator/servicer, then the installer/operator/servicer is encouraged to contact their CLEAN AIR INDUSTRIES distributor. It is strongly recommended that this manual be read in its entirety by the installer/operator/servicer prior to beginning any work on the system!
• INSTALLATION • OPERATION • SERVICE
UNIT IDENTIFICATION Model Number
____________________________________ ____________________________________ ____________________________________ ____________________________________ ____________________________________ ____________________________________ ____________________________________
Serial Number
Ship Date
Installation Date Customer Name Customer Address
Distributor Name ____________________________________ Distributor Address ____________________________________ ____________________________________
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TABLE OF CONTENTS
PRECAUTIONARY STATEMENTS
4
INTRODUCTION
5
TYPICAL DRAWINGS OF COLLECTORS
6
INSPECTION (Receipt of unit)
7
THEORY OF OPERATION
7
STANDARD FEATURES
7
OPTIONAL FEATURES
7
INITIAL INSTALLATION CONSIDERATIONS
8
MECHANICAL INSTALLATION
9
ELECTRICAL INSTALLATION
9
COMPRESSED AIR SUPPLY
10
SMOKE DETECTION/FIRE SUPPRESSION (OPTIONAL)
10
HEPA/SAFETY AFTERFILTERS (OPTIONAL)
10
PRE-START UP
11
START UP
11
PRE-COAT
12
SHUT DOWN
12
MAINTENANCE PROCEDURES
12
MAINTENANCE SCHEDULE
14
VALVE MAINTENANCE
15
TROUBLE SHOOTING CHART
16
WARRANTY STATEMENT
17
PARTIAL PARTS LIST
18
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1. PRECAUTIONARY STATEMENTS
APPLICATION OF AMTECH AUTOVENT SERIES
Process owners/operators (“responsible party”) are ultimately responsible for ALL installation, operation, and servicing of this unit.
1.1 Due to potential fire hazards, do not mix combustible substances with material that would be a potential source of ignition.
1.11 Examples of Combustible Materials: Wood Dust Paper Dust
Lint from fabric or buffing wheels Grinding dust from painted surfaces Aluminum or magnesium dusts
1.12 Examples of Potential Ignition Sources: Grinding dust from ferrous metals Hot ash or sparks from any source
1.2 Additionally, some substances can auto-ignite or spontaneously combust. Therefore, it would be prudent on behalf of the “responsible party” to conduct a thorough research on their material to identify any known hazards (keeping in mind, some hazards are unknown). 1.3 Unless the equipment was originally designed for collection of explosive material and proper disclaimer on record, this equipment must not be used for the collection of any materials where there is a risk of explosion. Pressure relief vents or explosion vents must not be applied to the equipment or adjoining systems.
1.4 Equipment location, installation and operation must comply with all local, state, and National Fire Codes. If unsure contact the appropriate authorities.
1.5 The electrical installation must conform to all local and state codes, as well as, the National Electric Code.
1.6 Events in industry have demonstrated that fires are NOT uncommon in some collection systems. Therefore, the overall design of the system, including: placement of the unit, fire detection/suppression, sparks mitigation efforts, and maintenance, should be fashioned with a mindset of “when a fire occurs”, NOT “if a fire occurs”. Fire detection/suppression systems, as well as, spark prevention measures are STRONGLY recommended. The smoke detection/fire suppression systems (if so equipped) should be installed by qualified individuals, and in accordance with any local and state codes (if any).
1.7 Painting, machining, grinding, sanding, deburring or any process to further manufacture or finish any volatile or potentially volatile material, liquid or solid, is strictly prohibited.
1.8 The air supply system should be installed by qualified individuals, and in accordance with any local and state codes (if any).
1.9 Workers and operators are to be instructed to keep burning objects, such as cigarettes, safely away from inlets leading to the equipment.
1.10 All personnel involved with the use of this equipment must comply with the statements pertaining to worker safety as noted in this manual.
