FARR GOLD SERIES DUST COLLECTOR
®
Installation, Operation and Maintenance Manual
#C-1000-21 Rev. M-2 (US Customary Units)
Customer
SOUTHERN PERU COPPER
Local Rep
Location
Job #
LIMA, PERU
N4539001
AIR POLLUTION CONTROL
Rep Phone
JUAN PABLO NORIEGA
+51 987744809
Camfil APC
3505 S. Airport Road, Jonesboro, AR 72401 | 870-933-8048
www.camfilapc.com | e-mail: filterman@camfil.com | 800-479-6801
Camtain™ GS2 on Pharmaceutical Dust
Multiple Gold Series on Soybean Seed Processing
Multiple Farr Gold Series units on a mining rock crushing application.
B
GS6 on Silica Powder
GS 8 on woodworking
GS48 on welding fume in Camfil APC’s own welding shop – Intake openings in the top of the duct every 20 feet facing
upwards towards the ceiling actually use the ceiling as a capture plenum to help draw in the weld smoke. This is much
more effective than facing the openings down.
GS16 on Plastic Powder Mixing
GS32 on Dried Food Ingredients
GS48 on Automotive Welding Fume with Material Drop-out Section
GS16 on Food Application
GS16 on Fumed Zinc Oxide
C
Table of Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 100 — Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
100.1 — Understand Signal Words and Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . .
100.2 — Warning Decals and Guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
100.3 — Lock-Out / Tag-Out Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
3
4
Section 200 — Receiving Your Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
200.1 — The Purchaser’s Responsibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
200.2 — System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
200.3 — How Your Equipment is Shipped. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
200.4 — Un-crating and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
200.5 — Understanding Your Serial Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
6
6
6
Section 300 — Installation of Your Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
300.1 — Gold Series Assembly Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Section 310 — Assembling Your Farr Gold Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
310.1 — Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
310.2 — Hoppers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
310.3 — Support Legs and Braces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
310.4 — Hopper Support Legs and Braces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
310.5.1 — Filter Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
310.5.2 — Channel Baffle Inlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
310.6 — Discharge Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
310.7 — Platform / Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
310.8 — Collector Top Access Rails. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
310.9.1 — Farr Gold Series Integrated Safety Monitoring Filter (iSMF) . . . . . . . . . . . 15
310.9.2 — Filter Installation / Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
310.9.3 — Differential Pressure Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Section 320 — Attaching Duct Work to Your Farr Gold Series. . . . . . . . . . . . . . . . . . . .
320.1.1 — Inlet Duct Design (Side View). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
320.1.2 — Inlet Duct Design (Top View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
320.2 — Inlet Flanges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
320.3 — Remote Mount Fan Discharges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
320.4 — Top Mount Fan Discharges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
320.5 — Discharge Hopper Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D
17
17
18
19
23
23
23
Section 330 — Field Utility Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
330.1 — Motor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
330.2 — Timer Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
330.3 — Solenoids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
330.4 — Solenoid Heaters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
330.5.1 — Collector Timer Control Connections. . . . . . . . . . . . . . . . . . . . . . . . . . .
330.5.2 — Integrated Safety Monitoring Filter - iSMF. . . . . . . . . . . . . . . . . . . . . . . .
330.6 — Compressed Air Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
330.7 — Sprinkler Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
25
25
25
28
29
29
30
31
Section 340 — Explosion Vents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
340.1 — Concerning Explosion Vents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
340.2 — General Explosion Vent Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
340.3 — Explosive Dusts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
340.4 — Explosion Vent Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
340.5 — Location of Vents and Vented Equipment . . . . . . . . . . . . . . . . . . . . . . . . .
340.6 — Ignition Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
340.7 — Vent Discharge Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
340.8 — Vent Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
33
34
34
35
35
36
36
36
Section 350 — Filter Installation and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
350.1 — Clean Seal Filter Upgrade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Section 360 — Precoating of Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
360.1 — Pre-Coating Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Section 370 — Glide Pack / Riga Flo SMF Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
370.1 — Transitioning: Top Mounting Arrangement. . . . . . . . . . . . . . . . . . . . . . . . .
370.2 — Remote Mounting Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
370.3.1 — Filter Assembly: Prefilter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
370.3.2 — Final Filter Holding Frame and Clips. . . . . . . . . . . . . . . . . . . . . . . . . . . .
370.3.3 — Final Filter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
370.3.4 — Magnehelic Gage and Accessory Kit . . . . . . . . . . . . . . . . . . . . . . . . . . .
370.4.1 — Magna Pac / Hepa Filter SMF Installation: Transitioning. . . . . . . . . . . . . .
370.4.2 — Filter Assembly: Prefilter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
370.4.3 — Final Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
370.4.4 — Magnehelic Gage and Accessory Kit . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
40
40
40
40
40
40
41
41
41
41
Section 380 — Overbag Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
E
F
Section 400 — Operation of Your Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.1 — System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.2 — Cleaning Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.3.1 — Cleaning Components: Header (Compressed Air Pressure Reservoir). . . .
400.3.2 — Solenoid/Diaphragm Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.3.3 — Pulsejet Blow Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.4.1 — Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.4.2 — Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.4.3 — System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.4.4 — Installing the Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.4.5 — Electrical Hookup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
43
44
44
44
44
46
47
48
49
49
400.4.6.1 — Dust Collector Controller Operation . . . . . . . . . . . . . . . . . . . . . . . . . .
400.4.6.2 — Run Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.4.6.3 — Offline Cleaning Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.4.6.4 — Standby Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.4.6.5 — Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.4.7 — Alarm Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.4.8.1 — Programming the Core Timer Module. . . . . . . . . . . . . . . . . . . . . . . . .
400.1.8.2 — Solenoid Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.1.8.3 — Solenoid On Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.1.8.4 — Solenoid Off Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.1.8.5 — Number of Offline Cleaning Cycles. . . . . . . . . . . . . . . . . . . . . . . . . . .
400.1.8.6 — Offline Cleaning Time Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.1.8.7 — Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.4.9.1 — ∆P Pressure Differential Meter Programming. . . . . . . . . . . . . . . . . . . .
400.4.9.2 — ∆P Alarm High Set Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.4.9.3 — ∆P Cleaning Low Set Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.4.9.4 — ∆P Cleaning High Set Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.4.9.5 — ∆P Unit of Measure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.4.9.6 — Security Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.4.9.7 — Zero Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.4.10.1 — Core Expander Module Addressing. . . . . . . . . . . . . . . . . . . . . . . . . .
400.4.10.2 — Communications Jumper Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.4.10.3 — Core Timer Module Status LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.4.10.4 — Expansion Module LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.5 — Dwyer DCT1000 Automatic Timer Controller Features. . . . . . . . . . . . . . . .
400.6 — Integrated Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.7 — Rotary Air Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.7.1 — Basic Cast Air Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.7.2 — Fabricated Air Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.7.3 — Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50
50
50
50
50
51
51
51
52
52
52
52
52
52
54
54
54
54
54
55
55
55
55
56
59
62
62
63
63
63
400.8 — Fan Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.9 — Startup Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.10 — Shutdown Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
400.11 — Recommended Timer Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
66
66
67
Section 500 — Preventive Maintenance and Troubleshooting. . . . . . . . . . . . . . . . . . . . .
500.1 — Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
500.2 — Hopper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
500.3 — Fan Motor Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
500.4 — Solenoid and Diaphragm Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
500.5 — Automatic Timer Control (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
68
68
68
69
69
500.6 — Cleaning and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
500.7 — Inspection Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
500.8 — Suggested Preventative Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . 70
Section 510 — Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
510.1 — High Pressure Drop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
510.2 — Moisture In Collector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
510.3 — Low Air Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
510.4 — Controller Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
510.5 — Dust Bridging in Hopper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
510.6 — Media Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
510.7 — Poor Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
510.8 — Poor Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
510.9 — Abnormal Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
510.10 — Repeat Fires or Explosions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
510.11 — Installation Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71
71
72
73
73
74
75
76
77
78
79
79
Section 600 — Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Section 700 — Replacement Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Section 800 — Job Specific Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
G
DO NOT DISCARD
THIS MANUAL!
It contains information
which when properly
used will insure proper
operation, continued
high performance,
and a long work life to
your unit.
Introduction
Congratulations on your selection of Camfil Air Pollution Control equipment. As the owner or operator
of this equipment, you have an important responsibility to see that it is operated and maintained in
a safe manner. The unit will require moderate attention to keep it in good operating condition. This
manual has been prepared to aid you in that effort. Throughout this manual, reference may be made
to various components, which may or may not be part of your particular system. They are included in
the interest of fully describing typical systems with all available options.
This manual covers the installation, operation and maintenance of the Farr Gold Series dust
collector. This air cleaning equipment is used to eliminate dust contaminants from the environment
making the facility or plant a healthier and safer work place. This unit has been assembled using
only quality materials and labor. This machine has been checked to make sure that it is operational
for you at the time of installation.
Prior to installing your equipment, thoroughly read and understand this manual. Locate all parts
and ensure that nothing is missing, has suffered shipping damage or has been damaged during
unloading. Familiarize yourself with each component of your system and its function using the
contents of this manual as a guide. Refer to any local codes or ordinances relating to equipment of
this type. They may affect the method or procedure used to install your system.
1
WARNING!
Do not attempt to operate or maintain this piece of equipment until you have read and thoroughly
understood all of the safety information contained in this manual.
All such information must be taken seriously. This piece of equipment contains moving parts and
potential pinch points, which can cause serious injury or death. If you do not understand anything
in this manual, seek assistance from your supervisor before operating this equipment.
Do not attempt to operate this equipment without factory-installed guards.
Replace damaged guards.
2
Section 100 — Safety Precautions
Camfil APC relies on the skills and expertise of its customer and any consulting engineers and/
or installing contractors hired by that customer to properly design and install the dust collection
system of which Camfil APC equipment is a part. It is the responsibility of the end user of this
equipment to take the necessary precautions to minimize the inherent risks associated with
combustible dust.1 Refer to Section 340 of this manual if you have an explosive dust. Read
this manual thoroughly and comply with the precautionary statements relative to worker safety.
Precautions must be taken to ensure that all electrical/air connections and regulation devices are
installed and operating properly.
100.1 — Understand Signal Words and Symbols
The symbols shown below appear on the equipment to alert you of potential hazards. When you
see these symbols you must read, understand, and heed the information that accompanies them.
100.2 — Warning Decals and Guards
See NFPA 654 Standard
for the Prevention of
Fire and Dust Explosions
from the Manufacturing,
Processing, and handling
of Combustible Particulate
Solids. And NFPA 68 Guide
for Venting of Deflagration.
1
3
This piece of equipment contains several warning decals located in many different locations. It is
the owner and operator’s responsibility to maintain the integrity of these decals and to ensure that
all operators of the equipment are aware of them and understand their meaning. Replacement
decals are available free of charge from your Camfil APC Service Representative, or by calling
Camfil APC direct at 1.800.479.6801. Part numbers for these decals are listed in the spare parts
list in Section 7.00 of this manual.
This piece of equipment may contain one or more safety guards to protect the operator(s) from
injury. It is the owner/operator’s responsibility to maintain the integrity of these guards and ensure
that they are in place when the equipment is in operation.
100.3 — Lock-Out / Tag-Out Requirements
Control of this equipment must be in accordance with OSHA Standard 1910.147 “Control of
Hazardous Energy (Lock-Out / Tag-Out)”. This standard “requires employers to establish a program
and utilize procedures for affixing appropriate lock-out / tag-out devices to energy isolating devices
and to otherwise disable machines or equipment to prevent unexpected energizing, start-up or
release of stored energy in order to prevent injury to employees”.
For further information on Lock-Out / Tag-Out requirements, see your company’s Safety Director or
refer to OSHA Standard 1910.147.
Before inspecting or servicing this equipment perform an approved Lock-Out / Tag-Out procedure
on the electrical service, the compressed air (or other gas) supply or any other energy source.
Marks the location of an
explosion relief vent. In
the event of an explosion
in the dust collector
there is a potential for
damage to personal
property, injury, or death.
Indicates the hazard of
being trapped inside
a dust collector. If the
main fan is activated
the collector door would
be sucked shut. The
door would be very
difficult to open against
the negative pressure
generated by the fan.
Identifies equipment
that will start without
warning.
Identifies hazards associated with rotating
machinery.
Identifies hazards associated with
compressed air sources.
Identifies hazards associated with belt and
chain drives.
Identifies hazards associated with
equipment that are considered confined
spaces.
4
Section 200 — Receiving Your Equipment
200.1 — The Purchaser’s Responsibility
A visual inspection of your equipment should be performed before it is removed from the truck.
Dents, scratches and other damage should be noted and photographed. The structural integrity of
the housing will be adversely affected by large dents. The equipment should be closely inspected
wherever cargo strap’s were used. Camfil APC should immediately be notified of any structural
damage to your equipment. It is the purchaser’s responsibility to file shortage reports and damage
claims with the carrier and your Camfil APC representative. The carrier is responsible for any
damage to the equipment while it is in transit unless specific arrangements are made otherwise.
The Farr Gold Series dust collector is shipped disassembled and must be assembled by installation
personnel. Unit assembly, with the exception of the electrical and air connections, can usually be
accomplished by anyone with a basic understanding of common hand tools.
Besides a common set of hand tools, a crane, fork-lift and/or chain-fall will be required to position
the fan and motor on top of the unit clean-air plenum and lift heavier components into position.
Camfil APC must rely on the skill,safety and expertise of its customers and the customer’s
installation contractor to ensure that all electrical, water, and air connections are made correctly,
also that all regulation devices are installed and operating properly.
200.2 — System Components
Your Farr Gold Series dust collection may consist of one or all of the following components:
Filter Module
Hopper Sections
Fan
Support Legs
Cross Braces
Assembly Hardware
Motor Starter
Figure 200.2.1
Maintenance Platform
Maintenance Ladder
Rotary Airlock
Screw Conveyors
Slide Gate Kits
Discharge Drums
Manual Cleaning Control
Fan
Filter Modules
Roatary Airlock and
Access Platforms
Support Legs
5
Automatic Timer Control
Fan Silencer
AR-Inlet
Self Dumping Hoppers
Absolute or Riga Flow Filters
Hopper
200.3 — How Your Equipment is Shipped
It is Camfil APC’s goal to ship our products as economically and practically as possible. In order
to save our customers shipping costs, it is our goal to load your collector on as few trucks as
necessary. The number and size of trucks required to transport your collector will depend solely
on the size of your unit. The trucks are loaded to minimize damage to the collector while loading,
shipping, and unloading. Typically, your collector will ship with the hopper, plenum, support
structure, fan and other accessories disassembled. These items will be loaded on the trucks
separately and placed on pallets for easy unloading. A fork-truck or crane may be needed to
unload your collector depending on the size of the unit. In general all assembly hardware will be
located in a box that will be placed in the inlet of the plenum section of your collector.
200.4 — Un-crating and Inspection
Each Farr Gold Series dust collector is normally shipped on two or more pieces. One skid contains
the filter module section. A second skid contains the hopper section and other skids will contain
fans, support legs, safety monitoring filters, airlocks and custom accessories.
Compare the number of items received against the carrier’s Bill of Loading. The project drawing
has a listing of all loose components shipped with the job. A copy of this drawing is included with
this manual submittal. Inspect all items for apparent damage. Immediately report any shortages or
obvious damage to the carrier and to your local Camfil APC Representative or call Camfil APC at
1-800-479-6801.
CAUTION!
Use extreme care
when handling the
unit components.
Careless handling can
damage delicate parts
or affect assembly
alignments.
When all skids are completely unpacked, check all items received against the material list on the
project drawing and or the packing list, which is always sent with the shipment. Further inspect the
unit and components for hidden damage. Again, report any shortages or damage to the carrier
and to your local Camfil APC Representative.
Do not return any damaged components without first contacting your Camfil APC Representative
to obtain Returned Goods Authorization (RGA). Carefully inspect all packing material so that small
parts are not inadvertently discarded.
200.5 — Understanding Your Serial Plate
Figure 200.5.1
Once you receive your equipment, it will be important to have the collector’s serial, model, and
part numbers. This information will be helpful when calling customer service or finding original
equipment supplied with the collector. This information is found on a white plate on the door of
your collector see Figure 200.5.1. Write this information in this book for easy access.
Your serial plate will show:
Date Manufactured
Farr Gold Series Model
Serial Number
Number of Filters
Gold Cone Filter #
Application Data
Completion date of the unit
Size of the unit (e.g., GS24 or GS12SQ)
Links the unit to the prints and engineering documents.
Number of filters in the unit.
Part number for replacement filters.
Air volume,static pressure, air to cloth ratio, dust type, explosive dust,
and KST rating pertaining to the units operating parameters.
6
Section 300 — Installation of Your Equipment
300.1 — Gold Series Assembly Tools
The following items may be required to install your unit:
Only trained, authorized personnel should be permitted to service or maintain electrical or safety
components. It is the buyers and installers responsibility to ensure that all applicable electrical and
safety codes are met.
Table 300.1.1
7
Description
Intended Use
1
SAE Socket Set
General tightening of fasteners
2
Common Screwdriver
Electrical connections
3
Phillips Screwdriver
Electrical connections
4
Impact Wrench
Installation of self-tapping screws and fasteners
5
Hammer Drill
Anchoring to floor
6
Masonry Bit
Anchoring to floor
7
Hammer
Installing Anchors
8
Wire Cutters
Electrical connections
9
Wire Nuts
Electrical connections
10 Electrical Tape
Electrical connections
11 Extension Cord
General use
12 Conduit
Electrical connections
13 3/4” or larger Black Iron Pipe or Equivalent
Compressed air connections
14 Fittings for Items 12 and 13
Compressed air and electrical connections
15 Thread Sealant
Compressed air connections
16 Alignment Punch
Aligning holes
17 Forklift or Overhead Hoist
Moving and positioning components
18 Wedge Anchors or Equivalent
Anchoring to floor
19 Transit or Carpenters Level
Leveling Unit
Section 310 — Assembling Your Farr Gold Series
310.1 — Hardware
Refer to Figure 3.11.1 for typical assembly points of a standard collector. Refer to the General
Dimension drawings for specifics, such as item part numbers, inlet and outlet locations, foundation
dimensions and accessories.
Locate the carton or cartons containing the installation hardware, normally located inside the inlet.
Inside this carton will be individual hardware cartons or containers labeled with the part numbers
and a check sheet to verify what each carton is.
Figure 310.1.1
Example 310.1.2
Apply rope caulk in a figure 8
pattern around bolt holes to
prevent leaking.
8
310.2 — Hoppers
Locate the hoppers and support legs. Remove the hoppers from the skids and place on a flat,
level surface. If your collector includes multiple hoppers place them in the correct configuration
as shown on the General Dimensions drawing. Using a tape measure or string line, square the
hoppers as necessary. Bolt the hoppers together using the corner support brackets and hardware
as shown on Figure 310.2.1.
On collectors that have half frames, the filter module to hopper bolt-holes are not symmetrical,
Match Line Labels are provided on the filter module and all hoppers. Turn the hopper or support
structure assembly so that the Match Line labels on the hoppers line up with the Match Line labels
on the bin-vent. The Match Line labels do not have to line up perfectly; they are intended only for
general hopper to bin-vent orientation
Figure 310.2.1
9
Scan to see Farr Gold Series
Instruction Video
Hopper and Leg Assembly
310.3 — Support Legs and Braces
Refer to Figure 310.2.1 for general assembly and your support structure drawing for specific
parts. Locate the support legs and bolt them to the corner support brackets. Locate the cross
braces and bolt them to the support legs. If your collector contains knee braces, bolt one end to
the support leg and the other end to the corner support bracket. Note: Do not tighten any of the
bolts until all bolts have been started.
310.4 — Hopper Support Legs and Braces
Lift the completed hopper or support structure assembly with a forklift or chain hoist and carefully
overturn into an upright position. Notice the slots for lifting in the corner support brackets in Figure
310.1.1. Move the assembly into final position. Ensure that inspection panels or optional device
connections are in the desired orientation.
Level the hopper flange(s) with a transit or carpenter’s level. Grout the support leg bases as
necessary. Anchor the support legs to the floor using appropriate concrete anchors (by installing
contractor).
310.5.1 — Filter Module
If your collector is equipped with a top-mounted fan, locate the fan mounting panel and clean the
area around the fan flange that will be in contact with the rope caulk. Clean the fan flange and
apply rope caulk, using the figure 8 configuration. Bolt the fan to the fan mounting panel using the
hardware included (Table 300.1.1). If you have a remote mount fan refer to Section 320 (Remote
Mount Fan Discharges) for further instructions.
Remove any dirt or other accumulation from the hopper flange. Line the hopper flange with
rope caulk as indicated in Figure 310.1.1 and Example 310.1.2, an “s” (zigzag) pattern is
recommended to ensure that there is a continuous seal on the flange.
Lift the filter module, using the lifting lugs provided and approved lifting equipment as in Figure
310.1.1. Failure to connect lifting cable to all (4) lifting lugs may result in damage to the collector.
On larger collectors, adequate cable length or a spreader bar is required to prevent damage to the
collector.
Clean the filter module flange and set onto the hopper flange, taking care not to damage the
flanges or rope caulk. Ensure that the orientation of the collector is as desired for your installation.
Note: On general collectors ensure that the “Match Line” label(s) on the filter module, line up with
the “Match Line” label(s) on the hopper(s) as in Figure 310.5.2.1.
Keep the weight of the collector fully supported by the crane or forklift until all hopper bolts have
been installed and tightened. Attach the filter module to the hopper, using 3/8-16 thread cutter
screws as in Figure 310.5.2.1. Use a drift or alignment pin to align holes as necessary. Insert bolts
into each of the four corners without tightening them. Insert the bolts from the corners to the center
of the collector. Note: Do not tighten bolts when starting to align hopper. Wait until all bolts have been
started before tightening. This will allow you to move and adjust the filter module as necessary.
10
310.5.2 — Channel Baffle Inlet
If your filter module is supplied with a lowered channel baffle assembly for the inlet, install at this
time as follows:
1. Channel baffle tabs fit to the inside of the frame as shown.
2. Attach center baffle channel if required (Figure 310.5.2.2).
3. Apply rope caulking to exterior of frame.
4. Position inlets and secure at corners with 3/8 -16 × ¾” cutter screws.
5. Use 3/8 -16 × 11/4” cutter screws in (4) places required for baffle.
6. Bolt inlets in place with remaining 3/8 -16 × ¾” cutter screws.
7. Position baffle tabs over long bolts and secure with 3/8”-16 flanged locknuts on inside of unit.
Figure 310.5.2.1
Refer to the
Installation DVD for
detailed procedures
for installation.
11
Figure 310.5.2.2
Refer to the
Installation DVD for
detailed procedures
for installation.
12
310.6 — Discharge Assembly
Figure 310.6.1
Locate the hopper discharge accessory supplied with
your collector. This will be a drum kit/slide gate, rotary
airlock or screw conveyor. Install the accessory to the
hopper discharge flanges using the General Dimensions
drawing and Section 320 as a guide.
Clean and apply rope caulk to the top surface of the slide
gate flange. Bolt the slide gate to the hopper discharge
flange; making sure that the slide gate is oriented so
that there is no interference with support bracing when
the handle is pulled out. Place drum lid/cover on the
drum. Slip the drum latching ring over the drum lid and
top of the drum. Be sure that the latching ring is on the
right side up. (The clamp will not latch if installed up side
down.) Slip one end of the flex hose over the collar on the
drum lid and fasten with a hose clamp. Slide the barrel
assembly under the hopper and slide the other end of the
flex hose onto the collar on the slide gate, fasten with a
hose clamp. Open slide gate.
Slide Gate
Hose Clamp
Flexible Hose
Hose Clamp
Drum Lid
Drum Latch Ring
NOTE
310.7 — Platform / Ladder
The installing
contractor must
brace the ladder
properly.
Please read the following Modular Platform Assembly Instructions and refer to figure 310.8.1.
1. Platform Support Brackets (items 5 and 6) are attached to the front of the support legs using
the same 5/8” hardware provided to secure legs to hopper. The support cross braces will be
bolted to the outside face of these brackets where applicable. Bolt knee brace to platform
support brackets with 1 5/8” bolt, 1 hex nut, 2 flat washers, and 1 lock washer.
2. Align platform weldments, Item 1, and bolt together with 6 5/8” bolts, 12 flat washers, 6 lock
washers, and 6 nuts per joint. (See Detail A)
3. Bolt front handrails (item 3) to platform weldments with 6 3/8”-16 × 1 1/4 bolts.
Do not tighten. (See Detail C)
4. Bolt end handrails (item 2 and 4) to platform weldments with 6 5/8” bolts, 6 flat washers,
6 lock washers, and 6 nuts per joint. Do not tighten. (See Detail B)
5. Bolt front handrails together with 1 3/8” NC × 5” bolt, 1 3/8”-16 flanged locknut, and 2 3/8” flat
washers. Do not tighten. (See Detail D on next page)
6. Attach each end handrail to the front handrail with 2 corner clamps. Corner clamps are bolted
together with 2 3/8”-16 × 1 1/4 bolts, 4 3/8” flat washers, and 2 3/8”-16 flanged lock nuts.
(See Detail F)
7. Tighten all fasteners.
13
8. Lift platform into position on top of platform support brackets and secure with 5/8” fasteners.
Bolt knee brace to front of platforms and tighten all connections before removing lifting device.
Figure 310.7.1
Parts / Descriptions
1. Modular Platform for Ladder
2. Hand Rail Ass’y, Side
3. Hand Rail Ass’y, Front
4. Hand Rail Ass’y, Side, Ladder
5. Knee Brace Bracket, L.H.
6. Knee Brace Bracket, R.H.
7. Right Arm
8. Left Arm
14
310.8 — Collector Top Access Rails
WARNING
Never attempt to lift
your dust collector by
the top hand rails.
If your collector is supplied with top hand rails, you should find for a drawing similar to
Figure 310.7.1 in your manual that will be specific to your order, detailing each part required.
Installation should not begin on the hand rails until the unit has been fully assembled and set in
place at the job site.
Each part will be tagged per the attached drawing for your collector top rail assembly and a
hardware kit will be provided with correct fasteners to attach your handrail assembly.
Do not attach with thread cutter screws as this may weaken your handrail structure.
Figure 310.8.1
Parts / Descriptions
1. Hand Rail Ass’y w/ Kickplate
2. Hand Rail Ass’y w/ Kickplate
3. Hand Rail Ass’y w/ Ladder
4. Collector Top Access Ladder
5. Handrail Corner Bracket
6. Safety Gate 19” – 211/2”
7. Bolt, HXH 3/8”-16 × 2.0 Zinc
8. Bolt, HXH 3/8”-16 × 4.0 Zinc
9. Nut, LK FLGD 3/8”-16
310.9.1 — Farr Gold Series Integrated Safety Monitoring Filter (iSMF)
15
The GS Integrated HEPA Filter is used down stream from a Farr Gold Series Dust Collector to
provide high efficiency filtration in applications requiring air recirculation. It contains a Camfil APC
XH HEPA Filter that is 99.97% efficient on 0.3 μm Particles. The filter is housed in a Farr Gold
Series frame which bolts directly to the roof of your FGS Collector. The filters are easily replaced
with the Farr Gold Series style access doors and filter seal mechanism.
310.9.2 — Filter Installation / Replacement
1. Disconnect electrical power to the fan and control box. Disconnect compressed air service
from the compressed air header. Bleed all air from the air header. Perform an OSHA approved
lock-out / tag-out procedure on these and any other energy sources. (Refer to Section 100.3
for more information.)
2. Open the access door at the front of the unit, swinging it out of the way.
Left Side
Clamp bar
Right Side
Clamp bar
3. Rotate the left side clamp bar counter clockwise and pull toward you until
it clears the clamp bar latch bracket. Then rotate the clamp bar clockwise
until it resets on the bottom of the HEPA filter module.
4. Rotate the right side clamp bar clockwise and pull toward you until it clears
the clamp bar latch bracket. Then rotate the clamp bar counter clockwise
until it rests on the bottom of the HEPA filter module.
Figure 310.9.2.1
Access
Door
Low Pressure
Tap
High Pressure
Tap
Filter Gasket
1/4” od
Black Tube
5. Pull the first filter out by sliding it off the clamp bar tubes.
6. Pull the second filter out.
Filter
Filter
Spacer
Spacer
Tab
7. Remove a new filter from the shipping carton, taking care not to cut or
otherwise damage the filter. With the gasket side up, place the bottom
edge of the filter on the clamp bar tubes. Push the filter in until it reaches
the Filter Stop at the end of the clamp bar tube.
8. Slide the filter spacer onto the clamp bars, the “tag” must be down (if equipped).
9. Install the second filter, push the filter in until the spacer is tight against the
back filter and the front filter is tight against the spacer.
Magnehelic Gauge
10. To seal the filters, repeat steps 2 and 3 in reverse order. Visually check the gasket to make
sure it is compressed when the clamp bars are latched.
The iSMF system has been certified as a passive flame front arresting device. It meets NFPA
performance based provisions and NFPA 654 and 101 Life Safety Objectives related to dust
collector deflagrations and explosions. According to NFPA 69 Chapter 15, this equipment must be
maintained per the manufacturers recommendations. Substituting filters other than original OEM
filters would violate the NFPA standards and void the performance based certification of this filter
system. Reference Camfil APC’s bulletin for the iSMF for more detailed information.
310.9.3 — Differential Pressure Monitor
A Magnehelic Pressure Monitor must be installed to monitor the differential pressure across the
filters. Locate the 1/8” NPT brass elbow fittings and black 1/4” OD tubing included with the gauge.
Install these fittings into the high and low pressure taps on the HEPA Housing. The high pressure
tap is located near the bottom of the housing and the low pressure tap is located near the top of
the housing. Using the black 1/4” OD tubing connect the low pressure tap in the housing to the low
pressure tap in the gauge and connect the high pressure tap in the housing to the high pressure
tap in the gauge.
Scan to see Farr Gold Series
Instruction Video
Safety Monitoring Filter
16
Section 320 — Attaching Duct Work to Your Farr Gold Series
320.1.1 — Inlet Duct Design (Side View)
This section covers flange details and design guidelines for ducting to your Farr Gold Series dust
collector. When you run ducting to your collector, it is important to follow these guidelines.
1. The straight length of duct entering the inlet should be a minimum of 2 duct diameters.
2. The transition angle from the duct to the inlet flange should be a minimum of 60°.
In figure 320.1.1 the Recommended design shows a vertical section of duct, a 90° elbow and a
horizontal length of a least 2 duct diameters before entering the inlet. The air direction will cause
the dust to be evenly distributed to the filters. In the Not Recommended design, the duct enters
the inlet at an angle. The air direction will force dust already in the hopper (previously pulsed off the
filters), to be re-entrained into the air stream.
Figure 320.1.1
Recommended
17
Not Recommended
320.1.2 — Inlet Duct Design (Top View)
In Figure 320.1.2.1 the Recommended design shows a straight section of duct that is at least 2
duct diameters long, before entering the inlet. The air direction will cause the dust to be evenly
distributed to all of the filters in the collector. In the Not Recommended design, the duct is not long
enough to allow the air to straighten out before entering the inlet. The air direction will force the
dust to one side of the collector, resulting in uneven dust loading on the filters.
Figure 320.1.2.1
Recommended
Not Recommended
18
320.2 — Inlet Flanges
Depending on the size and orientation of your Farr Gold Series collector, the inlet will have one or
more of three inlet designs. These inlets are configured and classified with the number of modules
that the collector uses to support the inlet plenum. Larger collectors may have more than one inlet
plenum and vary in the size of the inlet. Figure 320.2.1 shows dimensions of the one, two, and
three module inlets, respectively. When attaching duct work to these flanges always be sure to
caulk or place gasket material between the duct and collector before bolting them together.
Figure 320.2.1
Units are inches; bolt holes are 3/8”-16 NC
Single Module Inlet
Double Module Inlet
Triple Module Inlet
19
Units are inches; bolt holes are 3/8”-16 NC
Figure 320.2.2
Single Inlet Flange Drop-Out Module
Double Inlet Flange Drop-Out Module
Triple Inlet Flange Drop-Out Module
20
Figure 320.2.3
Units are inches; bolt holes are 3/8”-16 NC
Side Outlet Flange
Top Outlet Flange
21
Side Outlet Panel (Half)
Top Outlet Flange (Half)
Units are inches; bolt holes are 3/8”-16 NC
Figure 320.2.4
Top Outlet Double
Top Outlet Triple
22
320.3 — Remote Mount Fan Discharges
Remote mount fans provided by Camfil APC will be ducted to the collector by removing one
or multiple upper panels and attaching the duct work to the frame of the Farr Gold Series dust
collector. The duct work will be attached to the flange details on Figures 320.2.1 through 320.2.4.
These dimensions are the bolt patterns for the panel and frames. The side panels on the upper
section of the dust collector or top panels can be removed. The bolt pattern for the full sized side
panel and half sized side panels are in Figure 320.2.3, as well as the full and half sized top panels.
When attaching duct work to these flanges, always be sure to caulk or place gasket between the
duct and collector before bolting them together.
320.4 — Top Mount Fan Discharges
Top mount fans, provided by Camfil APC, are field mounted on the top of the Farr Gold Series
collector. All Camfil APC provided fans will have a fan damper supplied with the fan. When attaching
duct work to this flange, always be sure to caulk or place gasket between the duct and damper
outlet before bolting them together.
320.5 — Discharge Hopper Flange
Accessories will be attached to the hopper discharge flange. See your Camfil APC Team Site for
general dimensions drawing for the dimensions for your flange.
23
Section 330 — Field Utility Connections
Figure 330.1
24
WARNING!
330.1 — Motor Connections
Follow all Lock-out/
Tag-out procedures
before you make
these or any other
electrical connections.
Failure to do so can
result in property
damage, personal
injury, or death. Make
sure the circuit you
are working with is off
before you start. Only
a qualified electrician
should make these
connections. (See
Sect. 100.3)
Camfil APC can supply the fan, motor starter, and rotary air locks (or other discharge devices)
for our dust collectors. However, the customer or Camfil APC representative may elect to supply
the fan and other accessories. It is imperative that all equipment installed complies with your
local electrical code. Check your paper work and information plates to determine electrical
specifications for your equipment.
Mount the motor starter enclosure in a convenient location for operation. Use the enclosure as a
template for marking and drilling mounting holes. Possible locations include a support leg or plant
wall near the collector. Camfil APC recommends using J-style current limiting fuses sized at 150%
full load amperes of motor nameplate data. Consult National Electronic Code and all local codes
for proper sizing.
Fans provided by Camfil APC are designed for continuous duty. We recommend that the fans
not be cycled on/off more that two times per hour. Excessive cycling of the fans will result in
premature failure of the fan, fan motor, or motor starter. This can also void any warranty claims on
these items.
330.2 — Timer Control
This discussion refers to standard equipment that uses 120/220 VAC, single phase, 50/60 Hz
power. Refer to your General Dimensions drawing to confirm the electrical requirements of your
equipment. Connection instructions are the same regardless of the voltage source. Refer to the
documentation attached to this manual and the timer control box for further information regarding
the installation of your specific control.
If equipped, mount the Automatic Timer Control on a wall or stand close to the collector. It is
important to mount the timer near the collector so that you can monitor the performance. Keep
in mind that both pressure gage and electrical connections need to be made to the timer control.
Note: Do not mount the timer control to the dust collector side panels! Vibration from the pulse jets
may damage the sensitive electronic equipment.
330.3 — Solenoids
The solenoid cover is removed by loosening the two brass Phillips head screws on the bottom of
the housing. (The screws have a retaining ring on them and will not fall out.) The cover can then
be removed by lifting straight up. To wire your solenoids, follow Figures 330.3.1. Each solenoid
will have two wires attached – one specific for the numbered row of cartridges and a second wire
that will be attached to all of the solenoids (called the Common). The Common is factory pre-wired
on the solenoids, therefore only one connection will need to be made. Once the solenoid has been
wired, the corresponding wires will then be attached to the control board as shown in Section 400.
The Common will share a terminal with the L2 terminal (120 volt “return” power line). Solenoids can
be manually tested by inserting a small screw driver or paper clip into the bottom of the solenoid
and pushing upwards. This opens the solenoid valve port, causing the diaphragm valve to pulse.
For more information on the diaphragm and solenoids see the attached specification sheets.
25
Table 330.3.2 shows the number of solenoids and automatic timer controller outputs for the
standard Farr Gold Series models. For GS2 through GS60 models, there are at least as many
timer outputs as there are solenoids. Each timer output connects to an individual solenoid. For
GS72 through GS120 models, there are more solenoids than timer outputs.
Figure 330.3.1
Attach common wire to either end
of the pre-wired common terminals
Attach numbered hot (load) wired from
controller to corresponding solenoid
Table 330.3.2
Farr Gold Series Timer Requirements
# of Timer Outputs
# of Solenoids
/ Diaphragms
Dwyer
Determinator
T4 & P4
Double Timer
Outputs
GS2
2
6
10
10
N
GS4
4
6
10
10
N
GS6
6
6
10
10
N
GS8
4
6
10
10
N
GS10
5
6
10
10
N
GS12
6
6
10
10
N
GS16L
8
10
10
10
N
GS16SQ
4
10
10
10
N
GS20
5
10
10
10
N
GS24
6
10
10
10
N
GS32
8
10
10
10
N
GS36
12
22
20
20
N
GS48
16
22
20
20
N
GS60
20
22
20
20
N
GS72
24
22
20
20
Y
GS84
28
22
20
20
Y
GS96
32
22
20
20
Y
GS108
36
22
20
20
Y
GS120
40
22
20
20
Y
Model
NOTE
On models GS48
to GS120, multiple
headers (compressed
air reservoir) are
used. Some timer
outputs are connected
to two solenoids
each. Do not connect
a doubled timer
output to diaphragm
valves on the same
header; connect the
doubled up timer
outputs to valves on
separate headers.
