Learn how to setup, manage, and maintain your Amtech ATV Downflow Cartridge Collector by Clean Air Industries.
AMTECH AT V Downflow C artridge Dust Collector with Integral Blower User & Maintenance Manual
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Downflow Cartridge Dust Collector- ATV Series
Important!!!
Due to the nature and variety of dusts, it is impossible to list all potential hazards related to dust control equipment or systems. Additionally, it is impossible to list all potential hazards involved with installation/operation/servicing a dust 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
1.PRECAUTIONARY STATEMENTS
4
2.INTRODUCTION
5
3.TYPICAL DRAWINGS OF COLLECTORS
5
4.INSPECTION (Receipt of unit)
6
5.THEORY OF OPERATION
6
6.AVAILABLE OPTIONS
7
7.INITIAL INSTALLATION CONSIDERATIONS
8
8.MECHANICAL INSTALLATION
8
9.COMPRESSED AIR SUPPLY
9
10.ELECTRICAL/CONTROLS
10
11.SMOKE DETECTION/FIRE SUPPRESSION
12
12.PRE-START UP
12
13.FILTER INSTALLATION
13
14.START UP
13
15.SHUT DOWN
14
16.MAINTENANCE SAFETY
14
17.MAINTENANCE PROCEDURES
14
18.CARTRIDGE FILTER REPLACEMENT
17
TROUBLE SHOOTING CHART
19
WARRANTY STATEMENT
20
PARTIAL PARTS LIST
21
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1.0 PRECAUTIONARY STATEMENTS
APPLICATION OF AMTECH CARTRIDGE DUST COLLECTORS
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.
Examples of Combustible Materials: Wood Dust Paper Dust
Lint from fabric or buffing wheels Grinding dust from painted surfaces Aluminum or magnesium dusts
Examples of Potential Ignition Sources:
Grinding dust from ferrous metals Hot ash or sparks from any source
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). 1.2 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.
1.3 Equipment location, installation and operation must comply with all local, state, and National Fire Codes. If unsure contact the appropriate authorities.
1.4 The electrical installation must conform to all local and state codes, as well as, the National Electric Code.
1.5 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, spark 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 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).
1.6 The air supply system should be installed by qualified individuals, and in accordance with any local and state codes (if any).
1.7 Workers and operators are to be instructed to keep burning objects, such as cigarettes, safely away from inlets leading to the equipment.
1.8 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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2.0 INTRODUCTION
2.1 AMTECH cartridge dust collectors are designed to filter out solid particulates from air. In some cases, the separated air can be returned to the work space to lower heating/air conditioning costs. 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.
2.2 Installation is complete after: •
The unit is mounted (appropriately)
• Ductwork is connected/affixed (appropriately) • Electrical power is connected (appropriately) • Fire detection/suppression systems connected (appropriately). • Compressed air is connected (appropriately) • Pulse control system is wired and programmed (appropriately) • Dust container is connected to the collector (appropriately)
3.0 TYPICAL DRAWINGS OF COLLECTORS
Picture 1: ATV-8
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Picture 2: ATV-40
4.0 INSPECTION
4.1 Upon receipt of unit, the collector and the 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. Amtech LC should be notified immediately upon receipt of unit, regarding any missing/lost items/components/parts.
5.0 THEORY OF OPERATION
5.1 During normal operation, dirtied air is pulled into the top section of the cartridge collector cabinet. The cabinet design distributes the dirty air uniformly above the vertically arranged filter cartridges. The air then moves downward between the cartridge filters and towards the settling area, just below the cartridge filters. Once in the settling area, air flow is minimal; therefore, gravity is a deciding influence on the dust, which allows for removal in either the hopper or dust drawer, as configured. A portion of the dust will collect on the surface of the cartridge media as the air passes through the media, through the vertical venturi, into the horizontal clean air duct and to the blower. The dust that collects on the cartridge media will be directed towards the downward air flow by the reverse jet pulse cleaning system. This system is electronically controlled and is usually configured to monitor the differential pressure between the clean and dirty air. When the differential pressure reaches the adjustable set point, a brief burst of compressed air will be released through the venturi and into the core of the cartridge filter to impact the dust away from the filter surface. The dislodged dust is caught by the downward air flow and once again moved towards the settling chamber.
