Learn how to set up, use, and maintain your Amtech PCF Pre-Coat Feeder by Clean Air Industries.
AMTECH PCF Pre-Coat Feeder Series User & Maintenance Manual
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AMTECH PCF SERIES (Pulse Type) 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 pre-coat feeder system and associated equipment. 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 Amtech 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
INSPECTION (Receipt of unit)
5
INTRODUCTION
5
ELECTRICAL/MECHANICAL CONNECTIONS
5
OPERATION
8
STARTUP/SHUTDOWN
9
MAINTENANCE
9
CAUTION
9
PARTS LIST
10
WARRANTY STATEMENT
11
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1.0 PRECAUTIONARY STATEMENTS APPLICATION OF CLEAN AIR INDUSTRIES EQUIPMENT 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 Equipment location, installation and operation must comply with all local, state, and National Fire Codes. If unsure contact the appropriate authorities. 1.3 The electrical installation must conform to all local and state codes, as well as the National Electric Code. 1.4 Events in industry have demonstrated that fires can, potentially, occur in dust 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 this mindset. 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.
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1.5 The air supply system should be installed by qualified individuals, and in accordance with any local and state codes. 1.6 Workers and operators are to be instructed to keep burning objects, such as cigarettes, safely away from inlets leading to the equipment. 1.7 All personnel involved with the use of this equipment must comply with the statements pertaining to worker safety as noted in this manual. 2.0 INSPECTION 2.1 Upon receipt, the unit 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 upon of receipt of unit, regarding any missing/lost items/components/parts. 3.0 INTRODUCTION
3.1 Precoating is the process of applying a thin layer of absorbent material around the outer surface of a filter. Typical precoating materials include lime, diatomaceous earth, pearlite, and powdered cellulose. Precoating is usually performed for 2 main reasons: 1. New cartridge filters have low capture efficiency on submicron particles. Applying a layer of precoat increases the filters collection efficiency. 2. In heavy oil and smoke applications, new cartridge filters can easily become saturated, thus dramatically increasing
the differential pressure across the filters, resulting in lowering air flow. Applying a layer of precoat provides a "protective" or absorbing cover for the filter, which is subsequently removed by pulse jet cleaning. Typical loading rates for filters range from 0.5 to 2.5 lbs/filter.
3.2 The Amtech PCF series is designed to, continuously, inject a relatively small volume of precoat material into a dust collection system. The precoat feeding rate can be controlled by the cycle time (time on/time off) and the compressed
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air pressure of the pulse valves. The PCF series comes in two models, The PCF- 60, which has a 60-gallon hopper, and the PCF-150, which has a 150-gallon hopper. 4.0 ELECTRICAL/MECHANICAL CONNECTIONS 4.1 PCF series installation is complete once the electrical power, compressed air, and discharge duct are connected. If the automatic feed feature of the unit is desired to be active, then an extra set of "normally open" contacts are necessary on the motor starter (for the blower) and the switch set to “Auto”.
4.1.1 Standard wiring for this unit is 115V AC. Wiring should be completed by an electrician, and in accordance with all applicable national, state, and local codes. Bring customer supplied 115V power to H,N & G on the terminal Strip. To run in Auto Mode, Amtech’s recommended operation mode, so that the feeder turns on and off with the dust collector, connect 1 and 2 to a normally open contact on the motor starter for the dust collector.
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Figure 1- Electrical Diagram
Figure 2- PCF Parts Diagram
4.1.2 The compressed air supply should be clean and free of oil and water. All PCF series models are equipped with an air pressure regulator with a 3/8” NPT female inlet, shown right. Plumbing should be completed by competent tradesmen in accordance with all applicable national, state, and local codes. Compressed Air should be set at 60 PSI for the PCF-60 and 90 PSI for the PCF-150.
4.1.3 The discharge duct, shown right, should be connected to the main duct leading to the inlet of the dust collector. The PCF-60 is equipped with a 4ӯ discharge duct. The PCF- 150 is equipped with a 6ӯ discharge duct. Any feeder should be located as close to the dust collector, as possible, to ensure good suction. Ductwork should be completed by
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competent tradesmen in accordance with all applicable national, state, and local codes.
4.1.4 If equipped, PCF models can be maneuvered through the use of the fork pocket option, located on the bottom of the feeder. Only proper lifting equipment should be used to move PCF feeders. If the fork pocket option is not present, lift at your own discretion.
5.0 OPERATION
5.1 As was presented in the introduction section, typical precoating rates for cartridge filters vary from 0.5 to 2.5 lbs/filter, but rates can vary by application. The 2 major variables, that can be adjusted to deliver a rate of precoat material, satisfactory to your needs, are the pulse control board and the compressed air pressure. When adjusting the pulse control timer, “Time On” is for the length of time the valve is open. This can be set from 50 mSEC to 500 mSEC. The factory setting is 100 mSEC. “Time OFF” is the time delay between pulses. This can be set from 1 SEC to 180SEC. The factory setting is 60 SEC. The timer board has 10 stations. The factory wires a pulse valve to every second station, thereby increasing the time off to 2 SEC - 360 SEC. Your unit is factory set at approximately 100 mSEC for “Time ON” and 360 SEC for “Time OFF” (this cycle repeats until the pre-coat unit is turned off OR the blower is powered down, provided the contacts are connected appropriately). Additionally, the compressed air pressure going to the feeder can be adjusted, which could also have a significant impact on feeder rates. Typically, 60 PSI for the PCF-60, and 90 PSI for the PCF-150, is recommended. However, this value can be adjusted up or down depending on your choice of precoat material. NOTE: Excessive compressed air pressure will cause precoat material to escape the confines of the unit.