26
Figure 330.3.3
27
330.4 — Solenoid Heaters
WARNING!
If your collector is equipped with a solenoid heater, it will need to be wired at the job site. First,
turn off the power to the control panel, following lock out/tag out procedures. Locate the solenoid
enclosure, typically located above the air reservoir. Remove the cover by loosening the two Phillips
head screws on the bottom of the box. You will see a small trough and mounting holes directly behind
the solenoids. Place the heater element in the trough and secure with mounting clip provided. Install
and wire the thermostat using the screws provided as shown in Figure 330.4.1.
Follow all Lock-out/
Tag-out procedures
before you make
these or any other
electrical connections.
Failure to do so can
result in property
damage, personal
injury, or death. Make
sure the circuit you
are working with is off
before you start. Only
a qualified electrician
should make these
connections. (See
Sect. 100.3)
The heater can be wired to the 110V power supply for the standard Camfil APC FDC controller, but it
must not be wired from the timer board. (The heater is rated at 100 watts.)
Newer heating elements have the thermostat built into the heater and voltage is supplied direction to
the two wires on the element. They mount the same as the old thermostats. See Figure 330.4.2.
Figure 330.4.1
Parts / Descriptions
1. Heater Retaining Clip
2. Heater Element
3. Wiring Terminal Block
4. Thermostat Element
Figure 330.4.2
28
330.5.1 — Collector Timer Control Connections
Your collector is equipped with a Control Timer or Magnehelic gauge, which monitors the
differential pressure inside the collector. Locate the two 1/8” elbow fittings in the control package.
Install the elbow fittings in the factory supplied 1/8” NPT pressure taps in the upper and lower
end panels of the collector. See detail below for typical location of the ports. These ports will be
labeled “Dirty Air / High Pressure” and “Clean Air / Low Pressure”.
The factory supplies two 1/4” black polylines for the differential pressure connections. These line
are labeled to match the pressure taps on the collector. In like manner, the polyline fittings on the
bottom of the Collector Timer Control provided by Camfil APC are labeled in the same manner.
Simply connect the “Dirty Air / High Pressure” and the “Clean Air / Low Pressure ports on the
collector to the same ports on the Timer Control, using matching polylines.
If your collector is supplied with a Magnehelic gauge, those ports are labeled “High Pressure” and
“Low Pressure”. Otherwise, installation is the same as the Timer Controller connections.
Figure 330.5.1.1
330.5.2 — Integrated Safety Monitoring Filter - iSMF
If your collector is supplied with an Integrated Safety Monitoring Filter, iSMF, it will be provided
with a Magnehelic gauge kit. The installation procedures are identical to the instructions for the
Collector Timer Control Connections above with only one exception. The ports on the iSMF will be
labeled “iSMF Dirty Air / High Pressure” and iSMF Clean Air / Low Pressure”. The polylines will be
connected to the magnehelic gauge as noted above.
29
330.6 — Compressed Air Connection
NOTE
Supply the header (compressed air reservoir) with clean, dry compressed air between 90 and 105
psi. Oil or water in the compressed air lines will cause the filter media to fail. The airline should be
equipped with a manual shut-off valve, a filter/separator, an air regulator and a pressure gauge,
all located close to the unit. Camfil APC recommends that the compressed air supply be kept at
a dew point of -40 F. Make provisions for draining any condensation from the air reservoir with an
automatic tank drain or by other means.
See Figure 310.9.1.1
for an additional detail
of the Collector &
iSMF Assembly.
Total air consumption is variable and is dependent on the type and concentration levels of airborne
dust and the set points used for determining the cleaning cycle. See Table 330.6.1 for your
compressed air volume requirement. All air consumptions table calculations based on SCFM.
WARNING!
Connect your supply line to the 1” NPT coupling on either side of the header (¾” minimum air
supply line for GS2 – GS10, 1” supply line for anything larger than a GS10).
1. Slowly open the shut-off valve, allowing pressure to build in the tank.
2. When the header has reached full line pressure of 90 to 105 psi, close the shut-off valve.
3. Inspect the header, valves, fittings and solenoid valves for air leaks.
4. Tighten all fittings and clamps as required.
5. Re-open the air shut-off valve.
Farr Gold Series Air Consumption
Follow all Lock-out/
Tag-out procedures
before you make
these or any other
electrical connections.
Failure to do so can
result in property
damage, personal
injury, or death. Make
sure the circuit you
are working with is off
before you start. Only
a qualified electrician
should make these
connections. (See
Sect. 100.3)
(90–105 PSI Recommended)
GS2 – GS6
GS8 – GS48,
GS60
GS48L, GS56,
GS64 – GS120
Diaphragm Valve Size
1”
1½”
1½”
On Time (milliseconds)
150
150
150
Figure 330.6.1
Off Time (seconds)
Compressed Air Consumption (ft3/min.)
5
31.8
72.0
144.0
10
15.9
36.0
72.0
15
10.6
24.0
48.0
20
8.0
18.0
36.0
25
6.4
14.4
28.8
30
5.3
12.0
24.0
35
4.5
10.3
20.6
40
4.0
9.0
18.0
45
3.5
8.0
16.0
50
3.2
7.2
14.4
55
2.9
6.5
13.1
60
2.7
6.0
12.0
30
330.7 — Sprinkler Connections
NOTE
If you are supplying
more than one
sprinkler connection
coupling with a
single supply pipe,
the supply pipe
must be sized to
accommodate
the required flow
rate. Check local
codes and NFPA for
requirements.
If your collector is equipped with a sprinkler system, locate the sprinkler connection coupling(s).
Refer to the General Dimensions drawing for locations.
Figure 330.7.1 shows a side wall sprinkler head system. A single 1/2” orifice sprinkler head is
installed into a GS sprinkler flange. The sprinkler flange assembly is bolted to a lower side panel.
This assembly can be removed to replace the sprinkler head. There is one pipe connection for
each sprinkler head. Refer to Table 330.7.2 to determine the water flow rate and the size and
number of couplings required for your system.
Apply Teflon tape to the supply pipe and connect it to the sprinkler connection coupling(s).
Turn on water supply and inspect all connections for leaks.
Figure 330.7.1
Table 330.7.2
31
Model
# of Sprinklers
Flow Rate per Head
(gal/min)
Connection Size
GS2 – GS6
1
½” NPT
GS8, GS10, GS12, GS16, GS20
2
½” NPT each
GS12L, GS24
3
GS30, GS32, GS36
4
GS40, GS48, GS60
6
Single 1½” NPT
GS56 – GS120
8
Single 1½” NPT
* k factor for sprinklers is 5.6 gal/min per psi.5.
Pw = water pressure (psi) at sprinkler
See Figure 330.7.1 for GS2 – GS24 Sprinkler Instructions
See Figure 330.7.3 for GS32 – GS120 Sprinkler Instructions
5.6 Pw.5 each*
½” NPT each
Single 1½” NPT
Figure 330.7.3 shows an internal sprinkler system, which is used on large GS collectors. All sprinkler
heads are supplied through a single coupling, welded near the bottom of a lower side panel.
NOTE
Water leaks in the
collector will cause
cartridge failure and
hopper flow problems.
Figure 330.6.1
Sprinkler Connection
Coupling
SPRINKLER
CONNECTION
(See Table 330.7.2
for connection
COUPLING
(SEE TABLE
330.6.2
quantity
and size.)
FOR
CONNECTIONS
SIZE AND
NUMBER OF CONNECTIONS.
Sprinkler HeadHEAD (SEE TABLE
SPRINKLER
(See TableFOR
330.7.2
for quantity.)
330.6.2
QUANTITY)
32
Section 340 — Explosion Vents
Many common dusts used or generated by industrial processes are combustible. Solid particles
smaller than 420 μm (capable of passing through a U.S. No 40 standard sieve) are classified as
dusts. Special precautions should be taken to protect against injury, loss of life, and property
damage when conveying, collecting and processing explosive dusts. The National Fire Protection
Agency (NFPA) provides comprehensive guidelines for dealing with explosive dusts. Following
is a list of publications that are highly recommended by Camfil APC for use in determining if the
installation of your dust collection system meets all of the NFPA recommendations with regards to
conveying, collecting and processing explosive dusts.
•
NFPA 654
Standard for the Prevention of Fire and Dust Explosions from the Manufacturing,
Processing, and handling of Combustible Particulate Solids
•
NFPA 69
Standard on Explosion Prevention Systems
•
NFPA 68
Guide for Venting of Deflagrations
•
NFPA 664
Standard for the Prevention of Fires and Explosion in Wood Processing and
Woodworking Facilities
•
NFPA 651
Standard for the Machining and Finishing of Aluminum and the Production and
Handling of Aluminum Powders
•
NFPA 77
Recommended Practice on Static Electricity
This is not a complete comprehensive list of NFPA publications that may apply to your application
and NFPA publications sited in these publications should also be referenced when applicable.
340.1 — Concerning Explosion Vents
Camfil APC provides dust collectors that constitute only one component of a complete dust
collection system. In many cases the installation of an explosion vent on the dust collector is
insufficient in meeting the current NFPA recommendations. NFPA 654 states “Systems that handle
combustible particulate solids shall be designed by and installed under the supervision of qualified
engineers who are knowledgeable of these systems and their associated hazards”. The complete
dust collection system should be designed in a manner that conforms to the NFPA standards
and recommendations in order to minimize the risks associated with a deflagration. Camfil APC
does not participate in the design of the dust collection system and makes no guarantee that
the inclusion of an explosion vent on the dust collector will satisfy the requirements of the NFPA
recommendations.
The following is a list of safety precautions that have been paraphrased from the referenced NFPA
publications. These are provided to you solely for the purpose of demonstrating some of the
conditions that NFPA recommends when dealing with explosive dusts. The inclusion of this list in
this manual does not relieve the owner/operator of the responsibility to assure that the complete
system is designed and installed in accordance with the NFPA standards and recommendations.
33
340.2 — General Explosion Vent Guidelines
•
It is important to note that venting does not prevent a deflagration. Venting can, however,
minimize the destructive effects of a deflagration.
•
Refer to NFPA 654 Standard for design requirements for the complete dust collection system.
•
Systems that handle combustible particulate solids shall be designed by and installed under
the supervision of qualified engineers who are knowledgeable of these systems and their
associated hazards.
•
Several methods are available for the design of explosion protection for equipment. Explosion
venting is one acceptable method and can be combined with others. See NFPA 68, Section 3.1.1
•
Where an explosion hazard exists, isolation devices shall be provided to prevent deflagration
propagation from air–material separators upstream to the work areas. Isolation devices
include, but are not limited to, those listed in NFPA 654 section 3.1.3.1 §1 through §5.
•
The choice of the most effective and reliable means for explosion control should be based
on an evaluation that includes the specific conditions of the hazard and the objectives of
protection. Venting of deflagrations only minimizes the damage that results from combustion.
•
Substances other than oxygen can act as oxidants. NFPA 68 vent calculations apply only
where the oxygen in air is the only oxidant. If chemical oxidants are present as either
solid particulate or gas then explosion suppression and isolation equipment is required as
recommended in NFPA 69.
•
Situations can occur in which it is not possible to provide calculated deflagration venting
as described in NFPA 68. Such situations do not justify the exclusion of all venting. The
maximum practical amount of venting should be provided, since some venting should reduce
the damage potential. In addition, consideration should be given to other protection and
prevention methods.
•
It is not possible to successfully vent a detonation.
340.3 — Explosive Dusts
Solid particulates smaller than 420 μm (0.017 in) capable of passing through a U.S. No. 40 standard
(sieve) are classified as dusts. The fineness of a particular dust is characterized by particle size
distribution. The maximum pressure and Kst increase with a decrease in the dust particle size.
The combustion properties of a dust depend on its chemical and physical characteristics. The
use of published dust flammability data can result in an inadequate vent design if the dust being
processed has a smaller mean particle size than the dust for which data are available, or if other
combustion properties of the dust differ. Particle shape is also a consideration in the deflagration
properties of a dust. The flammability characteristics of a particular dust should be verified by test.
(See NFPA 68 Section B-5.)
34
340.4 — Explosion Vent Operation
•
Venting is one means of limiting the pressure generated in an enclosure by a deflagration. By
releasing expanding gases through an opening engineered for the purpose, it is possible to
limit the pressure generated to a reduced maximum pressure, Pred, that is below a pressure
that can cause unacceptable damage to the enclosure.
•
An explosion vent is a pressure-relieving device designed to open at a specific pressure
to reduce the maximum pressure rise during a deflagration in an enclosed vessel to an
acceptable level.
•
Vent closures shall be directed toward a restricted area, and the vent closure shall not be a
missile hazard.
•
Vents are provided on an enclosure to limit pressure development, Pred, to a level acceptable
to the user and the authority having jurisdiction. The level of pressure development can be
considered acceptable where no damage to the enclosure is likely, or where some degree of
permanent deformation is tolerable.
•
Shields that deflect the gas and pressure waves exiting a vent during a deflagration are not permitted.
•
Vents should function dependably. Closures should not be hindered by deposits of snow, ice,
paint, corrosion, or debris, or by the buildup of deposits on their inside surfaces. Closures
should not be bonded to the enclosure by accumulations of paint. The materials that are used
should be chosen to minimize corrosion. Clear space should be maintained on both sides of a
vent to enable operation without restriction and without impeding a free flow through the vent.
•
Vent closures should be maintained in accordance with Chapter 10 of NFPA 68 and the
manufacturers’ recommendations. The occupant of the property in which the deflagration vent
closures are located is responsible for inspecting and maintaining such devices.
•
The vent opening should be free and clear and should not be impeded. If the vent discharges
into a congested area, the pressure inside the vented enclosure increases. A major blast
pressure can be caused by the ignition of unburned gases or dusts outside the enclosure.
•
Appropriate signs should be posted to provide warning as to the location of a vent. Replacement
decals are available from Camfil APC and are listed in the spare parts section of this manual.
•
A vent closure should be inspected and properly maintained in order to ensure dependable
operation. In some cases, ensuring dependable operation can necessitate replacing a vent closure.
340.5 — Location of Vents and Vented Equipment
35
•
The fireball and blast pressure that are created by the venting process shall not impinge upon
unrestricted personnel pathways. Where an explosion hazard exists, dust collectors shall be
located outside of buildings. Exceptions include isolation and suppression systems as listed in
NFPA 654 Section 3.1.1
•
Flames and pressure waves that emerge from an enclosure during the venting process can
injure personnel, ignite other combustibles in the vicinity, result in ensuing fires or secondary
explosions, and result in pressure damage to adjacent buildings or equipment
•
Deflagration vents should not be located in positions that allow the vented material to be
picked up by air intakes.
•
The material discharged from an enclosure during the venting of a deflagration should be
directed outside to a safe location. Property damage and injury to personnel due to material
ejection during venting can be minimized or avoided by locating vented equipment outside
buildings and away from normally occupied areas. (See NFPA 68 Section 3.2.3.)
340.6 — Ignition Sources
•
Some types of ignition sources include electric (arcs, sparks, and electrostatic discharges),
mechanical (friction, grinding, and impact), hot surfaces (overheated bearings), and flames
(welding torches, and so forth).
340.7 — Vent Discharge Ducts
•
If a dust collector is located inside a building it should be located near an external wall and the
exhaust from the vent ducted to the outside.
•
The addition of a vent discharge duct can substantially increase the pressure developed
in a vented enclosure. (See NFPA 68 Section 5.4.) Sizing of the vent should take this into
consideration.
•
Ducts that are used to direct vented gases from the vent to the outside of a building should be of
noncombustible construction and should be strong enough to withstand the expected Pred. Ducts
should be as short as possible and should not have any bends. (See NFPA 68 Section 5.2.9.)
•
The duct length must be calculated per NFPA Guidelines if it extends beyond the Hydraulic
Diameter of the Vent and must not interfere with the operation of the vent.
•
Bird screens or weather hoods must be low restriction and their affect should be taken into
consideration when sizing the vent area.
340.8 — Vent Inspection and Maintenance
•
Camfil APC incorporates rupture diaphragm style explosion vents on their dust collectors.
Explosion vents should be inspected every three months. The inspection and maintenance
points are outlined below.
•
Remove obstructions such as snow, ice, dust inside and out if present, with equipment not running.
•
Replace safety decals if missing or illegible.
•
Tighten and replace bolts if missing.
•
Area around vent is free and clear of obstructions.
•
Check that flammable materials are not stored near the vent.
•
Rupture diaphragms have no moving parts and should be inspected for tears rips or cracks,
replace if present.
36
IMPORTANT
Camfil APC changed
their filter top pans
in October of 2012.
The filter removal tool
is used differently for
the different top pans.
The tool hooks on the
top of the older filters
with round gaskets
(see Figure 350.0.2).
For the new filters
with a square gasket
pattern the extraction
hook fits into the hand
hold on the bottom
of the top pan (see
Figure 350.0.3).
Section 350 — Filter Installation and Replacement
New units may ship with filter cartridges installed. We have many types of replacement filters
available for a wide range of applications. Refer to Section 700 — Replacement Parts List for
replacement filter and various parts identification. Care should be taken to make sure the correct
Camfil APC original equipment replacement filters are used to insure continued satisfactory
performance of the unit. For genuine Camfil APC replacement parts call 800-479-6801.
1. Disconnect electrical power to the fan and control box. Disconnect compressed air service
from the compressed air header. Bleed all air from the air header. Perform an OSHA approved
lock-out/tag-out procedure on these and any other energy sources.
(Refer to Section 100.3 of this manual for more information).
2. Open the access doors at the front of the unit, swinging them out of the way.
3. Unlatch the clamp bars as shown in Figure 350.0.1 below. With your left hand, rotate the right
clamp bar up and pull it toward you, until its locking tab clears the rectangular cut-out on the
left clamp bar. With your right hand, rotate the left clamp bar up and push it away from you
until its locking tab clears the rectangular cut-out on the right clamp bar. Rotate both clamp
bars down until they are vertical and clear of the cartridge extraction path.
4. Remove all dirty filter cartridges by sliding them off the clamp bar channels. Clean the
surface of the tube sheet in the areas where the filter gasket forms a seal. To reach the inside
cartridges Camfil APC provides a telescoping extraction pole with a hook on the end.
5. Remove a new cartridge from the shipping carton, taking care not to cut or otherwise damage
the filter media. Make sure the clamp bar handles are fully opened and will not interfere with
the cartridge during installation (see Figure 350.0.4 on next page). Grasp the new cartridge
by the top metal pan and set it onto the clamp bar channels. Holding the cartridge level, slide
it forward, pushing on the cartridge pan, do not push the media, taking care not to drag the
gasket along the tube sheet. Push the cartridge in just far enough to leave room for the next
cartridge to rest on the clamp bar channels. Repeat steps 4 and 5 until the row is full.
6. To seal the new cartridges, repeat the instructions in Step 3 in reverse order. With your left hand,
rotate the left clamp bar counterclockwise or up to between 80° and 90°. While pushing the left
clamp bar away from you, rotate the right clamp bar clockwise or up, with your right hand. Insert
the locking tab on the left clamp bar when it lines up with the rectangular cut-out on the right clamp
bar. Release the left clamp bar. With both hands rotate the right clamp bar clockwise or up and
pull it toward you, until the locking tab inserts into the rectangular cut-out on the left clamp bar (see
Figure 350.0.2 on next page). The clamp bars must be bent slightly if the locking tabs do not stay
inserted in the rectangular cutouts.
7. Repeat steps 3 through 6 until all the rows of cartridges are changed.
Figure 350.0.1
37
Scan to see Farr Gold Series
Instruction Video
Filter Change-Out
Figure 350.0.2 (left)
Figure 350.0.3 (right)
Filter extraction with hook on top of pan for
obsolete round gasket filters.
Filter extraction with hook in hand hole on
bottom of the ban for new square gasket filters.
Figure 350.0.4
350.1 — Clean Seal Filter Upgrade
The enhanced Gold Cone top pan features gaskets placed at the edge of the pan to prevent dust
from accumulating on the top. Now you simply place the hook in the recess located below the
pan. Do not hook the filter from the top of the pan. Place the new cartridge extraction pole sticker
directly over the old sticker on your Gold Series. If you have not received the new sticker or do
not have a cartridge extraction pole for your Gold Series industrial dust collector, please call the
number below for either one to be sent to you.
Do not attempt to hook
the filter cartridge from the
gasket on top of the pan as
the gasket will be damaged.
When using the cartridge
extraction pole to remove the
filter cartridges from the Gold
Series, be sure to hook each
cartridge in the recess below
the pan, as shown.
Use a brush to clean off the
dust collector seal area due
to the gaskets moving out to
the edges of the pan.
38
Section 360 — Precoating of Filters
In applications where the dust concentration is high and/or the dust particles are large (more than
0.5 μm), pre-coating of the filters is not required. In applications where the dust concentration is
low and/or the dust particles are small (less than 0.5 μm), pre-coating will result in a higher initial
efficiency and extended filter life. Maximum efficiency of the filter is not achieved until a dust
cake is formed on the media, which may take weeks without pre-coating. By applying a suitable
precoat dust, maximum efficiency can be attained in a few hours. This is desirable if the air is to
be recirculated through Safety Monitoring Filters (SMF), or if the dust is toxic. Also, if the collected
dust contains a considerable content of hydrocarbons or similar substances, the life of the filters
can be greatly increased by pre-coating.
360.1 — Pre-Coating Procedure
Table 360.1.1
Precoat Data
Model
Amount (lbs)
Perilite
Limestone
GS2
4
18
GS4
8
36
GS6
12
54
GS8
16
72
GS10
20
90
GS12
24
108
GS16
32
144
GS20
40
180
GS24
48
216
GS36
72
324
GS48
96
432
1. Ensure the filter cartridges are correctly installed. If using overbags, make sure they are not
installed at this time.
2. Install a clean, empty discharge container under the unit.
3. If a Safety Monitoring Filter (SMF) is installed, filters must first be removed from the system.
4. Disable the dust collector so that it does not pulse while the pre-coat is being applied. This
can be done by shutting off the compressed air and bleeding the compressed air reservoir or
turning off the power to the timer control.
5. Weigh out the appropriate amount of pre-coat dust according to Table 360.1.1.
6. Start the collector and feed the pre-coat dust into the collector. The dust can be fed into any suction
hood in the duct system. Should access not be easy through the duct system, the container under
the discharge can be removed allowing precoat to be fed through the hopper discharge.
7. Dust will be observed from the fan outlet. This is normal and should stop when all the pre-coat
dust is applied.
8. When all the dust has been applied, collect the dust from the discharge container and repeat
the above procedure.
9. Record the Magnehelic gauge reading and set the fan damper to correspond to the system
design airflow. Airflow can be measured by means of a Pitot tube, anemometer or similar device.
10. If using overbags, install them at this time.
11. Remove any remaining pre-coat dust from the outlet ducting, SMF housing and discharge
container. Discard according to local codes and procedures.
12. Re-enable the collector by either opening the compressed air line or turning on the power to
the timer control (see step 4). Do not pulse on continuous.
13. The system is now ready for operation.
39
Section 370 — Glide Pack / Riga Flo SMF Installation
Figure 370.3.1.1
370.1 — Transitioning: Top Mounting Arrangement
If a small unit (up to 1 high × 3 wide), a transition plate and air diffuser are supplied on the
air entering side of the filter housing. Typically this plate is supplied with the cutout to match
the blower or silencer opening with bolts attached. Apply rope caulk to the surface of contact,
between the opening and the bolt pattern. Remove bolts from the plate, line up bolt pattern of the
plate with the pattern of the silencer or blower. Assemble. If SMF assembly extends off of your
Farr Gold Series unit, supports should be added, either from ceiling or from the floor.
If a larger unit (1 high × 4 wide or larger) an actual transition will be supplied (optional) or supplied
by others is to be used. These typically will have diffusers built into them. These type transitions
will bolt directly from the blower or silencer to the actual SMF housing. Rope caulk or silicone is to
be used on each flange joint to seal the assembly.
370.2 — Remote Mounting Arrangement
All transitioning and ducting for this is supplied by others.
Figure 370.3.2.1
370.3.1 — Filter Assembly: Prefilter
Prefilter(s) 2” deep are supplied with your unit. This is to be installed as shown in Figure 370.3.1.1.
A metal “V” spacer is provided with every housing. This is to be installed (1 per) each individual
filter row. Assemble between the last filter and the door gasket. The open part of this spacer
should be facing the air entering or upstream side.
370.3.2 — Final Filter Holding Frame and Clips
The Holding Frame is located inside of the filter housing. Remove from housing. Procure Holding
Clips (PN – 114353000) Assemble to Holding Frame as shown in Figure 370.3.2.1 and
Figure 370.3.2.2. Assemble 4 clips per frame.
370.3.3 — Final Filter Assembly
Remove final filter from box (PN – 402994003). On the downstream face of the filter flanges there
are (4) small holes. Align filter so these holes line up with the hook end of the clips. Install filter with
the Air Flow Arrow pointing away from the holding frame. Pull spring clips out and latch hook part
into the holes of the filter flange. Install back into housing.
Figure 370.3.2.1
370.3.4 — Magnehelic Gage and Accessory Kit
Your SMF system includes a 0 – 4” gage and installation kit. Refer to the Accessory Kit instructions
for assembly. A port is supplied on the top of this unit for the gage connection.
40
370.4.1 — Magna Pac / Hepa Filter SMF Installation: Transitioning
Applies same as the Glide Pac / Riga Flo SMF. Insure all flange joints are sealed with either rope
caulk or silicone.
370.4.2 — Filter Assembly: Prefilter
Figure 370.4.2.1
This filter should be installed in the 2” wide track on the air entering or upstream side of the
housing. See Figure 370.4.2.1. A channel shaped spacer is supplied with your housing. Once
prefilter is installed, this spacer is to be installed in the track between the prefilter and the door
gasket.
370.4.3 — Final Filter
Carefully remove from box, from the sides of the filter. Do not reach for either face of the filter, as
this could cause damage to the filter media. Remove filter from plastic bag. Visually inspect both
faces of the filter, looking for any damage to either face. Once inspected, located Air Flow Arrow,
insuring the arrow is pointing downstream or towards the gasket. See Figure 370.4.3.1. Carefully
pick up the filter from the sides once again, lifting into the housing. Air Flow Arrow and gasket
should be pointing away from the prefilter or downstream. Place filter in each opening between the
welded channels with the gasket going against this surface of the housing. See Figure 370.4.3.2.
NOTE
On housings with two
high or more filter
housings, filters will
stack directly on the
filters below.
Procure Swing Bolts (PN – 063159002), Filter Hook (PN – 063343000) and 5/16-18 Hex Nut
(PN - 214946002). Assemble as shown in Figure 370.4.3.3. This will be typical four places for
each HEPA Filter installed. Hook end of the swing bolt will go into the first hole closest to the
downstream housing surface. See Figure 370.4.3.4. Tighten all four swing bolts to approximately
50% compression of the gasket with 30 in./lbs of torque.
370.4.4 — Magnehelic Gage and Accessory Kit
Your SMF system includes a 0-4” gage and installation kit. A ¼” NPT port is supplied on the top of
the unit. This is intended to do DOP injection for filter and seal testing. It can be used for the gage
kit, but not recommended. A penetration in the housing or duct work should be made for the gage
connections. Refer to the Accessory Kit instructions.
41
Figure 370.4.3.1
Figure 370.4.3.2
Figure 370.4.3.3
Figure 370.4.3.4
Section 380 — Overbag Assembly
If your application requires cartridge overbags your initial set of filters with your collector will
already have these installed. This instruction is for replacement cartridges. If your filters require
precoating, do this operation before assembly your new overbags.
This operation is much easier with two people performing the assembly. Remove filter cartridges
from the box. With one person holding the filter up by the top pan, the other person slips the
overbag up over the outside of the cartridge with the bungee/felt end first.
See Figure 380.1 and Figure 380.2.
Figure 380.1 (left)
Figure 380.2 (right)
Once bag is pulled to the underside of the pan, insert cable tie (included with the bag) through
the two bungee loops and tighten until loops are touching. Snip excess cable tie material off. See
Figures 380.3 and 380.4. Ensure that bungee rests against the felt and bag is tight to the bottom
of the pan. Assembly is complete.
Figure 380.3 (left)
Figure 380.4 (right)
42
Scan to see Farr Gold Series
Instruction Video
Filter Change-Out
Section 400 — Operation of Your Equipment
Camfil APC has prepared this proprietary user’s manual for the exclusive use of its customers. The
recommendations contained herein are based on proven techniques and on test data believed to be
reliable. It is intended that personnel having specialized training in accordance with currently accepted
practice and normal operating conditions use this manual. Variations in environment, changes in
operating procedures or extrapolation of data, may cause unsatisfactory results. Since Camfil APC
has no control over the conditions of service, it expressly disclaims responsibility for the results
obtained or for any consequential or incidental damages of any kind incurred.
The Farr Gold Series dust collector described in this manual is designed for the collection of welding
fumes and/or the capture of airborne particles generated from mixing, sanding, grinding and cutting
operations involving wood, metal, fiberglass, plastics, advanced composites or similar materials.
NOTE
Use caution when
working near an
operating collector.
Wear appropriate ear
and eye protection.
Hearing damage can
result from high noise
levels generated
during filter cleaning
or “pulsing” and
collected debris,
near the diaphragm
valve discharge, may
become a projectile,
creating the potential
for eye injury. Do not
operate with access
doors open! See
Section 100.3.
400.1 — System Operation
Incoming dust-laden air enters the inlet plenum where a baffle forces large or heavy particles to
drop out of the air stream and fall into the hopper. The clean air passes through the filter media
from the outside to the inside of the filter cartridge and exits through the open top of each filter
cartridge. The air then flows from the filters into the clean-air plenum, where it enters the fan inlet
and is exhausted. The dust is captured on the outside surface of the filter media.
The filter media can be made of several different fabrics
and materials depending on the application. However, the
high efficiency of these cartridges is due to the dust layer
or “cake” formed on the surfaces of the media. The media
primarily provides a surface on which dust particles collect
a combination of these mechanisms results in formation
of the dust cake on the filter and eventually increases
the resistance to air flow. The filter must be cleaned
periodically. A balance must be maintained between having
some dust cake formation to improve efficiency and an
acceptable increase in pressure drop. A timer controller or
Magnehelic gauge, monitoring the differential pressure (DP)
and pulsing accordingly, can maintain the dust cake with
minimal increase in pressure. By pre-coating your filter with
a special dust at start-up, you can increase initial efficiency
of your collector (see Section 360 – Precoating of Filters).
Clean, filtered air rises from the center of the Gold Cone
cartridge, through the clean air plenum and into the fan,
where it is exhausted. Dust laden air enters the inlet of the
collector. The baffle forces large or heavy particles to drop
into the hopper. Dust collected on the cartridges drops into
the hopper and is collected in a discharge device.
43
400.2 — Cleaning Filters
Figure 400.2.1
The Gold Cone cartridge elements are sequentially cleaned by back flushing with air. This
momentary airflow reversal is induced by a short burst of compressed air. The air is released
from the compressed air reservoir by a fast-acting, high-flow diaphragm valve. This “pulse” of air
dislodges the accumulated dust from the filter element. The dislodged dust then drops into the
hopper or collection drawers. Each pulse cleans a series of filter cartridges leaving the remaining
cartridges available to continue filtering the ventilation air. This allows the cleaning to take place
without the need to stop the ventilation system. Figure 400.2.1 shows a Gold Cone cartridge in
normal operation. Figure 400.3.1 demonstrates the pulse of compressed air cleaning a cartridge.
400.3.1 — Cleaning Components: Header (Compressed Air Pressure Reservoir)
A header is provided with a 1 in. NPT coupling at each end. Supply the header with clean, dry
compressed air between 90 and 105 psi. The air supply line should be equipped with a manual
shut-off valve, a filter/separator, an air regulator and a pressure gauge, all located near the unit.
400.3.2 — Solenoid/Diaphragm Valves
Solenoid-operated valves on the collector operate typically one diaphragm valve each. Diaphragm
valves on the air reservoir operates one pulsejet blowpipe each. The automatic timer control
energizes the solenoid, which causes the valve to decrease air pressure through the exhaust
port. This release of pressure also releases pressure from the outer chamber or back side of the
diaphragm valve. The resulting difference in air between the outer chamber and the compressed
air reservoir allows the diaphragm valve to open. This allows the air in the header to be released
into the pulsejet blowpipes. The size of the diaphragm valves is 1” or 1-1/2”, depending on the size
of the collector. See Section 700 — Replacement Parts Lists for the size of the diaphragm valves
on your collector.
400.3.3 — Pulsejet Blow Pipe
Each pulsejet blowpipe contains a nozzle for each cartridge up to 3 cartridges per pipe. These
nozzles are positioned above and directed into, the opening of the filter cartridge. As the pulse of air
reaches the nozzle, it is accelerated through the smaller diameter. The resulting shock wave travels
down the length of the inside of the filter cartridge, dislodging the dust from the filter cartridge.
Solenoid Valves
Figure 400.2.2
Diaphragm Valves
Header (Compressed Air Reservoir)
Pulse-Jet Blowpipe
Nozzle
Pulsing Air
Filter Cartridge
Dust
Dust
44
Section 400.4 — FDC Controller
Figure 370.4
45
Scan to see Farr Gold Series
Instruction Video
FDC Controller, Part 1
400.4.1 — Features
NEMA 4X
• Pad-lockable Enclosure
• Communicates via 2 wire CANbus network
• Universal input voltage 100-240 VAC, 50/60 Hz
• Up to 20 outputs on-board, expands to 990 outputs (with expansion boards)
• Solenoid current sense:
• – allows automatic system setup
• – senses 3 solenoids per output
• – monitor up to 2970 solenoids
• Diagnostic/program LEDs for “at-a glance” system status indication
• Finger-safe terminations
• Simple programming via push button and dial knob
• Non-volatile memory for program and status storage
• On-Demand operation with Camfil APC Differential Pressure Meter
• 3-digit, 7-segment alpha-numeric Display
• Settable alarm output relay normally open or normally closed on timer module
• 51 element tri-color LED meter movement
• Programmable ∆ P cleaning relay output
• Programmable ∆ P alarm relay output
• Cleaning status LED
• Alarm status LED
• 0-10” w.c. ∆ P range
• Source or sink 4 to 20 mA ∆ P output
• User selectable program access code
Programmable Parameters
• Solenoid ON-Time / OFF-Time
• Number of Offline Cleaning Cycles
• Offline Cleaning Cycle delay
• Run / Standby: enable / disable outputs
• Differential pressure cleaning limits: high set point / low set point
• High Differential pressure alarm limit
• Solenoid Fault alarm relay (normally open or normally closed)
• Outputs: 1 to 990 manual or auto-configured
• Units of measure (inches w.c. or kPa)
• Security code (user settable)
• ∆ P offset compensation
Status LEDs
• Differential Pressure
• Output
• Alarm (System Status)
• Output Pulsing
• Cycle Down
• Output Status
• CANbus Status
when illuminated
Display indicates ∆ P
Display indicates current output
∆ P & Solenoid Fault
Display indicates the next output to be pulsed
Unit in cycle down mode
Unit pulsing solenoids
CANbus transmission activity
46
Scan to see Farr Gold Series
Instruction Video
FDC Controller, Part 2
WARRANTY
All of Camfil APC
Dust Collector
Controller products
are warranted for
a period of 1 year
against defects
and workmanship.
Because certain
conditions may
apply to different
product categories,
contact the factory
for detailed warranty
information.
400.4.2 — Specifications
Inputs
Supply
100–240 VAC, 50 / 60Hz, 4 VA max @ 240 VAC without loads
Fuse
3A fast, 5x20 mm
∆ Pressure Switch Input
Dry contact, 4 mA @ 13 VDC max
Offline Clean Switch Input
Dry contact, 4 mA @ 13 VDC max
Solenoid Outputs
Solenoid Outputs
Up to 20 (10 per module)
Output Type
Triac
Output Rating
150 VA (at max ON, min OFF, 1 output selected)
Timing Accuracy
-2mS, +10 mS or +1% (whichever is greater), ON-time synchronized to AC line
Solenoid Fault Alarm Relay
Form-A contact, 3A @ 250 VAC/30 VDC, programmable normally open or normally closed
Meter Outputs
Alarm Output Type
Form A relay contact
Alarm Output Rating
5 A at 240 VAC/30 VDC
Control Output Type
Form-A relay contact
Control Output Rating
5 A at 240 VAC/30 VDC
Current Loop
Type
4 to 20 mA current loop, switch selectable sink/source, represents 0 to 10” w.c. ∆ P
Accuracy
±0.3 mA of displayed pressure
Measurement
Current of 4 to 20 mA = pressure of 0 to 10 in. water
Display Indicators
3-digit 7-segment LED display, 0.56 in. red
Program Parameters/Display Status/CANbus
Status
17 green LEDs
Alarm
1 red/yellow LED
Output Status
1 red/green LED
Solenoid Pulse Indication
10 green LEDs, 20 with expander
CANbus Status
Green LED
Displays
Units
Programmable for in. water or kPa
Bar graph Display
51 element tri-color LED analog differential pressure bar graph
Green = Differential pressure; Yellow = Cleaning set points; Red = Alarm set points
Digital Display
3-digit, 7-segment differential pressure display, 0.3 in. tall
Range
00.0 to 10.0 in. (00.0 to 02.5 KPa)
Discrete LED Indicators
Cleaning = Green; Alarm = Red / Yellow
Pressure Sensor
47
Type
Silicon piezo resistive transducer
Measurement Range
0.0 to 10.0 in. water (0 – 2.5 KPa)
Accuracy
±2% of full scale at 77°F (25°C); ±5% of full scale over temperature and voltage range
IMPORTANT
Parameter Ranges
ON-Time
0.10 – 0.50
OFF-Time
1 – 999 sec.