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2. INTRODUCTION
2.1 AMTECH AutoVent collectors ( AV’s ) are compactly designed and usually installed with a welding cell, to improve the air quality in a relatively, confined space, and at the same time inhibit welding smoke/fumes and dust from degrading the air quality in a larger area (such as the plant). The collectors for the AV ’s come in a 4, 6, 9, and 12 cartridge size, with a corresponding air flow rate of 2500, 4000, 6000, and 8000 cfm, respectively. A properly configured AV and welding cell can provide a relatively safe work station; however, given the combustible nature of welding fume/smoke and the inherent generation of sparks from grinding, prudent operation of the system and periodic maintenance is essential. Spark baffles and spark mesh are offered as an option on these units and are STRONGLY recommended. The collector is designed to be mounted in a variety of fashions including: suspension from the roof structure (provided the building structure is of adequate design), supported by legs, or placed directly on the floor. A dust drawer is available for floor mounted installations and for suspended or leg supported installations a hopper is available to facilitate the collection/removal of dust. The collector unit is positioned appropriately • The welding cell or other containment area (and curtain, if equipped) is assembled and connected to the collector • Electrical power is connected (appropriately) • Fire detection/suppression systems connected (appropriately – and if so equipped). • Compressed air is connected (appropriately) 2.2 Installation is complete after: • 2.3 MOST FILTERING MEDIA IS COMBUSTIBLE EVEN WHEN IT IS TREATED WITH FLAME RETARTANT MATERIALS. PRECAUTIONS SHOULD BE TAKEN TO PREVENT BURNING MATERIAL FROM COMING INTO CONTACT WITH THE FILTERING MEDIA. 2.4 FIRE OR SMOKE DETECTION DEVICES AND APPROPRIATE EXTINGUISHING SYSTEMS MAY BE REQUIRED DEPENDING ON LOCAL CODES AND AUTHORITIES. PLEASE VERIFY WITH THE APPROPRIATE AGENCIES WHICH MAY INCLUDE, BUT MAY NOT BE LIMITED TO THE FIRE DEPARTMENT, YOUR INSURANCE COMPANY AND LOCAL, STATE OR FEDERAL AUTHORITIES. SHOULD YOU HAVE ANY QUESTIONS, PLEASE CONTACT THE MANUFACTURER OR HER/HIS REPRESENTATIVE PRIOR TO OPERATING THE EQUIPMENT. 2.5 It is imperative that the equipment be verified, cleaned and properly maintained on a continual basis to ensure proper and safe operation. This maintenance can usually be performed on a contract basis if necessary. Contact your Distributor for details. 2.6 All employees should be familiar with the on/off controls. No burning, torches or cutting should be carried out in direct proximity to the unit. Where welding, cutting or grinding being performed, a suitable fire extinguisher(s) should be accessible.
2.7 Good judgment should be utilized at all times. If you are unsure about the system components or function, please contact your Distributor.
2.8 THINK SAFETY FIRST!
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3. TYPICAL DRAWINGS OF AUTOVENT COLLECTORS
(On the cover – AV-4 with Silencer and Metal Mesh Filter, AV-6 and AV-12 collectors are shown below)
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4. INSPECTION
4.1 Upon receipt of unit, the AutoVent collector, welding cell, and any optional components must be checked for damage or potential loss incurred during shipping. Damage must be noted on the bill of lading and a claim filed with the carrier immediately. CLEAN AIR INDUSTRIES should be notified immediately, regarding any missing/lost items/components/parts.
5. THEORY OF OPERATION
5.1 The AutoVent collector features (usually) a custom designed welding cell and a factory assembled collector. The system is designed to enhance the air quality both for a relatively confined area (where an individual/s can performing welding or grinding or other dust generating procedures) and the area surrounding the welding cell. During normal operation, air flows into the collector, through the (optional) metal baffles and (optional) metal mesh filters. The air then moves between the cartridge filters and towards the blower. A portion of the dust will collect on the surface of the cartridge media as the air passes through the filter media, and into the blower. The dust that collects on the cartridge media will periodically be dislodged by the reverse jet pulse cleaning system. This system is electronically controlled and is configured to monitor the differential pressure across the filter media. When the differential pressure reaches the adjustable set point, a brief burst of compressed air will be released into the core of the cartridge filter to dislodge the dust from the filter surface. The dislodged dust gradually migrates towards the settling chamber (dust drawer or hopper), for subsequent manual removal through the dust drawer or hopper.
6. FEATURES
6.1 Standard
6.1.1 DUST DRAWER – The dust drawer provides an area where dust can accumulate and easily be removed.
6.1.2 FIRE RETARDANT CARTRIDGE FILTERS – The filters have been treated with a chemical to “retard” against combustion; however, the cartridge filters are NOT “fire proof”, that is, under certain conditions the filters will combust. 6.1.3 TURBO DIGITAL PULSE CONTROL – This electronic device constantly monitors the differential pressure across the cartridge filters and, when the programmable set point is met, automatically reverse pulse cleans the cartridge filters. The unit also offers a cycle down feature, whereby the filters are cleaned offline on shutdown.