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6.0 AVAILABLE OPTIONS
6.1 ABRASIVE INLET – An abrasive inlet is an additional safeguard that helps prevent erosion of filters. The inlet consists of a metal plate which absorbs the impact from abrasive materials.
6.2 ACCUMULATOR - A 30- gallon, steel constructed, air accumulator tank with 1 ½” NPT outlet. Available for ATV-18 through ATV-40.
6.3 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.
6.4 CATWALK WITH LADDER - A catwalk with permanently affixed ladder affords safe and easy access to inspect/replace filters within the dust collector unit, when installed with the hopper option. Catwalk and ladder meet or exceed OSHA standards. 6.5 DRUM LID KIT – The drum lid kit provides a simple efficient connection from the dust collector hopper outlet to a dust storage drum. The kit includes flex hose, hose clamps, and drum lid with gasket and clamps for securing the lid to the dust storage drum.
6.6 DRUM OPTIONS - •
55 Gallon Drum 20 Gallon Drum
• •
10 Gallon Nordfab Quick Connect
6.7 DUST DRAWER - Available for ATV-8 through ATV-40
6.8 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 AMTECH Distributor to order a replacement.
6.9 FILTERS – •
Fire Retardant 80/20 Cellulose/Polyester Blend • Fire Retardant 80/20 Cellulose/Polyester Blend Wide Pleat • Fire Retardant Nanofiber • Spunbond • Other configurations available upon request
6.10 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). 6.11 HOPPER ACCESS DOOR - When removed, the hopper access door allows the installer/operator/maintainer to view inside the hopper. If any material has accumulated on the sides or bridged across the hopper outlet, then this access point can be used to facilitate the removal of material. 6.12 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).
6.13 SIDE INLET - Available for ATV-8 through ATV-40
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6.14 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. When installing a rectangular silencer, install on the flange side of the motor can. When installing a round silencer, install on top of the motor can (this may require a supplied cone to install) 6.15 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). 6.16 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).
6.17 CUSTOM PAINT
7.0 INITIAL INSTALLATION CONSIDERATIONS
7.1 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. Explosions and fires in collection systems are possible; therefore, systems should be designed and placed/affixed/mounted with those two aspects in mind and in accordance with any local, state, or national fire/safety codes/regulations. Should questions arise or assistance is needed consult your AMTECH distributor.
7.2 After the installation, access/clearance must be available to service the following components:
1. Filters 2. Fan 3. Valves 4. Controls 5. Dust storage container, such as dust drawer or dust drum.
7.3 Structural supports and hangers must be capable of supporting the load of the dust collector (plus options), the heaviest load of dust the collector can contain, and any reasonable number of maintenance technicians with a “ factor of safety ” that is acceptable to the responsible party of the equipment/building.
8.0 MECHANICAL INSTALLATION
NOTE: All mechanical installations must be performed by a qualified installer and in accordance with local, state, and national codes/regulations/laws (if any).
8.1 Prior to mounting the unit it may be advantageous to remove the cartridge filters to reduce the weight of the collector. Store filters in a safe location.
8.2 Depending on how your unit was shipped, the system may/may not have the hopper/legs/drawer attached. Should the installation require a hopper or dust drawer to be installed on the collector, the joining flanges must be sealed to eliminate air leaks. Use silicone or an equivalent high quality sealant.
NOTE: Leaks at the flanges of the hopper or dust drawer will cause excessive dust re-entrainment. Ensure no air leaks exist.