Timing Accuracy
-2 ms, +10 ms or +1% (whichever is greater), ON-time synchronized to AC line
Cycle Down Cycles
1 – 20, none
Cycle Down Delay
60-600 sec.
Communications
Type
CANbus architecture
Terminations
Screw terminals, #12 to #28 AWG, finger safe
Environmental
Operating Temperature
-40°F to +150°F (-40°C to +65°C)
Environmental Protection
Conformal coating for humidity and vibration
400.4.3 — System Overview
The Camfil APC Dust Collector Controller’s flexible design allows it to be adapted to many dust
collector configurations. The Core Timer Control Module will sequentially pulse up to ten outputs
in “On-Demand” mode based upon the Pressure Switch closure on the Pressure Differential
Meter. If more output capability is needed, up to 980 additional outputs can be controlled with
multiple Camfil APC Core Expander Modules connected to the controller. Furthermore, the
controller features a current sensing capability, which allows electrical fault monitoring for up to
three solenoids per output. This capability makes it possible to control and monitor up to 2,970
individual solenoids from one Control Module, and has the added convenience of providing an Auto
Configuration option for ease in initial setup.
Camfil APC products
are capable of use
in a wide array
of devices and
applications. Any
device or system
incorporating a
Camfil APC product
should be designed
that, in the event of
failure, malfunction,
or normal wear of
the product, the
device or system will
become inoperative
in a manner which
will prevent bodily
injury or property
damage. In order to
keep abreast with
the latest technology,
Camfil APC reserves
the right to change
components, design,
and specifications
without notice.
The Camfil APC Pressure Differential Meter is a digital/bar graph differential pressure (∆P)
control meter, and is designed to interface with the Camfil APC Core Timer Control Module. The
Pressure Differential Meter is capable of measuring differential pressure and displaying that value
in both analog bar graph and digital displays. Both Hi/Lo Cleaning and Hi Alarm set points can be
programmed. The Cleaning relay will change state when the measured pressure exceeds the High
Cleaning Set point, and will return to normal when the measured pressure goes below the Low
Cleaning Set point. The Alarm relay will change state whenever the measured pressure is equal
to or exceeds the window defined by the High Alarm Set point, and return to normal when the ∆
pressure falls below the set point. The Pressure Differential Meter will accept a 0-10” w.c. pressure
input. A 4-20mA output loop is provided from the internal pressure sensor. A 3-digit security code
is also provided to prevent unauthorized changes. The meter is equipped with non-volatile memory,
which will store all operating parameters when power is removed.
The Camfil APC Core Expander is the expansion output module in the Camfil APC Dust Collector
Controller. The Expansion Module operates in conjunction with the Core Timer Controller with up to 98
unique address expansion boards for a total of 990 outputs. The Expansion Output Core Expander
Module communicates with the Core Timer Controller Module through a twisted pair of wires using
CANbus architecture, which provides robust noise immunity. Two rotary switches on the Expansion
Module are used to set the address and provide a visual indication of the address selected.
48
Additionally, the simple five step intuitive programming procedure makes it easy to setup or
change any program item. Using a single Push-button/Encoder along with 19 LED’s and a 3-digit
display, the programming procedure can be self-taught in less than one minute. Following is a list
of the user programmable Controller functions:
•
•
•
•
•
•
•
•
Cycle Down Mode
Solenoid Pulse Times
Auto or Manual Output Configuration
Run/Standby Mode
∆ Pressure Control Set Points
∆ Pressure Alarm Set Points
Solenoid Fault Alarm Contact Configuration (N.O. or N.C.)
Output Pulsing Options
A universal input power supply lets you apply nominal input voltage ranging from 100 to 240 Vac,
50/60 Hz to the Controller, and the supplied voltage will be correspondingly switched to the outputs.
400.4.4 — Installing the Controls
The Camfil APC Dust Collector Controller is designed to be mounted in most industrial environments.
Its NEMA 4X enclosure also allows it to be mounted outdoors as well as in dusty environments.
•
WARNING
Make sure that
the circuit you are
working on is turned
off before you make
these connections.
Serious injury may
result if you do not
take the proper
safety precautions.
Before inspecting
or servicing the
equipment, perform
an approved lock-out/
tag-out procedure on
the electrical service,
the compressed air
(or other gas) supply,
and any other energy
source.
49
•
•
•
Do not Install these controllers in Hazardous environments without suitable protection.
Improper installation will void the warranty.
Do not install this unit in an area of high vibration.
Do not install this unit close to strong magnetic fields.
Do not install Conduit entries in the top of the controller. Conduit entries should always enter the
bottom of the enclosure to avoid moisture from entering into the controller.
400.4.5 — Electrical Hookup
Refer to the corresponding wiring diagrams, in the back of this manual, for proper wiring of
Controller. Connect Dust Collector Controller to a utility power source, which ranges from 100 to
240 VAC 50/60 Hz. Do not connect this unit to a “converter” or “inverter” type power source. This
unit should be installed on its own 15-amp circuit. Do not connect this unit to a power source that is
subjected to large switched loads, such as, electric motors, compressors, electric tools, etc.
For 120-volt input, using the supplied wire nuts, connect the “hot” or “high side” of the incoming
power source to wire lead labeled L1. Connect the “Neutral” to wire lead labeled L2.
For 240-volt input, using the supplied wire nuts, connect one side of the 240-volt line to the wire lead
labeled L1 and connect the other side of the 240-volt line to the wire lead labeled L2.
Connect the solenoid air valves to the terminal strip. These are labeled “Solenoid Outputs” and they
are numbered 1 through 10. (or terminals 11-20 if the Expander Module is present). You can connect
more than one solenoid on each output, as long as you do not exceed the 150 VA (Watt) rating on
each. The current sense circuit will only sense up to three solenoids per output. The return wires
“commons” from the solenoids will return to the “L2” terminals. Connect the 4 – 20 mA current loop
(if used) to receiver, and make sure to route any high voltage lines separate from the low voltage
4–20 mA current loop lines.
400.4.6.1 — Dust Collector Controller Operation
The Camfil APC Dust Collector Controller is shipped from the factory with the default program (see
details below). Power must be applied and solenoid(s) connected, in order to have a functioning
system. From this point, Program Items can be tailored to the specific application. There are four
basic modes of operation for the Controller; Run, Cycle Down, Standby, and Program. There are
also 2 alarm events that can be monitored.
400.4.6.2 — Run Mode
This mode is the normal functional operating state of the controller. The Pressure Differential Meter
Monitors the ∆P of the collector and controls the cleaning switch. The status of the dust collector
is available to the user by the information visible on the display as well as the information LEDs.
The display of the Core Timer will show the next output to pulse.
400.4.6.3 — Offline Cleaning Mode
The Offline Cleaning Mode allows the user to clean the dust collector filters “off-line” when the
fan shuts down by connecting an auxiliary set of N.O. contacts from the ventilation fan to the
cycle down input (Offline Cln.) of the Core Timer Module. The Offline Cleaning Mode is enabled by
programming a number between 1 and 20 in the “Offline Cleaning Cycles” program item, and by
programming the “Offline Cleaning Delay Time” program item with a value between 60 and 600
seconds. Offline Cleaning Mode is disabled (set to -) when the controller ships from the factory. If
the Offline Cleaning mode is enabled, normal operation of the controller occurs when the Offline
Cln. input is shorted. Opening the Offline Cln. input will begin the Offline Cleaning Delay time, which
is indicated by the flashing Offline Cleaning LED to the right of the display. During this time, the
solenoid outputs are disabled. At the end of this delay, the unit will cycle through all the selected
outputs as determined by the number of cycles selected with the “Offline Cleaning Cycles”
program item, beginning at output number 1. After all the cycles are finished, the Offline Cleaning
LED will stop flashing and turn on steady, when the Offline Cln. input is closed once again, the unit
shall resume normal operation and the Offline Cleaning LED will turn off.
400.4.6.4 — Standby Mode
To allow for normal maintenance or diagnostic investigation, the Standby Mode feature is available.
When the Standby Mode is invoked, all controller functions operate as in normal Run Mode with the
exception of the Solenoid Outputs, they are disabled.
400.4.6.5 — Program Mode
Easy access to view and change the program items is available through the Program Mode. While
in the Program Mode, normal operation of the controller is maintained, and any changes to any of
the Program Items do not take effect until they are saved into the memory. In other words, normal
dust collector filter cleaning can continue even while the controller is in Program Mode. If the
controller is allowed to remain in Program Mode for longer than 90 seconds without any interaction
on the Program Select knob, normal Run mode will automatically resume.
WARNING
Do not activate the
offline cleaning mode
unless you have
already wired the
timer to the motor
starter. If you do so,
when the timer is
shut off, the program
will wait for a signal
from the motor relay
to start the offline
cleaning cycle. It
will not return to
the normal cleaning
cycle until the offline
cleaning cycle is
completed. If you
have inadvertently
done this, go back to
the program mode
and reset the number
of offline cleaning
cycles to zero. Once
reset to zero, return
to the run mode on
the timer. If cleaning
does not start, it may
be necessary to turn
off the controller and
restart it.
50
400.4.7 — Alarm Events
Alarm events are generated either by faulty solenoid detection or by High ∆P alarm detection.
When a Solenoid Fault occurs, the Alarm Relay located on the Core Timer module changes
state and the “System Status Alarm” LED turns on. To acknowledge the alarm and view its
corresponding information, press the “Program Select” knob once to display the alarm condition.
At this time, the “System Status Alarm” LED changes from red to amber, and the “Display Status
Alarm” LED turns on indicating that the Display is showing alarm information. Press the knob once
again to view the output that was being pulsed when the alarm event occurred; a final knob press
returns the Display back to showing normal system status. If there are multiple alarm events, this
sequence of three knob presses will step through all of the outstanding alarm events currently
detected by the controller in order of occurrence. A High ∆P alarm occurs when the ∆P exceeds
the “High Alarm Set Point”. In the event of an Alarm condition, the Alarm LED will flash Red and the
Alarm Relay contacts located on the Pressure Differential Meter will change state. Pressing the
“Set/Alarm Cancel” button will return the relay contacts to its normal state and cause the Alarm
LED to change to solid Yellow to indicate that the alarm has been acknowledged. Note that an
Alarm will automatically cancel when the alarm condition is no longer present.
400.4.8.1 — Programming the Core Timer Module
During normal operation the “Run” LED will be on. To enter the Programming mode, press and hold
the “Program Select” knob switch about 2 seconds until the “Run” LED flashes and the Display
shows “pr9”. Release the knob. The “Program Select” knob can now be rotated either way to view
the various Program Items. Note that when a Program Item is selected as indicated by its LED,
the current value for that Program Item will be shown in the display. To change a value, press and
release the “Program Select” knob and the Program Item LED will flash. Turn the knob to set a new
value, then press and release it to enter the new value. The LED will stop flashing and again light
solid. Continue to view/change other Program Items in the same manner. When programming is
complete, rotate the “Program Select” knob until the “Run” LED is flashing, then press/release it.
The display will change from “Pr9” back to showing runtime information. If the system is left in the
Programming mode for more than 90 seconds without making a change, the unit will change back
to the Run Mode.
400.1.8.2 — Solenoid Output
Default: Total # of Outputs Avail
51
Select the “Solenoid Output” Program Item as described above. This value sets the last solenoid to
be pulsed, and is adjustable from 1 up to the maximum number of solenoids available. The number
of expansion boards connected to the system on power- up determines the maximum number of
solenoids available. On power-up the Controller “polls” the CANbus to determine the number of
outputs available. This number can be viewed by selecting “Output” Program Item. Note that when
manually selecting the last output in this manner, the “current sense” feature of the Controller is
not enabled, and that all solenoids from 1 through the last will be operated. To enable the “current
sense” feature, set the “Solenoid Output” Program Item to “A” (auto) and press/release the
“Program Select” knob. The Controller will briefly operate each output and record its corresponding
current consumption value to determine if there is a solenoid present at that output. During this
time the “Solenoid Output” LED will flash. When the test is complete the LED will again light solid
and the display will show the last output. This “auto” feature will allow the system to monitor the
current value of each solenoid output and report changes as to “overcurrent”, “undercurrent” or
“shorted output”, where the output is always On”. The “auto” feature also allows unused inputs in
the middle of the sequence to be skipped.
400.1.8.3 — Solenoid On Time
Default: 150 ms
Select the “Solenoid On Time” Program Item as described above. This value sets the ON duration
of the solenoid, and is adjustable from 0.10 to 0.50 seconds.
400.1.8.4 — Solenoid Off Time
Default: 15 seconds
Select the “Solenoid Off Time” Program Item as described above. This value sets the OFF duration
of the solenoid, and is adjustable from 1 to 999 seconds.
400.1.8.5 — Number of Offline Cleaning Cycles
Default: --Select the “Number of Offline Cleaning Cycles” program item as described above. This value sets
the number of cleaning cycles the unit will attempt after the “Offline Cln” switch is opened. The
number of cycles is adjustable from 1-20, and “- - -” equals “disabled”.
400.1.8.6 — Offline Cleaning Time Delay
Default: 60 seconds
Select the “Offline Cleaning Time Delay” program item as described above. This value sets the
delay from the time the “Offline Cln” switch is opened until the Offline Cleaning sequence begins.
This time is adjustable from 60 to 600 seconds.
400.1.8.7 — Standby
Select the “Standby” mode as described above. This mode allows the outputs to be disabled, while
the monitoring functions of the Controller continue to operate. To change modes, select “Standby”,
then select either “Sby” or “run”.
400.4.9.1 — ∆P Pressure Differential Meter Programming
During normal operation the display will show the pressure differential being measured. To enter
the Programming mode, press and hold the “Set” button 2 seconds until the digital display shows
the “Low Alarm Set point” as indicated by the Low Alarm LED (red) flashing. (Note that if a security
code has been entered, the display will show “0.0.0.” first. To enter a code, see below). To change
a value, press the “up arrow” or “down arrow” button. To move to the next parameter, press the
“Set” button. Once in the Program Mode, all of the items must be sequenced through in order to
exit into normal operation mode. If the system is left in the Programming mode for more than 30
seconds without making a change, the unit will change back to the normal operating mode and not
save any changes. See Figure 400.4.9 on the next page.
WARNING
Do not activate the
offline cleaning mode
unless you have
already wired the
timer to the motor
starter. If you do so,
when the timer is
shut off, the program
will wait for a signal
from the motor relay
to start the offline
cleaning cycle. It
will no return to the
normal cleaning
cycle until the offline
cleaning cycle is
completed. If you
have inadvertently
done this, go back to
the program mode
and reset the number
of offline cleaning
cycles to zero. Once
reset to zero, return
to the run mode on
the timer. If cleaning
does not start, it may
be necessary to turn
off the controller and
restart it.
52
Figure 1 – Pressure Differential Meter
Programming
Normal Operation
Range
0-10"
Default = 6"
Pr ess
t o Ad
SET
Change
Range
0-10"
Default = 1.5"
Cleaning Low
Set Point
SET
nc e
Pr ess
t o Ad
va
Change
Range
0-10"
Default = 2"
Cleaning High
Set Point
SET
nc e
Pr ess
t o Ad
va
Change
Units
" w.c. / kPA
Default = " w.c.
Unit of Measure
nc e
Pr ess
t o Ad
SET
va
Change
Range
0.0.0-2.5.5
Default = 0.0.0
Security Code
nc e
Pr ess
t o Ad
SET
va
Press to
Calibration
Ex i t Prog
SET
Mode
ram
53
Change
High Alarm
Set Point
nc e
Once in Program
Mode, all items
must be sequenced
through in order
to exit into normal
operation. If no
changes are made
after 30 seconds, the
unit will automatically
return to
normal operation.
SET
va
To enter program
mode, press and hold
the “SET” button for 2
seconds and release.
The display should
then show the first
program parameter
(High Alarm Set
Point) and flash the
corresponding LED.
Use the up and down
buttons to change the
value. Press the “SET”
button when done to
advance to the next
parameter.
sec . to
r2
ra
Prog m
PRESSURE
DIFFERENTIAL METER
PROGRAMMING
Press fo
Figure 400.4.9
Change
Press & Hold Up
& Down for 2 Sec.
to Zero Calibrate
Notes:
1.To enter program mod
button for 2 seconds an
then show the first prog
point), and flash it's corr
"UP/DOWN" buttons to
"SET" button when don
parameter.
2. Once in Program Mo
through in order to exit
changes are made after
automatically return to N
400.4.9.2 — ∆P Alarm High Set Point
Default: 6.0 in wg
To view the “Alarm High Set point”, enter the programming mode in the sequence as described
above. The Alarm High LED (red) will flash and the digital display will show the current value.
To change this value, press either the “up arrow” or “down arrow” button. Note that the “Alarm
High Set point” cannot equal or be less than the “Cleaning High Set point”. If the “Alarm High Set
point” is set to greater than 10.0, the digital display will show “---” which indicates that the alarm
is disabled. Once the programming mode is exited, the “Alarm High Set point” LED will not be
displayed if disable d. To continue programming, press the “Set” button again.
400.4.9.3 — ∆P Cleaning Low Set Point
Default: 1.5 in wg
To view the “Cleaning Low Set point, enter the programming mode in the sequence as described
above. The Cleaning Low Set point (yellow) will flash and the digital display will show the current
value. To change this value, press either the “up arrow” or “down arrow” button. Note that the
“Cleaning Low Set point” cannot be less than or equal to the “Alarm Low Set point”, or be greater
than the “Cleaning High Set point”; however, it can be equal to the Cleaning High Set point to allow
for zero hysteresis. To continue programming, press the “Set” button again.
400.4.9.4 — ∆P Cleaning High Set Point
Default: 2.0 in wg
To view the “Cleaning High Set point, enter the programming mode in the sequence as described
above. The Cleaning High Set point (yellow) will flash and the digital display will show the current
value. To change this value, press either the “up arrow” or “down arrow” button. Note that the
“Cleaning High Set point” cannot be greater than or equal to the “Alarm High Set point”, or be less
than the “Cleaning Low Set point”; however, it can be equal to the Cleaning Low Set point to allow
for zero hysteresis. To continue programming, press the “Set” button again.
400.4.9.5 — ∆P Unit of Measure
Default: IN
To view the “Units of Measure”, enter the programming mode in the sequence as described above.
The digital display will show “IN” or “PA” which equals the units of measure to be displayed (Inches
Water or kilopascals). This setting can be toggled by pressing either the “up arrow” or “down
arrow” button. To continue programming, press the “Set” button again.
400.4.9.6 — Security Code
Default: 0.0.0
To view the “Security Code”, enter the programming mode in the sequence as described above.
The digital display will show a number from “0.0.0” to “2.5.5”. This is the security code option.
Note that decimal points have been added between the digits to help distinguish this number from
other programming values. If the number is left at “0.0.0.” the operator will not be prompted to
enter a code when programming. If any other number is entered here, the user will be prompted
at the beginning of the programming sequence to enter that number. If the number is entered
correctly, the programming sequence will continue. If the number is entered incorrectly, the display
will revert to normal operation. If the security code is forgotten, Camfil APC Customer Service must
be contacted for an emergency security code.
54
400.4.9.7 — Zero Calibration
To calibrate the Pressure Differential Pressure meter, advance the programming until the display
flashes set. With the system shut down (Blower stopped) press and hold the Up and the Down
arrow buttons simultaneously until display stops flashing. Press the set button one time to exit
programming and check to see if the meter is reading “00.0”.
400.4.10.1 — Core Expander Module Addressing
Default: 01
The address of the Expansion Module is set by means of two rotary switches. Using a small
screwdriver set the address of the board from 01 to 98. Note that addressing of the boards must
start with 01 and continue in sequence up to a maximum of 98, however, it is not necessary that
the boards be physically connected to the CANbus in any particular order. It is allowable to set
multiple boards to the same address in order to have their outputs operate in parallel, however, if
this is done the Main Controller must be programmed for Manual Outputs (the Auto-Configuration
must not be used as the current-sense feature will not report correctly). Address 00 is used to put
the board in an “off-line” mode. This allows the board to be taken off the CANbus without physically
disconnecting the wires. Note that the Main Controller will continue to sequence through these
outputs even though they are not available.
400.4.10.2 — Communications Jumper Logic
There are two jumpers on the T2610-020 that set the end-of-line termination resistance. When the
Expansion Module is physically the last unit on the CANbus (furthest from the Main Controller), both
jumpers must be on pins 2-3 (right). When the Expansion Module is on any other position on the
CANbus, both jumpers must be on pins 1-2 (left).
400.4.10.3 — Core Timer Module Status LEDs
Alarm (Display Status)
When pressing the “Program Select” knob to view and cancel an alarm event, this LED will light to
indicate that the display is showing alarm event information.
Output
When in Run mode, this LED will light when the value displayed represents the next output to fire.
Alarm (System Status)
This LED will flash Red when an Alarm occurs, and will light Yellow when the Alarm is
acknowledged. An Alarm can be acknowledged by pressing the “Program Select” switch, which will
cause the Alarm output to turn off. The Alarm will reset when the fault is clear.
Output Pulsing
This LED will flash whenever an output is activated, and will remain “On” for the duration of the “On
Time”. This LED represents an output that is being fired, either locally or remotely.
55
Offline Cleaning
If the Offline Cleaning feature has been enabled, this LED will start to flash when the “Offline Cln”
input is opened and will continue flashing for the duration of the Offline Cleaning Delay and the
Offline Cleaning Sequence. At the completion of the programmed number of Offline Cleaning
Cycles, the LED will light solid and remain on until the “Offline Cln” input is closed. The Offline
Cleaning Cycle can also be cancelled by closing the input again.
Output Status
The Output Status LED will light Green whenever the outputs on the Controller or expansion board
are scheduled to fire. In case of an output related alarm (overcurrent, etc), the LED will turn Red
until the Alarm is cleared or the outputs are no longer in queue.
CANbus Status
The CANbus Status LED will light whenever the unit is transmitting.
400.4.10.4 — Expansion Module LEDs
Solenoid Pulse Indication
There are 10 Green LEDs, which represent the 10 triac outputs on the Expansion Module. Each
LED will light for the duration that its corresponding output is on.
Output Status
The Output Status LED will light Green whenever the outputs on the Expansion Module are
scheduled to fire. In case of an output related alarm (overcurrent, etc), the LED will turn Red until
the Alarm is cleared or the outputs are no longer in queue.
CANbus Status
The CANbus Status LED will light whenever the unit is transmitting.
Figure 400.4.10.1
56
Figure 400.4.10.2
Pressure Differential Meter Wiring
57
Figure 400.4.10.3
Figure 400.4.10.4
58
400.5 — Dwyer DCT1000 Automatic Timer Controller Features
The DCT1000 is designed for on-demand or continuous cleaning applications. Continuous cleaning
applications do not require external inputs and can be used for time based “on demand” cleaning
through use of the cycle delay feature. For on-demand applications, the plug-in pressure module
can be used to take full advantage of all the DCT1000 features.
Last Output Setup
The last Output Setup selects the last channel to be activated. When first selected, the display will
flash the last output available in the system. With single board installations this will be the number of
channels installed, typically 10 or 22. This value becomes more important when multiple modules are
installed. The last output value flashed will be the sum of all channels available in the system.
After the last available channel indication has completed, the currently programmed last channel
value is displayed. This value may be changed using the Up and Down buttons. The minimum
value is one while the maximum value is the maximum number of installed channels, including all
expansion modules. You may restore the factory default setting by pressing both Up and Down
simultaneously and holding for about for seconds. The default value is the maximum number of
channels. Pressing Select will change the setup mode to Time Off Setup.
Time Off Setup
Time off defines the period between solenoid activations when no channels are enabled. This may
be set between one second and 255 seconds. The factory default is 15 seconds. The display
will show the current time off setting when the time off setup mode is entered. The value may be
changed using the Up and Down buttons. Pressing both Up and Down simultaneously and holding
for approximately four seconds will restore the default value of 15. Pressing the Select switch will
change the setup mode to Time On Setup.
Time On Setup
Time On Setup sets the solenoid on time. The display will indicate the currently programmed time
on setting. This is measured in milliseconds. Using the Up and Down buttons, the value may be
changed. The value may be set between 10 msec and 600 msec in 10 msec increments. Pressing
the Up and Down buttons simultaneously for approximately four seconds will restore the factory
default value of 150 msec. Pressing the Select button will advance the setup mode to the High
Limit setup if the pressure module is installed. With no pressure, it will step to Cycle Delay Setup.
High Limit Setup
The High Limit Setup, available only with a pressure module installed, sets the pressure at which
the cleaning cycle will begin. This value may be between zero and the pressure module calibration
pressure. Normally, the High Limit should be above the Low Limit. If, however, the High Limit
pressure is set below the Low Limit, the cleaning cycle will begin when the High Limit is exceeded
and stop when the pressure falls below the High Limit. The Low Limit in this case will have no
effect. Pressing both Up and Down buttons simultaneously and holding for about four seconds will
restore the factory settings for High Limit to 2.0 in wg. The high limit should never be set higher
than 2.0 in wg. This value should only be used on light loadings and is not recommended for
fibrous dusts. Pressing Select will change the system to the Low Limit Setup Mode.
59
Low Limit Setup
The operation of the Low Limit, available only with a pressure module installed, is identical to the
High Limit except that the default Low Limit pressure is 1.5 in wg. The low limit should never be set
higher than 1.5 in wg.
High Alarm Setup
The operation of the High Alarm Setup is identical to the High and Low Limit Setup and is only
available when a pressure module is installed. The High Alarm default is 6 in wg. The upper
settable value is the calibration pressure of the pressure module and the lower limit is zero.
Pressing Select will change the system to the Low Alarm Setup mode.
Low Alarm Setup
The operation of the Low Alarm Setup is identical to the High and Low Limit Setup. The Low Alarm
default is 0” (zero) w.c. The upper settable value is the calibration pressure of the pressure module
and lower limit is zero. Pressing Select will change the system to the Cycle Delay Setup mode.
Figure 400.5.1
NEMA 4X
Enclosure
On Demand
Off
Continuous
This value should only be used on light loadings and is not recommended for fibrous dusts. The
upper settable value is the calibration pressure of the pressure module and the lower limit is zero.
Pressing Select will change the system to the High Alarm Setup Mode.
Selector
Switch
Cycle Delay Setup
The Cycle Delay inserts a delay time between the end of the last cycle and the beginning of the
first cycle. This may be set to between zero and 255 minutes. The factory default is zero. Setting
the value to zero will disable the delay. Pressing Select will change the system to the Down Time
Cycles Setup mode.
Down Time Cycles Setup
The Down Time Cycles Setup will select a value between zero and 255 minutes. The factory
default is one minute. Selecting zero will disable the operation. When the down time cycles is
activated by shorting the down time cycles input to the common terminal, the system will enter a
forced cleaning mode for the programmed duration. The cycle delay, if one is programmed, will
not be inserted in the timing cycle. Pressing Select will change the system to the Auto Alarm Reset
Setup mode, if a pressure module is installed, or to Process when no pressure module in available.
Auto Alarm Reset Setup
The Auto Alarm Reset Setup, available only when a pressure module is installed, allows the auto
alarm reset time to be selected. This value may be set between zero and 255 seconds. The
factory default value is five seconds. When the auto alarm reset is enabled by shorting the auto
alarm reset terminal to a common terminal, the alarm will be reset after the pressure returns to
the normal range and the time-out has expired. Pressing Select will change the system to Process
mode.
Restoring Factory Defaults
The DCT1000 has been programmed with factory default values that meet most industry operating
conditions. In the event that you want to restore all of the parameters to the original factory default
values:
1. Return the master controller to the process mode.
2. Press and hold both Up and Down buttons.
The display will indicate a 10 second countdown, at the end of which all parameters will be
restored to factory defaults. Releasing the switches prior to the end of the count will stop the
process and no modification will be made. Likewise, in each of the parameter setup modes,
pressing and holding the Up and Down buttons simultaneously will reset the individual default value,
leaving other settings unchanged.
60
Figure 400.5.2
Dwyer DCT1000 Timer
Plug-in Pressure Module
Wiring Diagram
High Com Low Alarm Man DT Alarm
Limit Limit Com Mode Ovr Cln Reset Com
3 Position Selector
Switch
NC
NC
Continuous
L1
L2
Blue
Blue
Set up
Up
Status
Select
Run
Alarm
Reset
Down
Power
On
Black
Contacts
Red
4-20 MA
Source
External
Internal Alarm
Off
On
Demand
Manual
Override
Process (IN H2O)
Last Output
Time Off (sec)
Time On (msec)
High Limit
Low Limit
High Alarm
Low Alarm
Cycle Delay (Min)
Down Time Cycles
(Min)
Auto Alarm Reset
(Sec)
Daisy Chan
In Out
4-20 MA
Output
Programmable Controller
Equipment
Do Not Use
SlowBlow Fuses
L1 L2 Sol.
Com.
Outputs (300 VA Max)
L1
L2
Line Voltage
85V Min to 270 V Max
50/60HZ
White
On
Demand
Off
Continuous
On Demand
On
Demand
External
Solenoid
Connections
Off
Continuous
Off
Switch Positions
61
120/1/50-60 VAC
200VA To Solenoids
16 AWG Wire Min.
On
Demand
Off
Continuous
Continuous
400.6 — Integrated Control Panel
The Integrated Control Panel (ICP) is a pre-engineered Dust Collector control center. This control
center includes a main disconnect, motor starter (fan), transformer, (FDC) timer control board, and
all necessary switches / interval wiring. If options such as Rotary Airlock or Screw Conveyors are
ordered with the dust collector, these controls will be added to the control panel. Other system
controls may be added at customer’s request. Please see section 400.4 of this manual for wiring
diagram and operating instructions for the FDC timer controller. A custom wiring diagram is
created for each project application and is included inside the motor starter enclosure.
Figure 400.6.1
400.7 — Rotary Air Lock
Consult the information packet attached to your RAL (Rotary Air Lock) before proceeding with installation
and wiring. If you do not have an information packet with your RAL, please record your serial number
and contact Camfil APC Customer Service at 1-800-479-6801 for a replacement packet.
Unless a special RAL has been ordered for your system, Camfil APC supplies two standard types of
airlocks, with many options available, please contact your sales representative for further information.
Figure 400.7.1
62
400.7.1 — Basic Cast Air Lock
WARNING
Control of this
equipment must be
in accordance with
OSHA Standard
1910.147 “Control
of Hazardous Energy
(Lock-out/Tagout)”. This standard
“requires employers
to establish a
program and utilize
procedures for
affixing appropriate
lock-out/tag-out
devices to energy
isolating devices
and to otherwise
disable machines
or equipment to
prevent unexpected
energizing, start-up,
or release of stored
energy.” Failure to
do so can result in
property damage,
personal injury, or
death. Insure circuit
you are working
with is off before
you start. Only a
qualified electrician
should make these
connections. (See
Section 100.3)
For further information
on Lock-out/Tag-out
requirements, see
your company’s
Safety Director
or refer to OSHA
Standard 1910.147.
63
Basic construction of cast iron body and end plates, 8 blades with beveled wipers; 3/4 HP drive,
3 phase, 60Hz, 230 – 460V Direct Drive, 22 RPM with a capacity of 0.49 cu. ft. per revolution.
Weight: 234 lbs
400.7.2 — Fabricated Air Lock
Operational Specifics
Model
Height
10
12
# Holes
RPM
12
27 1/4”
28
14
16
33 1/4”
20
37 1/4”
24
43 1/4”
16
21
16
ft3 / rev
Weight
1.85
400 lbs.
2.75
410 lbs.
3
470 lbs.
4.51
690 lbs.
8.5
950 lbs.
15
1325 lbs.
Fabricated construction from 10ga
and 1/4” HRS, 8 Vane with PVC rubber
wipers; 2HP drive, 3 phase, 60Hz,
230 – 460V Chain Drive with OSHA
Chain Guard. Consult Table 400.7.2
for operational specifications.
400.7.3 — Installation
Camfil APC recommends you place a disconnect near to the control panel of your dust collector
for ease of service and maintenance. Connect the rotary air lock to your hopper flange with the
supplied bolts in your start up kit. Ensure that you use supplied rope caulk between the flanges to
prevent air or dust leaks. Install the wiring per diagrams and instructions on the inside electrical
covers and in the information packet with your air lock. Bump rotation to ensure motor is turning
in the correct direction. Secure and lock-out the rotary air lock until the unit is ready to go into
operation per start-up procedures found in section 400.8.
400.8 — Fan Operation
Fans provided by Camfil APC are designed for continuous duty. We recommend that the fans
not be cycled on/off more than two times per hour. Excessive cycling of the fans will result in
premature failure of the fan, fan motor, and/or motor starter. This can also void any warranty
claims on these items.
Consult the information packet attached to your fan before proceeding with installation and wiring.
If your fan does not include an information packet contact the fan supplier. If Camfil APC supplied
your fan, contact Camfil APC Customer Service at (1-800-479-6801).
Trained and experienced personnel should make the selection of the fan that you require. The
selection of fan size is usually made from a fan performance table or a fan curve published by the
fan manufacturer. Refer to your General Dimensions drawing to determine the airflow rate and static
pressure required for your application. A performance table and fan curves for the standard fans
provided by Camfil APC have been included for reference when making changes to your system.
60 HZ Fan Performance Table
Camfil APC Fan Sizes
Fan
Part #
HP
FS1
208188-001
FS2
208189-001
FS3
Static Pressure (in wg) vs Air Flow (cfm)
Model
5
6
7
8
9
10
11
12
13
14
3
126GI-1.0-60-8
—
1320
1173
989
769
360
—
—
—
—
5
146GI-1.5-60-10
—
—
—
—
—
—
1367
1228
1069
810
208181-001
5
15PLR-2.0-60-9
2750
2580
2440
2231
2022
1639
—
—
—
—
FS4
208182-001
7.5
15PLR-3.0-60-9
4100
3894
3683
3368
3052
2473
—
—
—
—
FS5
208183-001
10
18PLR-4.0-60-9
4500
4415
4225
4158
4000
3850
3600
3491
3234
2926
FS5A
221511-001
15
18PLR-5.0-60-9
5661
5506
5345
5177
5000
4801
4583
4333
4029
3609
FS6
208184-001
15
18PLR-6.0-60-9
6800
6622
6420
6237
6000
5775
5500
5236
4851
4389
FS6A
221512-001
20
18PLR-8.0-60-9
7899
7682
7458
7222
7000
6695
6390
6039
5610
5015
FS7
208185-001
20
18PLR-8.0-60-9
9075
8829
8575
8316
8000
7700
7300
6982
6468
5852
FS8
208186-001
25
18PLR-10.0-60-9
11100
10816
10500
10187
9850
9433
9000
8552
7924
7169
FS9
208187-001
30
20PLR-11.0-60-9
12425
12153
11876
11591
11296
10985
10655
10300
9912
9478
FS9A
221513-001
25
30PLR-12.0-60-9
16193
15400
14507
13444
12000
—
—
—
—
—
FS10
211973-001
30
30PLR-14.0-60-9
19000
18200
16100
15800
14000
—
—
—
—
—
FS11
211974-001
40
30PLR-16.0-60-9
21200
20200
19000
17800
16100
12800
—
—
—
—
FS12
211975-001
40
30PLR-18.0-60-9
24000
23000
21600
20100
18200
15000
—
—
—
—
FS13
211976-001
50
33PLR-20.0-60-9
23975
22900
22100
21200
20050
18790
17111
14590
—
—
FS14
211977-001
50
33PLR-22.0-60-9
26300
25300
24350
23300
22050
20620
18775
16000
—
—
FS15
218611-001
60
33PLR-24.0-60-9
28600
27600
26500
25300
24100
22350
20400
—
—
—
FS16
218612-001
60
33PLR-26.0-60-9
31200
30150
29000
27600
26100
24300
22300
—
—
—
FS17
218613-001
75
33PLR-28.0-60-9
33200
32100
30800
29300
28000
26050
23850
—
—
—
FS18
218614-001
75
36PLR-30.0-60-9
34950
33000
32200
31200
30100
29100
28850
26500
24800
22500
FS19
218615-001
75
36PLR-32.0-60-9
36200
35350
34300
33400
32250
31100
30000
28350
26650
24300
FS20
218616-001
100
36PLR-34.0-60-9
38050
37000
36150
35000
34100
32700
31200
29800
27900
25500
FS21
218617-001
100
36PLR-36.0-60-9
40400
39350
38300
37150
36100
34700
33250
31600
29600
27150
FS22
218618-001
100
36PLR-38.0-60-9
42600
41650
40500
39400
38200
36600
35000
33300
31200
28700
FS23
218619-001
100
36PLR-40.0-60-9
45900
44600
43400
42100
40900
39400
37800
36200
33800
30800
64
50 HZ Fan Performance Table
Camfil APC Fan Sizes
Fan
Static Pressure (in wg) vs Air Flow (cfm)
Part #
HP
Model
5
6
7
8
9
10
11
12
13
14
FS1-50
209217-001
5
146CGI-1.0-50-9
1564
1408
1251
1095
916
—
—
—
—
—
FS2-50
209218-001
5
PB1706-1.5-50-9.5
—
—
FS3-50
209219-001
7.5
PB1708-2.0-50-9
—
2320
—
—
1525
1460
1375
1280
1180
1030
2200
2080
1980
1860
1760
1630
1490
1320
FS4-50
209220-001
7.5
18PLR-3.0-50-9
3950
3760
3555
3320
3000
—
—
—
—
—
FS5-50
209221-001
10
18LR-4.0-50-9
5135
5020
4370
4215
4000
—
—
—
—
—
FS6-50
209222-001
15
18PLR-6.0-50-9
7900
7520
7130
6620
6000
—
—
—
—
—
FS7-50
209223-001
20
20PLR-8.0-50-9
9380
9140
8870
FS8-50
209224-001
25
20PLR-10.0-50-9
11900
11600
11100
8490
8000
7510
6980
—
—
—
10650
10150
9400
8550
—
—
—
FS9-50
209225-001
30
22PLR-12.0-50-9
13650
13300
12850
12250
12000
11600
11150
10510
9800
8700
FS10-50
218620-001
40
22PLR-14.0-50-9
16200
15700
15250
14800
14300
13750
13400
12700
13800
10750
FS11-50
218621-001
50
24PLR-16.0-50-9
17700
17300
16800
16450
16000
15700
15300
14700
14250
13750
FS12-50
218622-001
40
36PLR-18.0-50-9
FS13-50
218623-001
50
36PLR-20.0-50-9
23800
22750
21500
20000
18000
—
—
—
—
—
26300
25200
23750
22000
20000
—
—
—
—
—
FS14-50
218624-001
50
36PLR-22.0-50-9
29200
27800
26200
24300
22000
—
—
—
—
—
50 HZ Fan Performance Table
Camfil APC Fan Sizes
Static Pressure (in wg) vs Air Flow (cfm)
Fan
Part #
HP
Model
8
9
10
11
12
13
14
15
16
FS1-HS
218625-001
7.5
FS2-HS
218682-001
7.5
FS3-HS
218626-001
FS4-HS
218627-001
FS5-HS
PB1506-1.0-60-17
1810
1735
1660
1570
1490
1370
1320
1225
1100
950
PB1606-1.5-60-15
—
—
—
—
1710
1630
1560
1490
1415
1335
10
PB1608-2.0-60-14.5
—
—
—
2400
2290
2160
2040
1920
1790
1660
20
PB1908-3.0-60-17
—
—
—
—
—
3185
3140
3100
3050
3020
218628-001
15
20PLR-4.0-60-14
4920
4780
4680
4520
4370
4210
4000
3700
3530
FS6-HS
218629-001
20
20PLR-6.0-60-14
7310
7110
6930
6680
6500
6280
6000
5670
FS7-HS
218630-001
30
20PLR-8.0-60-14
9830
9610
9320
9050
8750
8430
8000
7590
FS8-HS
218631-001
40
20PLR-10.0-60-14
12100
11560
11450
11200
10740
10300
10000
FS9-HS
218632-001
40
20PLR-12.0-60-14
14300
14000
13700
13250
12750
12300
11800
FS10-HS
218633-001
50
22PLR-14.0-60-14
16000
15700
15450
15100
14750
14400
14000
FS11-HS
218634-001
60
22PLR-16.0-60-14
18300
17850
17600
17250
16800
16400
16000
FS12-HS
218635-001
75
24PLR-18.0-60-14
19750
19550
19200
18800
18550
18250
FS13-HS
218636-001
75
36PLR-20.0-60-14
27450
26500
25550
24500
23400
FS14-HS
218637-001
75
36PLR-22.0-60-14
30000
29950
27975
26700
25500
FS15-HS
218638001
75
36PLR-24.0-60-14
32900
31800
30800
29400
FS16-HS
218639001
100
36PLR-26.0-60-14
35500
34300
33050
31700
FS17-HS
218640001
100
36PLR-28.0-60-14
38000
36800
35500
FS18-HS
218641001
100
36PLR-30.0-60-14
40950
39500
38200
65
17
18
19
20
—
—
—
1225
1105
—
1530
1380
1180
2930
2875
2805
—
—
—
—
5210
—
—
—
—
7090
—
—
—
—
9450
8800
8200
—
—
—
11250
10600
9650
—
—
—
13750
13300
12750
12300
11700
11150
15600
15200
14600
14100
13300
12600
18000
17700
17250
16800
16600
16200
15800
22100
20000
—
—
—
—
—
—
23700
22000
—
—
—
—
—
—
28050
26500
24000
—
—
—
—
—
—
30100
27300
26000
—
—
—
—
—
—
33850
32200
30300
28000
—
—
—
—
—
—
36650
34950
32800
30000
—
—
—
—
—
—
400.9 — Startup Procedure
1. Make a routine check of the fan, discharge devices, ductwork, electrical wiring, cartridges
(clamped in position) and compressed air connections.