6.2. Optional
6.2.1 AFH/AFS - After filter housings are available with either HEPA or Safety filters. HEPA filters are 99.97% efficient at specified flow/pressure rates and Safety filters are 95% efficient at specified flow/pressure rates. 6.2.2 EXPLOSION VENT - An Explosion Vent is designed to relieve rapid pressure build up, as is experienced from an explosion within the dust collector. If your explosion vent should experience a burst, then contact your CLEAN AIR INDUSTRIES Distributor to order a replacement. 6.2.3 FIRE SUPPRESSION – Fire suppression is available in a variety of technologies. Fire suppression systems should be installed by qualified individuals and in accordance with any local, state, or national codes/regulations/laws (if any).
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6.2.4 HOPPER – The hopper and leg accessory increases the dust storage capability of the unit.
6.2.5 SPARK BAFFLES – Metal spark baffles are impingement type filters that help eliminate sparks. Baffles should be removed for cleaning on a regular basis.
6.2.6 METAL MESH FILTERS – The metal mesh filters provide a durable surface for the deposition of welding smoke/fume. Filters should be periodically removed and cleaned (soap and water).
6.2.7 PNEUMATIC VALVE KIT - A pneumatic valve kit includes a pressure regulator, coalescing filter, and pressure gage. This kit helps insure that clean dry air is being supplied to the pulse valves at the proper air pressure. NOTE: The coalescing filter requires periodic maintenance/replacement (life span is a function of supplied air quality).
6.2.8 SILENCER - Silencers are manufactured from 11 and 14 gauge carbon steel. The silencers are lined with a minimum of 3” of a sound damp ing material.
6.2.9 SMOKE DETECTION – Smoke detectors are available in a variety of models. Smoke detectors should be installed by qualified individuals and in accordance with any local, state, or national codes/regulations/laws (if any). 6.2.10 SPRINKLERS - Unless otherwise requested, the sprinklers discharge at 165 o F. Sprinklers must be connected to the plant’s main sprinkler system and in accordance with any local, state, or national codes/regulations/laws (if any). 6.2.11 SPUNBOND WASHABLE FILTERS – The spunbond filters are 100% polyester, therefore, washing with mild soap and water is possible. Typically, the filters can be washed 3 to 4 times before degradation of the material occurs.
7. INSTALLATION
7.1 Initial Considerations
7.1.1 The location of the unit(s) must be planned to maximize effective operation and simultaneously afford access for service/maintenance, while keeping safety considerations at the forefront. Fires in collection systems are not uncommon; therefore, systems should be designed and placed with that aspect in mind and in accordance with any local, state, or national fire/safety codes/regulations. Thought should also be given to electrical and compressed air sources, keeping in mind that the collector will need to be connected with electricity, compressed air, and fire detection/suppression systems (optional). Should additional questions arise or assistance is needed consult your CLEAN AIR INDUSTRIES distributor. 7.1.2 The AV collector is designed to be mounted in a variety of fashions including: suspension from the roof structure (provided the building structure is of adequate design), supported by legs, or placed directly on the floor. Check with your building architect/engineer to determine if placement is appropriate.
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7.1.3 After the installation, access/clearance must be available to service the following
components:
1. Filters/Baffles 2. Fan/Motor 3. Valves 4. Controls 5. Dust drawer or hopper
7.2 Mechanical
NOTE: All of the mechanical installation must be performed by a qualified installer and in accordance with local, state, and national codes/regulations/laws (if any).
7.2.1 The AutoVent Collector is usually coupled to a welding cell. Placement/movement of the unit inside the factory/building is usually a major concern. Ensure you have enough room in front of the access doors and/or dust drawers for easy filter access, as well as, all around the unit for access in the event of maintenance or emergency.
7.2.2 Check with your building architect/engineer to determine if placement is appropriate, especially if the unit is being suspended by an overhead structure.
7.2.3 After placement, the collector should be properly secured to the floor using tapered anchor bolts or properly secured to an overhead structure. CONSULT YOUR BUILDING ARCHITECT/ENGINEER.