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8.3 If the unit should include a Leg/Hopper assembly, then position the main body in the planned installation location. Assemble the leg kit to the hopper as illustrated in the “typical” drawing on the cover page of this manual (if more detailed instructions are necessary, then contact your Amtech distributor). Anchor the Leg/Hopper assembly to the concrete floor using 3/4” tapered anchor bolts, 1 per anchor pad for a total of 4 each, tapered anchor bolts. 8.4 Use silicone or equivalent high quality sealant on all flanges and place the collector on the Leg/Hopper assembly. Using the supplied bolts, nuts and washers secure the collector to the Leg/Hopper assembly. A drift pin or alignment tool will aid in the aligning the holes. 8.5 Should the collector include a Cradle/Hopper assembly for suspension from overhead, locate and attach the Cradle/Hopper assembly to adequate overhead structure. Be certain the overhead structure and suspension connectors are capable of easily handling the total weight of the collector, all attached components/options and the maximum added weight due to dust load and personnel with a factor of safety that is acceptable to the responsible party of the equipment/building.
NOTE: Should questions arise concerning total weight, consult your AMTECH Distributor or AMTECH Factory.
8.6 Should the collector include a factory installed dust drawer, position the collector in the planned location and secure it in place using 3/4” tapered anchor bolts, 1 per anchor pad for a total of 4 each.
9.0 COMPRESSED AIR SUPPLY
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).
9.1 The compressed air supply is used to clean the dust coated cartridge filters with a high pressure reverse jet pulse. A 2” diameter (minimum 1.5” diameter) dedicated supply with a minimum of 90 PSI and a maximum of 100 PSI is recommended. If a supply line smaller than 1.5” is used, then a 30-gallon accumulator tank should be installed with a 2” line from the tank to the collector manifold. The largest supply line available should feed the accumulator tank. The unit has a 2” diameter connection. 9.2 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 destroying the cartridge filters and causing excessive differential pressure across the filters, which results in greatly reduced air flow along with premature filter replacement.
NOTE: The air line MUST be free of oil and water to avoid failure of the cartridge filters.
9.3 A 200 PSI gage must be 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.
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9.4 When installing the compressed air supply to the air manifold(s), refer to the diagrams below.
10.0 ELECTRICAL/ CONTROLS
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).
10.1 The blower motor is typically configured to operate with 208-230/460 volt, 60 cycle, and 3 phase electrical power unless specified otherwise with the equipment order. Electrical power is connected to the J-box on the blower section of the collector. Below the J-Box is a decal that confirms the voltage the motor was set up for at the
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factory. Should this need to be changed to the other voltage listed above, the motor will have to be rewired in accordance to the data label on the motor. Access the motor from the top discharge of the collector. It is recommended that the blower motor be energized through a motor starter with over load protection. The electrical components must be sized and selected in accordance with local, state, and national codes. 10.2 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. 10.3 When the reverse jet pulse cleaning system is initiated, a sequential timer board or a digital reverse pulse controller controls the air solenoid valves, releasing a brief burst of compressed air backwards through the filters to expel the collected dust off the filter cartridges and down towards the settling area. This process can be a continuous cycle during normal operation by wiring the sequential timer in parallel with the motor starter coil. Combination Motor starters, IF supplied by Clean Air Industries usually contain a 115V Transformer. IF your unit is equipped with a sequential timer or digital reverse pulse controller, then it is recommended that the timer/ controller be wired to receive power from the transformer. 10.4 IF your unit is so equipped, the sequential timer board, when energized, provides continuous cleaning by sequentially operating the pulse valves with an adjustable time period between pulses. The length of time that the valve is open can also be adjusted. 10.5 IF your unit is so equipped, the digital reverse pulse controller can be set for continuous cleaning or to monitor “ differential pressure ” across the filters and energize the valves for a “specified” differential pressure (high set point). The controller will continue energizing the reverse jet pulse cleaning until the “specified” differential pressure (high set point) is reduced to a “specified” differential pressure (low set point). The digital reverse pulse controller also allows the operator to adjust the length of time that the valve is open, as well as, several other functions. NOTE: Instructions that detail the operation of each pulse control is available under separate cover. Additionally, if your unit was originally ordered with a sequential timer or digital reverse pulse controller, then a copy of the instructions should have been supplied with the unit. 10.6 The sequential timer or the digital reverse pulse controller box must be mounted in a safe, accessible location, where it can be easily monitored. Once mounted, the solenoids on the valves must be wired to the control. As a general rule, the closest valve to the filter access door is valve number 1 and the farthest valve from the door is the last valve of the collector.