2. Make sure the collector doors are closed and latched and the slide gate is in the open position.
3. Close the fan damper to approximately 25% of its designed operational setting.
4. Supply compressed air and electrical power to the collector. Clean dry air should be regulated
between 90 and 105 psi. Power requirements may vary and will depend on what equipment
was provided with the collector.
5. For processes generating hot or moist gases, preheat the collector to prevent moisture
condensation on the filters, even if the collector is insulated.
6. Turn on the collector fan and hopper discharge devices. Make sure the fan rotates in the
direction indicated by the wheel rotation arrows on the fan.
7. Adjust the damper to the desired airflow and lock the damper in position. Note, on start up
with clean filters the fan will move more than the design air flow. In some cases exceeding the
design air flow can cause premature failure of the filters. The fan damper should be adjusted
to the design air flow and then re-adjusted after the filters load up to the operating pressure
drop of around 2 in wg
8. If the filters need to be pre-coated, refer to Section 360 of this manual.
9. Inspect operating equipment to confirm they are working correctly. Fan should be running in
the correct direction without excessive vibration or unusual noise. Airlocks should be operating
and slide gates should be open on the hopper.
400.10 — Shutdown Procedure
1. Shutdown the process or dust generating operation to which the dust collector is installed.
2. Continue operation of the fan, dust removal device, and cleaning mechanisms for at least
20 minutes to assure good removal of the collected dust. This will also purge much of the
process moisture that may be still in the collector.
3. Shut off the fan and perform the necessary lock-out/tag-out procedures.
4. If the cartridges are going to be replaced with this shutdown, it will be necessary to continue
to pulse the collector for an additional 20 minutes after the fan is shut down. This will assure
that the cartridges are clean and much lighter for removal. (Note – if the cartridges are not to
be removed do not pulse the unit after the fan is turned off, as this will remove the filter cake
already formed on the cartridges)
5. Close the compressed air line valve and perform the necessary lock-out/tag-out procedures.
6. Turn off power to the controller, discharge devices, or other electrical equipment. Perform the
necessary lock-out/tag-out procedures.
66
7. The collector is now ready for replacement of the cartridges, maintenance, or storage.
8. If the collector is located outside or is subject to condensation formation, install a heater or
allow a warm air stream to flow through the collector while it is shutdown.
400.11 — Recommended Timer Settings
The following settings apply to any model timer that is shipped with a Farr Gold Series Dust
Collector. These settings represent a recommended starting point and the optimum operation
settings may vary for your application. If your system is set to operate on differential pressure
cleaning then the cleaning system will automatically use the minimum amount of compressed
air to maintain stable operation of the dust collector. Adjusting the settings above would only be
necessary on the most aggressive applications. If your system is set to clean continuously then it
would be beneficial to take the time to adjust the settings to achieve stable operation with the least
amount of compressed air consumption. This will also result in longer cartridge life.
CAUTION
To optimize the cleaning system operation for continuous cycle cleaning, perform the following procedure:
Over cleaning the
cartridges will result
in higher emissions,
shorter cartridge
life, and raise energy
costs.
1. Make sure the timer is set at the recommended settings above at start up.
2. Monitor the pressure on the collector for 4 weeks. If the pressure is less than 2 in w.g. after
this period, the cleaning system can be adjusted to reduce air consumption.
3. Increase the pulse frequency by 2 seconds or reduce the pulse duration by 10 milliseconds.
4. Repeat steps 2 and 3 until the dust collector stabilizes at 2 to 3 in w.g.
These adjustments may have to be reversed as the filters age.
Recommended Settings
Pulse Duration (on time)
67
150 milliseconds This is Camfil APC’s recommended setting.
Pulse Frequency
(off time)
15 seconds
Increasing this value will decrease compressed air
consumption. Decreasing this value will increase
compressed air consumption. You would decrease
this value if your application involves high dust
loads and dust that does not easily release from
the cartridge. On applications with light dust
loads this value can be increased to conserve
compressed air.
High DP Set Point
2 in wg
Initiates differential pressure cleaning.
Low DP Set Point
1.5 in wg
Stops differential pressure cleaning.
High Alarm
6 in wg
This value will protect the cartridges from damage
due to high differential pressures.
Section 500 — Preventive Maintenance and Troubleshooting
Your Farr Gold Series Dust Collection system requires very little maintenance to achieve maximum
life and efficiency. The following items should be periodically serviced:
500.1 — Filter Elements
Pressure drop across Gold Cone filter elements normally increases rather rapidly when the filter
elements are new and clean, but then climbs much more slowly throughout the rest of their service
life. Typically, when the Gold Cone elements cannot be cleaned below a differential of 6 inches
water gauge or greater, they have reached the end of their service life and require replacement.
Other indications for replacement are cartridges that have been in service over 2 years or
cartridges that have been damaged by moisture, high heat or other perilous conditions.
500.2 — Hopper
At the start/end of each shift, check the hopper or discharge container at the bottom of the unit.
Locate the handle on the front of the slide gate (if equipped) and pull to ensure that the gate is
open. Dispose of any waste accumulation according to federal, state and local environmental
regulations. During operation, the gate should remain open allowing the collected material to
flow freely into the discharge container. Under no circumstances should the hopper be used to
store collected material. Empty and replace full collection containers frequently. Do not over fill
containers, as this will inhibit performance of the collector.
500.3 — Fan Motor Lubrication
The most common cause of premature bearing failure is improper lubrication. The fan motor
provided with Farr Gold Series dust collectors may vary. Camfil APC often provides the fan with
the collector, but many times the fan is provided by other sources. If Camfil APC provided the fan,
it will be one of two types. One type has sealed-for-life bearings and requires no maintenance. The
other type motor provided with the fan has grease fittings on the top and bottom of the motor. If
safety permits, the initial lubrication may be done while the motor is running until some purging
occurs at the seals. Hours of operation, temperature and environmental conditions will affect the
lubrication frequency. Adjust frequency depending on the condition of the purged grease.
Use extreme caution when working around rotating machinery. Remove all jewelry, loose clothing
or anything that could encounter rotating components. Failure to follow these precautions may
result in serious injury such as the loss of limbs or death!
Lubricate the grease fittings with a high quality NLGI No. 2 or No. 3 multi-purpose ball bearing
grease having rust inhibitors and anti-oxidant additives.
Lubricate bearings prior to an extended shutdown or storage period. Rotate the motor shaft
monthly to prevent corrosion.
Suggested greases are:
• Shell Alvania No. 2
• Mobil Mobilith 22
• Gulf Gulfcrown No. 2
• American-Rykon Premium 2
68
500.4 — Solenoid and Diaphragm Valves
The solenoid and diaphragm valves may require periodic maintenance depending on the quality of the
compressed air supplied to the unit. Check each valve periodically to see that it is operating properly
by inserting a small screw driver or paper clip into the bottom of the solenoid and pushing upward.
500.5 — Automatic Timer Control (if equipped)
The automatic timer control does not require any routine maintenance. Check periodically to verify
that the board is operating properly and the user-defined settings have not been tampered with.
Dirt and moisture can damage the timer board. Check the enclosure periodically to ensure that no
condensation is forming on the inside and that dust has not collected on the circuit board or inside
the enclosure. See Section 400.4 for additional information.
500.6 — Cleaning and Repair
The external and internal surfaces of the unit should be treated as any other painted metal surface
subject to corrosion. Examine the unit for any damage to the surface coating and repair as
necessary. Keep the external surfaces clean to prevent the possibility of hidden damage occurring.
Periodic application of a quality automotive wax will prolong the life of painted surfaces and make
them easier to clean.
500.7 — Inspection Log
An inspection log should be maintained to assure that a proper maintenance routine is followed.
The following page is an example of a commonly used inspection log. Copy and use this inspection
log or contact Camfil APC, Customer Service Department (1-800-479-6801) for a copy.
69
500.8 — Suggested Preventative Maintenance Schedule
Date Time Inspector Notes
DAILY
Check Controller &
Pressure Drop
Walk through
system, listen &
observe unusual
operation
1. Record Differential Pressure (DP)
“w.g.
“w.g.
“w.g.
“w.g.
“w.g.
2. Are any Control indicators alarms on?
Y/N
Y/N
Y/N
Y/N
Y/N
1. Is timer sequencing correctly?
Y/N
Y/N
Y/N
Y/N
Y/N
2. Are solenoids & diaphragm valves operating?
Y/N
Y/N
Y/N
Y/N
Y/N
3. Is hopper discharge device (ex. Airlock) operating
Y/N
Y/N
Y/N
Y/N
Y/N
4. Is dust being removed from system properly?
Y/N
Y/N
Y/N
Y/N
Y/N
5. Any visual stack emissions? Or Opacity meter?
Y/N
Y/N
Y/N
Y/N
Y/N
1. Lubricate bearings of screw conveyor/airlock
□
□
□
□
□
2. Operate diaphragm valves
□
□
□
□
□
3. Are valves operating and in sequence?
Y/N
Y/N
Y/N
Y/N
Y/N
4. Any visible filter cartridge/tube sheet leaks?
Y/N
Y/N
Y/N
Y/N
Y/N
5. Verify accuracy of temperature indicating equip.
□
□
□
□
□
6. Is hopper emptying properly?
□
□
□
□
□
1. Record compressed air pressure.
PSIG
PSIG
PSIG
PSIG
PSIG
2. Clean compressed air filter tap.
□
□
□
□
□
3. Check for clogged air lines.
□
□
□
□
□
WEEKLY
Inspect operations
- airlock/screw
conveyor,
diaphragm valves,
cartridges, control
panel, air lines, etc.
Check compressed
air lines, including
line filters and
dryers
MONTHLY
1. Is there any corrosion or material build-up on fans?
Inspect fan
operation
Y/N
Y/N
Y/N
Y/N
Y/N
2. Check drive belts for wear and tension.
□
□
□
□
□
3. Inspect and lubricate appropriate items.
□
□
□
□
□
4. Inspect housing for corrosion.
□
□
□
□
□
Y/N
Y/N
Y/N
Y/N
Y/N
2. Check hoses and clamps.
□
□
□
□
□
3. Check access doors/seals for leaks/deterioration.
□
□
□
□
□
4. Check air lines & fittings for leaks.
□
□
□
□
□
5. Check accuracy of indicating equipment.
□
□
□
□
□
1. Check inlet baffle for wear.
□
□
□
□
□
2. Inspect filter cartridges thoroughly.
□
□
□
□
□
3. Check ducts for material build-up.
□
□
□
□
□
4. Inspect paint, insulation, etc. for corrosion.
□
□
□
□
□
5. Check fan belts tension and wear.
□
□
□
□
□
6. Check airlock/screw conveyor for general wear.
□
□
□
□
□
2. Check all hardware connections and visible welds.
□
□
□
□
□
3. Check door gaskets.
□
□
□
□
□
4. Check diaphragm valves for proper operation.
□
□
□
□
□
1. Any visible filter cartridge/tube sheet leaks?
Inspect system
operation for leaks
ANNUALLY
Inspect system
operation for wear,
leaks, corrosion, &
material build-up
1. Record pulse duration/delay.
Inspect system for
general operation
70
Section 510 —
Troubleshooting
Guide
510.1 — High Pressure Drop
Cause
Solution
Cleaning mechanism not
properly adjusted
•
•
•
•
•
Increase cleaning frequency
Perform off-line cleaning
Check performance of diaphragm and solenoids (repair)
Check performance of timer controller (adjust or repair)
Check compressed air supply (should be 90 - 105 psi)
Control Timer failure
•
•
•
•
•
•
See actions following Timer/Controller Failure
Verify controller is operational
Check for appropriate power connections
Check to see if timer is indexing to all contacts
Check output on all terminals
Check accuracy of Magnehelic Gauge (if applicable)
Pulse Valve failure
•
•
•
•
Check wiring between controller and solenoid valves
Check tubing between solenoid valves and diaphragms
Check diaphragms (replace or repair)
Check solenoid valves (replace or repair)
Blinding of Filter Media
•
•
•
•
•
•
•
•
Check designed airflow against actual airflow, adjust damper accordingly
Check collection point vs. suggested collection points adjust
Minimize excess airflow, use appropriate ducting
Change filter media type ( consult Technical Services)
Install overbags to prevent blinding
Perform off-line cleaning
Add more compartments or modules and filter media
Evaluate dust to find correct Air-to-Cloth Ratio (Camfil APC lab)
End of Cartridge service life
•
•
Replace cartridges (service life is determined by the application)
Consult After Market Sales (1-866-639-7151)
Improper start up of collector
•
•
•
•
Restart collector using suggested procedure in manual
Damper fan and slowly open as system starts up
Preheat the collector before start up
Use pre-coat dust to season the cartridges
Moisture in collector
•
•
•
•
•
See sections following Moisture in Collector
Check for leaks in collector or ductwork Insulate collector
Purge system after shutdown
Preheat unit before operation
Check compressed air dryer (-40 degree dew point)
Temperature too high
•
•
•
Measure air temperature in collector and compare to design
Use dilution air to reduce temperature in collector
Install alternate media that can tolerate higher temperature
•
Check to find type of baffle
(channels, abrasion resistant inlet velocities, inlet velocities plate, or none)
Remove plugged baffle
Replace baffle with the appropriate style for application
Reduce moisture in the collection system-see above"
Inlet baffle plugging, causing
high velocities
71
•
•
•
Heavier dust loading than
design
(scalping of product)
Check designed airflow against actual airflow, adjust damper accordingly
Check collection point vs. suggested collection points (adjust)
Minimize excess airflow, use appropriate ducting
Minimize overfeeding of process equipment
Change filter media type (consult Tech. Services)
Install over-bags to prevent blinding
Perform off-line cleaning
Add more compartments, modules or filter media
Collector undersized
(high air to cloth ratio)
Check fan damper and fan speed, adjust accordingly
Minimize excess airflow, use appropriate ducting
Confirm appropriate location of pickup points and hoods
Change filter media type (consult Tech. Services)
Collector undersized Install overbags to prevent blinding
Perform off-line cleaning
Add more compartments, modules or filter media
Evaluate dust to find correct air to cloth ratio (Camfil APC lab)
510.2 — Moisture In Collector
Cause
Solution
Leaks in the collector and
ducting
Check ductwork on inlet and outlet to assure good caulking
Check ductwork on inlet and outlet to assure tightened bolts
Check frame and panels caulking (re-caulk if necessary)
Check frame and panels for tightened bolts ( replace or tighten)
Leaks in the collector
Check ductwork for any leaks or punctures (repair or replace)
Check door gasket for leaks (repair or replace)
Install moisture resistant or washable cartridges
Check hopper flange at corners and seam of module
Check double or triple inlet where bolted to seam on multiple frames
Water or moisture in
compressed air supply
Open drain valve on air header to see if water comes out
Check to see if compressed air supply has an air dryer installed
Verify air dryer is rated for -40 degree dew point
Replace desiccant in the dryer
Replace dryer Install timed drain valve on header
Scalping of process moisture
(processes using water - i.e.
Banbury Mixer)
Check designed capture velocity of hood vs. actual (adjust)
Check designed location of collection point vs. actual (relocate)
Reduce airflow at collection point
Minimize water overflow in process equipment if possible
Move the collection point of process if possible
Install moisture resistant or washable cartridges
Insufficient preheating
Run the system with hot air before process gas flow is introduced
Insulate the collector if it is to be located outside
Install a by-pass line to allow pre-heating of the collection system
Install a heating system inside the collector
Install moisture resistant or washable cartridges
72
System is not purged
after shutdown
•
•
•
•
•
Keep fan running for 5 to 10 minutes after process is shut down
Insulate the collector if it is to be located outside
Install a bypass line to allow pre-heating of the collection system
Install a heating system inside the collector
Install a moisture resistant or washable cartridges
Wall temperature below
dew-point
•
•
•
•
•
•
If the collector is located outside, it must be insulated
Preheat collector before operation
Purge collector after process shutdown
Install a bypass line to allow heating of the system while off-line
Install a heating system inside the collector
Install moisture resistant or washable cartridges
Cold spots through
insulation
•
•
•
Locate cold spots and repair insulation
Eliminate direct metal line through insulation
Install moisture resistant or washable cartridges
510.3 — Low Air Pressure
Cause
Solution
Regulator set to low
•
•
•
Adjust regulator to 90-105 psi of compressed air
Install a regulator or gauge on the air header if possible
Consult Customer Service (1-800-479-6801)
Line too small
•
•
•
Compressed Air Supply 3/4” minimum supply line for GS10 and under
1” minimum supply line for everything larger than GS10
Consult Customer Service (1-800-479-6801)
Compressor too small
(for total plan requirements)
•
•
•
•
Perform a compressed air audit, reduce usage where possible
Repair leaks and reduce unnecessary loss of air
Replace compressor with larger unit
Add another compressor to system
Compressed air consumption
too high
•
•
•
Look for leaks in the compressed air system (repair)
Check to make sure air header drain valve is closed
Check to make sure diaphragm is not stuck in open position
Restrictions in compressed
air piping
•
•
•
Check compressed air line to be sure it is clean
If a hose is run to the air header, be sure there are no kinks
Check all valves in the line to be sure they are opened completely
Compressed air dryer plugging
•
•
•
•
Replace desiccant in the dryer
Bypass dryer temporarily
Replace dryer
Consult Compressed Air Supplier
510.4 — Controller Failure
73
Cause
Solution
Lack of power
•
•
•
•
•
•
Confirm that power is supplied to board, correct if necessary
Confirm that power supplied matches board requirements
Confirm all breakers and switches are in the ‘on’ position
Check fuse, replace if necessary
Check controls ‘ on / off switch, turn it to ‘on’
Replace control board
Fuse blown
•
•
Replace Fuse
Replace control board
•
•
•
•
•
Check to see if timer is indexing to all contacts
Check output on all terminals
Check wiring between controller and solenoid valves (repair)
Check power connections to board (correct if necessary)
Confirm the type of controller used and refer to appropriate section in
this manual or the controller manual
•
•
•
Confirm the type of controller used and refer to appropriate section in
this IOM manual or the controller manual
Confirm accurate number of terminals wired into the control board
Confirm designed High and Low set points (adjust accordingly)
Bad control board
•
•
Replace board; consult replacement part list for correct part number
Consult Aftermarket (1-866-639-7151)
Bad magnehelic gauge (if
applicable)
•
•
•
•
Confirm accuracy of the gauge, adjust as necessary
Sensor hoses are backwards, switch connections of tubing
Replace Magnehelic gauge; see replacement parts list for correct part number
Consult Aftermarket (1-866-639-7151)
Moisture or contamination in
control box
•
•
•
Confirm that the controller housing door has been shut
Confirm NEMA rating of housing and upgrade if necessary
Remote mount controller away from the dust collector
Vibrations causing failure
•
•
•
Locate controller indoors
Consult Customer Service (1-800-479-6801)
Remote mount controller away from the dust collector
Improper wiring
Improper programming
510.5 — Dust Bridging in Hopper
Cause
Solution
Dust Stored in hopper
•
•
•
•
•
Keep the slide gate or discharge open at all times
Remove dust continuously
Keep rotary airlock and screw - conveyors running
Store collected dust in drums, bags, or bins instead of hopper
Install bin - level indicator
Rotary airlock malfunction
•
•
•
•
•
•
•
•
Confirm the airlock speed for application, make adjustment
Check for correct rotation of blades, reverse direction if necessary
Lubricate bearings or motor if applicable
Replace bearings or motor if applicable
Replace gasket or caulk on hopper flange
Confirm correct application of airlock - replace if necessary
Refer to airlock manual for further information
Consult airlock manufacturer
Screw conveyor malfunction
•
•
•
•
•
•
•
•
Confirm screw conveyor speed for application, make adjustment
Increase the conveyor opening by making it wider and flared
Lubricate bearings or motor if applicable
Replace bearings or motor if applicable
Replace gasket or caulk on hopper flange
Confirm correct application of conveyor, replace if necessary
Refer to screw conveyor manual for further information
Consult screw conveyor manufacturer
74
Moisture in collector
•
•
•
•
•
•
•
•
•
•
See sections following Moisture in Collector
Assure that only dry compressed is used, install air dryer
Insulate collector if it is located outside
Preheat the collector before operation
Purge the collector of all high humidity process air after operation
Inspect and repair any leaks in the collector or ducting
Prevent scalping of moisture from process
Move collector indoors
Install compressed air purge (air sweep) equipment
Install bin-level indicator
Discharge opening too small
•
•
•
Install compressed air purge (air sweep) equipment
Install hopper with larger discharge opening
Install bin-level indicator
Hopper slope insufficient
•
•
•
Install compressed air purge (air sweep) equipment
Install hopper with increased hopper angle
Install bin-level indicator
510.6 — Media Failure
75
Cause
Solution
End of cartridge service life
•
•
Replace cartridges (service life determined by application)
Consult Aftermarket (1-866-639-7151)
High pressure drop
•
•
•
•
•
•
•
•
•
•
•
•
•
•
See sections following High Pressure Drop
Check and adjust cleaning mechanism
Increase air pressure to cleaning mechanism
Check and repair diaphragm valves
Check, program, and repair timer / controller
Check and correct any inlet plugging
Check and reduce moisture present
Check temperature, use appropriate media or use dilution air
Change media area or media type
Perform off-line cleaning
Check fan speed and damper accordingly
Install overbags to prevent blinding
Confirm appropriate location of pickup points and hoods
Add more compartments or modules
Moisture / Water Present
•
•
•
•
•
•
•
•
See sections following Moisture in Collector
Assure that only dry compressed is used, install air dryer
Insulate collector if it is located outside
Preheat the collector before operation
Purge the collector of all high humidity process air
Inspect and repair any leaks in the collector or ducting
Prevent scalping of material from process by adjusting system
Move collector indoors
Temperature too high
•
•
•
Measure air temperature in collector and compare to design
Use dilution air to reduce temperature in collector (change fans)
Install alternate media that can tolerate higher temperatures
Application too abrasive
•
•
•
•
•
•
Replace baffle plate with abrasion resistant material
Reduce velocity of inlet air, damper fan
Install filter cartridges of different media type
Install additional modules to reduce Air-to-Cloth ratio
Confirm appropriate location of pickup points and hoods
Install pre-filter to collect larger particles (Cyclone or Drop-out module)
Conveying velocity too great
•
•
•
•
•
•
•
Reduce airflow, damper fan if possible
Confirm appropriate location of pickup points and hoods
Minimize excess air flow, use appropriate ducting
Change media area or media type
Perform off-line cleaning
Change inlet baffle design (solid strike plate, perforated, etc.)
Add more compartments or modules
Compressed air too high during
pulsing
•
•
Regulate pressure to 90-105 psi of compressed air
Install a pressure gauge on air header to monitor supply pressure
Inlet air not properly baffled
•
•
Install correct baffle (channel, abrasion resistant plate)
Replace channel baffle with abrasion resistant material
Channel baffle worn or missing
•
•
Replace channel baffle
Replace channel baffle with abrasion resistant material
510.7 — Poor Efficiency
Cause
Solution
End of cartridge service life
•
•
Replace cartridges (service life determined by application)
Consult Aftermarket (1-866-639-7151)
Insufficient filter cake formation
•
•
•
•
•
•
Use pre-coat dust for start-up
Check for adequate airflow at collection points and hoods (adjust)
Allow more time for collector to build dust cake; it may take weeks
Reduce cleaning frequency
Change media type or surface area in filter cartridge
Use pre-coat to assist in the capture of other forms of dust
Wrong filter media used
•
Replace cartridges with correct filter media for application
Cleaning cycle too frequent
•
•
•
•
•
Check programming on controller and adjust accordingly
Check and calibrate Photohelic or Magnehelic gauge
Increase the amount of time between pulse events
Increase the “high” set point on the collector
Refer to the appropriate section in manual for your type of controller
Leaking of cartridges
•
•
•
•
•
•
Check for puncture in media, see sections following Media Failure
Perform a colored trace dust test to discover the source of leak
Check for leaking gaskets, clean tube sheet to assure good seal
Check temperature, use appropriate media or use dilution air
Change media type or total area in cartridges
Check for abrasion
Temperature too high
•
•
•
Measure air temperature in collector and compare to design
Use dilution air to reduce temperature in collector
Install alternate media that can tolerate higher temperature
76
Leaking gaskets
•
•
•
•
•
Confirm correct placement of cartridges, prevent ramping of filters
Confirm locking mechanism is in the closed position
Remove filters and clean tube sheet to assure a good seal
If cam-bars are not bent, replace support brackets for cam-bars
Replace cartridges
Cartridge cam-bars not sealing
•
•
•
Confirm correct placement of cartridges, prevent ramping of filter
Confirm locking mechanism is in the closed position
If cam-bars are bent, replace cam-bars
510.8 — Poor Airflow
77
Cause
Solution
Fan malfunction
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Check to see if the fan is turned to the “on” position
Check required fan power requirement vs. what is supplied
Check that power supply is “hot”
Incorrect wheel rotation, correct motor wiring
Damage to fan wheel - replace wheel
Wheel mounted backwards on shaft, rotate wheel orientation
Temperature too high, replace motor for one better suited
Bent shaft, replace shaft
Broken or damaged belt; adjust, repair, or replace belt
Build-up of dirt or dust, clean fan
Bad or damaged bearings; lubricate, repair or replace bearings
Confirm correct motor starter is used
Check condition and repair the motor starter
Check that all fuses and switches are operational
Check for faulty wiring or shorts in wiring
Consult the fan manufacturer
Replace fan/motor if necessary
Refer to appropriate fan manual
Fan sized incorrectly
•
•
•
Take airflow readings and compare to the design of application
Evaluate fan performance (fan curve) vs. design of application
Replace fan with larger or smaller unit, depending on application
Motor Overloads
•
•
•
•
•
•
•
•
•
•
•
•
•
Speed set too high on motor, slow motor down
Fan over capacity, replace with larger fan
Density of gas/dust above design, replace with larger fan
Wrong direction of wheel rotation, rotate wheel orientation
Shaft bent, repair or replace
Poor alignment, realign motor and housing
Bind on wheel in housing, repair and realign motor and housing
Bearing wear; lubricate, repair or replace bearings
Temperature too high, replace motor for one better suited
Build-up of dirt or dust, clean fan
Short in wiring, repair or rewire fan
Defective motor, replace
Consult fan manufacturer
Plugged cartridges
•
•
•
•
•
•
•
•
•
•
•
See sections following High Pressure Drop
End of cartridge service life, replace cartridges
Check and clean pulsing mechanisms
Increase compressed air pressure or volume
Eliminate moisture in collector
Check and repair the timer / controller
Inspect and clean inlet baffles
Perform off-line cleaning of filter cartridges
Install overbags
Add more compartments or modules and filter media
Increase filter media area or change filter media type
Air leaks in the collection
system
•
•
•
•
Repair or replace any damaged ductwork or collection hoods
Replace missing screws, bolts, gaskets, or caulk
Seal any holes or punctures in the system
Damper any unused collection points
Duct sized incorrectly
•
•
•
•
•
•
Perform a system balance to discover possible problems
Review duct design, adjust blast gates to designed settings
Rework ducts to achieve desired performance
Poor inlet or outlet design, redesign for optimal performance
Install new blower to compensate for poor airflow
Consult installer of ductwork
Collection point incorrectly
positioned
•
•
•
•
•
Reference: Industrial Ventilation — A Manual of Recommended Practice
Resize duct according to industrial standard
Change hood type to improve collection performance
Reposition collection point or hood to improve performance
Consult installer of ductwork
510.9 — Abnormal Noise
Cause
Solution
Normal noise level of fan
operation
•
•
•
•
•
•
Most Camfil APC provided fans range from 89 to 99 decibels
To reduce sound levels, install a fan silencer - Call Customer Service for a Quote.
Enclose fan in a foam lined housing
Enclose the entire collector inside a separate room
Relocate the collector away from production areas
Consult manufacturer of fan
Vibrating or resonance of
ductwork
•
•
•
•
•
•
•
Support and brace ductwork, or improve existing supports
Tighten flanges between the collector and the ductwork
Tighten flanges between the fan and the ductwork
Re-apply gaskets or caulk all the flanges
Place rubber padding between ductwork and support structures
Adjust fan speed and setting to minimize vibrations
Consult ductwork installer
Housing of fan vibrating
•
•
•
•
•
•
Damaged wheel, replace or repair wheel
Damaged housing, replace or repair housing
Broken or loose belt, repair or replace belt
Worn coupling, replace coupling
Broken or loose bolt or screws, replace or tighten bolts and screws
Unstable foundation or supports, tighten or shim housing
78
Fan impeller hitting the inlet of
the fan
•
•
Balance or adjust fan wheel
Consult manufacturer of fan
Bad bearings in the fan
•
•
•
Lubricate bearings
Replace bearings
Consult manufacturer of fan
Constant “Hissing” sound
•
•
•
•
Compressed air being lost, check compressed air line connection
Diaphragm stuck open, check and repair diaphragm
Check for air leak into system
Check drain valve on air header, close if necessary
Rotary airlock or screw
conveyor noise
•
•
•
•
•
•
Tighten screw or blade on device
Tighten screw trough or airlock to hopper discharge flange
Re-apply caulk or gasket to flanges
Lubricate bearings in device
Replace bearings in device
Consult manufacturer of rotary airlock or screw conveyor
Electric “Humming” sound
•
•
•
Defective starting relay, replace relay
Replace motor starter
Consult manufacturer of motor starter
510.10 — Repeat Fires or Explosions
Cause
Solution
•
Consult Camfil APC and install the required life safety measures as prescribed
in NFPA 654: Standard for the Prevention of Fire and Dust Explosions from the
Manufacturing, Processing, and Handling of Combustible Particulate Solids.
•
•
•
•
•
•
•
•
•
Consult Camfil APC and install the required life safety measures as prescribed
in NFPA 654: Standard for the Prevention of Fire and Dust Explosions from the
Manufacturing, Processing, and Handling of Combustible Particulate Solids.
Control sources of ignition, open flames, sparks etc.
Install a sprinkler system inside the collector
Install a spark control device, arrester, trap, or detect and quench system
Install a high efficiency Cyclone or drop out box to catch sparks
Install a fire protection system in the duct work
Use only explosion resistant fan & discharge devices (NEMA-7/9)
Controller housing should be rated NEMA 7/9
Install fire resistant filter cartridges
•
•
•
•
•
•
•
•
Install a spark control device, arrester, trap, or detect and quench system
Install a high efficiency Cyclone or drop out box to catch sparks
Install a sprinkler system inside the collector
Install a fire protection system in the ductwork
Use only explosion resistant fan & discharge devices (NEMA-7/9)
Controller housing should be rated NEMA 7/9
Minimize flame or sparks in process
Install fire resistant filter cartridges
Dust is explosive
Dust is flammable
Process generates sparks
510.11 — Installation Problems
79
Cause
Solution
Missing Parts
•
•
•
Reference packing slip and inventory items (report missing items)
Loose parts will be shipped in a box placed inside the inlet plenum
Thoroughly check all boxes before discarding
•
•
•
•
Consult manufacturing drawings for correct arrangement
Re-drill braces to match leg bolt holes
Re-drill legs to match cross-brace bolt holes
Contact Camfil APC to replace cross-braces
•
•
•
•
•
Bin vent or hopper misaligned, rotate plenum 180 degrees, install
per match line stickers
Wrong assembly procedure, insert bolts in corners, work to center
Use alignment pins to match flanges during assembly
Drill and tap new holes to match corresponding flange
Flange bent during shipping, replace hopper
Fan flange does not match top
panel bolt pattern (top mount
fans only)
•
•
•
•
Wrong top panel, replace panel (if Camfil APC provided fan)
Drill or cut flange into blank top panel (if other than Camfil APC fan)
Use alignment pins to match flanges during assembly
Fan misaligned, rotate fan until flanges match
Hopper flange doesn’t match
discharge device flange
•
•
•
•
•
•
Discharge device misaligned, rotate to match hopper flange
Wrong assembly procedure, insert bolts in corners, work to center
Use alignment pins to match flanges during assembly
Drill and tap new holes to match corresponding flange
Flange bent during shipping, replace hopper
Consult manufacturer if other than a Camfil APC discharge device
Controller does not operate
•
•
•
•
•
•
See section following Controller Failure
Check for correct power supplied to control board (correct)
Check for off switches, breakers, or blown fuses (replace or correct)
Check for improper wiring, correct as needed
Bad control board, replace if necessary
Consult Customer Service (1-800-479-6801)
Collector leaks dust
•
•
•
•
•
•
Locate and seal any dust leakage points in the collector
Caulk any leaking flanges or panels
Insert any missing bolts or fittings
Replace door gaskets if leaking
Check and repair door lock mechanism if necessary
Weld or caulk any holes or gaps in welded seems
Air header leaks
•
•
•
Check drain plugs, close if open
Check and repair diaphragm valves
Check connection to compressed air supply line, repair if necessary
Legs & cross-braces do not
match holes
Bin vent flange doesn’t match
hopper
80
Section 600 — Definitions
Abrasion Resistance
The ability of a fiber or fabric (media) to withstand surface wears.
ACFM
Actual cubic feet of gas per minute. The volume of gas flowing per minute at the operating
temperature, pressure, elevation and composition.
Air-to-Cloth Ratio
The ratio between ACFM flowing through a dust collector and the square feet of filter area available
(ACFM/Ft2). Sometimes referred to as the velocity of air through the cloth.
Blinding
Blockage in a fabric or media by dust that cannot be discharged by the cleaning mechanism,
resulting in a reduced gas flow and an increased pressure drop across the media. Once enough
material has built up, airflow is severely restricted and the bags have to be cleaned or replaced.
Brownian Movement
Sub-micron particles are diffused, increasing the probability of contact between the particles and
collecting surfaces.