NOTE: Should questions arise concerning total weight, consult your CLEAN AIR INDUSTRIES Distributor or CLEAN AIR INDUSTRIES Factory. 7.3 Electrical
NOTE: All of the electrical installation must be performed by a qualified electrician and in accordance with local, state, and national codes/regulations/laws (if any).
7.3.1 The blower motor is typically configured to operate with 208-230/460 volt, 60 cycles, and 3 phase electrical power, unless specified otherwise with the equipment order. The electrical connections to the blower (and wiring) must be sized and selected in accordance with local, state, and national codes. 7.3.2 The blower is designed to rotate clock wise when viewed from the motor side (top of blower). If the blower is running in reverse, the air volume will be approximately 50% of the designed air volume and excessive noise will be generated. Therefore, once the motor is wired, check motor rotation by energizing the blower motor for a brief instant (“JOG”). If direction is reversed, then correct. Switching two (2) of the 3-phase connections on the output side will reverse the direction of rotation.
7.3.3 Your unit is equipped with the “ Turbo Digital Pulse Control ” , this feature will need to be connected to a 115 volt power source. Power consumption is less than 50 Watts.
7.3.4 If your unit is equipped with any optional electrical features, then these will need to be connected to the appropriate power source.
NOTE: Instructions that detail the operation of Turbo Digital Pulse Control is available under separate cover. A copy of the instructions should have been supplied with the unit.
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NOTE: The digital reverse jet pulse controller with “Pulse on Shut down” feature must be wired with a continuous 115 volt supply. The control must not be wired in parallel with the fan motor starter. (Exception is when using an Amtech combination motor starter with disconnect as this has a dedicated 115V transformer.)
7.4 Compressed Air
NOTE: The compressed air installation should be performed by a qualified installer and in accordance with local, state, and national codes/regulations/laws (if any).
7.4.1 Compressed air is used to clean the dust coated cartridge filters with a high pressure reverse jet pulse. A 1.5 inch diameter dedicated supply with a minimum of 90 PSI and a maximum of 100 PSI is recommended. An air regulator may be necessary to step down the supply air if the plant pressure is above the recommended rating. NOT complying will result in component damage. 7.4.2 The air supply line to the accumulator tank must include water, oil and particulate filtration. Water and especially oil in the compressed air will significantly reduce the effectiveness of the reverse jet pulse cleaning by contaminating the cartridge filters and causing excessive differential pressure across the filters, which results in greatly reduced air flow along with premature filter replacement. 7.4.3 A 200 PSI gage has been pre-installed to monitor air pressure. Prior to the final connection of the air line to the collector manifold, the air line should be purged. This will remove debris that could damage the valves and block the nozzles in the blow pipes.
NOTE: The compressed air source must be free of oil (and water). Oil (and water) will cause premature failure of the cartridge filters.
7.5 Smoke Detection/Fire Suppression (OPTIONAL)
NOTE: All of the smoke detection/fire suppression installation must be performed by a qualified technician and in accordance with local, state, and national codes/regulations/laws (if any).
7.5.1 Smoke detection and fire suppression is an important aspect of the installation procedure. Fires are a common occurrence in dust collection systems and the comprehensive collection system should be designed for when a fire occurs, not if. Various systems are available for smoke detection and an even greater list of fire suppression technologies exist. Fire sprinkler systems for collectors MUST be properly connected. In most cases, this is the closest building’s fire sprinkler system. ALL smoke detection/fire suppression systems should be periodically inspected and maintained.
7.6 HEPA/SAFETY AFTERFILTERS (OPTIONAL)
NOTE: All of the smoke detection/fire suppression installation must be performed by a qualified technician and in accordance with local, state, and national codes/regulations/laws (if any).
7.6.1 The AutoVent collector with HEPA/SAFETY afterfilter assembly option can be shipped with/with out the HEPA/SAFETY afterfilter assembly (including top plate of the collector) attached. Therefore, if in some cases, it may be necessary to install. In that situation, complete the following steps: • Locate the collector, the top outlet panel (attached to the HEPA/SAFETY afterfilter assembly), and supplied bolts.
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• Apply silicon sealant to the top portion of the AutoVent collector (where the top outlet panel/HEPA/SAFETY afterfilter assembly attaches). • Place the top outlet panel/HEPA/SAFETY afterfilter assembly on top of the main unit (align the bolt holes). • Insert and hand tighten the supplied bolts to secure the assembly. • After all bolts have been “hand tightened”, then “snug” the bolts. DO NOT OVER TIGHTEN!