10.7 The sequential timer board or the digital reverse pulse controller requires 115 volts (60 cycles) input power. Power consumption is less than 50 Watts.
10.8 The valves operate on 115 volts (60 cycles). The power required is 22 watts. The terminal block on the sequential timer board or digital reverse pulse controller is labeled for the input power and the valve outputs.
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.) 10.9 The digital reverse pulse controller, that monitors filter differential pressure, requires pneumatic hoses to be connected. Beside the filter access door are 2 ports which should be connected to the digital reverse pulse controller (if so equipped). These ports are labeled “HIGH” and “LOW”. At the base of the digital reverse pulse
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control enclosure are 2 port s also labeled “HIGH” and “LOW”. Interconnect the ports between the collector and pulse control with air tight tubing.
10.10 Nominal Full Load Amperes are as follows:
Voltage
Horse Power
208V
230V
460V
575V
3
10.0
8.0
4.0
3.5
5
15.00
13.0
6.5
5.0
7.5
20.0
18.0
9.0
7.0
10
30.0
24.0
12.0
10.0
15
40.0
37.0
18.5
15.0
20
55.0
48.0
24.0
20.0
25
70.0
60.0
30.0
24.0
30
78.0
71.0
35.5
28.0
40
110
92
46
37
50
130
110
55
45
11.0 SMOKE DETECTION/FIRE SUPPRESSION (OPTIONAL)
NOTE: All smoke detection/fire suppression installations must be performed by a qualified technician and in accordance with local, state, and national codes/regulations/laws (if any).
11.1 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.
12.0 PRE-START UP
12.1 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.
12.2 Check that rotary air locks, screw conveyors or any other directional dependent components are rotating the correct direction.
12.3 Check the compressed air system for leaks. Confirm 90 PSI minimum air pressure and 100 PSI maximum air pressure.
12.4 Ensure that no air leaks exist in the seams of any field assembled cabinet components such as hoppers, dust drawers, plenums, filter cabinets, drum lid kits, drums, etc. Warning: Compressed air pressure higher than 100 PSI can damage the filters and the dust collector’s structural integrity.
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12.5 Check that the compression couplings of the pulse valves are tight.
12.6 Energize the sequential timer. The suggested “ on time ” is 0.10 seconds and “ off time ” is 30 seconds. The digital reverse pulse control has been preset at the factory. However, it is recommended to verify that each valve will pulse, by manually activating the valves through the pulse control.
12.7 Check each valve for leaks. NOTE: It is normal for the bleed air port to release a burst of air at each pulse.
12.8 Check the adequacy of air supply by assuring no less than 35% drop in pressure during pulse.
13.0 FILTER INSTALLATION
13.1 Should the filters be shipped separately from the collector, then they must be installed, as follows, prior to start up.
NOTE: Electrical power and compressed air supply MUST be disconnected before beginning the filter installation.
13.2 Inside the collector unit, ensure that the horizontal flange around the vertical venturi is clean. Take care NOT to damage the filter cartridge. Place the filter cartridge with the gasket side down on the flange. Rotate filter slightly to assure no binding and proper location on the flange.
13.3 Most AMTECH Series ATV dust collectors utilize two filters, stacked vertically on each venturi. Position the second filter directly on top of first, gasket side down, concentric with lower filter.
13.4 Place the filter cap, with gasket side down, on top of the second filter cartridge. Turn the “T” handle, clockwise, down a gainst filter cap so that the dimple 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.)