Bridging
Material handling problem characterized by the particulate forming a cavity over the discharge or
opening of a hopper or storage vessel. Also, the accumulation of collected dust between two or
more filter elements.
Can Velocity
In a dust collector with the filter elements suspended from the tube sheet, “can velocity” is the
upward air stream speed calculated by dividing the open cross sectional area of the dust collector
(less the area of the filter bottom) into the full volume of the exhaust fan (ACFM/Ft2 = Feet per
Minute), Ref. Interstitial Velocity. Note: This does not apply to the Farr Gold Series because of the
cross flow design.
Clean Air Plenum
The dust collector area, through which gases are directed, located on the clean side of the filter media.
Collection Efficiency
The measure of a dust collector’s ability to remove particulate from the inlet gas, typically
expressed in percent or emission rate (grains per cubic foot).
Dew point
The temperature at which condensation begins to form as the gas is cooled.
Diaphragm Valve
A compressed air valve operated by a solenoid valve that opens to allow a pulse to a series of filters.
81
Differential Pressure
The change in pressure or the pressure drop across a device. The difference between static
pressures measured at the inlet and outlet of a device, Ref. Pressure Drop.
Dust Cake
A dust build-up on the filter elements that increases the efficiency of the filter media.
Dust Loading
The weight of solid particulate suspended in an air stream, usually expressed in grains per cubic
foot (or grams per cubic meter).
Electrostatic Forces
The presence of an electrostatic charge on the particles and the filter can increase dust capture.
Emissions
Particulate that escapes through or around a dust collector into the atmosphere.
Fan
A device for moving air and dust through a ventilation system. If the fan is on the dirty air side of
the collector, it is called a positive system. If the fan is on the clean air side of a collector, it is
called a negative system.
Filter Media
The air permeable material utilized in a dust collector, which provides a barrier to remove dust
from the air stream.
Hopper
The section of a dust collector located below the dust collector housing utilized for the
accumulation and discharge of the collected dust.
Impingement
The physical contact of a dust-laden gas flow against a filter media. Typically referred to the
abrasive wear caused by this impact.
Inches of Water
A unit of pressure equal to the pressure exerted by a column of water one inch high at standard
conditions (70OF @ sea level), usually expressed as inches water gauge (“w.g.) or inches water
column (“w.c.).
Interstices
The openings or voids in a filter media. In addition, the openings or voids between filter elements.
Interception
Particles that do not cross the fluid streamlines come in contact with the fibers because of the
fiber size.
Inertial Collection
Dust particles strike the fibers placed perpendicular to the airflow direction instead of changing
direction with the air stream.
Interstitial Velocity
Velocity of a gas as it passes between a compartment of filter elements calculated at its highest
value, Ref. “Can Velocity” for formula. Note: This does not apply to the Farr Gold Series because of
the cross flow design.
82
Magnehelic Gage
An instrument used to measure differential pressure drop.
Manometer
A U-shaped tube filled with a specific liquid. The difference in height between the liquid in each leg
of the tube gives the difference in pressure on each leg of the tube. Used to monitor differential
pressure.
Micron (μm)
A unit of length, 1/1000th of one millimeter (1/24,000th of an inch).
Negative Pressure System
A system where the fan is located after the dust collector on the clean air side, pulling air through
the system.
OEM
Original Equipment Manufacturer.
Particulate
Any airborne solid material.
Permeability
A measure of fabric porosity of openness, expressed in cubic feet of air per minute per square
foot of fabric at a 0.5” w.c. pressure differential.
Photohelic Gauge
An instrument used to measure the differential pressure drop and to initiate the cleaning system by
means of adjustable “high” and “low” set points for automatic actuation of a sequential timer.
Positive Pressure System
A system with a fan located prior to a dust collector on the dirty side, pushing air through the
system.
Precoat
Material added to the air stream at start-up to aid in establishing the initial dust cake on the filter
media.
Pressure Drop
A measure of the resistance the gas stream encounters as it flows through the system. It may be
referred to as pressure differential across the media, across the dust collector, or the pressure
drop across the entire system, depending upon the points of measurement.
Pulse Cycle
The interval of time between pulsing one row of filters and pulsing that row again.
Pulse Duration (On-Time)
The length of time a pulse lasts, generally described as the length of time the electrical signal
holds the solenoid pilot valve open.
83
Pulse Delay (Off-Time)
Elapsed time between pulses in a dust collector cleaning system.
Pulse Clean Dust Collector
A dust collector using short intermittent pulses of compressed dry air to clean dust
from the filter media.
Re-entrainment
The phenomenon where dust is collected from an air stream and is then returned to the air stream.
This occurs when dust is dislodged from a filter media during cleaning and is again captured by the
same or an adjacent filter media.
Rotary Airlock Valve
Device having a star wheel (rotor) designed to provide an air tight seal between the negative or
positive pressures of the collector and the outside atmosphere.
Screw Conveyor
A revolving screw operating in a fixed trough for conveying material from one point to another.
Note: Should a screw conveyor be used in a dust collector system, an airlock is still required to
ensure ventilation air does not pass through the conveyor.
SCFM
Standard cubic feet per minute. The volume of gas flow per minute at standard temperature and
pressure conditions (70OF @ sea level).
Solenoid Valve
An electromechanical plunger device that is either “normally open” or “normally closed”. In use with
a dust collector, it is for the relief of air pressure to activate a compressed air device such as a
diaphragm valve.
Timer, Sequential
An electrical mechanism that activates a dust collector’s cleaning system.
Tube sheet
A steel plate on which the open end of the filter elements are connected. This wall separates the
clean air and dirty air plenums of the dust collector.
84
NOTE
As of October
2012 Camfil APC
has changed the
gasket geometry of
all of its filters to a
square pattern that
eliminates dust build
up on top of the filter
pans. The following
table provides a
cross reference for
replacement filters.
85
Section 700 —- Replacement Parts List
Following is a list of common replacement parts and equipment that you will need to keep your
dust collector operational in the future. To know what specific filters and components match
your specific collector and application, refer to your bill of lading or original packing slip. This
information should be recorded in this manual for future reference. If this information is not
available to you, please contact your Camfil APC Representative or Camfil APC Customer Service
at 1-800-479-6801 for genuine Camfil APC replacement parts.
Farr Gold Series
Model
Part #
Media Type
Replaces
GS-GR-325
325325-001
PolyTech Standard
211497-001
GS-FR-325
325325-002
PolyTech Fire Retardant
211497-004
GS-CB-325
325325-003
PolyTech Carbon Impregnated
211497-002
GS-XG-325
325325-004
eXtreme Standard Green
211497-020
GS-XF-325
325325-005
eXtreme Fire Retardant
211497-019
GS-XC-325
325325-006
eXtreme Carbon Impregnated
211497-021
GS-SY-325
325325-007
Synthetic (Spun bond polyester)
220660-001
GS-XS-325
325325-008
eXtreme Synthetic (Spun bond polyester) 220660-002
GS-HG-325
325325-009
PolyTech Hi-Efficiency Standard
211497-005
GS-HF-325
325325-010
PolyTech Hi-Efficiency Fire Retardant
211497-006
GS-HC-325
325325-011
PolyTech Hi-Efficiency Carbon
211497-014
GS-DPS-225
225225-001
Dura-Pleat Standard
205637-001
GS-DPA-225
225225-002
Dura-Pleat Aluminized
205637-002
GS-DPO-225
225225-003
Dura-Pleat Hydro-Oleophobic
205637-003
GS-DPT-200
225225-004
Dura-Pleat Teflon (PTFE)
205637-004
GS-MDPS-185
225185-001
Dura-Pleat Standard
210737-001
GS-MDPA-185
225185-002
Dura-Pleat Aluminized
210737-002
GS-MDPO-185
225185-003
Dura-Pleat Hydro-Oleophobic
210737-003
GS-MDPT-185
225185-004
Dura-Pleat Teflon (PTFE)
210737-004
Tenkay
PolyTech Media Type
HemiPleat Gold Cone for Tenkay Mark III
HemiPleat Gold Cone for Tenkay Mark III
27" (686 mm) Long x 12.75" (324 mm) Dia.
34" (864 mm) Long x 12.75" (324 mm) Dia.
Model No.
Part No.
Model No.
Part No.
HMPTS - Standard
HMPTL-197
211922-001
HMPXL-244
211872-001
HMPTF - Fire retardant
HMPTFL-197
211922-002
HMPFXL-244
211872-002
HMPTC - Carbon impregnated
HMPTCL-197
211922-003
HMPCXL-244
211872-003
HMPTU - High efficiency
HMPTUL-197
211922-004
HMPUXL-244
211872-004
HMPTUF - Fire retardant, Hi-Eff.
HMPTUFL-197
211922-005
HMPUFXL-244
211872-005
HMPTXFR - eXtreme Fire Retardant
HMPTXFRL-197
211922-009
HMPXFRXL-244
211872-009
HMPTXST - eXtreme Green
HMPTXSTL-197
211922-010
HMPXSTXL-244
211872-010
TK-SY - Synthetic
TK-SY-197-27"L
211922-011
TK-SY-244-34"L
211872-011
TK-XS - eXtreme Synthetic
TK-XS-197-27"L
211922-012
TK-XS-244-34"L
211872-012
Other Items
Row
Camfil APC Part #
Description
Filter Accessories
1
084404-000
Pamic Filter
2
208721-001
Cartridge Removal Tool
3
203774-001
Pre-Coat, Dust, Expanded Perlite 20 lb. bag
4
207087-001
Overbag, Nylon, for Gold Cone Cartridge
5
After Filters
6
049880-005
30/30 Pre-Filter 24×24×2
7
049880-006
30/30 Pre-Filter 24×12×2
8
059413-001
30/30 Pre-Filter, 24×24×4 CL2
9
402994-003
Riga-Flo Filter, 24×24×12, MERV14
10
402994-006
Riga-Flo Filter, 24×12×12, MERV14
11
855210-008
HEPA Filter, 24×24×12, 2000 CFM @ 1.35" (Absolute)
12
855210-006
HEPA Filter, 24×12×12, 2000 CFM @ 1.35" (Absolute)
13
855210-007
HEPA 23-3/8×23-2/8×11-1/2
14
855210-005
HEPA 23-3/8×11-3/8×11-1/2
15
855210-147
HEPA 11-3/8×23-3/8×11-1/2
16
855210-004
HEPA Filter, 24×24×12 1080 CFM @ 1"
17a
855211-367
iSMF HEPA Filter, 21×36×12, 2650 CFM @ 1.35" (Absoulte)
17b
404810-003
iSMF RIGA-FLO Filter, 21×36×12, 2650 CFM@1.35”
86
87
18
After Filter Fasteners
19
114353-000
C-99 Spring Fastener (for Riga-Flo 200 Filters)
20
063159-002
Swing Bolt (for Absolute 2000 HEPA Filters)
21
043911-002
Wing Nut (for Absolute 2000 HEPA Filters)
22
063343-000
Clamp (for Absolute 2000 HEPA Filters)
23
After Filter Gage & Pneumatics
24
033988-003
Magahelic Gage, 0-4"
25
033988-025
Gage Accessory Kit
26
048624-005
1/4" Black Poly Tubing
27
067401-000
Elbow Restrictor - 1/8" MPT TO 1/4" TUBE
28
Determinator
29
203180-001
DT-10 NEMA, 4× Determinator Timer Kit
30
203180-002
DT-20 NEMA, 4× Determinator Timer Kit
31
203180-003
DT-10 NEMA, 9 Determinator Timer Kit
32
203180-004
DT-20 NEMA, 9 Determinator Timer Kit
33
Replacement Boards
34
203187-001
DT-10 Replacement Board - 10 Terminal
35
203187-002
DT-20 Replacement Board - 20 Terminal
36
Dwyer
37
203180-D10
Dwyer 10 Timer Control Kit
38
203180-D22
Dwyer 22 Timer Control Kit
39
208029-010
Dwyer DCT101 NEMA 4× w/ DP Module
40
208029-022
Dwyer DCT022 NEMA 4× w/ DP Module
41
Replacement Boards (Dwyer)
42
208026-022
Dwyer Timer Board DCT1022 22
43
208026-010
Dwyer Timer Board DCT1010 10×
44
208027-010
Dwyer DP Module DCP100 10" W.G.
45
T4 P4
46
122943-004
T4-10 COMPLETE KIT - NEMA 4
47
123060-001
T4-10 COMPLETE KIT - NEMA 7/9
48
122943-001
P4-10 COMPLETE KIT - NEMA 4
49
Components
50
122361--011
T4-10 Replacement Box - NEMA 4
51
122361-001
P4-10 Replacement Box - NEMA 4
52
122363-001
Control Board FOR T4 & P4
53
122999-001
P4 Photohelic Gage, Replacement
54
112727-000
P3 Photohelic Gage, Replacement
55
124157-000
Photohelic Gage Kit 0"-.8" W/MTTG BRKT
56
Dust Collector Controller
57
214538-001
Basic Dust Collector Controller (BDC10) w/o Gage
58
214538-002
Basic Dust Collector Controller (BDC20) w/o Gage
59
214538-010
Camfil APC Dust Collector Controller Kit (FDC10)
60
214538-020
Camfil APC Dust Collector Controller Kit (FDC20)
61
214382-001
DFA-T2610-010 Timer Board
62
214383-001
DFA-T2610-020 Expander Boards
63
214384-001
DFA-PS700-A10 Pressure Differential Meter
64
Static Pressure Devices
65
074680-000
M3 Magenehelic Gage Kit w/ MTTG BRKT
66
033988-003
Magenehelic Gage 0"-4" Replacement
67
033988-006
Magenehelic Gage 0"-8" Replacement
68
124157-000
Photohelic Kit 0"-4"
69
078235-001
Straight Connector Male
70
Dust Discharge Devices
71
209572-010
Positive Pressure Drum Kit
72
094562-001
55-Gallon Drum
73
209573-010
Drum Cover w/ Lid; 10” opening
74
207551-007
Hose Clamp for 10" Flex Hose
75
069441-015
Flex Hose - 10" - per foot
76
206019-001
Manual Slide Gate
77
210511-001
Drum Ring / Lever Lock
78
221115-001
Level Indicator, ATEX Dual Voltage
79
Valves
80
084416-002
1" Diaphragm Valve Goyen
81
212659-001
1" Diaphragm Valve (Compression Fitting)
82
084416-005
11/2" Diaphragm Valve Goyen
83
212506-001
11/2" Diaphragm Valve (Compression Fitting)
84
084416-012
Repair Kit, 1" Diaphragm Valve Goyen
85
084416-016
Repair Kit, 1-1/2" Diaphragm Valve Model 4510 or 4512 Goyen
86
084415-002
Solenoid Valve (Single) Goyen
87
223075-001
Solenoid Heater 120 VAC 100 watt w/ Thermostat Goyen
88
223075-002
Solenoid Heater 24 VDC 48 watt w/ Thermostat Goyen
89
221866-010
Diaphragm Valve 1.0” Autel Gold
90
221866-015
Diaphragm Valve 1.5” Autel Gold
91
221866-R10
Repair Kit, Diaphragm Valve 1.0” Autel Gold
92
221866-R15
Repair Kit, Diaphragm Valve 1.5” Autel Gold
88
89
93
Dust Collector Hardware
94
204574001
Door Gasket Material - 13.5' per Door
95
205764001
Door Hinge
96
205229001
Gold Bolt (price each, minimum of 100 per order)
97
074492000
Rope Caulk
98
251159001
Camfil APC Green - Touch-up Paint (1 GALLON)
99
Safety Decals
100
205821001
Label, Entrapment 6"×3"
101
205822001
Label, Explosion 6"×3"
102
205819001
Label, Safety Instructions 3"×6"
103
205965001
Label, Warning Auto Start
104
205818001
Label, Warning Compressed Air 2×4
105
205820001
Label, Warning Lockout 3"×6"
106
205816001
Label, Danger Blades 2"×4"
107
217096002
Replacement Filter Label Black
108
Explosion Vents
109
209410001
Explosion Vent Assembly 11.6 SF
111
209408001
Explosion Vent 11.6 SF
112
Sprinkler
113
075090001
Sprinkler Vertically Mounted
114
205885001
Sprinkler Head, Horizontally Mounted
The following is a part list and diagram of common hardware parts on your collector. To identify
your replacement part, match the item in the list with the balloon number on the diagram. Check
the description to be sure you have the specific part for your collector.
Item
Part #
Description
221866-010
Diaphragm Valve - 1” (GS2 - GS6)
221866-015
Diaphragm Valve - 11/2” (GS8-GS120)
2
219942-001
Elbow, male 1/8 npt to 1/4 od tube (on solenoids)
3
222213-001
Elbow, male 1/4 npt to 1/4 od tube (on valves)
208192-002
Bulkhead Connector; fitting, dresser nut and lock ring (GS2-GS6)
208192-001
Bulkhead Connector; fitting, dresser nut and lock ring (GS8-GS120)
5
098683-002
Brass Drain Cock
6
048624-005
1/4” diameter black plastic tubing
067497-002
Solenoid box - 2 solenoids
067497-004
Solenoid box - 4 solenoids
067497-006
Solenoid box - 6 solenoids
067497-008
Solenoid box - 8 solenoids
067497-010
Solenoid box - 10 solenoids
067497-012
Solenoid box - 12 solenoids
8
084415-002
Solenoid valve - single (included in item 7)
9
205745-001
Clamp Bar - Right hand - (2) filters deep
205745-002
Clamp Bar - Right hand - (4) filters deep
205745-003
Clamp Bar - Right hand - (6) filters deep
205745-004
Clamp Bar - Right hand - (5) filters deep
205745-005
Clamp Bar - Right hand - (3) filters deep
205745-006
Clamp Bar - Right hand - (1) filters deep
205744-001
Clamp Bar - Left hand - (2) filters deep
205744-002
Clamp Bar - Left hand - (4) filters deep
205744-003
Clamp Bar - Left hand - (6) filters deep
205744-004
Clamp Bar - Left hand - (5) filters deep
205744-005
Clamp Bar - Left hand - (3) filters deep
205744-006
Clamp Bar - Left hand - (1) filters deep
11
204574-001
Door Gasket
12
205757-001
Door Hardware Kit
13
205764-001
Door Hinge
14
205756-007
Door Frame Assembly
15
205756-006
Door Assembly
16
205229-001
Gold Bolt (100 minimum quantity per order)
1
4
7
10
90
17
206019-002
Manual Slide Gate
18
069441-015
Flex Hose - 10” Diameter
19
207551-007
Hose Clamp - 10” Diameter
20
209573-010
Drum Cover with Gasket
21
210511-001
Drum Latch ring
22
094562-001
55 Gallon Drum
23
N/A
24
210274-001
Differential Pressure Filter Kit
206913002
Single Inlet
206914002
Double Inlet
206915002
Triple Inlet
26
209586002
Baffle Channel
27
208872002
Channel Baffle
28
N/A
29
208721001
Cartridge removal Tool
30
217052001
Tool Holder Clip
25
91
Fan (Refer to your fan name plate, bill of lading, or original packing slip
for part no.)
Reservoir (specific to collector size)
Gold Series Industrial Dust Collector
Document List
810 Sales Order Specific Certified Drawings
810.1
Top Level Drawing
810.2
Installation Kit Drawing
810.3
Support Drawing
810.4
Platform Assembly
810.5
Top Handrail Assembly
810.6
NA
820 Blower Data
820.1
Fan curve and data sheets
820.2
Fan manual
830 Collector Discharge information
830.1
Airlock – Drawing, motor and electrical data sheet, and airlock manual
830.2
Level Indicator Data – electrical sheet
830.3
NA
830.4
NA
830.5
NA
840 Controls
840.1
Electrical Drawings
840.2
Specific Timer Manuals
840.3
NA
850 Explosion/Fire Protection Equipment
850.1
NA
850.2
NA
850.3
NA
850.4
NA
850.5
NA
850.6
NA
850.7
NA
850.8
NA
850.9
Broken Bag Detector
850.10
NA
850.11
NA
860 Remote mounted special HEPA or Rigaflow
A
B
C
SILENCER
(10GA STEEL &
INSULATION)
.563
(12 PLCS)
4-7/8"
TYP
TAG:AIRLOCK
2222-FE-005A
51"
SCALE
1:48
36"
SCALE
1:48
WEATHER HOOD
(10GA STEEL)
TEST STACK
(10GA STEEL)
21-1/2"
TAG:FAN
2222-FA-005A
29-1/8"
285-1/4"
(REF)
13/16"
TYP
5/8-11 BOLT,
NUT & WASHER
6"X6"X3/8"
STRL ANGLE
W/ 2"X2"X1/4"
CROSS BRACING
8
7
6
SOLENOID VALVES
1" NPT
SUPPLY AIR
WEATHERHOOD
W/ BIRDSCREEN
BROKEN BAG
DETECTOR
TEST STACK
W/ TEST PORT
& BROKEN BAG
DETECTOR
SILENCER
(FIELD SUPPORT)
5
A
INTEGRATED CONTROLLER
(NEMA 4; 460 VAC)
LOCATION TO BE
DETERMINED IN THE
FIELD
SLURRY TANK
36 X 36-1/2"H
(TAG#: 222-TK-005)
LEVEL
INDICATORS
FIELD BOLTED
W/ 3/8-16 THRD
CUTTING BOLT
4
B
A
3
The reproduction, distribution and utilization of this document as well as the communication of its contents to others without express authorization is prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.
233053TS1
233053WH1
219294001
208165108
208165044
11
12
13
14
SLANTED
BAFFLES
C C
3
53-3/8"
68-1/8"
*
*
*
*
1
1
2330030017035
N04539C01
1/32
0.060
0.030
2
FRACTIONAL:
2 PLACE DECIMAL:
3 PLACE DECIMAL:
ANGULAR:
TOLERANCES ARE:
INSIDE BEND RADII =
1 METAL THICKNESS
DIMENSIONS ARE IN INCHES
UNLESS OTHERWISE NOTED:
1
EA
EA
EA
NON-TOUCHSCREEN
X
Date
2
www.camfilapc.com
Do not scale Print
Legal Owner
Rev.
7/29/2021
4100373008-CDTO-P32-Z21
approved by
SEC
GS24/20 DUST COLL RAL 7035
TAG: 2222-DC-005A
title, supplementary title
created by
weight
SJK
projection method 3
lbs
DFT
SJK
date of issue
7/29/2021
Rev.
E
N04539001
Identification number
1
CK
SEC
APP
D
1/1
Sh. size sheet
cross reference
document type
1:48
scale
SON
N04539
THIS IS A CERTIFIED SALES DWG
CAMFIL ORDER NO.: N04539
P.O.NO.:
CAMFIL APC
JUAN PABLO NORIEGA
CUSTOMER REP:
SOUTHERN PERU COPPER
CORPORATION SUCURSAL PERU
AV.CAMINOS DEL INCA #171
LIMA, PERU
JOB/LOCATION:
REVISED, CHANGED IT-6 (2339290030-30" AR INLET) TO
2339290024-(24" AR INLET (NEW),
UPDATED CFM TO 12,000, ROTATED FAN 90°CCW,
CHANGED ORIENTATION OF PLATFORM HANDRAILS &
UPPER HANDRAILS,
CERTIFIED DRAWING
Revision Description
CFM: 12,000 @ 10.0" W.G.
AIR-TO-CLOTH RATIO: 1.85:1
APPLICATION: CONVEYING (ROCK DUST)
APPLICATION DATA:
1,773 LBS
700 LBS
530 LBS
4,640
565
2,471
3,240
594
1,527
TOTAL WEIGHT:16,040 LBS
9. WEIGHTS (COLLECTOR & FILTERS):
(AR INLET):
(HOPPER & SUPPORT):
(PLATFORM & LADDER):
(TOP HANDRAILS & LADDER):
(FAN):
(SILENCER,TEST STACK,
& WEATHERHOOD):
(AIRLOCK):
(SLURRY TANK):
LBS
LBS
LBS
LBS
LBS
LBS
-3 TO 1 PSIG
8. EXPLOSION VESSEL STRENGTH: 9.75 PSIG
7. OPERATING VESSEL PRESSURE:
6. CLEANING SYSTEM REQUIRES 60 SCFM OF
CLEAN DRY COMPRESSED AIR WITH
FACTORY SETTINGS AT 90 PSI.
5. IMPORTANT NOTE:
FANS TYPICALLY EXPERIENCE
FOUR TO TEN TIMES THE FULL LOAD
AMPS DURING START-UP. CIRCUITS
AND FUSES MUST BE ADJUSTED
ACCORDINGLY.
4. SOLENOID ENCLOSURE NEMA 4 RATED,
INTEGRATED TIMER CONTROL ENCLOSURE
NEMA 12 RATED, OTHER ELECTRICAL DEVICE
ENCLOSURES & FARR DUST COLLECTOR TIMER
ENCLOSURE NEMA 4X RATED.
NEMA 4-INDOOR/OUTDOOR USE
NEMA 4X-INDOOR/OUTDOORS+CORROSION
PROTECTION. NEMA 12-INDOOR USE,
NO WATER PROTECTION
(DUST TIGHT ONLY)
3. SOLENOIDS REQUIRE 120/1/60 VAC.
2. INTEGRATED TIMER CONTROLS REQUIRE
480VAC THREE PHASE 60 HZ.
1. MODULAR CONSTRUCTION FROM 10 Ga & 7
Ga HRCS
ITC/AO FOR SO# N04539
BLWR/DMP NYB, 11-60-10, 40HP
AIRLOCK 12"X12" MEYER W/O SPSW
FLTR-GS-HG-325-MINING
PNT,PWDR,LIGHT GRAY RAL7035
PNT,PWDR,FARR YELLOW,RAL 1018
FIGURE EIGHT STICKER ASSY
WEATHER HOOD,SZ33 SILENCER
TEST STACK,SZ33,77"
SLURRY DISCHARGE,12DM24H
TOP HANDRAILS, N04539001
SNLCR,BOLTED,SZ33
AR INLET,UHMW,DBL,24"
INSTALLATION KIT FOR N04539001
GS PLTFRM,WRP,24,LFT SDE,STK
GS24 SUPPORT,177-1/8"H END ACC
GS HPPR,2X3,97,11.25,ACC,VP,2LI
MODEL: GS24/20 DUST COLL RAL 7035
E
DESCRIPTION
1
GS24 MODULE FOR N04539001
SALES ORDER
EA
LBS
LBS
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
SPECIFICATIONS:
20
325325020
2126150027035
235
60
1
1
1
1
221306006
9
1
N04539101
10
1
233384024
1
1
233672001
1
1
1
224762039
N04539H01
233053001
1
QTY. UNITS
N04539M01
PART NUMBER
2
2339290024
7
8
6
5
4
3
2
1
ITEM NO.
BLWR/DMP NYB,
11-60-10, 40HP
(TAG:2222-FA-005A)
1" NPT COMPRESSED AIR
REGULATOR W/ GAUGE INCLUDED.
LOCATION TO BE DETERMINED IN
THE FIELD.
(RECOMMENDED TO BE MOUNTED
AWAY FROM DIRECT SUNLIGHT &
FREEZING TEMPERATURES).
SCALE
1:48
B
112"
(TEST PORT)
SCALE
1:48
FOOTPAD DETAIL
SECTION A-A
C
L
120-3/4"
C
L
54-1/4"
C
L
66-1/2"
C
L
INLET FLANGE DETAIL
SECTION C-C
SCALE 1 : 12
.437
(12 PLCS)
ON C
L
24.125
I.D.
25.874
B.C.
40.00
(SLURRY TANK
FLANGE)
11-1/2"
SQ
(8)
.50
HOLES ON A
38.5" B.C.
ON C
L
11-1/2" SQ BASE PLATE
W/ (4)
0.750" HOLES ON
9-1/2"CENTERS
WRAP-AROUND
PLATFORM & HANDRAILS
(PAINTED SAFETY YELLOW)
12X12 HDX AIRLOCK
3-60-480VAC 1.5HP
W/ ZERO SPEED SWITCH
NEMAB
(TAG: 2222-FE-005A)
HOPPER ACCESS
PANEL W/
VIEWPORT
ACCESS DOOR
SS DIAPRAGM VALVE
TUBING & FITTINGS
COMPRESSED AIR
HEADER W/1-1/2"
DIAPHRAGM VALVES
PLATFORM
TEST STACK
SUPPORT
HANDRAIL
TOP HANDRAILS
W/LADDER
FOR FAN ACCESS
(PAINTED SAFETY
YELLOW)
**THE CUSTOMER ASSUMES THE RESPONSIBILITY FOR CONTACTING THEIR INSURANCE UNDERWRITER
AND ADVISING CAMFIL/FARR IN REGARD TO SPECIFIC APPLICATION REQUIREMENTS OF EXPLOSION
VENTING OR IF ADDITIONAL FIRE PROTECTION AND SAFETY EQUIPMENT MAY BE REQUIRED. THE
BUYER IS ALSO CAUTIONED TO ADHERE TO PRESCRIBED OSHA, NFPA, FEDERAL, STATE AND LOCAL
CODES AND REGULATIONS APPLICABLE TO INDUSTRIAL VENTILATION SYSTEMS, WHICH CAMFIL/FARR
EQUIPMENT MAY BE APPLIED ON.
SECTION B-B
SCALE 1 : 8
HOPPER/SLURRY
FLANGE DETAIL
(MATERIAL:
7GA STEEL)
11-1/4"
SQ
14-5/8"
B.C.
SQ
16-1/4"
SQ
GRATING
(GRIP STRUT 12GA
GALVANIZED STEEL)
269-1/4" C
L
(OUTLET)
D
29-1/8"
TAG: DUST DOLLECTOR
2222-DC-005A
47-3/16"
DOUBLE INLET
UHMW LINED
(7GA STEEL &
1/2" UHMW)
240-5/8" C
L
(AIR SUPPLY)
31-1/8"
54"
SIL
77"
TST STK
24-5/8"
WTHR HD
E
60-7/8"
155-5/8"
4
80-1/8"
5
177-1/8"
27.125
O.D.
39-3/8"
C
L
(TYP)
C
L
78-3/4"
C
L
25-5/8"
24" AR INLET
UHMW LINED
(7GA STEEL &
1/2" UHMW)
36-1/2"
6
222"
(INLET)
7
300-1/4"
8
302-1/4"
A
B
C
D
E
A
B
C
D
E
The reproduction, distribution and utilization of this document as well as the communication of its contents to others without express authorization is prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.
8
8
7
7
6
6
5
5
1/32
0.060
0.030
2
FRACTIONAL:
2 PLACE DECIMAL:
3 PLACE DECIMAL:
ANGULAR:
TOLERANCES ARE:
INSIDE BEND RADII =
1 METAL THICKNESS
DIMENSIONS ARE IN INCHES
UNLESS OTHERWISE NOTED:
A
4
www.camfilapc.com
Do not scale Print
Date
7/14/2021
Legal Owner
Rev.
4
3
3
074492000
226446001
217062001
206314006
216426024
216603001
216602001
216600001
216606001
216604001
215160044
215160108
226349001
225654001
232630001
221115001
230980512
230980500
230980501
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
SD
approved by
1
1
1
2
1
1
1
1
1
2
1
1
3
1
1
1
1
1
3
2
QTY.
2
lbs
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
UNITS
INSTALLATION KIT FOR N04539001
title, supplementary title
AT
created by
projection method 3
Revision Description
weight
207171001
1
FIRST ISSUE
PART NUMBER
ITEM NO.
2
DFT
A
7/14/2021
date of issue
N04539101
Identification number
Rev.
CK
SD
1
APP
B
1/1
Sh. size sheet
cross reference
document type
1:6
scale
SON
AT
BRKN BAG DET,CABLE,30FT
BRKN BAG DET,REM ELECT,20-240V
BRKN BAG DET,REM PROBE,12"
LEVEL IND, ATEX, DUAL VOLTAGE
FILTER/REG KIT,1"NPT,SHUTOFF
GS REGISTRATION DOOR TAG
EXTENSION,IMPACT 1/2"DRIVE,5"L
PNT,AEROSOL,FARR YELLW,RAL1018
PNT,AEROSOL,LT. GRAY RAL 7035
BOLT KIT,AIRLOCK & HPPR DISCH
BOLT KIT,AR INLET
BOLT KIT,STD INLET
BOLT KIT,FAN/SILENCER 3/8"HDW
BOLT KIT,FAN PANEL, 3/8" HDW
GS24 SUPPORT HARDWARE KIT
GS HPPR-FILT KIT 2X3
CAMFIL APC PRE-SHPMNT CHECKLIST
IOM MANUAL,JOB SPECIFIC
SEALANT TAPE 1/8X1/4 GREY 40FT
CTN,22X11X16.7 W/R RSC,C
EN_DescriptionII
1
A
B
C
D
E
A
B
C
D
1
1
1
8
7
1/2"-13 X 1.5" BOLTS ARE FOR
ATTACHING THE (4) DOGBONE SHAPED
CORNER CLAMPS TO EACH OTHER.
1/2"-13 X 5" BOLTS ARE FOR
ATTACHING THE HANDRAILS TO EACH
OTHER.
CORNER BRACKET IS FASTENED WITH
1/2"-13 X 3" BOLTS.
CORNER BRACKETS ARE FOUND IN
HARDWARE KIT WHICH IS LOCATED
IN HARDWARE KIT.
NOTE:
DETAIL A
SCALE 1 : 24
The reproduction, distribution and utilization of this document as well as the communication of its contents to others without express authorization is prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.
6
5
6
2
1
5
5
1/32
0.060
0.030
2
FRACTIONAL:
2 PLACE DECIMAL:
3 PLACE DECIMAL:
ANGULAR:
TOLERANCES ARE:
INSIDE BEND RADII =
1 METAL THICKNESS
DIMENSIONS ARE IN INCHES
UNLESS OTHERWISE NOTED:
130-3/8"
B
4
3
5
1
1
3
1
1
1
233383001
233383002
233383004L
233383005
225418001
216729023
N04539H01HDW
EA
EA
EA
EA
EA
EA
EA
UNITS
TOP HNDRL,47-7/32"H,PNT
www.camfilapc.com
3
SEC
approved by
2
DFT
SJK
CK
SEC
date of issue
8/3/2021
Rev.
B
N04539H01
Identification number
1
B
1/1
Sh. size sheet
cross reference
document type
scale
1:48
0.0 lbs
0
SON
N04539
APP
HARDWARE KIT FOR N04539H01
SAFETY GATE,23"-27",LSG-24
TOP PLTFRM LADDER,7RUNG CAGE
TOP MNT HNDRL, 18" H, PTD
TOP HNDRL,47-3/16,25-5/8CT,LFT
weight
TOP HANDRAILS, N04539001
title, supplementary title
SJK
created by
projection method 3
Revision Description
DESCRIPTION
1
TOP HNDRL,47-7/32"H,LDR ACC,PNT
88-3/8"
131-5/8"
QTY.
PART NUMBER
2
CHGD IT-1 (233383001-TOP HNDRL) QTY FROM 7 TO 5,
CHGD IT-3 (233383003-HNDRL CT OUT) TO 233338004LHNDRL CT OUT LFT, QTY 1, CHGD IT-4 (233383004HNDRL CT OUT) TO 233383005-HNDRL CT OUT, QTY 3,
ADDED IT-7 (N04539H01HDW-HARDWARE KIT) QTY 1
7
6
5
4
3
2
1
ITEM NO.
122-7/8"
Do not scale Print
Date
8/3/2021
88-3/8"
Legal Owner
Rev.
4
87"
4
3
6
18-1/4"
E
7
47-1/4"
8
54-1/4"
A
B
C
D
E
A
B
C
D
8
6
142"
3
141-1/8"
7
7
6
6
183-1/8"
The reproduction, distribution and utilization of this document as well as the communication of its contents to others without express authorization is prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.
9
9
2
13
13
3
5
1
1
1
8
11
1/32
0.060
0.030
2
FRACTIONAL:
2 PLACE DECIMAL:
3 PLACE DECIMAL:
ANGULAR:
TOLERANCES ARE:
INSIDE BEND RADII =
1 METAL THICKNESS
DIMENSIONS ARE IN INCHES
UNLESS OTHERWISE NOTED:
1
13
13
14
11
4
10
7
3
1
220580003
233384002
233384005
233384004
233384003
225070003
225070001
233384001
216729023
6
7
8
9
10
11
12
13
14
1
4
2
3
1
2
1
1
1
1
1
2
1
5
QTY
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
UNITS
2
www.camfilapc.com
3
scale
date of issue
7/30/2021
Rev.
B
GS PLTFRM,WRP,24,LFT SDE,STK
1
main-assembly unit
233384024
2
CK
SEC
APP
B
1/1
Sh. size sheet
cross reference
document type
1:50
Farr Gold Series
lbs
DFT
SJK
Identification number
SEC
approved by
weight
SON
N04539
SAFETY GATE,23"-27",LSG-24
HNDRL,PLTFRM,55-1/2"H,PNT
BACKING PLATE,FULL,1/2" BOLTS
BACKING PLATE, FULL, NO DOOR
PLTFM HNDRL,LADDER ACC,PNT
PLTFM HNDRL,CORNER,PNT
HANDRAIL BRACE,TEST STACK,PNT
HNDRL,PLTFM,END,55-1/2"H,PNT
CORNER BRACE,PLTFM SPRT
BOLT KIT,5 MOD PLATFORM,
BOLT KIT,4 MOD PLATFORM,
PLATFORM SUPP KIT,1-5MOD,STD
MOD PLATFORM,CORNER,GRIP,49.5"
title, supplementary title
SJK
created by
projection method 3
Revision Description
DESCRIPTION
1
MODULAR PLATFORM,FULL,GRIP,48"
MOVED TEST STACK HANDRAIL TO FRONT RIGHT
224934005
224931001
3
5
224929004
2
224934004
224929001
1
4
PART NUMBER
3
ITEM NO.