8. PRE-START UP
8.1 If not already verified in the electrical section, check rotation of fan by tur ning “ON” for a brief instant (JOG) and verifying rotation. Rotation must be clockwise when viewed “OVER THE MOTOR” from the discharge side. If the rotation is correct, start the motor.
8.2 Check the compressed air system for leaks. Confirm 90 PSI minimum air pressure (maximum 100 PSI).
Warning: Compressed air pressure higher than 100 PSI can damage the filters and the dust collector’s structural integrity.
8.3 Check that the compression couplings of the pulse valves are tight.
8.4 Manually activate (if so equipped) the reverse cleaning valves.
8.5 Check each valve for leaks. NOTE: It is normal for the bleed air port to release a burst of air at each pulse.
8.6 Check the adequacy of air supply by assuring no less than 35% drop in pressure during pulse.
9. START UP
9.1 Apply compressed air to the manifold.
9.2 Energize (push the START button) for the main blower.
9.3 Energize the Turbo Digital Pulse Control (reverse jet pulse control).
9.4 Energize the other auxiliary equipment, as required.
9.5 COMMENTS REGARDING FILTER DIFFERENTIAL PRESSURE DURING OPERATION:
9.5.1 Depending on operating conditions, reaching equilibrium for filter differential pressure may vary from a few hours to several weeks. Low dust loading will normally develop 2- 3” w.g., normal loading typically generates 3-6 ” w.g., and high loading varies from 6 - 10 ” w.g. 9.5.2 Low dust loading typically shows a steady level of differential pressure with very little fluctuations once equilibrium is reached. By contrast, heavy loading can produce s ignificant “Ups and Downs” in operating differential pressure. 9.5.3 If your unit is equipped with the programmable pulse control, then it is usually necessary to gradually (over a period of weeks or months) raise the high and low set points to reflect the normal buildup on the filters.
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10. OPTIONAL PRE-COAT
10.1 The pre-coat is a specially formulated conditioner that enhances the performance of filter cartridges. It creates a highly permeable, protective layer on the surface of the filter media. Pre-coat applied to new filters forms a protective barrier on the surface of the filter media that stops fine particles from becoming trapped in the media structure. By keeping particulate on the surface, away from the media, the media remains open over a longer period of time and this means longer filter life. This feature also improves cake release as surface-loaded dust releases more easily during pulse cleaning. 10.2 When replacing cartridge filters, the new filters need to be pre-coated with silica based cellulose or other acceptable pre-coat material available on the market. The following steps should be taken to introduce the pre-coat to the cartridges: • Power up the fan • Slowly introduce (1/2 lb. per cartridge) the pre-coat
10.3 Pre-coat can be obtained through your distributor or from CLEAN AIR INDUSTRIES .
11. SHUTDOWN
11.1 De-energize (push the STOP button) the blower motor. The digital reverse pulse cleaning systems are equipped with an “ Off Line Cleaning ” feature which activates the reverse jet pulse cleaning. This element will clean the filter cartridges while the unit is off line, for a preset number of pulses. Once the cleaning cycle is complete the collector is ready to be energized when needed.
11.2 Secure power to the digital reverse pulse control.
11.3 Secure power to the other auxiliary equipment.
CAUTION: Off line cleaning can cause pressure waves to feed back through system. Precautions may be necessary to prevent dusting.
12. Maintenance
12.1 Procedures
12.1.1 Dust Drawer or hopper: The dust drawers (or hopper contents) should be checked and emptied periodically. The frequency of this step will depend on the number of shifts operating and conditions in the plant; however, it is a good practice to frequently remove residue build up. 12.1.2 HEPA/SAFETY afterfilters: The HEPA/SAFETY afterfilters (if so equipped) are located on top of the unit (inside the HEPA/SAFETY afterfilter assembly). Periodically, these filters should be inspected and replaced. Condition of the HEPA/SAFETY filter will generally be a function of the Magnehelic gage (for the HEPA/SAFETY filters – NOT the cartridge filters) reading. To examine: • Remove the two wing nuts for each filter • Lift off the filter “tie down” bar • Remove HEPA/SAFETY filters • Install new HEPA/SAFETY filters • Install HEPA/SAFETY filter “tie down” bar • Install the two wing nuts for each filter.