14.0 START UP
14.1 It is recommended that new filters be properly pre-conditioned with pre-coat before start up. Please contact your Clean Air Industries Distributor for assistance. Start system fan and confirm the designed air volume and actual air volume are within 10%. If the air volume is more than the designed volume, then adjustments should be made to reduce the actual volume to within 10% of the designed volume.
14.2 If the air volume is low, and the filters are NOT contaminated then adjustments should be made. Consult your Clean Air Industries Distributor.
14.3 Apply compressed air to the manifold. Turn the reverse jet pulse control on. Apply power to other auxiliary equipment as required.
14.4 COMMENTS REGARDING FILTER DIFFERENTIAL PRESSURE DURING OPERATION:
14.4.1 Depending on operating conditions, dust loading, and the air-to-cloth ratio, 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.
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14.4.2 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. 14.4.3 M ake immediate “Off - Time” time reductions on the timer board dial if significant increases in operating differential pressure become realized. However, if differential pressure drops, monitor the system before increasing the “Off - Time”, and then only in small steps. NOTE: A critical step during “Start U p ” is to reach an acceptable operating equilibrium point. This operating condition must be reached gradually in order not to damage the filters by binding. While achieving equilibrium, you may want to clean the filters more often than required instead of not often enough. Gradually and tentatively increase the valve “Off Time” until equilibrium is reached. Also, making notes and recording results will help the operator gage the effectiveness of various AMTECH filters and filter pretreatment. Should questions arise contact your Clean Air Industries distributor.
15.0 SHUTDOWN
15.1 The “ Shutdown ” procedure consists of de-energizing 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 CAUTION: Off line cleaning can cause pressure waves to feed back through the inlet of the collector and the attached duct work. Precautions may be necessary to prevent dusting.
16.0 MAINTENANCE SAFETY
CAUTION: Personnel involved with the AMTECH collector must be familiar with the operation and the information in this manual. Please make sure all personnel have read and understood the manual.
16.1 Secure all electrical power to the unit (Lock and tag out the unit).
16.2 Secure compressed air flowing into the unit (Lock and tag out the air flow). Additionally, bleed the air system to remove any residual air pressure.
16.3 All areas below the collector must be “OFF - LIMITS” when overhead work is performed.
17.0 MAINTENANCE PROCEDURES
17.1 With sound periodic and routine maintenance programs you should receive a long service life from your AMTECH collector. Maintenance schedules may be adjusted by a competent operator/servicer of the system, as a result of experience, determined after a reasonable period of operation.
17.2 Routine maintenance consists of the following:
17.2.1 Observe the filter differential pressure at least once every 8 hours of operation. Each application will vary. Refer to “Comments Filter Differential Pressure during Operation” on page 8.
17.2.2 Remove any moisture that has accumulated in the compressed air manifold and accumulator.
17.2.3 Ensure that the collected dust material is removed from the dust storage container, as necessary, and disposed of in accordance with ALL local/state/national laws/regulations.
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17.2.4 Ensure that the cleaning schedule is appropriate to maintain pressure differential equilibrium.
17.2.5 Confirm that the reverse jet pulse cleaning takes place at the predetermined schedule.
17.2.6 Ensure a compressed air supply of 90 PSI.
17.2.7 Perform general housekeeping on collector and surrounding area.
17.2.8 Inspect smoke detection/fire suppression system.
17.3 Periodic maintenance consists of the following:
17.3.1 Replace filters when reverse jet pulse cleaning is no longer effective in reducing differential pressure to the normal operating range. (See cartridge filter replacement on page 14)
17.3.2 Clean the internal parts of the reverse jet pulse control with a quality electrical cleaning chemical.
17.3.3 Clean the internal components of the fan control.
17.3.4 Remove any accumulated dust from the pressure port that is connected to the Magnehelic Gage or Reverse Jet Pulse Control or both. This is located inside the dust collector on the dirty air side. NOTE: The diaphragms which enable the measurement of differential pressure on the “Magnehelic Gage” OR “Pulse Control” are EXTREMELY fragile, and the use of compressed air will damage these units.