Do not scale Print
Date
7/30/2021
Legal Owner
Rev.
B
11
4
55-1/8"
5
85-5/8"
E
8
122-3/4"
47-1/4"
A
B
C
D
E
1
564
587
8
1
88
155
8
3
213
4 184
1
*252
OUTLET FLANGE
5
216
173
8
237
8
307
8
273
8
7
Ø16
1
202
1
82
Visit us on the Web: http://www.nyb.com
Phone: (800) 208-7918 Email: nyb@nyb.com
08/05/2021
2021-00066-001-02A
DRAWING NUMBER
DATE
THE NEW YORK BLOWER COMPANY
7660 Quincy Street
Willowbrook, IL 60527-5530
DRAWN DL
CERTIFIED DRAWING
104.0% Diam.
Size 334 S20 GI
CW\TH
Arr-4V
NOTICE: This drawing is the property of THE NEW YORK BLOWER
CO. and is loaned subject to the condition that it shall not be
reproduced, copied, loaned or submitted to outside parties without
our consent.
CUSTOMER CAMFIL USA INC
CUSTOMER'S NO. 0421923
FILE NO. 2021-00066
TAGGING P/N 2330030017035
SO# N04539
PO# 0421923
23
INLET FLANGE
*VARIES SLIGHTLY WITH MOTORS OF DIFFERENT MANUFACTURE
7
Ø16
1
202
185
8
155
8
4
22
185
8
A
The
New York Blower
Company
Date:
File:
Sequence:
Revision:
Control:
Chg Order:
Processor:
Customer:
CAMFIL USA INC
Purchase Order:
Tagging:
0421923
P/N 2330030017035
SO# N04539
PO# 0421923
FAN INFORMATION
Quantity:
Product Line:
Size:
Class/Wheel Type:
Rotation:
Arrangement:
Discharge:
Motor Position:
Motor By:
Mounting By:
QTY
8/5/2021
2021-00066
1
A
DRIVE INFORMATION
DESCRIPTION
Motor Sheave
Motor Bushing
Fan Sheave
Fan Bushing
Belt
Belt Centers:
1
5
DL
Office Reference:
1
Series 20 General Industrial
334
NA / AH
CW
4
TH
53903
Bearing Mfg. & Model:
NYB
NYB
Total fan wt. With accessories:
1527 lbs
PART NUMBER
SF:
Belt Tens:
in
FAN PERFORMANCE DATA
Capacity
Operating
Volume (CFM)
12000
Pressure (in wg) Speed (RPM) Power (BHP)
(FSP) 10
1770
30.6
Temp (F)
Density (lb/ft3)
Altitude (FT)
60
0.0477
11500
SALES MEMO INFORMATION
QTY DESCRIPTION
1
Furnish a CW TH Size 334 S/20 Arr. 4V fan with AH wheel built to accommodate a 324/326TC motor
frame per TI [per SPA 21F0020.2], 104.0 % diameter
1
Max SS
1956
Drawing#
40 HP, 1800 RPM, 3-60-460 V., Premium EFF., Severe Duty IEEE841 ENCL., FRAME 324TC, 1.00
S.F., F INSULATION, F1 Conduit Box Location, Cast Iron Frame Construction, Ball Bearing, MFG:
WEG, MFG PART: 04018ST3QIE324TC-W22 (N10), QUOTE: 223707595-0, Rated (nameplated) for
3510 M.A.S.L. , C-Face Footed, Drain holes correctly positioned for vertical shaft down operation,
NEMA Design B, Renameplated 1.0 SF, Lead-time: Modify from stock 4 week(s)
The New York Blower Company
http://www.nyb.com
Page 1 of 2
QTY
1
1
1
1
1
1
DESCRIPTION
Motor Mounting, frame 324TC
Special Diameter Construction
Cleanout Door: Bolted-Flush, Steel, 9:00 (standard)
Flanged Inlet: Steel
Flanged Outlet: Steel
Damper: Outlet, Opposed Blade, Standard/Sleeve Bushings, 300°F, Steel, control arm: Drive Side
1
Coating: Fan, All Surfaces, Alkyd Enamel, Camfil Gray (SMOOTH), RAL 7035, CC28, nyb Standard
Prep, Group: OEM
Coating: Damper: Outlet, External, All Surfaces, Alkyd Enamel, Camfil Gray (SMOOTH), RAL 7035,
CC28, nyb Standard Prep, Group: OEM
Shop to unwire motor after testing
Include Camfil IM-901 manual with shipment of fan.
Provide Camfil Damper Decal (p/n A9801783)
Shop to not coat motor or overspray paint onto motor
Furnish heat treated and stamped wood, shipping materials.
Furnish a special Camfil 4H inlet assembly including an extension, "J" dimension of 8-1/8-inches with
inlet flange bolt hole pattern to be on centerlines****Size 30 fans and up*****
1
1
1
1
1
1
1
1
Provide special Camfil Skeleton Shipment crate with fan wrapped in plastic and provide a Camfil Fan
Nameplate (p/n A9805810) attached to the housing scroll
1
Shop to review housing weldments and grind down any high weld spots that would prevent water from
draining off fan drive side
Furnish a G2.5 wheel balance after the wheel is coated
Balance the fan assembly (with inlet flange mounted to the test structure) to 0.10 in/sec filter-in at
units operating speed in both the horizontal and vertical planes
1
1
1
1
1
Furnish multi-purpose clear sealant (p/n AMA00163) between the motor c-face and the housing drive
side plate
Provide Camfil Damper Decal (p/n A9801783) on the scroll side
Camfil Quality Checklist must be completed prior to shipment. Checklist to be shipped with fan
1
1
1
1
Camfil Decal Centered on the Housing Scroll, Opposite Fan Discharge
Drive side sub-assembly to be designed to prevent water pooling.
Damper arm to be visible from the scroll per TI 12-1592
Mount the motor so that the conduit box is opposite the discharge of the fan
1
Caulk seams between skip welds on drive side structurals to prevent water buildup
1
Furish a 4 point lift single drive side plate to include motor mounting platform for motor feet per TI 16839****Size 30 fans with 286TC frame****
1
Caulk exterior of flanged inlet assembly between gussets with Clear silicone (p/n AMA-0009)
1
1
Furnish wheel retainer
Certified Documents: To-scale Composite Drawings, DWG format, with STP File
1
FAN INSTALLATION AND MAINTENANCE MANUAL REFERENCE NUMBER.
Additional Notes
Drawing#
2021-00066-001A_IM.PDF
REV. A: UPDATE CAPACITIES AND DIAMETER (DL - 08/05/2021)
The New York Blower Company
http://www.nyb.com
Page 2 of 2
Performance Curve
Date:
05-Aug-21
Performance
Options:
Outlet Damper
104.0% Diameter Wheel
Temperature:
Altitude:
60° F
11500 FT
File:
Cust. No.:
Customer:
2021-00066-001
421923
CAMFIL USA INC
3505 S. Airport Road
Product Line:
Series 20 General Industrial
Size:
334
Wheel Type:
AH
Capacity:
Operating
Volume (ACFM): 12,000
Press. (in wg):
10 (FSP)
Speed (RPM):
1770
Power (BHP):
30.6
Density (lb/ft3):
0.0477
Max Safe Speed: 1956
DL
A
25
45
40
20
35
30
25
20
10
Power (BHP)
Pressure (in wg)
15
15
10
5
5
0
0
5000
10000
15000
20000
0
25000
Volume (ACFM)
sp
System Curve
The New York Blower Company http://www.nyb.com
Pt (SP)
bhp
Pt (bhp)
8/5/2021 Page 1
Sound Performance
Date:
05-Aug-21
File:
Cust. No.:
Customer:
Product Line:
Size:
Capacity:
Volume (CFM):
Press. (in wg):
Speed (RPM):
Power (BHP):
Density (lb/ft3):
Max Safe Speed:
Temperature: 60° F
Altitude:
11500 FT
2021-00066-001
DL
421923
CAMFIL USA INC 3505 S. Airport Road
Series 20 General Industrial
334
Operating
12,000
10 (FSP)
1770
30.6
0.0477
1956
A
The sound ratings shown here are fan sound power (Lw) levels (reference:10-12 watts) by octave bands
for a fixed point of operation and speed. They are the result of laboratory tests based on reverberant room
techniques per AMCA bulletin 300 and processed using procedures shown in AMCA bulletin 301. Fan Lw
ratings include both inlet and outlet sound, and the effects of end reflection. For a known installation the
ratings can be used to calculate either sound pressure levels, or dB(A) at a particular location.
SOUND POWER LEVELS (Lw) IN dB RE 10-12 WATTS
LW Fan
Lw Inlet
Lw Outlet
Lw HRN
63
95
92
92
90
125
102
99
99
94
250
107
104
104
95
500
101
98
98
87
1000
101
98
98
89
2000 4000 8000
100
95
93
97
92
90
97
92
90
88
82
79
The estimated sound pressure level outside the fan due to an open
inlet OR outlet is 89 dBA at 5 ft.
The estimated sound pressure level outside the fan when BOTH inlet
and outlet are ducted is 80 dBA at 5 ft (Housing Radiated Noise).
dB values shown (based on Q=1) are approximate and are offered for users' convenience in estimating
noise levels in an installation. nyb cannot guarantee a dB level since it has no control over the installation
and other factors in the environment which may affect that level.
The New York Blower Company http://www.nyb.com
8/5/2021 Page 1
Installation, Maintenance, and Operation Manual
Series 20 General Industrial, Arrangement 4V
Size 33, AH, TH, CW
Product:
File No.
2021-00066-01
Customer:
Customer PO:
0421923
CAMFIL USA INC
WORD ABOUT SAFETY
Beginning in June 2012, the WARNING signage to the right
has been placed on all nyb fans, as specified by ISO and
recommended by the European Union. Air moving equipment
involves electrical wiring, moving parts, sound, and air velocity or
pressure which can create safety hazards if the equipment is not
properly installed, operated and maintained. To minimize this
danger, follow these instructions as well as the additional
instructions and warnings on the equipment itself.
All installers, operators and maintenance personnel should study
AMCA Publication 410, "Recommended Safety Practices for Air
Moving Devices", which is included as part of every shipment.
Additional copies can be obtained by writing to New York Blower
Company, 7660 Quincy St., Willowbrook, IL 60527.
ELECTRICAL DISCONNECTS
Every motor driven fan should have an independent disconnect switch to isolate the unit from the electrical supply. It should be
near the fan and must be capable of being locked by maintenance personnel while servicing the unit, in accordance with OSHA
procedures.
MOVING PARTS
All moving parts must have guards to protect personnel. Safety requirements vary, so the number and type of guards needed to
meet company, local and OSHA standards must be determined and specified by the user. Never start a fan without having all
safety guards installed. Check regularly for damaged or missing guards and do not operate any fan with guards removed. Fans
can also become dangerous because of potential “windmilling”, even though all electrical power is disconnected. Always block
the rotating assembly before working on any moving parts.
SOUND
Some fans can generate sound that could be hazardous to exposed personnel. It is the responsibility of the system designer and
user to determine sound levels of the system, the degree of personnel exposure, and to comply with applicable safety
requirements to protect personnel from excessive noise. Consult nyb for fan sound power level ratings.
AIR PRESSURE AND SUCTION
In addition to the normal dangers of rotating machinery, fans present another hazard from the suction created at the fan inlet.
This suction can draw materials into the fan where they become high velocity projectiles at the outlet. It can also be extremely
dangerous to persons in close proximity to the inlet, as the forces involved can overcome the strength of most individuals. Inlets
and outlets that are not ducted should be screened to prevent entry and discharge of solid objects.
ACCESS DOORS
The DANGER decal to the right is placed on all nyb cleanout
doors. These doors, as well as access doors to the duct system,
should never be opened while the fan is in operation. Serious
injury could result from the effects of air pressure or suction.
Quick-opening doors must have the door handle bolts securely
tightened to prevent accidental or unauthorized opening. Bolted
doors must be tightened for the same reason.
Danger:
Do not Enter/Confined Space
RECEIVING AND INSPECTION
The fan and accessories should be inspected on receipt for any shipping damage. Turn the wheel by hand to see that it rotates
freely and does not bind. If dampers or shutters are provided, check these accessories for free operation of all moving parts.
F.O.B. factory shipping terms require that the receiver be responsible for inspecting the equipment upon arrival. Note damage or
shortages on the Bill of Lading and file any claims for damage or loss in transit. nyb will assist the customer as much as
possible; however, claims must be originated at the point of delivery.
Version
2020.9.14
10/2/2020 11:45:09 AM
Page 1 of 8
Copyright 2017 New York Blower
HANDLING
Fans should be lifted by the base, mounting supports, or lifting eyes/lugs only. Never lift a fan by the wheel, shaft, motor, motor
bracket, housing inlet, outlet, or any fan part not designed for lifting. A spreader should be used to avoid damage.
On direct drive Arrangement 7 or 8 fans, lifting holes are provided in the motor base to assist in handling the fan assembly. These
lifting holes should be used in conjunction with the lifting eyes/lugs when lifting and positioning the fan onto its foundation. A
heavy round steel bar or appropriate fixture can be passed through the lifting holes to simplify attachment of the lifting device. Be
sure to follow all local safety codes when moving heavy equipment.
STORAGE
Whenever possible, fans and accessories should be stored in a clean, dry location to prevent rust and corrosion of steel
components. If outdoor storage is necessary, protection should be provided. Cover the inlet and outlet to prevent the
accumulation of dirt and moisture in the housing. Cover motors with waterproof material. Remove any fan and motor drain plugs
to minimize moisture buildup. Refer to the motor manufacturer's IM manual for further motor storage instructions.
Any stored bearing can be damaged by condensation caused by temperature variations. Therefore, nyb fan bearings are filled
with grease at the factory to exclude air and moisture. Such protection is adequate for shipment and subsequent immediate
installation and operation.
For long term or outdoor storage, mounted bearings should be immediately regreased and wrapped with plastic for protection.
Split housed bearings may require additional grease to completely fill the bearing housing cavity. Rotate the fan wheel and
motor shaft by hand at least every two weeks to redistribute grease on internal bearing parts. Each month the fan and
motor bearings should be purged with new grease to remove condensation, since even a filled bearing can accumulate moisture.
Use caution when purging, as excessive pressure can damage the seals. Rotate the shaft while slowly adding grease.
For Belt-Driven units, belts should be slackened to prevent damage to shaft, belts, and bearings.
Check shutters for free operation and lubricate moving parts prior to storage. Inspect the stored unit periodically to
ensure the above precautionary storage measures are still in tact.
Prior to start-up, split housed bearings should have excess grease removed such that the grease level is level with the bottom of
the shaft.
FAN INSTALLATION
nyb wheels are dynamically balanced when fabricated. Fully assembled fans are test run at operating speeds to check the entire
assembly for conformance to nyb vibration limits. Nevertheless, all units must be adequately supported for smooth operation.
Ductwork or stacks should be independently supported as excess weight may distort the fan housing and cause
contact between moving parts. nyb recommends using flexible connectors at the inlet and outlet to prevent vibration
transmission from the fan to the system and vice versa. Flexible connectors also eliminate loading issues temming from
thermal expansion in systems with high temperature air systems. Where vibration isolators are used, consult the nyb certified
drawing for proper location and adjustment.
Slab-Mounted Units
A correctly designed and level concrete foundation provides the best
means of installing floor-mounted fans. The mass of the base must
maintain the fan/driver alignment, absorb normal vibration, and resist
lateral loads. The overall dimensions of the concrete base should
extend at least six inches beyond the base of the fan. The weight of
the slab should be two to three times the weight of the rotating
assembly, including the motor. The foundation requires firmly
anchored fasteners such as the anchor bolts shown in Figure 1.
Hammer-drilled expansion fasteners can be used in less demanding
applications.
Move the fan to the mounting location and lower it over the anchor
bolts, leveling and supporting the fan base with shims at each bolt
hole location. Fasten the fan securely, ensuring that the fan base is
not put into a bind when tightening anchor bolts. This may cause
distortion that can be transferred to the bearing housings, causing
excessive vibration and premature bearing failure. You should
consider grouting in fans sized 40 and larger. When grout is used,
shim the fan at least 3/4-inch from the concrete base. Do not rely on
grout to support the fan structure. (See Figure 1.) When isolation is
used, check the nyb certified drawing for installation instructions.
Figure 1
Elevated Units
When an elevated or suspended structural steel platform is used, it must have sufficient bracing to support the unit load and
prevent side sway. A poorly designed support structure can experience resonance triggered by the fan operating speed. The
platform should be of welded construction to maintain permanent alignment of all members.
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Copyright 2017 New York Blower
START-UP
A start-up checklist is available on nyb's Maintenance manuals page under the support tools menu.
Visit the following link to view the checklist: https://www.nyb.com/pdf/Catalog/IandM/NYBStartUpChecklist.pdf
Safe operation and maintenance includes the selection and use of appropriate safety accessories for the specific installation. This
is the responsibility of the system designer and requires consideration of equipment location and accessibility as well as adjacent
components. All safety accessories must be installed properly prior to start-up.
Safe operating speed is a function of system temperature and wheel design. Do not under any circumstances exceed the
maximum safe fan speed published in your nyb certified drawing package, which is available from your nyb field sales
representative.
Procedure
1. If the drive components are not supplied by nyb , verify with the manufacturer that the starting torque is adequate for the
speed and inertia of the fan.
2. Inspect the installation prior to starting the fan. Check for any loose items or debris that could be drawn into the fan or
dislodged by the fan discharge. Check the interior of the fan as well. Turn the wheel by hand to check for binding.
3. Check drive installation and belt tension.
4. Check the tightness of all setscrews, nuts and bolts. Ensure that anchor bolts are also properly torqued. When furnished,
tighten hub setscrews with the wheel oriented so that the setscrew is positioned underneath the shaft.
5.
6.
7.
8.
Install all remaining safety devices and guards. Verify that the supply voltage is correct and wire the motor.
Check to ensure that neither the fan nor motor shaft are rotating.
"Bump" the starter to check for proper wheel rotation.
Use extreme caution when testing the fan with ducting disconnected. Apply power and check for unusual sounds or excessive
vibration. If either exists, see the section on Common Fan Problems. To avoid motor overload, do not run the fan for more
than a few seconds if ductwork is not fully installed. Without the ductwork attached, normal operating speed may not be
obtained without motor overload. Once ductwork is attached, check for correct fan speed and complete installation. Ductwork
and guards must be fully installed for safety.
NOTE: Shut the fan down immediately if there is any sudden increase in fan vibration.
Fan Shutoff for Fans with Elevated Airstream Temperatures (Greater than 200° F)
High temperature, rotating equipment such as fans must be protected from “heat soaking”. Fan wheels must be rotating
whenever the airstream temperature is above 200°F. to prevent the shaft from “sagging” causing a permanent bend in the shaft.
After the airstream temperature has fallen below 200°F, the fan can be shutdown. Start-up and shut down procedures are
required to prevent this. If a power failure occurs, rotate the shaft manually if necessary.
If a shaft is bent due to heat soaking or binding a sudden increase in fan vibration will occur. The shaft will need to be removed,
checked for straightness and straightened or replaced.
FAN MAINTENANCE
nyb fans are manufactured to high standards with quality materials and components. Proper maintenance will ensure a long and
trouble-free service life. Do not attempt any maintenance on a fan unless the electrical supply has been completely
disconnected and locked out. In many cases, a fan can windmill despite removal of all electrical power. The rotating assembly
should be blocked securely before attempting maintenance of any kind.
The key to good fan maintenance is regular and systematic inspection of all fan parts. Inspection frequency is determined by the
severity of the application and local conditions. Strict adherence to an inspection schedule is essential.
Regular fan maintenance should include the following:
1. Check the fan wheel for any wear or corrosion, as either can cause catastrophic failures. Check also for the buildup of
material which can cause unbalance resulting in vibration, bearing wear and serious safety hazards. Clean or replace the
wheel as required.
2. Check the V-belt drive for proper alignment and tension (see section on V-belt drives). If belts are worn, replace them as a set,
matched to within manufacturer’s tolerances. Lubricate the coupling of direct-drive units and check for alignment (see section
on couplings).
3. Lubricate the bearings, but do not over lubricate (see the bearing section for detailed specifications).
4. Ceramic-felt shaft seals require no maintenance, although worn seals should be replaced. When lip-type shaft seals are
provided, lubricate them with "NEVER-SEEZ" or other anti-seize compound. Schedule in accordance with the bearing
lubrication table.
WARNING: Do not remove or loosen the fan hub from the fan wheel. Removing or loosening the fan hub from the fan
wheel will cause imbalance and void the warranty.
5. During any routine maintenance, all setscrews and bolts should be checked for tightness. See the corresponding table for
correct torques.
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Page 3 of 8
Copyright 2017 New York Blower
6. When installing a new wheel or cone, the proper wheel-to-inlet cone clearance must be maintained (see Figure 3 for correct
wheel dimension).
7. WARNING: When installing any new rotating components (wheel, shaft, bearings, coupling, drive components, or motor), it
is recommended that the procedures in the Start-Up section are followed. Fan vibration readings should be taken and a trim
balance be performed if excessive vibration is experienced.
WHEEL CONE CLEARANCE
Figure 3 (Dimensions are in inches)
Fan Size
33
"D" Dim
11 5/16
WHEEL BALANCE
Airstreams containing particulate or chemicals can cause abrasion or corrosion of the fan parts. This wear is often uneven and
can lead to significant wheel imbalance over time. When such wear is discovered, a decision must be made as to whether to
rebalance or replace the wheel.
The soundness of all parts should be determined if the original thickness of components is reduced. Be sure there is no hidden
structural damage. The airstream components should also be cleaned to remove any build-up of foreign material. Specialized
equipment can be used to rebalance a cleaned wheel that is considered structurally sound.
Balance weights should be rigidly attached at a point that will not interfere with the housing nor disrupt airflow. Remember that
centrifugal forces can be extremely high at the outer radius of a fan wheel. Welding is the preferred method of balance weight
attachment. Be sure to ground the welder directly to the fan wheel. Otherwise, the welding current could pass through the fan
bearings and damage them.
GOVERNMENT WARNINGS
Disposal of material should be made in accordance to local government regulations.
California Prop 65 - WARNING: This product contains a chemcial known to the state of California to cause cancer
and/or birth defects or other reproductive harm.
COMMON FAN PROBLEMS
Excessive Vibration
Premature Component Failure
A common complaint regarding industrial fans is “excessive
vibration”. nyb is careful to ensure that each unit is
precisely balanced prior to shipment; however, there are
many other causes of vibration including:
1. Loose mounting bolts, setscrews, bearings or couplings.
2. Misalignment or excessive wear of couplings or bearings.
3. Misaligned or unbalanced motor.
4. Bent shaft due to mishandling or material impact.
5. Accumulation of foreign material on the wheel.
6. Excessive wear or erosion of the wheel.
7. Excessive system pressure or restriction of airflow due to
closed dampers.
8. Inadequate structural support, mounting procedures or
materials.
9. Externally transmitted vibration.
1. Prolonged or major vibration.
2. Inadequate or improper maintenance.
3. Abrasive or corrosive elements in the airstream or surrounding
environment.
4. Misalignment or physical damage to rotating components or
bearings.
5. Bearing failure from incorrect or contaminated lubricant or
grounding through the bearings while arc welding.
6. Excessive fan speed.
7. Extreme ambient or airstream temperatures.
8. Improper belt tension.
9. Improper tightening of wheel setscrews.
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Copyright 2017 New York Blower
Inadequate Performance
Excessive Noise
1. Incorrect testing procedures or calculations.
2. Fan running too slowly.
3. Fan wheel rotating in wrong direction or installed
backwards on shaft.
4. Wheel not properly centered relative to inlet cone.
5. Damaged or incorrectly installed cut off sheet or diverter.
6. Poor system design, closed dampers, air leaks, clogged
filters, or coils.
7. Obstructions or sharp elbows near inlets.
8. Sharp deflection of airstream at fan outlet.
1. Fan operating near “stall” due to incorrect system design or
installation.
2. Vibration originating elsewhere in the system.
3. System resonance or pulsation.
4. Improper location or orientation of fan intake and discharge.
5. Inadequate or faulty design of supporting structures.
6. Nearby sound reflecting surfaces.
7. Loose accessories or components.
8. Loose drive belts.
9. Worn bearings.
REPLACEMENT PARTS
It is recommended that only factory-supplied replacement parts be used. nyb fan parts are built to be fully compatible with the
original fan, using specific alloys and tolerances. These parts carry a standard nyb warranty.
When ordering replacement parts, specify the part name, nyb shop and sequence number, fan size, type, rotation (viewed
from drive end), arrangement and bearing size or bore. Most of this information is on the metal nameplate attached to the fan
base. For assistance in selecting replacement parts, contact your local nyb representative or visit the below link:
https://www.nyb.com/replacement-parts-form/
Order Example (prior to 2013):
Part required: Wheel
Shop/control number: B-10106-100
Fan description: 33" PLR
Clockwise rotation
Arrangement: 1
Bearing: Link-Belt P335, 2-3/16 Bore
Order Example (after to 2013):
Part required: Wheel
Shop number: 2013-XXXXX Wheel
Fan description: 36 ACF
Year of Manufacture: 2013
Fan Description: ACF SW Fan Class
3 Arr-9
Suggested replacement/component parts include:
Wheel
Shaft
Bearings
Shaft Seal
Inlet Cone
-
Damper
Motor
Coupling
Sheaves
V-Belts
LIMITED PRODUCT WARRANTY
All products are warranted by nyb to be free from defects in materials and workmanship for a period of one (1) year after
shipment from its plant, provided buyer demonstrates to satisfaction of nyb that the product was properly installed and maintained
in accordance with nyb's instructions and recommendations and that it was used under normal operating conditions.
This warranty is limited to the replacing and/or repairing by nyb of any part or parts which have been returned to
with nyb's written authorization and which in nyb's opinion are defective. Parts not manufactured by nyb but installed by nyb in
equipment sold to the buyer shall carry the original manufacturer’s warranty only. All transportation charges and any and all sales
and use taxes, duties, imports or excises for such part or parts shall be paid for by the buyer. nyb shall have the sole right to
determine whether defective parts shall be repaired or replaced.
This warranty does not cover any customer labor charges for replacement of parts, adjustments or repairs, or any other work
unless such charges shall be assumed or authorized in advance, in writing, by nyb.
This warranty does not cover any product which, in the judgement of nyb, has been subject to misuse or neglect, or which has
been repaired or altered outside nyb's plant in any way which may have impaired its safety, operation or efficiency, or any product
which has been subject to accident.
This warranty shall be null and void if any part not manufactured or supplied by nyb for use in any of its products shall have been
substituted and used in place of a part manufactured or supplied by nyb for such use. There are no warranties, other than those
appearing on the acknowledgement form INCLUDING NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE, given in connection with the sale of the goods sold hereunder. The buyer agrees that his sole and
exclusive remedy, and the limit of nyb's liability for loss from any cause whatsoever, shall be the purchase price of the goods sold
hereunder for which a claim is made.
Version
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Page 5 of 8
Copyright 2017 New York Blower
FAN OUTLET DAMPER
Installation
Dampers are designed and manufactured with flanges and mounting holes to
match the fan’s outlet flange. Gasketing may
be used between the flanges as required.
Standard construction of nyb fan outlet dampers requires dampers to be
mounted with the control arm and linkage positioned on the inlet side of the fan
with the control arm pointing toward the fan. (Figure 1)
Figure 1
Maintenance
Routine maintenance of dampers should include periodic inspection of the vanes and rods in the airstream to determine if replacement is
necessary due to airstream corrosion or abrasion.
Vane rod bearings and linkage bushings should be inspected for looseness or wear and replaced when necessary. Standard dampers may
require occasional lubrication of friction points with 30W oil.
Optional flanged ball bearings with grease fittings should be lubricated with lithium base NLGI Grade No. 2 grease every six (6) months
during typical operation.
Optional stuffing box packing should be repacked with 1/8” diameter graphite packing when leakage is excessive.
Operation
Air moving across a damper exerts a considerable amount of force on the
damper vanes. Vanes tend to close as a result of this force. A locking bolt is
provided on the control arm to hold the vanes in the desired position, (Figure
2). See separate Catalog Sheet for Outlet Dampers for Centrifugal Fans for
calculating required operating torque.
For manual operation of the damper, the locking bolt should be loosened
sufficiently to permit movement of the control arm to the desired position. The
locking bolt should be retightened to maintain the desired position.
For electric, hydraulic, pneumatic or mechanical operation of the damper, the
locking bolt should be removed from the control arm. This allows freedom of
movement for the damper and operator linkage.
Figure 2
Shipping
Fan outlet dampers are shipped mounted on fans whenever possible. Shipment on separate skids may be required when the size of the
fan/damper combination poses shipping difficulties.
Receiving and Inspection
Unpack and inspect the damper. Loosen the control arm locking bolt and operate the damper from the closed to open positions several times
to insure that the vanes and linkage move freely and do not bind. Any visible sign of damage should be noted on the Bill of Lading.
Handling and Storage
Damper should be lifted by the external case only, never by the vanes, linkage, control plate or control arm.
Whenever possible, dampers should be stored in clean, dry locations to prevent rust and corrosion. If outdoor storage is necessary, damper
should be as well protected as possible against the elements.
If long term storage is required, routine maintenance procedures should be followed and the damper should be modulated periodically to
insure free movement of vanes and linkage.
Replacement Parts
Dampers can be disassembled in the field by removing control plate,
control arm, linkage, case side, and vane/rod sub-assemblies in that
order without removing the remainder of the damper case from the fan
or ductwork.
Only ordinary hand tools are required to replace vanes, bearings and
bushings.
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Page 6 of 8
Required Ordering Information:
Fan Size and Type: __________
Rotation: __________
Damper Type: __________
Optional Features: __________
nyb File Number: __________
Copyright 2017 New York Blower
INFORMATION AND WARNINGS
ON ALL NYB FANS
Beginning in June 2012, warning signage has been placed on all nyb fans in the form of readily understandable
symbols or pictograms, as specified by ISO and recommended by the European Union. The following is a brief
description of each pictogram:
General Hazard
Hand Crush from above
Electrical Hazard due to
motor
Entanglement of
Hand/Rotating Shaft
Danger of having hands
or fingers cut
Do Not Enter/Confined
Space
Mandatory Instructions:
Hand Crush / Pinch Point
Possiblity of entaglement
of hand or fingers
Lock Power Supply in Off
Position and wait for shaft
to stop rotating prior to
opening and servicing
Read Installation,
Maintenance, and
Operating Manual
Hot Surfaces
Lift Here
Version
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Page 7 of 8
Copyright 2017 New York Blower
SPECIFY ROTATION AS VIEWED FROM DRIVE SIDE
RIM
LS
DH
BP/RD
ARROW INDICATES CLOCKWISE ROTATION
ROTATABLE
CENTRIFUGAL FANS
4
1
5
3
8
6
2
4
5
7
NON-ROTATABLE
CENTRIFUGAL FANS
PARTS LIST
8
1.INLET HANGER ASSEMBLY
2.INLET PLATE ASSEMBLY
3.ROTATABLE HOUSING ASSEMBLY #
4.WHEEL *#
5.SHAFT *
6.DRIVE SIDE HANGER ASSEMBLY
7.HOUSING/BEARING PEDESTAL
ASSEMBLY (NON-ROTATABLE) #
8.BEARINGS *
* Suggested Repair Parts
# Order for parts must
specify rotation
When ordering replacement parts
supply nyb shop number from
nameplate and complete description
of parts required.
For assistance in selecting replacement parts, contact your local
nyb representative or visit: http://www.nyb.com.
Form 718 JLK
830 – Collector Discharge Information
295-A-008
Effective 8/01/2019
Rotary Airlock Feeders
INSTALLATION, OPERATION &
MAINTENANCE INSTRUCTIONS
Read this manual carefully before installing, operating or maintaining this equipment. Failure to do so could
result in serious injury or death.
Save this manual
HDX SERIES
UDV SERIES
DDV SERIES
Your Source for Bulk Handling/Air Process Equipment
Wm. W. Meyer & Sons, Inc.
1700 Franklin Blvd • Libertyville, Illinois 60048-4407 • 800-963-4458 • 847-918-0111 • Fax: 847-918-8183
e-mail: sales@wmwmeyer.com · websites: http://www.meyerindustrial.com or www.wmwmeyer.com
1
TABLE OF CONTENTS
Safety Precautions....................................................................................... 2
Application and Models............................................................................... 7
Installation................................................................................................... 8
Start-Up Procedure.................................................................................... 10
Proper Handling and Maintenance............................................................ 11
Parts List and Drawing............................................................................... 13
SECTION I
SAFETY PRECAUTIONS
TO THE OWNER, AND INSTALLATION, OPERATION AND MAINTENANCE PERSONNEL
The safety of the operator and those people that may come into contact with the Rotary Airlock Feeder
Valve is of great importance to Wm. W. Meyer & Sons, Inc. (“Meyer”). The decals, shields, guards
and other protective features designed, furnished or recommended for this machine are there for
your protection. BEFORE attempting to install, operate or perform maintenance on this Equipment
READ carefully and UNDERSTAND all safety instructions contained in this Installation, Operation, and
Maintenance Instructions. Failure to do so could result in serious injury or death.
Equipment owner responsibilities
Equipment owners are responsible for understanding the contents of this document and compliance
with applicable government laws and regulations and appropriate industry standards. Appropriate
plant safety and equipment training is the responsibility of the plant owner. This Manual is intended to
assist the owner in the training process. The installation, operation and maintenance of this equipment
should be restricted based on the following:
•
Installation and maintenance of equipment must be performed by qualified mechanics/millwrights/
maintenance personnel that are familiar with the relevant contents of this manual.
•
Installation of any electrical equipment must be completed by qualified electricians, in
compliance with applicable codes and ordinances.
Because Meyer is not always aware of the application and does not always have access to the
installation, your participation in the safe installation, operation and maintenance of your Rotary
Airlock Feeder is critical. The owner/operator is responsible for any hazards related to the material that
is being processed through the equipment. If you have any safety or operational questions pertaining
to the design or applications of the Rotary Airlock Feeder we encourage you to contact the factory at
(800) 963-4458.
Consult the factory for the availability of manuals in other languages.
2
SIGNAL WORD DEFINITIONS
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
Indicates a hazardous situation which, if not avoided, could result in death or serious
injury.
Indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
Indicates information that is important, which if not followed, may cause damage to
the equipment.
IMPORTANT SAFETY INFORMATION
To reduce the risk of serious injury or death:
•
Be qualified.
o Operation of this equipment must be limited to those that are properly trained in its use.
o
•
Servicing or maintaining this equipment must be performed by trained maintenance personnel
only.
Read all safety information.
o Read and understand all the safety related information contained in this manual prior to
attempting to perform any work on this equipment.
o Obey all the safety labels on the equipment. Do not remove any safety labels. If the equipment
is missing any labels (see “SAFETY LABELING” section), contact the factory immediately, before
putting the equipment into service.
o For add on equipment; motor, switches, etc. refer to the appropriate manufacturer’s safety
information.
•
Heavy – handle safely. The weight of this equipment and its component parts could cause serious
injury if dropped or mishandled during installation, service, or maintenance. Always use safe
handling and rigging methods.
•
Guard and avoid dangerous internal parts. The internals of this equipment contains moving part(s)
that will crush and cut any body parts they come in contact with, resulting in serious injury or
death.
o Equipment can start without warning.
o Inlet and outlet flanges must always be permanently fastened to mating system components
or permanently guarded. Components and guards must be designed such that no access to
the interior of the equipment is allowed during operation. See “HAZARD IDENTIFICATION” for
process integration and installation details.
o Never open access covers/door or reach inside the equipment for any reason while it is in
operation.
•
Guard external moving parts. Unguarded external moving parts expose personnel to pinch points,
which could result in serious injury or death.
o Never operate this equipment without guards attached.
3
o Any accessory or auxiliary components installed with this equipment must have protective
guarding correctly installed and permanently fastened in place.
•
Keep clear. Always keep hands, feet, or other body part, loose clothing, jewelry, away from the
inlet/outlet, drive, components/accessories, and associated equipment.
•
Lockout/Tagout all sources of energy and relieve pressure before installing, servicing, or
maintaining this equipment. This includes but is not limited to: motors, switches, cylinders, and
solenoids.
o Equipment may start remotely, without warning, if energized.
o Hazardous voltage presents the risk of electrical shock.
o Equipment may be under pressure – pressurized gas and material could cause serious injury or
death.
o Equipment surfaces may be hot; allow them to cool before performing any work.
HAZARD IDENTIFICATION
Principle of operation
Rotary Airlock Feeders are components that are used as an airlock transition point, sealing pressurized
systems against loss of air or gas while maintaining a flow of material between components with
different pressure. They are a particularly versatile component which can be utilized in a wide variety
of material handling applications. By their nature, Rotary Airlock Feeders are of no use by themselves;
they are only useful when added as a component to a material handling system as part of a larger
process.
Amputation hazard
Rotary Airlock Feeders have tight clearances and powerful motors. If either the inlet or discharge
openings are left unguarded, the Rotary Airlock Feeder’s rotor presents a serious personal injury
hazard, including but not limited to amputation. Any part of the human body in the way of a rotor and
the housing will be cut off.
Guarding discharge
As a courtesy, the Rotary Airlock Feeder is shipped with an attached discharge flange guard. This
guard should not be removed and should remain in place during operation. However, due to the vast
number of potential applications in which Rotary Airlock Feeders can be used, it is neither feasible nor
practical for Meyer to supply a discharge guard which will be effective in every possible application or
process. If the supplied discharge flange guard does not work for your specific application or process,
alternative suitable guarding must be utilized to ensure safe operation. “Alternative suitable guarding”
could be another piece of equipment, chute, bin or custom discharge guard. It is imperative that the
Rotary Airlock Feeder should not be operated without the discharge opening fully guarded such that no
contact can be made with the moving parts inside of the equipment. It remains the owner/operator’s
responsibility to ensure that the Rotary Airlock Feeder is safely integrated for the particular process
and application for which it was purchased and that the discharge opening remains guarded at all times
during operation.