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12.1.3 Metal Mesh Filters: The metal mesh filters (if so equipped) should periodically be inspected and cleaned. Any buildup of material in the filters can lead to fires. To examine: • Remove the access panel • Pull out metal mesh filters • Wash with soap and water, and air dry • Replace metal mesh filters • Replace the access panel. 12.1.4 Spark Baffles: The spark baffles (if so equipped) should be periodically cleaned with mild soap and water. To examine: • Remove the access panel • Pull out spark baffles • Wash with soap and water, and air dry • Replace spark baffles • Replace the access panel. 12.1.5 Cartridge Filters: The cartridge filters will need to be replaced periodically. The frequency varies from a few weeks to a few years, depending on factors such as density of fumes/dust, particle size, humidity of air, oil or grease contents of matter, etc… To change out: • Open dust collector filter access door. • Locate the T-Handle above the first filter(s) to be replaced. • Rotate the T-Handle counterclockwise to loosen and obtain clearance for removing the filter cap. Gently remove the filter cap, exercising effort in keeping dust from falling inside the clean air duct opening. Retain the filter cap. • Gently remove the filter, exercising effort in keeping dust from falling inside the clean air duct opening. • Place the filter cap over the clean air duct opening at the bottom. This will help prevent material from entering the clean air duct during the remainder of the filter replacements. Take note that the gaskets on the filters are located on the bottom of each filter. • Repeat steps for remaining filters. • To install new filters remove the filter cap from the clean air duct opening and place new filter, taking care to install the filter with the gasket down. Place filter cap with gasket si de down on top of the filter cartridge and centered on opening. Turn “T” handle, clockwise, down against filter cap so that the dimple on the filter cap penetrates the threaded bore of the “T” handle. Continue to rotate “T” handle until gaskets are approximately 30% compressed. (If over tightening you will see the outer edge of the filter pleats begin to curve.) Ensure that the filter and filter cap are aligned properly to facilitate a leak-free fit. • After all of the new filters have been installed, close and secure the Dust Collector Filter access Door. • NOTE: Discard filters in accordance with all local, state, and national codes/regulations.
12.1.6 Drain Valve: Periodically open the drain valve attached below the tank to drain the liquid build-up in the air tank.
NOTE: Electrical power and compressed air supply MUST be disconnected before beginning the filter installation.
NOTE FOR NON-WASHABLE (PAPER FILTER) FILTER CARTRIDGES: Do not wet or clean the cartridge filters with any liquid as it may form unwanted blockage on the filter media.
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12.2. Maintenance Schedule
12.2.1 Daily Inspection
12.2.1.1 Check exhaust for visible dust, refer to troubleshooting. 12.2.1.2 Check compressed air system for air leakage (low pressure);
repair as necessary.
12.2.1.3 Empty dust drawers.
12.2.2 Weekly Inspection
12.2.2.1 Inspect metal mesh filters. Clean if necessary.
12.2.3 Monthly Inspection
12.2.3.1 Check filter cartridges for leaks and proper fastening; repair or
replace as necessary.
12.2.3.2 Check spark baffles and clean as necessary. 12.2.3.3 Open the air tank drain cock located under the air tank to expel
any condensation.
12.2.3.4 Check the compressed air line regulator, dryer, and filter for
proper operation. (by others)
12.2.4 Three Months
12.2.4.1 Check the filter cartridges. 12.2.4.2 Check all electrical apparatus for proper operation. 12.2.4.3 Check discharge air condition for signs of dust.
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12.3 Valve Maintenance
During pulse valve maintenance, refer to the diagram, below, for replacement parts.
Item Description
DP 20 (3/4") DP 25 (1") DP 40 (1 1/2")
1
Core Tube
TP10
TP10 NGP M10 BH10
TP10 NGP M10 BH10
2 Plunger Assembly NGP
3 4
Nut & Washer
M10 BH10
Coil
5 PG9 6 Screws & Washer M 6 X 20 M 6 X 20 M 6 X 20 7 Cover C 25 C 25 C 25 8 Diaphragm M 25 M 25 M 25 9 Screws & Washer M 8 X 20 10 Middle Cover I C 40 11 Diaphragm Spring S R 12 Main Diaphragm M 40 13 Body BDD 20 BDD 25 BDD 40 14 Conic Seal GCON20 GCON25 GCON40 15 Seal Retainer OG20 OG25 OG40 16 Coupling TDAL20 TDAL25 TDAL40 Connector PG9 PG9
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13. Troubleshooting
Perform troubleshooting of the collector in accordance with the following:
Troubleshooting Chart
TROUBLE
POSSIBLE CAUSE(S)
CORRECTIVE ACTION
Visible dust from outlet
1 – Cartridge is improperly installed.