Each PCF series feeder comes with a “Constant Feed” feature. This feature is used when new filters are installed in the dust collector and is located on top of the feeder, right behind the access door. During normal operation, this valve should remain OFF. Once new filters have been installed, this valve can be turned ON, creating a constant feed of precoat
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material into the dust collector, coating the newly installed filters faster than what normal operation would produce. AT MINIMUM, enough precoat material should be applied to the filters until the differential pressure, across the filters, increases by 0.5” w.g. This value can be exceeded to the user’s satisfaction. Once the appropriate differential pressure value is reached, the “Constant Feed” valve should be turned OFF. The feeder will now run in standard operation. Differential pressure, across the cartridge filters in the collector, can be monitored with a pulse controller, or a magnehelic gauge, if so equipped.
7.0 STARTUP/SHUTDOWN
7.1 Ensure that all mechanical/electrical connections have been made.
7.2 Ensure that precoat material is in the unit.
7.3 Ensure blower on the dust collector is operating!
7.4 Turn the PCF feeder switch to "HAND" (manual). If your unit is properly wired for automatic operation, then the switch can be turned to “AUTO”.
7.5 To power down the feeder, turn the switch to "OFF", and power down the blower on the dust collector.
8.0 MAINTENANCE
8.1 The Amtech PCF series feeders should provide years of trouble-free service. However, if you should experience an issue with your feeder, please contact your Amtech distributor.
8.2 Feeders will require periodical refills of precoat material. The frequency of these refills will be a function of your choice for cycle time.
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9.0 CAUTION
9.1 The bulk density, and hence conveying velocity, of precoat materials can vary. Ensure your systems conveying velocity is sufficient for your choice of precoat material. REPLACEMENT PARTS LIST AMTECH PCF SERIES
DESCRIPTION
PART #
QTY
PCF-60 : NOZZLE, WHISPERBLAST, ROUND, ¼ NPT
4484 4539 4167 4194 4572 4574 2422 4575 4576
4 4 1 1 5 1 1 1 1 1 1 6 6 1 1 7 1 1 1 1 1 1
VALVE, DIAPHRAGM, ¼”
REMOTE SOLENOID ENCLOSURE, 4 VLV, 120VAC, 1/8” NPT 4540
LATCH, DOOR
GASKET, PORON, ¾ x ¼ BULKHEAD, BRASS, ¼
PER FT
SHUT-OFF, ¼ MALE x ¼ FEMALE
BLAST GATE, 4ӯ
COMPRESSED AIR FILTER/REGULATOR, 3/8 NPT
MOUNTING BRACKET, REGULATOR
CONTROL PANEL TIMER, 110VAC
PCF-60-CP
4483
PCF-150 : NOZZLE, WHISPERBLAST, ROUND, ¼ NPT
4484 4539 4167 4194 4572 4574 2511 4575 4576
VALVE, DIAPHRAGM, ¼”
REMOTE SOLENOID ENCLOSURE, 6 VLV, 120VAC, 1/8” NPT 4541
LATCH, DOOR
GASKET, PORON, ¾ x ¼ BULKHEAD, BRASS, ¼
PER FT
SHUT-OFF, ¼ MALE x ¼ FEMALE
BLAST GATE, 6ӯ
COMPRESSED AIR FILTER/REGULATOR, 3/8 NPT
MOUNTING BRACKET, REGULATOR
CONTROL PANEL TIMER, 110VAC
PCF-150-CP
4483
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CLEAN AIR INDUSTRIES TEN YEAR LIMITED WARRANTY
ITEMS NOT COVERED BY THIS WARRANTY ARE DUCT WORK, WIRING AND INSTALLATION WHICH IS NOT PERFORMED BY CLEAN AIR INDUSTRIES. CLEAN AIR INDUSTRIES WARRANTS THAT ALL NEW AMTECH PRE- COAT MACHINES 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 TEN YEARS FROM THE DATE OF SHIPMENT, SUBJECT TO THE TERMS AND CONDITIONS OF THIS LIMITED 10 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. 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 MACHINE OR COMPONENT REQUIRES SERVICE, IT MUST BE PERFORMED BY AN 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 10 YEAR WARRANTY THE OWNER MUST NOTIFY THE DISTRIBUTOR OR CLEAN AIR INDUSTRIES IN WRITING OF ANY DEFECT WITHIN 14 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.
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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 REPLACEMENT PARTS MAY VOID THIS WARRANTY.
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