17.3.5 Replace the cartridge filter caps after every 4th filter change or before if failure of gasket seal occurs.
NOTE: BE CERTAIN THAT THE FLOW OF COMPRESSED AIR IS TURNED OFF AND THE RESIDUAL PRESSURE RELIEVED BEFORE SERVICING ANY COMPONENTS THAT CONTAIN COMPRESSED AIR.
17.3.6 Follow the manufacturer’s maintenance schedule for the compressed air filters.
17.3.7 Tighten the couplings of the valves for the reverse jet pulse cleaning.
17.3.8 Remove any moisture that has accumulated in the compressed air manifold and accumulator.
17.3.9 Inspect and clean diaphragm valves. A thorough cleaning normally rectifies operational problems with valves; however, any worn or damaged parts are to be replaced. Use the following procedure to inspect and repair valves:
17.3.9.1 Main Diaphragm
a. Switch off air supply and drain the system. b. Unscrew the main diaphragm cover bolts and remove the valve cover. c. Inspect the spring and diaphragm for dust and damage. Remove dust with water and
replace damaged parts with diaphragm repair kits for 1” or 1.5” valves. d. Replace valve cover and valve cover bolts.
17.3.9.2 Solenoid Diaphragm
a. Switch off air supply and drain the system. b. Unscrew the bonnet bolts and remove the bonnet. c. Inspect the diaphragm for dust and damage. Remove dust with water and replace
damaged parts with diaphragm repair kit for 1” or 1.5” valves. d. Replace the valve bonnet and valve bonnet bolts.
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17.3.9.3 Solenoid Coil
a. Switch off air supply and drain system. b. Apply proper voltage to the coil and listen for a pronounced “Click” as the pole
moves.
c. If a pronounced “Click” occurs and the valve does not function follow instructions for
replacing the main diaphragm and solenoid diaphragm.
d. If the “Click” is not heard, replace solenoid with either a part for 1” valve or 1.5”
valve.
17.3.10 When servicing pulse valves, refer to the diagram below.
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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17.3.11 Check and replace, if necessary, the access door gaskets and dust drawer gaskets, if applicable.
17.3.12 Inspect smoke detection/fire suppression system.
18.0 CARTRIDGE FILTER REPLACEMENT
NOTE: Depending on the contaminant being collected, it is STRONGLY advised to wear TYVEK suits, safety gloves, and an appropriate dust respirator when handling dirty filters.
18.1 Open Dust Collector Filter Access Door (Picture 1).
Picture 1
18.2 Locate the T-Handle above the first filter(s) to be replaced. (Picture 2)
Picture 2
18.3 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.
18.4 Gently remove the top filter, exercising effort in keeping dust from falling inside the clean air duct opening.
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18.5 Gently remove the bottom filter, exercising effort in keeping dust from falling inside the clean air duct opening 18.6 Place the filter cap over the clean air duct opening at the bottom (Picture 3). 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.
Picture 3
18.7 Repeat steps 2 through 6, for remaining filters.
18.8 To install new filters remove the filter cap from the clean air duct opening and place new filter(s), taking care to install the filter(s) with the gasket down. Place filter cap with gasket side down on top of the top 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 filters and filter cap are aligned properly to facilitate a leak-free fit.
18.9 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.
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Trouble Shooting Guide
Symptom
Possible Cause
Remedy
Blower does not start.
a. Open electrical supply circuit. b. Blower motor not wired for available voltage. a. Incorrect overload protection installed. b. Loose or incorrect termination of motor wiring. c. Incorrectly sized wire for motor load. a. Filter cartridges not properly installed. b. Damaged filter cartridge. c. Damaged filter cap(s). d. Worn filter cap. e. Loose filter clamping “T” Handle.
a. Trace circuit back from correct interruption. b. Rewire motor within motor box for proper voltage per motor data label. a. Replace overload protection with correctly sized components. b. Check all terminations of motor wiring.
Blower motor starts but does not continue operating.
c. Rewire motor circuit with proper wire size.