1 – Check cartridge installation; repair as necessary. 2 – Re-install filters.
2 – Cartridges too loose. 3 – Damaged cartridges. 4 – Damaged gaskets.
3 – Replace damaged cartridge. 4 – Replace gasket or cartridge.
Cartridge filtering action rapidly impaired.
1 – Inadequate cleaning air supply. 2 – Improper solenoid valve operation.
1 – Check air supply. 2 – Check solenoid valves; steady rush of air indicates open valve; no air pulse indicates a plugged valve; possibly due to electrical failure; repair as necessary. 3 – Replace pulse controller. 4 – Check collector for excessive moisture or high relative humidity; either will seriously affect collector operation; correct moisture level in air stream. 5 – Check fan rotation, fan speed, damper position, outlet cfm; correct as necessary to obtain specified air flow. 6 – Replace with cartridges of proper media for type of air. 7 – Check air temperature; correct reason for overheat condition. 8 – Ground collector and its components. 1 – Check fan rotation; correct if wrong. Switching two of the 3-phase connections will reverse the direction of rotation of the motor. 1 – Check reason for high temperature; correct if possible. 2 – Check composition of air; consult with factory on compatibility of cartridge material with air stream. 3 – Eliminate moisture from air; replace cartridge. 4 – Check cartridge for damage from over clamping. 5. Check for impingement.
3 – Defective pulse controller. 4 – Excessive moisture entering collector and blinding cartridges.
5 – Incorrect air flow (too high or too low).
6 – Incorrect cartridge filters media for air composition. 7 – Air temperature higher than specification. 8 – Static electricity build-up in collector.
Air flow through system below design rating
1 – Incorrect fan rotation
Filter cartridge deteriorate rapidly.
1 – High collector temperature.
2 – Chemical composition of air stream incompatible with cartridge material. 3 – Moisture in air stream. 4 – Incorrect cartridge installation. 5 – Abrasion by impingement of high velocity particles.
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14. WARRANTY STATEMENT
CLEAN AIR INDUSTRIES TWO YEAR LIMITED WARRANTY
ITEMS NOT COVERED BY THIS WARRANTY ARE DUCTWORK, WIRING AND INSTALLATION WHICH IS NOT PERFORMED BY CLEAN AIR INDUSTRIES. CLEAN AIR INDUSTRIES WARRANTS THAT ALL NEW AMTECH DUST COLLECTORS/AIR CLEANERS ARE FREE FROM DEFECTS IN MATERIAL AND WORKMANSHIP UNDER NORMAL USE AND SERVICE. CLEAN AIR INDUSTRIES WILL REMEDY ANY SUCH DEFECTS IF THEY APPEAR WITHIN TWO YEARS FROM THE DATE OF SHIPMENT, SUBJECT TO THE TERMS AND CONDITIONS OF THIS LIMITED 2 YEAR WARRANTY AS STATED BELOW. 1. THIS LIMITED WARRANTY IS GRANTED BY CLEAN AIR INDUSTRIES , 127 FRANKLIN ROAD, RUSSELLVILLE, KY 42276. 2. THIS WARRANTY SHALL EXTEND TO ANY OWNER WHO HAS PURCHASED THE EQUIPMENT OTHER THAN FOR THE PURPOSE OF RESALE. 