4
Guarding inlet
In most applications, the Rotary Airlock Feeder will be integrated into a process, system or application
where the inlet opening of the Feeder will be guarded by virtue of being attached to another piece
of equipment (bin, hopper, etc.) However, there may be instances or situations where the inlet of
the Rotary Airlock Feeder becomes accessible (i.e. through a clean out door or access hatch on the
attached equipment) to a user. As noted above, due to the vast number of potential applications in
which a Rotary Airlock Feeder may be used, it is neither feasible nor practical for Meyer to design or
supply an inlet flange guard that will work for every possible application or process. It is the owner/
operator’s responsibility to ensure that the Rotary Airlock Feeder is safely integrated for the particular
process and application for which it was purchased and that the inlet opening remains guarded at all
times during operation.
Training
The owner also bears the responsibility to ensure that personnel who may be working around a rotary
valve are properly trained. Personnel must be aware that: (1) anything coming into contact with the
moving vanes will be cut off/amputated; (2) rotary valves can start without warning; (3) before working
on, cleaning, repairing or maintaining a rotary valve, Lockout/Tagout procedures must be strictly
followed; and (4) rotary valves must not be operated without guarding in place. Before working around
a rotary valve, personnel must read the Operator’s Manual.
SAFETY LABELING
The safety labels shown are affixed to your Rotary Airlock Feeder. A Safety Supplement Data sheet and
an auxiliary “DANGER” label have been packed with your equipment at the time of shipment. Because
Rotary Airlock Feeders can be used in a vast number of applications and in a number of configurations,
it is possible that the safety labels affixed to the equipment may be obscured when installed and
integrated into a customer’s particular application or process. Thus, Meyer supplies the auxiliary
“DANGER” label for the installer’s or plant manager’s discretionary placement to best ensure that
anyone approaching the unit is alerted to the hazards presented by rotating parts and how to safely
interact with the equipment. Additional Safety Supplements and “DANGER” labels are available at no
charge; contact Meyer (800-963-4458), sales@wmwmeyer.com.
5
The following recommendations are offered to assist in the placement of the safety labels. The
objective is for anyone who approaches the Rotary Airlock Feeder sees the label alerting him or her
how to avoid the hazard.
•
Place labels in locations that all personnel operating and maintaining the Rotary Airlock Feeder or
any other people that may have access to the equipment will readily see as they are preparing to
work on the equipment and/or as they approach it.
•
Due to the location of the Rotary Airlock Feeder, labels may have to be located near it, for example;
on nearby structural steel or adjacent equipment. This location needs to be the point of access
where the label can be easily seen and the hazard is clearly associated with the Rotary Airlock
Feeder.
If you have received a unit without labels or if labels fall off or are damaged, contact Meyer
immediately (800-963-4458) to obtain replacements at no charge, prior to installation, use or
maintenance.
Please provide unit operating temperature at time of request.
6
INFORMATION FOR SAFETY AND SERVICE
Because of the wide variety of material handling systems for which a Rotary Airlock Feeder must be
tailored, many considerations determine the proper size, design, materials of construction, operating
speed, type of driver, etc. A description of every Meyer Rotary Airlock Feeder is kept on file at the
factory for a substantial period of time. These specifications can be referenced by supplying the serial
number to your local Meyer Representative. If you have any safety or equipment related questions,
we encourage you to contact the Meyer factory based on the cover contact information.
The serial number is located on a metal identification label permanently affixed to every Rotary Airlock
Feeder before it leaves the factory. To aid us in providing you with service, application assistance and
help with spare part requirements, please record the following:
Type/Size _________________________________
Serial Number _____________________________
Date of Installation__________________________
SECTION II
APPLICATION & MODELS
A. Application
Meyer Rotary Airlock Feeders (also called Rotary Valves) are used in pneumatic conveying systems,
dust control equipment, and as volumetric feed-controls to maintain an even flow of material through
processing systems.
The rotary airlock is used to separate two vessels or areas of differing pressure while allowing the
transfer of material. Rotary Airlock Feeders are also widely used as volumetric feeders for metering
materials at precise flow rates from bins, hoppers or silos into conveying or processing systems.
Rotary Airlock Feeders have wide application in industry wherever dry flee-flowing powders, granules,
crystals, or pellets are used. Typical materials include: cement, sugar, minerals, grains, plastics, dust, fly
ash, flour, gypsum, lime, coffee, cereals, pharmaceuticals, etc.
B. Models
The HDX, UDV and DDV differ mainly in their drive configuration and the number of options available.
The HDX and UDV use a chain drive while the DDV has a direct drive mounted on one head plate.
The DDV is provided with a standard 22 RPM direct drive with motor and either a beveled edges or
urethane seal strips.
The UDV comes standard in 15, 20 and 25 RPM chain driven rotor speeds. The chain drive includes a
motor, reducer and drive guard/base. Rotors are available with beveled edges or urethane seal strips.
The standard speed for the HDX is 15 or 20 RPM, plus a wide variety of drive and special speed
configurations. Many coatings, housings and rotor options are available to meet the most demanding
applications.
7
SECTION III
INSTALLATION
A. RECEIVING AND INSPECTION
Upon receipt of equipment and material from Meyer, the following basic steps should be taken. The
equipment is heavy and proper handling procedures should be used (See the “Heavy - handly safely”
information in the “IMPORTANT SAFETY INFORMATION” section).
1. Use the packing list to determine that all the items shipped have been received. Your equipment
was carefully crated for safe shipment when given to the carrier. If items are missing, contact
Meyer, per the contact information at the end of this section.
2. Check for damage. Damage in transit is the responsibility of the carrier. Title to your equipment
and all other items in the shipment were transferred to you as soon as the shipment left our dock,
thus it is your responsibility to handle any claim. In the event damage has occurred:
a. Be sure to have the driver sign a copy of the freight bill with a notation about any damage and
contact their office before the driver leaves your premises.
b. Contact the carrier to arrange for an independent inspector to come out to inspect the damage
and to prepare the inspection report. It is imperative that this inspection is done before you
start to unpack or use any of the equipment.
c. If there are any visible problems with your unit or any other items in the shipment, you or the
driver must note in detail the damage on all copies of the freight bill before signing for the
shipment. Then immediately call Meyer.
d. Photographic records of the damage are helpful to communicate the extent and type of damage
as well as provide a clear record.
e. In addition to inspecting damaged equipment you should also check the condition of the safety
labels to ensure they have not been damaged or come off. If they have, contact the factory for
replacements prior to installation.
f.
Concealed Damage: If Equipment or goods are discovered to be damaged in shipment at a later
date, contact the carrier and Meyer, immediately.
g. In all cases of damage in transit, contact Meyer, for assistance in determining whether or not
this damage may, in any way, affect safety or proper operation. Please contact us so that we
can assist you with replacement parts or with any questions about the claim process, using the
following contact information:
Wm. W. Meyer & Sons, Inc.
800-963-4458 or 847-918-0111
1700 Franklin Blvd
sales@wmwmeyer.com
Libertyville, IL 60048
B. STORING THE ROTARY VALVE
Short Term Storage (Up to 4 weeks)
1. If moved to storage, the equipment should be located in a dry area, preferably inside. Outside
storage will require adequate protection from the weather.
8
2. The inlet and outlet of the Rotary Valve should be securely covered to protect the interior while in
storage. For prolonged storage an anti-rust compound should be applied to all interior surfaces.
See the motor and reducer manuals for storage instructions.
3. After storage and prior to start-up, the Rotary Valve and its drive train should be inspected by
qualified personnel.
Long Term Storage
1. Coat the interior of the valve with a rust preventative product.
2. Provide and install gasketed or sealed metal covers for inlet and outlet flanges with at least four cap
screws in each flange. Keep covers on unit until ready for service.
3. Read and follow the motor, speed reducer, and other equipment manufacturer’s instructions for
long term storage.
4. Plug all conduit box openings on motors and switches.
5. Store off the floor in a dry, adequately ventilated, indoor area not subject to extreme temperature
changes.
6. If stored for more than 6 months, turn the rotor 20 revolutions every month. Leave the rotor in a
different angular position after turning.
Placing In Service after Long Term Storage
1. Drain and re-fill gear the speed reducer per the manufacturer’s recommendation.
2. Follow the motor manufacturer’s instructions for removing the motor from storage.
3. Clean the anti-rust product from the interior of valve.
C. INSTALLATION
When installing, verify that the openings will be properly guarded and that the labels will be visible (see
“HAZARD IDENTIFICATION” section).
The internals of this equipment has parts that can crush and cut. Before installing
the equipment ensure that Lockout/Tagout procedures have been followed. Failure
to do so will lead to serious injury or death if a body part contacts a moving internal part.
1. We recommend that inlet and outlet flanges remain covered until the valve is ready to be attached
to the mating equipment.
2. Prior to installing the valve and with the power disconnected, check to ensure no foreign objects
have been left inside or have accidentally fallen into the valve.
3. Rotary Valves must be installed with the top and bottom flanges parallel to the mating system
flanges and adequately supported to prevent distortion.
4. Ensure that the inlet and outlet flanges are permanently fastened to mating components or are
permanently guarded.
5. If electrical connections are made as part of the installation, they must be done by a qualified
electrician, in accordance with applicable codes and standards. Standard rotation for this
equipment is clockwise as viewed from the drive end, unless otherwise stated. Rotation should
only be checked after proper guarding has been completed. See “HAZARD IDENTIFICATION” for
process integration and installation details. In order to check for the proper rotation, a portion of
the rotor shaft will need to be observed. The safest way in which to do this is by placing a mark on
the shaft between the bearing and packing gland nut. The mark must be made prior to energizing
9
the motor. If that is not practical, the non-drive end bearing cap can be removed so that the end
of the shaft is visible. For standard clockwise rotation the non-drive end of the shaft will rotate
counter clockwise. Do not touch the exposed rotor shaft. “Bump start” the motor and check for
proper rotation. Replace the bearing cap after rotation has been established.
SECTION IV
START-UP PROCEDURE
Prior to use, the operator must read and understand all the safety related
information including all warnings and guarding instructions. Verify that all guarding
is in place and area is clear of all non-essential personnel. Failure to do so could lead to serious injury
or death.
1. The general appearance of the rotary airlock feeder and surrounding area should be visually
inspected to determine that the unit can be operated safely and without causing any damage. Be
sure all guards are in place and access to the inlet or outlet is not possible.
2. The speed reducer was filled with lubricant prior to shipping but the level should be checked before
initial use.
3. Start the rotary airlock feeder and be alert for unusual noise; scrapping/squealing, or vibration. If
noise or vibration occurs shutdown the unit. Do not attempt to correct the problem without first
contacting the factory. Doing so could void warranty coverage.
4. There is no “break-in” period with rotary airlock feeders. It is, however, recommended that it
should be monitored during the initial operation and on a regular schedule with particular attention
paid to the following:
a. Motor and Speed Reducer – monitor for excessive heat, vibration or unusual noise which may
indicate a problem.
b. Bearings – check for excessive heat, vibration or unusual noise.
c. Seals – the type of seal depends on the model and options on the unit. If there is leakage
around the shaft carefully tighten the packing gland nuts until the leakage stops.
d. Drive – the drive should run smoothly with minimal vibration. If an issue exists contact the
factory for an application review.
In general, observe the equipment for any unusual vibration, heat, or noise. Check the flange and
purge connection fasteners for tightness and leaks. Any utility service piping and associated valves and
gauges should also be checked. Make sure all accessories are operating properly.
10
SECTION V
PROPER HANDLING AND MAINTENANCE
The internals of this equipment has parts that can crush and cut. Follow Lockout/
Tagout information in the “IMPORTANT SAFETY INFORMATION” section before
service or maintenance. Failure to do so will lead to serious injury or death if a body part contacts a
moving internal part. In addition the equipment and parts are heavy, see the “Heavy – handle safely”
information in the “IMPORTANT SAFETY INFORMATION” section.
The Meyer Rotary Airlock Feeder has been manufactured from the finest materials available and to
exacting standards of workmanship. Very close and precise tolerances assure the best possible fit and
seal between all components. As with any quality product, it should be given proper handling and care,
as outlined below:
•
Never switch a rotor from one rotary valve to another without contacting the factory. Due to
temperature and application considerations, not all parts are interchangeable. Some housings and
rotors are “mated”.
•
Use special care and handling to avoid damaging (i.e., nicking, scoring, gouging, galling, etc.) any
internal surface, edge or contour of the housing, rotor or head plate. Any degradation of these
machined surfaces may upset the internal clearances, cause the valve to bind and cause extensive
damage.
•
Rotary Airlock Feeders of cast iron construction without any special purpose surface coating (such
as electroless nickel) are subject to rust and corrosion when exposed to moisture. If water is used
as a cleaning agent, be sure the valve is completely dry and rotor is free to turn before returning to
service.
•
Sealed and pre-lubricated bearings are normally supplied with the Rotary Airlock Feeder. If the
Rotary Valve components are to be submerged in a cleaning tank or similar type of bath, the
bearings must first be removed from the head plate.
•
Always clean and inspect one valve at a time and reassemble immediately to avoid mismatching
parts.
LUBRICATION
•
Speed Reducer
o Lubrication instructions are published by the particular reducer manufacturer.
•
Bearings
o Ball Bearing Units
Rotary Airlock Feeders with ball bearings utilize pre-lubricated, sealed, anti-friction ball bearings
that do not require regreasing. Regreasable bearings are available upon request. Super Lube®,
which is NLGI #2 synthetic grease, is used at the factory when regreasable bearings are installed.
Replacement grease must be compatible with this or all the existing grease must be purged
from the bearing. Regreasing is done by first removing the bearing caps and using a grease gun
to pump grease into the bearings. When the new grease is forced out of the bearing seals, this
indicates that the old grease is out and the bearing has the correct amount of new lubricant.
11
o Spherical Bearing Units
These bearings are an open style that requires external seals and periodic regreasing. The
factory’s standard grease for these bearings is Super Lube® for applications below 500˚F. For
applications above this temperature, consult the factory for the proper lubricant to use.
•
Seals/Packing Gland
UDV and DDV use a split packing gland nut design which allows the packing gland nuts to be
removed from the valve for easier servicing of the packing. UDV and DDV feeders are supplied with
graphite impregnated aramid fiber within the packing gland housing. Special UDV valves may be
supplied with higher temperature seal materials, if the application requires.
Standard HDX Feeders are supplied with graphite impregnated aramid fiber packing within
the packing gland housing. Maintenance is limited to tightening the packing gland hex nuts or
replacement of the packing rings in each head plate, when wear/leakage becomes excessive.
Simply loosen the packing gland retainer hex nuts and slide the packing gland nut away from the
housing to remove the packing. Optional Teflon Chevron, U-Cup, or braided Teflon shaft seals
are also available. The aramid fiber packing and braided Teflon packing is of the split ring type.
Replacement of Teflon Chevron and U-Cup packing requires the removal of the head plates. High
temperature split ring packing is used in applications above 500˚F.
Gas Purge or Grease Purge seals are available as an option on HDX Feeders. When gas (most
commonly air) purge is selected, a lantern ring is supplied inboard of the packing rings. Compressed
gas is introduced to the lantern ring through a drilled hole in the head plate. Optional filter/
regulator/gauge and solenoid valve are available to control the air/gas pressure and flow into the
airlock. The air/gas should be turned on, for a minimum of 5 minutes, before the valve is started
and turned off, a minimum of 5 minutes, after the valve is stopped to insure that dust does not
enter the lantern ring. If the rotary valve is on a multi pick up pressure conveying system, the gas
purge should be left on even when the unit is not feeding the system. It can be shut off after the
conveying system is shut down. The required gas flow is application dependent with the pressure
typically 10-15 PSIG above the valve operating pressure.
When grease purge is selected, a lantern ring is sandwiched between two rows of packing. Grease
is introduced to the lantern ring through a drilled hole in the head plate. The packing is pre-greased
with Super Lube® at the factory, use it or an equivalent NLGI #2 as needed. Higher temperaturerated greases may be required when the product temperature exceeds 275°F.
•
Chain
The roller chain furnished with standard feeders is pre-lubricated at the factory. The chain should
be oiled periodically with a brush or spout can every 50 hours of operation according to the chain
manufacturer. This interval can vary depending on the environment. In our experience, due to the
low speed application, the chain can be lubricated when the reducer oil is changed. A good grade
of non-detergent petroleum based oil should be used with the viscosity shown below:
Ambient Temperature
(Deg F)
Lubricant
20-40
40-100
100-120
120-140
SAE 20
SAE 30
SAE 40
SAE 50
SEAL STRIP REPLACEMENT (Instructions are available upon request.)
12
SECTION VI
PARTS LIST & DRAWING
DDV ROTARY AIRLOCK
7 8
2
6
1
5
18
10
17
4
11 14 12
15
9
12 13 14 11
3
10
26
16
28 27 29
21 22
19
20
24 25
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Description
HOUSING
DRIVE HEADPLATE
BLIND HEADPLATE
ROTOR
SEALSTRIP
SEALSTRIP HOLDER
SEALSTRIP HEAD BOLT
SEALSTRIP HEX LOCKNUT
PACKING RING
PACKING NUT
STUD
LOCK WASHER
HEX NUT
CENTERLOCK HEX LOCKNUT
HEX HEAD CAP SCREW
Qty.
1
1
1
1
***
***
***
***
6
4
4
**
**
**
**
23
ITEM Description
16
BEARING
17
BLIND END BEARING CAP
18
HEX HEAD BOLT
19
KEYSTOCK
20
GEARBOX
21
HEX HEAD BOLT
22
NORD LOCK WASHER
23
MOTOR
24
HEX HEAD BOLT
25
LOCK WASHER
26
FLANGE GUARD
27
FLAT WASHER
28
HEX BOLT
29
HEX NUT
Qty.
2
1
**
1
1
**
**
1
**
**
1
**
**
**
** AS REQUIRED
*** OPTIONAL
13
SECTION VI
PARTS LIST & DRAWING
UDV ROTARY AIRLOCK
8
6
7 13
5
1
22
15
9
23
2
15
14
22
16 21 17
3
41
4
25 10
8 29 30
43 42 20
36
37
31
35
12 18
33
24
40
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
14
39 38
26
Description
HOUSING
DRIVE HEADPLATE
BLIND HEADPLATE
ROTOR
SEALSTRIP
SEALSTRIP HOLDER
SEALSTRIP BOLT
CAPSCREW
BEARING CAP BOLT
DRIVEBASE TO HEADPLATE BOLT
DRIVEBASE AND MOTOR BOLT
GEARBOX TO MOTOR BOLT
SEALSTRIP NUT
PACKING RING
PACKING NUT
PACKING NUT STUD
PACKING NUT AND DRIVEBASE WASHER
GEARBOX TO MOTOR WASHER
GEARBOX NUT
DISCHARGE GUARD NUT
PACKING NUT LOCKNUT
BEARING
34 27
28
11 32 19
11 17
QTY. ITEM Description
1
23
BEARING CAP
1
24
DRIVE BASE
1
25
DRIVEBASE TO HEADPLATE WASHER
1
26
GEARBOX SPACER
*** 27
GEARBOX BOTTOM BRACKET
*** 28
GEARBOX TOP BRACKET
*** 29
DRIVEBASE LOCKWASHER
**
30
DRIVEBASE NUT
2
31
GEARBOX
8
32
GEARBOX WASHER
**
33
MOTOR
4
34
DRIVEN SPROCKET
*** 35
DRIVE SPROCKET
6
36
DRIVEN KEY
4
37
DRIVE KEY
4
38
CHAIN
**
39
CHAIN MASTER LINK
**
40
DRIVE GUARD
**
41
FLANGE GUARD
**
42
FLANGE GUARD WASHER
4
43
FLANGE GUARD BOLT
2
QTY.
1
1
**
2
1
1
4
4
1
**
1
1
1
1
1
**
1
1
1
**
**
** AS REQUIRED
*** OPTIONAL
SECTION VI
PARTS LIST & DRAWING
HDX ROTARY AIRLOCK
6
11 23
2
15
14
7
5
9 11
1
36
4
35
37
3
24 13 34
8
16
10
17
28
18
20
32
11 22
ITEM
1
2
3
4*
5*
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Description
HOUSING
HEADPLATE
ROTOR
BEARING
PACKING
PACKING GLAND NUT
BLIND END BEARING CAP
HEX HEAD BOLT
HEX HEAD BOLT
BEARING CAP
HEX NUT
HEX NUT
HEX NUT
PACKING GLAND STUD
HEAVY HEX NUT
MOTOR BASE
SPEED REDUCER
LOCK WASHER
LOCK WASHER
31
30
Qty.
1
2
1
2
**
2
1
**
**
1
**
**
**
4
4
1
1
**
**
27
29
26
25
ITEM Description
20
HEX BOLT
21
HEX BOLT
22
FASTENER
23
HEX BOLT
24
HEX BOLT
25
DRIVE GUARD BACKPLATE
26
DRIVE SPROCKET
27
DRIVEN SPROCKET
28
DRIVEN SPROCKET KEY
29
DRIVE SPROCKET KEY
30
CHAIN
31
DRIVE GUARD
32
MOTOR
33
FLAT WASHER
34
FLAT WASHER
35*
SEAL STRIP
36*
SEAL STRIP HOLDER
37
FLANGE GUARD
33 21 12
Qty.
**
**
**
**
**
1
1
1
1
1
**
1
1
**
**
***
***
1
21 19
* RECOMMENDED SPARE PARTS
** AS REQUIRED
*** OPTIONAL
15
SAFETY SUPPLEMENT
Effective 8/1/2019
ATTENTION INSTALLERS/OPERATORS FOR YOUR PROTECTION:
1.
Read and understand the Operating Manual accompanying this equipment before
performing any work.
2.
Additional safety label kits available from Meyer upon request at no charge. This is
part of our effort to ensure this equipment is installed, operated and maintained
in the safest possible manner. Affix these labels in locations to achieve maximum
visibility and thereby alert any personnel that may ever be on-site that a potential for
injury could occur.
3.
Under no circumstances should this equipment be installed or operated in a manner
that permits access to the interior of the valve.
4.
Inlet and Outlet Flanges must always be permanently fastened to mating system
components.
5.
In the event that the inlet or outlet is ever exposed, proper guarding to prevent access
to the valve interior must be installed immediately and prior to start-up.
Every unit is shipped with an attached discharge flange guard. DO NOT OPERATE
equipment with unguarded inlet or outlet.
6.
Never operate the valve with the drive chain guard or drive coupling guard removed
or loose.
7.
Always follow LOCKOUT-TAGOUT procedure before performing any work.
8.
Always keep loose clothing, hands, feet or any parts of your body, tools and/or any
foreign objects away from all moving equipment and away from any potential pinch
point.
9.
Never remove any access doors (inspection port covers) above, below, or on the valve
itself without first locking out power.
10. Consult your plant safety director, system designer, installation manager or the Meyer
factory if you have any questions regarding the proper installation, operation and
maintenance of this equipment.
Wm. W. Meyer & Sons, Inc.
1700 Franklin Blvd • Libertyville, IL 60048 • Phones: 800-963-4458, 847-918-0111• Fax: 847-918-8183
Website: http://www.meyerindustrial.com
File # 295-J-006
ROTARY AIRLOCK FEEDER/VALVE SAFETY PRECAUTIONS
ALWAYS DISCONNECT
POWER WHEN
WORKING ON THE
VALVE. FOLLOW
LOCKOUT-TAGOUT
PROCEDURE.
NEVER OPERATE
VALVE WITH THE
DRIVE CHAIN GUARD
REMOVED
DO NOT OPERATE
VALVE WITH
UNGUARDED INLET
OR OUTLET. A FLANGE
GUARD IS SHIPPED
WITH THE VALVE.
SAFETY LABELS
Locate all of the safety labels on your equipment and know their meaning before operating your
Rotary Airlock Feeder.
NOTE: Contact Wm. W. Meyer & Sons, Inc. at 800-963-4458 for free replacement safety label kit.
DANGER
STOP
DANGER
NEVER OPERATE EQUIPMENT WITH UNGUARDED
INLET OR OUTLET
FLANGE GUARD
Wm. W. Meyer & Sons, Inc., Libertyville, IL
800-963-4458
www.meyerindustrial.com
295-J-006
Effective 8/1/2019
Rotonivo
®
Table of contents
1
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
2
Page
Safety notes / Technical support
G2
3
--------------------------------------------------------------------------------------------------------Introduction
G3
--------------------------------------------------------------------------------------------------------Function
4
G4
--------------------------------------------------------------------------------------------------------Technical data
G6
5
--------------------------------------------------------------------------------------------------------Approvals
G14
--------------------------------------------------------------------------------------------------------Options
6
G15
--------------------------------------------------------------------------------------------------------Mounting
G16
--------------------------------------------------------------------------------------------------------Electrical installation
7
G19
--------------------------------------------------------------------------------------------------------Signal and alarm output
8
G24
--------------------------------------------------------------------------------------------------------Setting / Sensitivity / Maintenance
G26
9
--------------------------------------------------------------------------------------------------------Notes for use in Hazardous Locations
G27
10
Subject to technical change
We assume no liability for typing errors.
All dimensions in mm (inches).
Different variations than specified are possible.
Please contact our technical consultants.
11
12
RN 3000 / 6000
gi010112
page G1
1
2
Rotonivo
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
®
Safety notes / Technical support
Notes
•
•
Installation, maintenance and commissioning must be carried out only by qualified technical personnel.
The product must be used only in the manner outlined in this instruction manual.
3
Special attention must be paid to warnings and notes as follows:
WARNING
4
Relates to a caution symbol on the product and means, that a failure to observe the necessary
precautions can result in death, serious injury and/or considerable material damage.
WARNING
5
Failure to observe the necessary precautions can result in death, serious injury and/or
considerable material damage.
This symbol is used, when there is no corresponding caution symbol on the product.
6
7
8
CAUTION
Failure to observe the necessary precautions can result in considerable material damage.
Safety symbols
In manual and on
product
Description
CAUTION: refer to accompanying documents (manual) for details.
Earth (ground) Terminal
9
10
Protective Conductor Terminal
Technical support
Please contact your local supplier (address details at www.uwt.de). Otherwise please contact:
11
UWT GmbH
Westendstr. 5
87488 Betzigau
Germany
Tel. 0049-(0)831/ 57123-0
Fax. 0049-(0)831/ 76879
info@uwt.de
www.uwt.de
12
page G2
gi010112
RN 3000 / 6000
Rotonivo
®
Introduction
1
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
2
Applications
The ROTONIVO is an electromechanical Level limit switch and is
used for level monitoring of bulk goods.
The ROTONIVO is normally screwed into the lateral container wall so
that it is level with the filling height to be registered and monitored.
The units can be delivered with a wide range of Ex-approvals for
use in Hazardous Areas.
The device can also be mounted from the top of the container. In this
case an extension piece is used to mount the probe level with the height
to be registered.
They can be equipped for process over- and lowpressure and also
for very high or low process temperatures.
The length of the probe can be up to 10m (394“) with an extension tube
or rope.
Selected applications:
•
building materials industry
lime, styrofoam, moulding sand, etc.
•
food industry
milk powder, flour, salt, etc.
•
plastics industry
plastics granules etc.
•
timber industry
•
chemical industry
•
mechanical engineering
RN 3002-rope
RN 6002-rope
4
The use of a sliding sleeve for the version RN 3002 / 6002 is
recommended so that the switch point can be changed easily
during operation of the device.
5
6
RN 3001
RN 6001
with pendulum shaft
RN 3002
RN 6002
optional
sliding
sleeve





3
7
RN 3001
RN 6001

8
9
RN 3004
RN 6004
10
RN 3003
RN 6003
11
12
RN 3000 / 6000
gi010112
page G3
1
Rotonivo
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
®
Function
2
3
4
A brushless synchronous motor drives a rotating measuring vane.
When the material level reaches the measuring vane, it is
handicapped in its rotation. The motor is freely suspended within
the housing. The caused reaction torque is used to operate a switch
giving a signal output and to stop the motor (figure 2).
When the paddle becomes free again due to falling material level, a
spring draws the motor back into his operating position, the switch
returns to his initial position and the motor is switched on. The output
signal is switched back (figure 1).
Signal output delay:
The version "Universal voltage" and "PNP" has an integrated
adjustable delay for the signal output.
Option fail safe alarm
With the fail safe alarm it is possible to recognize a fault of the unit in
time and to initiate an alarm relay. The following faults are observed:
•
•
•
•
•
Motor
Gear
Electronic for motor power supply
Supply voltage failure
Defect of the connecting wires
Switchable signal output (Fail safe high /low)
With version "Universal voltage", "PNP" and optional "AC" a
switchable signal output FSH/FSL is integrated.
5
Switch for
motorstop
Switching
part
Switch for
signal output
6
7
Figure 1
Figure 2
Selection guide
8
RN 3001
RN 6001
RN 3001
RN 6001
pendulum shaft
RN 3002
RN 6002
RN 3002-rope
RN 6002-rope
RN 3003
RN 6003
RN 3004
RN 6004
9
10
11
Full detector
x
Demand detector
Empty detector
Vertical mounting
x
Oblique from the top
x
Horizontal mounting
x
Oblique from the bottom
x
x*
x
x
x
x
x*
x
x
x
x*
x
x
x
x
x
x*
x
x**
x
x
x
x
* consider max. permitted mech. traction force
** only with option "bearing at tube end"
12
page G4
gi010112
RN 3000 / 6000
Rotonivo
1
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
®
Function
2
Shaft sealing and metal material
Application
Sealing material (1)
NBR
Metal
FPM (Viton)
PTFE (Teflon)
Animal feed press
Bearing
Aluminium
Stainless steel (2)
1.4301/ SS 304
x
Synthetic granules, powders
x
x
x
x
x
x
Dust filter (temp. up to 392°F)
x
x
x
x
x
x
x
Wood chip dryer
x
x
Pressure conveying vessel, 8bar
x
x
Sugar
x
x
Flour
x
x
Carbon black
x
x
(1)
4
x
Bitumen
Cement
3
x
Salt
Dust filter (temp. up to 302°F)
Stainless steel
5
6
Delivered in version with process temperature and process pressure as following (see also option pos.17):
NBR:
FPM (Viton):
PTFE (Teflon):
max 80°C and max. 0.8bar
max. 150°C and max. 0.8bar
max. 250°C and max. 0.8bar
max. 80°C/ 150°C/ 250°C and max. 5bar/ 10bar
(2)
In particular cases 1.4404 (SS316L) is recommended
7
Electronic
RN 3000
Output signal
Power supply
SPDT (1)
DPDT
PNP
FSH/FSL (2)
Adjustable
delay
Fail safe
alarm
AC version
24V or 48V or 115V or 230V AC
•
-
-
option
-
-
DC version
24V DC
•
-
-
-
-
-
DC version
24V DC PNP
-
-
•
•
•
-
Universal voltage 24V DC / 22...230V (±10%) AC
•
-
-
•
•
option
Multivoltage
•
-
-
-
-
-
DPDT
PNP
FSH/FSL (2)
Adjustable
delay
Fail safe
alarm
-
option
-
option
24V DC/ 115V AC/ 230V AC
8
9
RN 6000
Output signal
Power supply
SPDT (1)
•
with
option
FSH/FSL
-
-
-
-
option
Universal voltage 24V DC / 22...230V (±10%) AC
-
•
-
•
•
option
Multivoltage
•
-
-
-
-
-
AC version
24V or 48V or 115V or 230V AC
•
DC version
24V DC
(1)
(2)
24V DC/ 115V AC/ 230V AC
10
11
Microswitch, with Universal voltage Relais
Switchable signal output (Fail safe high /low)
12
RN 3000 / 6000
gi010112
page G5
1
2
Rotonivo
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
®
Technical Data
Housing versions
3
Series RN 3000
Standard
Series RN 6000
Standard
Series RN 6000
de explosionproof with increased
safety terminal box
Series RN 6000
d flameproof /explosionproof
4
5
6
7
8
Extensions
RN ..001
9
10
11
Process
temperature
A
150 / 250°C
(302 / 482°F)
200mm
(7.87”)
600°C
(1112°F)
400mm
(15.7”)
Thread / Flange
Temperature
extended shaft
Triclamp
12
page G6
gi010112
RN 3000 / 6000
Rotonivo
®
Technical Data
1
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
2
RN ..002
Process
temperature
A
150 / 250°C
(302 / 482°F)
200mm
(7.87”)
600°C
(1112°F)
400mm
(15.7”)
3
4
5
Thread / Flange
Without sealing
and bearing at
tube end (see also
option pos. 32)
Temperature
extended shaft
6
Triclamp
RN ..002 rope
Type standard (pos.1 C)
(max. 4kN load)
Type reinforced (pos.1 H)
(max. 28kN load)
7
8
9
10
Temperature
extended shaft
600°C (1112°F)
Thread / Flange
11
Temperature
extended shaft
150 / 250°C
(302 / 482°F)
Thread / Flange
12
RN 3000 / 6000
gi010112
page G7
1
2
Rotonivo
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
®
Technical Data
RN ..003
3
4
5
Temperature
extended shaft
Process
temperature
B
80°C (176°F)
0.8 bar (11.6psi)
10mm
(0.39”)
80°C (176°F)
5/ 10bar (73/ 145psi)
75mm
(2.95”))
150/ 250°C
(302/ 482°F)
0.8/5/10 bar
(11.6/73/145psi)
210mm
(8.27”)
Material
C
steel
ø55mm (2.17”)
aluminium
ø60mm (2.36”)
Vane
D
50mm x ..mm
(1.97” x ..”)
139mm (5.47”)
98mm x ..mm
(3.86” x ..”)
187mm (7.36”)
RN ..004
6
Process
temperature
A
150 / 250°C
(302 / 482°F)
200mm
(7.87”)
600°C
(1112°F)
400mm
(15.7”)
7
8
Thread / Flange
9
Temperature extended shaft
Triclamp
RN 3005
10
Process
connection
11
12
page G8
gi010112
RN 3000 / 6000
Rotonivo
1
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
®
Technical Data
Measuring vanes
code B,C,E,F,G,I
rectangular vane
Code
Type
a
b
B
C
E
F
G
I
rectangular
rectangular
rectangular
rectangular
rectangular
rectangular
50mm (1.97'')
50mm (1.97'')
50mm (1.97'')
98mm (3.86'')
98mm (3.86'')
98mm (3.86'')
98mm (3.86'')
150mm (5.90')
250mm (9.84'')
98mm (3.86'')
150mm (5.90'')
250mm (9.84')
code A
boot-shaped vane 40x98
2
code P
notched 40x80
3
4
code K
hinged vane 98x200 double sided
to lead in 1½“ socket
(length of socket
max. 40mm (1.57”))
code D
boot-shaped vane 35x106
5
fold together
to feed
through
socket 1½“
and 1¼"
code S
hinged vane 98x100 single
sided
6
to lead in 1¼“ socket
(length of socket
max. 40mm (1.57”))
7
code R
boot-shaped vane 28x98
8
to lead in 1“ or
M32x1.5 socket
socket
b*
1½“ / 1¼“
1" / M32x1.5
37mm (1.46'')
28mm (1.1")
*delivery according to selected thread size
9
insertion of the hinged vane through a long socket
code M
rubber vane 98x250
10
spring
11
12
RN 3000 / 6000
gi010112
page G9
1
Rotonivo
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
®
Technical Data
2
Electrical data
Connection terminals
3
4
5
see page G22/23
Cable entry
M20 x 1,5 screwed cable gland
NPT 1/2“ conduit connection
NPT 3/4” conduit connection (only RN 6000)
Protection class
I
III (Version 24V DC PNP)
Overvoltage category
II
Pollution degree
2
Power supply
see page G22/23
Installed load
see page G22/23
Signal and alarm output
see page G22/23
Isolation
Power to signal and alarm output: 2225 Vrms
Signal output to signal output (DPDT): 2225Vrms
Indicating light
By built-in LED (apart form AC version)
Mechanical data
6
Housing
Aluminium housing, powdercoated, RAL 5010 gentian blue
RN3000: optional plastic PA6 GF, RAL 5010 gentian blue
Degree of protection
RN 3000: IP 66 (EN 60529)
7
RN 6000: IP 66 (EN 60529), NEMA 4, Type 4
Types with process connection and extension in stainless steel:
IP 66 (EN 60529), NEMA 4X, Type 4X (not for: RN 600* with process temperature ≥ 150°C (302°F),
RN 6002 with sliding sleeve, RN 6003)
8
9
10
Process connection
Material: aluminium or stainless steel, 1.4301 (304) / 1.4305 (303) or stainless steel 1.4404 (316L)
Thread: Metric or G (DIN 228) or NPT (tapered ANSI B 1.20.1) according to selection
Triclamp
Flanges: according to selection
Vane shaft and
measuring vane
Material: stainless steel, 1.4301 (304) / 1.4305 (303) or stainless steel 1.4404 (316L)
Tolerance length "L“
± 10mm (± 0.39“)
Bearing
Ball bearing, dust-tight
Sealing
Radial rotary shaft sealing
Material: NBR (Acrylnitril-Butadien-rubber)
FPM (Viton)
PTFE (Teflon)
Graphite based (version 600°C/1112°F)
11
See also selection guide on page G5.
Friction clutch
Protects the gear unit against impacts of the measuring vane
Speed of measuring vane
1 rotation or 5 rotations per minute
12
page G10
gi010112
RN 3000 / 6000
Rotonivo
®
Technical Data
Overall weight
(ca.)