Dust Discharge from Collector outlet.
a. Reinstall filters.
b. Replace damaged filters. c. Replace damaged filter cap(s). d. Replace all filter caps. e. Tighten loose “T” Handle.
Insufficient Air Flow
a. Blower rotating backwards.
a. Check blower rotation. Blower should be rotating clockwise when viewed looking down over the motor. Refer to page 5 under Electrical for changing rotation direction. b. Check that all access panels, doors, dust drawers, drum lids and flex hose connections are tight. c. Check exhaust area for blockage and eliminate all material that causes restrictions. d. Remove and replace filter cartridges. e. Increase available air volume. f. Increase air pressure to Maximum of 100 PSI. g. Eliminate source of contamination and purge compressed air line. h. Confirm input power to timer board or controller. Refer to pulse control manual for further information. i. The “on - time” and “off - time” must be set to optimize filter pressure differential equilibrium. Refer to page 10 of this manual and to the timer board controller manual for additional detail.
b. Collector not sealed properly.
c. Blower exhaust area blocked.
d. Filter cartridges need to be replaced. e. Compressed air volume inadequate. f. Compressed air pressure inadequate. g. Compressed air contaminated with oil or water. h. Pulse cleaning not working.
i. Pulse cleaning not set up as required.
Clean, repair or replace valves. Refer to page 13.
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WARRANTY STATEMENT
2 YEAR LIMITED WARRANTY
ITEMS NOT COVERED WITH THIS WARRANTY ARE FILTERS AND DUCTWORK, WIRING AND INSTALLATION NOT SUPPLIED 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 24 MONTHS FROM THE DATE OF INSTALLATION, SUBJECT TO THE TERMS AND CONDITIONS OF THIS LIMITED 2 YEAR WARRANTY 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 WITH THE EXCEPTION OF COMPONENTS NOT MANUFACTURED BY CLEAN AIR INDUSTRIES , SUCH AS, ELECTRICAL OR ELECTRONIC EQUIPMENT SUCH AS MOTORS, MOTOR STARTERS, PULSE CONTROLS AND VALVES. THOSE ITEMS NOT MANUFACTURED BY CLEAN AIR INDUSTRIES HAVE A ONE YEAR MANUFACTURERS WARRANTY. 4. IF WITHIN THE WARRANTY PERIOD ANY AMTECH 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 14 DAYS OF ITS DISCOVERY. 6. THIS LIMITED WARRANTY DOES NOT APPLIED TO ANY PART OR COMPONENT THAT IS: DAMAGED IN TRANSIT OR WHEN HANDLING; HAS BEEN SUBJECT TO MISUSE, NEGLECT OR ACCIDENT; HAS NOT BEEN INSTALLED, OPERATED AND SERVICED ACCORDING TO AMTECH’S INSTRUCTION; HAS BEEN OPERATED BEYOND THE FACTORY RATED CAPACITY; OR ALTERED IN ANY WAY THAT WOULD AFFECT ITS PERFORMANCE. THERE IS NO WARRANTY DUE TO NEGLECT, ALTERATION OR ORDINARY WEAR AND TEAR. AMTECH’S 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 DAMAGES 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 TO YOU. 8. THIS WARRANTY GIVE YOU SPECIFIC RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS THAT VARY FROM STATE TO STATE. 9. ANY WARRANTY WORK WILL BE PERFORMED WITHIN A REASONABLE TIME, USUALLY WITHIN 60 DAYS AFTER NOTICE OF DEFECT AND DELIVERY TO THE CLEAN AIR INDUSTRIES FACTORY, SUBJECT TO DELAY BEYOND CLEAN AIR INDUSTRIES CONTROL. 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 EXPRESS 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 TO YOU. 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 IN UNITS COMPLETED ON THE EFFECTIVE DATE OF SUCH CHANGE.
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REPLACEMENT PARTS LIST AMTECH MODEL ATV-XX S/N XXXXXX
PART DESCRIPTION
PART NO.
QTY. PER UNIT
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