3. ALL COMPONENTS MANUFACTURED BY CLEAN AIR INDUSTRIES ARE COVERED BY THIS WARRANTY. FILTERS AND COMPONENTS NOT MANUFACTURED BY CLEAN AIR INDUSTRIES , SUCH AS ELECTRICAL OR ELECTRONIC EQUIPMENT, MOTOR STARTERS, MOTORS, PULSE CONTROLS AND VALVES CARRY A ONE YEAR MANUFACTURERS WARRANTY. THERE IS NO WARRANTY AS TO USEFUL FILTER LIFE, AS THIS DEPENDS ON APPLICATION, HOURS IN USE, ETC. 4. IF WITHIN THE WARRANTY PERIOD ANY CLEAN AIR INDUSTRIES UNIT OR COMPONENT REQUIRES SERVICE, IT MUST BE PERFORMED BY A CLEAN AIR INDUSTRIES SERVICE REPRESENTATIVE OR CLEAN AIR INDUSTRIES DISTRIBUTOR. CLEAN AIR INDUSTRIES WILL NOT PAY SHIPPING CHARGES OR LABOR CHARGES TO REMOVE OR REPLACE SUCH DEFECTIVE PARTS OR COMPONENTS. IF THE PART OR COMPONENT IS FOUND BY INSPECTION TO CONTAIN SUCH DEFECTS IN MATERIAL AND WORKMANSHIP, IT WILL BE EITHER REPAIRED OR EXCHANGED FREE OF CHARGE AND RETURNED FREIGHT COLLECT. 5., IN ORDER TO OBTAIN THE BENEFITS OF THIS 2 YEAR WARRANTY THE OWNER MUST NOTIFY THE DISTRIBUTOR OR CLEAN AIR INDUSTRIES IN WRITING OF ANY DEFECT WITHIN 10 DAYS OF DISCOVERY. 6. THIS LIMITED WARRANTY DOES NOT APPLIED TO ANY PART OR COMPONENT THAT IS: DAMAGED IN TRANSIT OR HANDLING; HAS BEEN SUBJECT TO MISUSE, NEGLECT OR ACCIDENT; HAS NOT BEEN INSTALLED, OPERATED AND SERVICED ACCORDING TO PROPER INSTRUCTION; HAS BEEN OPERATED BEYOND THE FACTORY RATED CAPACITY; OR ALTERED IN ANY WAY THAT WOULD AFFECT PERFORMANCE. THERE IS NO WARRANT DUE TO NEGLECT, ALTERATION OR ORDINARY WEAR AND TEAR. CLEAN AIR INDUSTRIES LIABILITY IS LIMITED TO REPLACEMENT OF DEFECTIVE COMPONENTS AND DOES NOT INCLUDE THE PAYMENT OF THE COST OF LABOR CHARGES TO REMOVE OR REPLACE SUCH DEFECTIVE COMPONENTS OR PARTS. 7. CLEAN AIR INDUSTRIES WILL NOT BE RESPONSIBLE FOR LOSS OF USE OF ANY PRODUCT, LOSS OF TIME, INCONVENIENCE, OR ANY OTHER INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGE WITH RESPECT TO PERSONAL PROPERTY, WHETHER AS A RESULT OF BREACH OF WARRANTY, NEGLECT OR OTHERWISE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE EXCLUSION OR LIMITATION IN THE PRECEDING SENTENCE MAY NOT APPLY. 8. THIS WARRANTY PROVIDES SPECIFIC RIGHTS. OWNERS MAY ALSO HAVE OTHER RIGHTS THAT VARY FROM STATE TO STATE. 9. WARRANTY WORK WILL BE PERFORMED WITHIN A REASONABLE TIME, USUALLY WITHIN 60 DAYS AFTER NOTICE OF DEFECT AND DELIVERY OF THE DEFECTIVE PRODUCT TO THE CLEAN AIR INDUSTRIES FACTORY, SUBJECT TO ANY DELAY BEYOND THE CONTROL OF CLEAN AIR INDUSTRIES . 10. ANY WARRANTY BY CLEAN AIR INDUSTRIES OF MERCHANTABILITY, FITNESS FOR USE OR ANY OTHER WARRANTY (EXPRESS, IMPLIED OR STATUTORY), REPRESENTATION OR GUARANTEE OTHER THAN THOSE SET FORTH HEREIN, SHALL EXPIRE AT THE EXPIRATION DATE OF THIS EXPRESSED LIMITED WARRANTY. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE LIMITATION IN THE PRECEDING SENTENCE MAY NOT APPLY. 11. CLEAN AIR INDUSTRIES RESERVES THE RIGHT TO MAKE CHANGES IN THE DESIGN AND MATERIAL OF ITS PRODUCTS WITHOUT INCURRING ANY OBLIGATION TO INCORPORATE SUCH CHANGES INTO UNITS MANUFACTURED PRIOR TO THE EFFECTIVE DATE OF SUCH CHANGES. 12. USE OF UNAPPROVED FILTERS OR REPLACEMENT PARTS MAY VOID THIS WARRANTY.
sales@clean-air.com
1-866-665-1829
www.clean-air.com
15. Replacement Parts List
Model AV-XX S/N XXXXXXXXXX
Description
Quantity
Part Number
sales@clean-air.com
1-866-665-1829
www.clean-air.com
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