1
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
RN 3000
Version
80°C
(176°F)
2
Extension
150/250/600°C
(302/482/662°F)
Aluminium *
Stainl. steel *
Aluminium
Stainl. steel *
RN 3001
1.2kg
(2.6 lbs)
1.5kg
(3.3 lbs)
+1.2kg
(+2.6 lbs)
-
-
RN 3002
1.3kg
(2.9 lbs)
1.6kg
(3.5 lbs)
+1.2kg
(+2.6 lbs)
+1.3kg/m
(+2.9 lbs per 39.3“)
+2,7kg/m
(+5.9 lbs per 39.3“)
RN 3002-rope
2.1kg
(4.6 lbs)
2.4kg
(5.3 lbs
+1.2kg
(+2.6 lbs)
-
+0,25kg/m
(+0.6 lbs per 39.3“)
RN 3003
3.7kg**
(8.1 lbs)
6.1kg**
(13.4 lbs)
+1.2kg
(+2.6 lbs)
+0.4kg/100mm
(+0.9 lbs per 3.93”)
+0.6kg/100mm
(+1.3 lbs per 3.93”)
RN 3004
1.3kg
(2.9 lbs)
1.6kg
(3.5 lbs)
+1.2kg
(+2.6 lbs)
+0.15kg/100mm
(+0.3 lbs per 3.93”)
+0.3kg/100mm
(+0.7 lbs per 3.93”)
RN 3005
1.3kg
(2.9 lbs)
1.6kg
(3.5 lbs)
3
* Process connection
** Version with flange 150x150x12mm (5.9x5.9x0.47”), L=250mm (9.84”)
All weights are without flanges (except RN 3003) and smallest measuring vane.
RN 6000
Extension
150/250/600°C
(302/482/1112°F)
Aluminium *
Stainl. steel *
RN 6001
1.5kg
(3.3 lbs)
1.8kg
(4.0 lbs)
RN 6002
1.6kg
(3.5 lbs)
RN 6002-rope
5
6
Version
80°C
(176°F)
4
Aluminium
Stainl. steel *
+12kg
(+2.6 lbs)
-
-
1.9kg
(4.2 lbs)
+1.2kg
(+2.6 lbs)
+1.3kg/m
(+2.9 lbs per 39.3“)
+2,7kg/m
(+5.9 lbs per 39.3“)
2.4kg
(5.3 lbs)
2.7kg
(5.9 lbs)
+1.2kg
(+2.6 lbs)
-
+0.25kg/m
(+0.6 lbs per 39.3“)
RN 6003
4.0kg**
(8.8 lbs)
6.4kg**
(14.1 lbs)
+1.2kg
(+2.6 lbs)
+0.4kg/100mm
(+0.9 lbs per 3.93”)
+0.6kg/100mm
(+1.3 lbs per 3.93”)
RN 6004
1.6kg
(3.5 lbs)
1.9kg
(4.2 lbs)
+1.2kg
(+2.6 lbs)
+0.15kg/100mm
(+0.3 lbs per 3.93”)
+0.3kg/100mm
(+0.7 lbs per 3.93”)
All mentioned weights are with Standard-housing.
By use of de-housing:
+1.4kg (+3.1lbs)
d-housing:
+1.0kg (+2.2lbs)
7
8
9
10
*
Process connection
**
Version with flange 150x150x12mm (5.9x5.9x0.47”), L=250mm (9.84”)
All weights are without flanges (except RN 6003) and smallest measuring vane.
11
12
RN 3000 / 6000
gi010112
page G11
1
Rotonivo
®
Technical Data
2
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
Operating conditions
Ambient temp. (housing)
-20 .. +60°C (-4 .. +140°F)
-40 .. +60°C (-40 .. +140°F) version with heating of housing (pos. 26)
-20 .. +60°C (-4 .. +140°F) version with heating of housing (Pos. 26) and plastic housing in ATEX
and IEC-Ex
Process temperature
-25 .. + 80°C
-25 .. +150°C*
-25 .. +250°C*
-25 .. +600°C*
3
4
(-13 .. +176°F)
(-13 .. +302°F)
(-13 .. +482°F)
(-13 .. +1112°F) (not for version RN 3003 / 6003, not for Ex-approvals)
Version with heating of housing (pos. 26):
-40 .. +80°C (-40 .. +176°F)
-40 .. +150°C* (-40 .. +176°F)
-40 .. +250°C* (-40 .. +482°F)
-40 .. +600°C* (-40 .. +1112°F) (not for version RN 3003/ RN6003)
5
* with temperature extended shaft
For versions with Ex-approvals: see remarks on page G30.
6
7
Min. powder density /
sensitivity
see section “Sensitivity” on page G29.
Output signal delay
Version
Sensor free -> covered*
Sensor covered -> free
AC, DC, Multivoltage
ca. 1.3 sec
ca. 0.2 sec
Universal voltage
ca. 1,5 sec + 0 ..20 sec adjustable
ca. 0,2 sec + 0 ..60 sec adjustable
*after blocking of the masuring vane
Features of bulk material
Hardly any limitations.
Max. permitted mechanical
torque
RN 3001 / 6001:
8
max. 50 Nm
RN 3002/ 6002
RN 3004/ 6004:
Steel:
max. 500 Nm
Alu:
max. 180 Nm
max. 50 Nm
9
Type RN 3003 / 6003 on request.
10
Protective measures in case of high load: mounting of an protective canopy above the probe (horizontal
installation) or fixing of the extension tube.
Max. tractive force
RN 3001 / 6001 pendulum shaft:
RN 3002 / 6002-rope:
Max. process pressure
-0.9 .. +0.8bar (-13.1 .. 11.6psi) or -0.9 .. +5 bar (-13.1 .. 73psi) or -0.9 .. +10 bar (-13.1 .. 145psi)
-0.1 .. +0.1bar (-1.5 ..1.5psi) for 600°C (1112°F) version
For pressure over 0.8 bar (11.6psi) the Teflon sealing is used.
For versions with Ex-approvals: see remarks on page G30.
Relative Humidity
0-100%, suitable for outdoor use
11
Altitude
400N (only applicabel as full detector)
4kN (type standard)
28kN (type reinforced)
max. 2.000m (6.562ft)
12
page G12
gi010112
RN 3000 / 6000
Rotonivo
1
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
®
Approvals
RN 3000
RN 6000
2
General Purpose *
(Ordinary Locations)
• •
•
•
CE
FM
CSA
EN 61010-1 (IEC/CB)
Hazardous Locations *
• •
ATEX
Dust explosion
Gas explosion
•
•
• •
IEC-Ex
FM
ATEX II 1/2 D Ex t IIIC T! Da/Db IP6X
flameproof
flameproof / increased safety
flameproof
flameproof / increased safety
Gas explosion
flameproof
•
Gas explosion
flameproof / increased safety
CSA
Dust explosion
•
Gas explosion
flameproof
•
Gas explosion
flameproof / increased safety
•
GOST-R Ex
/ RTN Ex
4
IEC-Ex d IIC T! Gb
IEC-Ex de IIC T! Gb
5
Cl. II, III Div. 1 Gr. E,F,G
Dust explosion
•
•
ATEX II 2G Ex d IIC T! Gb
ATEX II 2G Ex de IIC T! Gb
IEC-Ex t IIIC T! Da/Db IP6X
Dust explosion
Gas explosion
•
•
•
3
XP Cl. I Div. 1 Gr. B-D Cl. I Zone 1 AEx d IIC
Cl. I Zone 1 AEx de IIC
Cl. II, III Div. 1 Gr. E,F,G
Ex DIP A20/21
XP Cl. I Div. 1 Gr. B-D Cl. I Zone 1 Ex d IIC
Cl. I Zone 1 Ex de IIC
6
Dust explosion
7
Detailed allocation of types and electronic modules to approvals: see selection list.
EMC
Pressure Equipment
Directive (97/23/EC)
• •
EN 61326 -A1
The units are not subject to this directive, because they are classified as „pressure-keeping equipment“
and do not have a pressurized housing (see Art.1, clause 2.1.4).
The units are designed and manufactured in accordance to the Pressure Equipment Directive.
8
The unit is NOT intended for use as a "equipment part with safety function" (Art.1, clause 2.1.3).
If the units should be used as "equipment part with safety function", please contact the manufacturer.
* Depending on selected version
9
10
11
12
RN 3000 / 6000
gi010112
page G13
1
Rotonivo
®
Options
2
Weather protection
cover
3
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
If the measuring device is used outdoors, the use of the weather
protection cover is recommended. It protects the device from all
atmospheric influences such as:
•
rain water
•
condensation water
•
excessively high temperatures due to insolation
•
excessively low temperatures in winter
Material: PE, weather and temperature stable
Not available for housing version d and de.
For use in Hazardous Locations: only permitted for zone 2 and 22
or Division 2.
4
Sliding sleeve
Process connection and material as chosen
Version with selection code pos. 30:
Only for applications without process pressure.
Not available for Ex-approvals.
5
6
RN 3002 / 6002
Version with selection code pos. 31: For applications with process
pressure. Sealing material to the extension tube: viton.
Mounting set
Screws and washers for fixing the unit on a flange.
Flat gasket
On the face sealing of the process connection thread.
Incl. sealing face for version with G 1 1/2" thread.
Not available for 600°C version.
7
LED
(Glass window in lid)
To see the indicating light on the electronic module from outside.
LED
Not available for housing version d and de.
8
Glass window
Bulb in cable gland
Bright indicating light seen from outside.
Not available for use in Hazardous Locations.
9
Plug
10
Used instead of cable gland.
Not available for use in Hazardous Locations and FM / CSA general purpose.
Connection of the plug wires to the internal terminals of the unit must be done on site or according to
customer demands.
Valve connector (incl. mating plug)
4-pole (incl. PE), max. 230V, enclosure plastic, IP65
Plug M12 (without mating plug)
4-pole, max. 25V or 5 -pole , max. 60V
Enclosure brass, IP67
11
Plug Han 4A (incl. mating plug)
5-pole (incl. PE), max. 230V, enclosure zinc, IP65
12
page G14
gi010112
RN 3000 / 6000
Rotonivo
®
Options / Mounting
EHEDG approval
1
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
2
EHEDG conform design (material and construction in contact
with the process).
Approved with flush welding socket
Material: aluminium or 1.4301(304) or 1.4404 (316L)
(details see: mounting instructions EHEDG version, page G17).
Food grade material
3
Food grade material in contact with the process food (sealing and grease FDA conform). The option does not
automatically implement a food conform design (food conform gaps, surface and radiuses).
Mounting
4
5
General Safety Instructions
Process pressure
Improper installation may result in loss of process pressure.
Chemical resistance
against the medium
Materials of construction are choosen based on their chemical compatibility (or inertness) for general
purposes. For exposure to specific environments, check with chemical compatibility charts before
installing.
Mechanical load
The torque at the fastening spot must not exceed the specified ratings. See page G13 for details.
Mounting location
Keep away from incoming material and from silo walls.
The installation has to be carried out, that the sensor elements cannot hit the wall of the silo. The flow of
the medium and fixtures in the container must be considered. This is especially important for extension
length of more than 3000mm (118“)
Sliding sleeve
Tighten both straining screws M8 with 20 Nm
to obtain resistance against pressure
6
7
8
Flange mounting
A plastic seal must be used to tighten the flange.
EHEDG-approval /
Food grade material
The materials are available for the use under nornal and predictable applications (according to directive
1935/2004 Art.3). Other conditions can influence the safety.
Additional Safety Instructions for Hazardous Locations
9
10
Installation regulations
For devices to be used in Hazardous Locations the respective valid installation regulations must be
observed.
Sparks
The installation has to be done in a way, that mechanical friction or impact does not cause sparks
between the aluminium enclosure and steel.
Sealings for flanges and sliding
sleeve
For process temperatures over 230°C the delivered sealings of the flanges and of the sliding sleeve must
be checked regulary for good order and condition.
11
12
RN 3000 / 6000
gi010112
page G15
1
Rotonivo
®
Mounting
2
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
Mounting instructions
Rotatable housing
3
4
5
Threaded connection
The housing can be rotated against the
threaded connection after mounting.
RN 6000: For the d- and de- housing:
Fixing screw must be unfastened
to enable rotation. Fix the screw
again, when the housing has the
right position.
Fixing screw
Housing
Direction of the cable glands
When the unit is mounted from the side, ensure, that the cable glands face downwards and are closed
to avoid water penetration into the housing.
Sealing
Seal the process connection thread with teflon tape against process pressure.
Alternative use of a flat gasket is possible (option pos. 15)
EHEDG-approval
Seal the thread with teflon tape against process pressure.
Metal-metal sealing:
• The support muß be plane and without any gap. No teflon tape (or similar) is allowed to be in between. • Fixing torque 100Nm
6
The quality of the welding with the container wall must be according to the respective regulations
(e.g. gaps, transitions, surface finish).
A
Length of extension L
7
Flush welding
socket
RN ..001
28mm
(1.1”)
RN ..002/
RN ..004
38mm
(1.5”)
8
metal-metal
sealing
9
seal thread with
teflon tape
welding with
container wall
Dimension of flush welding socket (for optional on site manufacturing):
Surfaces in contact with
process Ra <=0.8um
Section A
Section B
10
11
Dimensions in mm
* suggested values
(in brackets values to be
adhered bindingly)
12
page G16
gi010112
RN 3000 / 6000
Rotonivo
®
Mounting
RN 3001
RN 6001
1
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
2
A
Full detector vertical and oblique from the top
max. „L“ = 600 mm (23.62”)
B
With pendulum shaft: Full detector vertical from the top.
Observe max. pulling force.
C
Full detector horizontal
max. „L“ = 300 mm (11.8”)
D
Demand or empty detector horizontal
max. „L“ = 150 mm (5.9”)
Protective angle recommended depending on load.
E
Empty detector oblique from the bottom
max. „L“ = 150 mm (5.9”)
Protective angle recommended depending on load.
4
Horizontal mounting: Boot shaped vane recommended (min. mech.
load, because the vane aligns to the movement of the material).
RN 3002
RN 6002
A
Full detector vertical from the top
max. „L“ = 3.000 mm (118“)
5
6
Remark:
Deviation up to max. 10° from vertical installation with option
„Bearing at tube end“ possible.
B
3
7
Full detector vertical from the top
max. „L“ = 4.000 mm (158“)
Support from side recommended.
8
RN 3002-Rope
RN 6002-Rope
A
Full detector vertical
B
Demand detector vertical
C
Empty detector vertical
9
max. „L“ = 10.000 mm (394“)
Observe max. tractive force.
10
11
12
RN 3000 / 6000
gi010112
page G17
1
Rotonivo
®
Mounting
2
RN 3003
RN 6003
3
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
A
Full detector horizontal
B
Demand detector horizontal
C
Empty detector horizontal
Protective angle recommended depending on load.
4
5
RN 3004
RN 6004
6
7
A
Full detector vertical and oblique from the top
B
Full detector horizontal
C
Demand or empty detector horizontal
Protective angle recommended depending on load.
D
Empty detector oblique from the bottom
Protective angle recommended depending on load.
Horizontal mounting: Boot shaped vane recommended
(min. mech. load, for the vane aligns to the movement of the
material).
8
9
10
11
12
page G18
gi010112
RN 3000 / 6000
Rotonivo
®
Electrical installation
1
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
2
General Safety Instructions
Handling
In the case of improper handling or handling malpractice, the electric safety of the device cannot be
guaranteed.
Installation regulations
The local regulations or VDE 0100 (Regulations of German Electrotechnical Engineers) must be observed.
Version 24V DC PNP (Protection class III): The Isolation of the connected power supply and the signal output
must cope with the regulations.
Fuse
Use a fuse as stated in the connection diagrams (see pages G22 and G23).
RCCB protection
In the case of a fault, the supply voltage must be automatically switched off by a RCCB protection switch to
protect against indirect contact with dangerous voltages.
Power supply switch
A voltage disconnection switch must be provided near the device.
Wiring diagram
The electrical connections are made in accordance with the wiring diagram.
Supply voltage
Compare the supply voltage applied with the specifications given on the electronic module and name plate
before switching the device on.
Cable gland
The screwed cable gland and closing element must have following specifications:
Ingress protection IP66, temperature range from -40°C to +70°C, UL or VDE certified (depending on the
country where the unit is installed), pull relief. Make sure that the screwed cable gland safely seals the
cable and that it is tight (danger of water intrusion). Cable glands that are not used have to be sealed with a
blanking element.
Conduit system
In case of using a conduit system (with NPT thread) instead of a cable gland the regulations of the country,
where the unit is installed, must be observed. The conduit must have a tapered thread either NPT1/2“ or
NPT3/4” in accordance with the unit and ANSI B 1.20.1. Not used inlets must be closed tight with a metal
blanking element.
Field wiring cables
All field wirings must have insulation suitable for at least 250V AC. The temperature rating must be at least
90°C (194°F).
Microswitch protection
Provide protection for microswitch contacts to protect the device against inductive load surges.
Protection against static
charging
The housing of the unit must be grounded to avoid static charging of the unit. This is particularly important
for applications with pneumatic conveying and non-metallic containers.
RN 3000
4
5
6
7
8
9
Additional Safety Instructions for Hazardous Locations
Extenal equipotential
bonding terminal
3
RN 6000
10
Connect to equipotential
bonding of the plant
Field wiring
A strain relief must be provided for the field wiring cables, when the device is installed with the factory
provided cable glands.
Field wiring terminals for
“de” housing
Fixing torque :
Remove wire isolation:
11
0,5-0,6Nm
9mm
12
RN 3000 / 6000
gi010112
page G19
1
Rotonivo
®
Electrical installation
2
Cable glands and conduit
system for ATEX / IEC-Ex
(Dust and Gas Hazardous
Locations)
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
Installation according to the regulations of the country, where the product is installed.
Not used entries have to be closed with blanking elements certified for this purpose.
Where available the factory provided parts must be used.
3
A strain relief must be provided for the field wiring cables, when the device is installed with the factory
provided cable glands.
The diameter of the field wiring cable must match to the clamping range of the cable clamp.
If other than the factory provided parts are used, following must be ensured:
The parts must have an approval adequate to the approval of the level sensor (certificate and type of
protection).
The approved temperature range must be from the min. ambient temperature of the level sensor to the max.
ambient temperature of the level sensor increased by 10K.
The parts must be mounted according to the instructions of the supplier.
4
5
6
Installation of a flameproof/ explosion proof enclosure with a conduit system:
In a conduit system single electric conductors are installed in a certified pipe system. This pipe system is in a
flameproof / explosion proof construction as well. The flameproof / explosion proof enclosure and the pipe
system needs to be sealed from each other by a certified flameproof seal of a type “d” or explosion proof of a
type “XP”.This seals shall be installed directly in or at the conduit entries of the flameproof / explosion proof
enclosure. Not used entries have to be closed with blanking elements certified for this purpose (flameproof type
“d” or explosion proof type “XP”).
Conduit system for
FM and CSA
(Dust and Gas Hazardous
Locations)
7
8
General requirements:
In addition the regulations of the country must be observed. The used flameproof seals and blanking elements
must have an adequate type approval and a temperature range of at least –40°C (-40°F) to +80°C (176°F). In
addition they shall be suitable for the conditions and correctly installed. Where available the provided original
parts of the manufacturer must be used.
Installation of a flameproof enclosure “d” with a conduit system:
In a conduit system single electric conductors are installed in a certified pipe system. This pipe system is in a
flameproof construction as well. The flameproof enclosure “d” and the pipe system needs to be sealed from
each other by a certified flameproof seal. Conduit entries of a flameproof enclosure “d” shall have installed the
flameproof seal within 18 inches from the enclosure wall. Not used entries have to be closed with adequate
blanking elements of a certified flameproof type AEx Cl.1 Div.1 A.
Commissioning
Commissioning only with closed lid.
Opening the lid
Units with Dust Explosion approval:
Before opening the lid take care, that no dust deposits or whirlings are present.
Do not remove the lid (cover) while circuits are alive.
9
RN 6000:
Units with flameproof GasExplosion approval (d-housing):
To prevent ignition of hazardous atmospheres, do not remove the lid (cover) while circuits are alive.
10
11
12
page G20
gi010112
RN 3000 / 6000
Rotonivo
®
Electrical installation
1
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
2
Connection
RN 3000:
Standard housing
3
Connecting
terminals
4
5
RN 6000:
Standard and d-housing
de-housing
Connection is done directly
on the PCB
6
Connection is done on the terminals
inside the increased safety area.
7
Motor is
internally
connected to
the housing
(grounded)
Protective
conductor
terminal
Connection
terminals
8
Connecting
terminals
9
Protective
conductor
terminal
10
11
12
RN 3000 / 6000
gi010112
page G21
1
2
3
Rotonivo
®
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
Electrical installation Series RN 3000
Version:
- AC
- DC
- Universal voltage
- Multivoltage
Power supply:
• AC version:
24V or 48V or 115V or 230V 50/60Hz max. 4VA
All voltages ±15% (1)
Supply voltage as selected.
External fuse (power supply): max 10A
max.1.5mm²
(AWG16)
• DC version:
24V DC ±15% (1) max. 2.5W
External fuse: not required
4
max.10A
• Universal voltage:
24V DC ±15% (1) max.4W
22 .. 230V 50/60Hz ±10% (1) max.10VA
External fuse (power supply): not required
• Multivoltage:
24V DC max. 2.5W or
115V 50/60Hz
max. 4VA or
230V 50Hz
max. 6VA
All voltages ±15% (1)
External fuse (power supply): not required
5
Signal
Alarm
output (2) output
L N PE*
+ Power supply
With option
Rotation control
(2)
Set the voltage-selector on the PCB to the desired
voltage.
6
View of
PCB
7
(1)
Voltage selector
including ±10% of EN 61010
Signal and alarm output:
8
9
Micro switch (with version Universal voltage: relay)
SPDT contact
max. 250V AC, 2A, 500VA (cosj = 1)
max. 300V DC, 2A, 60W
Version:
- PNP
10
Power supply:
max.1.5mm²
(AWG16)
24V DC ±15% (1)
(1)
including ±10% of EN 61010
Input current: max. 0.6A
Signal output:
Load max.0.4A
Output voltage equal to input voltage, drop <2,5V
Open collector
Protected against short circuit and overload
11
+ - Load PE*
Power
supply
* Protection against static charge:
The PE terminal of the unit must be grounded to avoid static charging of the unit.
This is particularly important for applications with pneumatic conveying.
12
page G22
gi010112
RN 3000 / 6000
Rotonivo
®
1
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
Electrical installation Series RN 6000
Version:
- AC
- DC
- Multivoltage
2
Power supply:
max.4mm²
(AWG12)
• AC version:
24V or 48V or 115V or 230V 50/60Hz max. 5VA
All voltages ±15% (1)
Supply voltage as selected.
External fuse (power supply): max 10A
3
max.10A
• DC version:
24V DC ±15% (1) max. 2.5W
External fuse (power supply): not required
• Multivoltage:
24V DC
max. 2.5W or
115V 50/60Hz
max. 4VA or
230V 50Hz
max. 6VA
All voltages ±15% (1)
External fuse (power supply): not required
Signal
Alarm
output (2) output
L N PE
+ Power supply
With option
Rotation control
(2)
Set the voltage-selector on the PCB to the desired
voltage.
Voltage
selector
View of
PCB
5
6
Internal
fuse
200mA T
(1)
4
7
including ±10% of EN 61010
Signal and alarm output:
Micro switch SPDT contact
max. 250V AC, 5A, non inductive
max. 30V DC, 4A, non inductive
Version:
- Universal voltage
8
Power supply:
max.4mm²
(AWG12)
24V DC ±15% (1) max.4W
22 .. 230V 50/60Hz ±10% (1) max.10VA
(1)
including ±10% of EN 61010
9
Signal and alarm output:
max.10A
max.10A
Relay DPDT contact
max. 250V AC, 5A, non inductive;
max. 30V DC, 4A, non inductive
External fuse (power supply): not required
Signal output DPDT
Alarm
output (2)
With option
Rotation control
(2)
10
L N PE
+ Power supply
11
* Protection against static charge:
The PE terminal of the unit must be grounded to avoid static charging of the unit.
This is particularly important for applications with pneumatic conveying.
12
RN 3000 / 6000
gi010112
page G23
1
2
3
Rotonivo
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
®
Signal and alarm output
Overview
Signal output:
Switching logic
Overview of signal and alarm output for the different electronic versions: see page G5
Versions without FSH/FSL
RN 3000
DC
RN 3000
Multivoltage
RN 6000
DC /
Multivoltage
green
LED1
green
red
LED1
red
4
red
5
Versions with FSH/FSL
FSH: Use this setting when sensor is used as a full detector.
Power failure or line break is regarded as „full“ signal (protection against overfilling).
6
FSL: Use this setting when sensor is used as an empty detector.
Power failure or line break is regarded as „empty“ signal (protection against running dry).
7
LED
8
yellow
green
9
LED
10
green
yellow
Factory setting: FSL
Power
failure
11
12
page G24
gi010112
RN 3000 / 6000
Rotonivo
®
Signal and alarm output
1
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
2
Signal output:
Delay
Sensor covered -> free
Factory setting = 3 sec
3
Sensor free -> covered
Factory setting = 1 sec
Alarm output
(Rotation control)
4
Switching and timing behaviour:
If the sensor is not covered, the rotating paddle shaft will send pulses at 20 sec intervals. In
case of fault, the pulses are missed. After 30 sec the alarm relay will open.
RN 3000
Universal voltage
yellow or green
(see page before)
5
red
LED
No fault
RN 6000
AC or DC
6
Fault
7
LED2
red
LED2
off
LED2
LED1
RN 6000
Universal voltage
No fault
Fault
8
yellow or green
(see page before)
red
9
LED
No fault
Fault
10
Connection example:
Full detector with maximum safety:
The output signal opens in case of:
• full signal or
• failure of supply voltage or
• defect of the connection wires or
• defective unit
11
Signal output
12
RN 3000 / 6000
gi010112
page G25
1
Rotonivo
®
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
Settings: Sensitivity / Maintenance
2
Adjustment of
the sprig
The spring is adjustable in 3 positions. It should be changed only if necessary.
„Fine“:
for light material
„Medium“: suitable for nearly every material (factory setting)
„Coarse“: for very sticky material
3
The spring can be changed via a small plier.
RN 3000
RN 6000
4
Spring
5
fine medium
coarse
6
Sensitivity
The table shows approximate values for the minimum densities, at which a normal function should be possible.
*Minimum density in g/l = kg/m³ (lb/ft³) (without guarantee)
7
Vane
Vane completely covered with bulk material
Bulk material covers vane up to 100mm (3.93“)
Spring adjustment
Spring adjustment
Boot shaped vane 40x98
200 (12)
Boot shaped vane 35x106
200 (12)
300 (18)
100 (60)
150 (9)
Boot shaped vane 28x98
300 (18)
500 (30)
150 (9)
200 (12)
Vane 50x98
300 (18)
500 (30)
150 (9)
250 (15)
Vane 50x150
80 (4.8)
120 (7.2)
40 (2.4)
60 (3.6)
Vane 50x250
30 (1.8)
50 (3)
15 (0.9)
25 (1.5)
Vane 98x98
100 (60)
150 (9)
50 (3)
75 (4.5)
Vane 98x150
30 (1.8)
50 (3)
15 (0.9)
25 (15)
fine
8
9
10
11
100 (60)
medium
(factory setting)
150 (9)
medium
(factory setting)
300 (18)
fine
Vane 98x250
20 (1.2)
30 (1.8)
15 (0.9)
15 (0.9)
Hinged vane 98x200 b=37 double sided
70 (4.2)
100 (60)
35 (2.16)
50 (3)
Hinged vane 98x200 b=28 double sided
100 (60)
150 (9)
50 (3)
75 (4.5)
Hinged vane 98x100 b=37 single sided
200 (12)
300 (18)
100 (60)
150 (9)
Hinged vane 98x100 b=28 single sided
300 (18)
500 (30)
150 (9)
250 (15)
The above mentioned data is a guideline and is for loose, non compacted material.
During the filling the bulk density can change (e. g. for fluidised material).
*For versions with option 26 (heating of housing) the above mentioned data must be multipied by 1.5.
Maintenance
Generally the device requires no maintenance.
12
page G26
gi010112
RN 3000 / 6000
Rotonivo
®
1
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
Notes for use in Hazardous Locations
2
Zone classification
Useable in zone
20, 21, 22
21, 22
22
0, 1, 2
1, 2
2
Dust applications
Gas applications
ATEX
Category
1D
2D
3D*
1G
2G
3G
IEC-Ex
Equipement Protection
Level (EPL)
Da
Db
Dc
Ga
Gb
Gc
3
*) in case of conductive dust
additional requirements for the
installation are necessary.
4
General Notes
Marking
Devices with Ex approval are marked on name plate.
Process pressure
The device construction allows process over-pressure up to 0.8/5/10 bar (11.6/73/145psi) (see name
plate). These pressures are allowed for test purposes. The definition of the Ex approvals are only valid for a
container-over-pressure between -0.2..+0.1 bar (-2.9..+1.45psi).
For higher or lower pressures the approvals are not valid.
Process and ambient
temperature
The permitted temperature ranges are marked on the name plate.
5
6
Permitted zones for mounting in partition wall
RN 3000
Standard
housing
Version with
d- and de-housing
(flameproof /
increased safety)
EPL
(IEC-Ex)
Category
(ATEX)
Zone
EPL
(IEC-Ex)
Category
(ATEX)
Zone
RN 6000
Standard
housing
RN 6000
de-housing
RN 6000
d-housing
7
Version with
Standard
housing
Gb
Db
Db
2G
2D
2D
1
21
21
Gb
Da
Da
2G
1D
1D
1
20
20
8
9
RN 3001
RN 6001
10
RN 3003
RN 6003
RN 3002
RN 3004
RN 6002
RN 6004
11
RN 3002-rope
RN 6002-rope
12
RN 3000 / 6000
gi010112
page G27
1
Rotonivo
®
Level limit switch
Series RN 3000 / 6000
Technical information / Instruction manual
Notes for use in Hazardous Locations
2
Max. Surface Temperature and Temperature Code
The temperature marking on the name plate
refers to the instruction manual.
In the following tables the relevant temperature ratings are shown.
3
The maximum surface temperature (resp. temperature class) is the warmest temperature of the unit which could occur during malfunction
(according to Ex-definition).
4
Max. ambient
temperature
30°C (86°F)
5
40°C (104°F)
50°C (122°F)
60°C (140°F)
Enclosure directly mounted to the process connection
Temperature
Max. process
Max. surface
class
temperature
temperature
(Division system)
T5
90°C (194°F)
50°C (122°F)
T4A (1)
120°C (248°F) (1)
100°C (212°F)
T5
60°C (140°F)
120°C (248°F) (1)
T4A (1)
110°C (230°F)
70°C (158°F)
T4A
120°C (248°F) (1)
80°C (176°F)
120°C (248°F)
T4A
Temperature
class
(Zone system)
T5
T4 (1)
T4
Ambient side
Process side
T4
T4
6
Max. ambient
temperature
7
8
60°C (140°F)
9
10
(1)
Enclosure mounted offset to the process connection
Temperature
Max. process
Max. surface
class
temperature
temperature
(Division system)
90°C (194°F)
120°C (248°F)
T4A
100°C (212°F)
120°C (248°F)
T4A
110°C (230°F)
120°C (248°F)
T4A
120°C (248°F)
120°C (248°F)
T4A
130°C (266°F)
130°C (266°F)
T4
140° C (284°F)
140° C (284°F)
T3C
150° C (302°F)
150° C (302°F)
T3C
160° C (320°F)
160° C (320°F)
T3C
170° C (338°F)
170° C (338°F)
T3A
180° C (356°F)
180° C (356°F)
T3A
190° C (374°F)
190° C (374°F)
T3
200° C (392°F)
200° C (392°F)
T3
210° C (410°F)
210° C (410°F)
T2D
220° C (428°F)
220° C (428°F)
T2C
230° C (446°F)
230° C (446°F)
T2C
240° C (464°F)
240° C (464°F)
T2B
250° C (482°F)
250° C (482°F)
T2B
Temperature
class
(Zone system)
T4
T4
T4
T4
T4
T3
T3
T3
T3
T3
T3
T2
T2
T2
T2
T2
T2
Ambient side
Process side
With use of electronic "Universal voltage"
11
12
page G28
gi010112
RN 3000 / 6000
TABLE OF CONTENTS
SYMBOLOGY KEY
3-PHASE POWER DISTRIBUTION WIRING
3-PHASE POWER DISTRIBUTION WIRING CONTINUED
120 VAC CONTROL. PULSE CLEANING WIRING DETAIL
120 VAC CONTROL. ALARM COMPONENTS WIRING DETAIL
INDUSTRIAL CONTROL PANEL ENCLOSURE LAYOUT
TERMINAL STRIP & LEGEND PLATE DETAILS
BILL OF MATERIALS
A11637-001
A11637-002
A11637-003
A11637-004
A11637-005
A11637-006
A11637-007
A11637-008
A11637-009
A11637-010
A11637-011
A11637-012
1
2
3
4
5
6
7
8
9
10
11
12
24VDC CONTROL DISTRIBUTION WIRING CONTINUED
24VDC POWER DISTRIBUTION WIRING DETAIL
120 VAC CONTROL. POWER DISTRIBUTION WIRING DETAIL
DRAWING DESCRIPTION
DRAWING #
SHEET #
N04539C01
SHEET #:
1
A11637-001
DWG #:
200729
PROJECT #:
OF
REV:
-
12
04/07/2021
CKD. BY:
DATE:
CUSTOMER #:
SB
DWN. BY:
TABLE OF
CONTENTS
DESCRIPTION:
SOUTHERN PERU
COPPER CORPORATION
CUSTOMER NAME:
This drawing and all information
within it is the sole property of
Automation Outfitters, Inc. It
is unlawful and therefore may not
be reproduced or redistributed
without prior written consent of
Automation Outfitters, Inc. or
one of it's representatives.
info@automationoutfitters.com
3208 Neil Circle
Jonesboro, AR 72401
Ph: (870) 910-5200
Fax: (870) 910-5201
AUTOMATION
BY
REVISION
DATE
NO.
OUTFITTERS
MOTOR PROTECTOR
OVERLOAD RELAY
MOTOR STARTER
FUSED DISCONNECT
DISCONNECT
LEVEL SENSOR
XX
HP
MOTOR
RELAY N.O. CONTACT
RELAY COIL
TERMINAL
X A
FUSE
LIGHT
PUSHBUTTON
MUSHROOM HEAD PUSHBUTTON
SECOND N.O. CONTACT
SELECTOR SWITCH
1
POWER SUPPLY
SOLENOID
JUMPER
CONTROL
TRANSFORMER
N04539C01
SHEET #:
2
A11637-002
DWG #:
200729
PROJECT #:
OF
REV:
-
12
04/07/2021
CKD. BY:
DATE:
CUSTOMER #:
SB
DWN. BY:
SYMBOLOGY
KEY
DESCRIPTION:
SOUTHERN PERU
COPPER CORPORATION
CUSTOMER NAME:
This drawing and all information
within it is the sole property of
Automation Outfitters, Inc. It
is unlawful and therefore may not
be reproduced or redistributed
without prior written consent of
Automation Outfitters, Inc. or
one of it's representatives.
info@automationoutfitters.com
3208 Neil Circle
Jonesboro, AR 72401
Ph: (870) 910-5200
Fax: (870) 910-5201
AUTOMATION
BY
REVISION
DATE
NO.
OUTFITTERS
215
214
213
212
211
210
209
208
207
206
205
204
203
202
201
200
L1
480 VAC
to 300
L2
480 VAC
to 301
L3
480 VAC
to 302
T2
L3
L2
L1
L3
SET TO 2.1 AMPS
734,802
L2
L1
T2
T1
L3 T3
802
L2
L1
RAL MOTOR
STARTER
M802-1
48 A
733,801
T3
T2
T1
BLOWER MOTOR
OVERLOAD RELAY
OL202-1
ROTARY AIRLOCK
MANUAL MOTOR PROTECTOR
CB207-1
BLK_4 AWG
L3 T3
801
L2
BLK_12 AWG
L3
L2
L1
L3
L2
MAIN FUSE DISCONNECT
DS201-1
80 AMP
BLOWER
MOTOR STARTER
M801-1
L1
L1 T1
CUSTOMER SUPPLIED
480 VAC/3 PH/60 Hz/51.2 F.L.A.
40
HP
2222-FA-005A
BLOWER MOTOR
FLA: 48
RPM: 1775
PF: .82
FRAME: 324TC
2T3
2T2
1.5
HP
2222-FE-005A
ROTARY AIRLOCK
FLA: 2.1
RPM: 1440
Hz:60
PF: 0.76
FIELD DISCONNECT (PROVIDED BY OTHERS
AS REQUIRED BY LOCAL CODE)
DS207-1
2T1
1T3
1T2
FIELD DISCONNECT (PROVIDED BY OTHERS
AS REQUIRED BY LOCAL CODE)
DS202-1
1T1
FIELD WIRED
FACTORY WIRED
AUTOMATION
N04539C01
SHEET #:
3
A11637-003
DWG #:
200729
PROJECT #:
OF
REV:
-
12
04/07/2021
CKD. BY:
DATE:
CUSTOMER #:
SB
DWN. BY:
3-PHASE POWER
DISTRIBUTION
WIRING
DESCRIPTION:
SOUTHERN PERU
COPPER CORPORATION
CUSTOMER NAME:
This drawing and all information
within it is the sole property of
Automation Outfitters, Inc. It
is unlawful and therefore may not
be reproduced or redistributed
without prior written consent of
Automation Outfitters, Inc. or
one of it's representatives.
info@automationoutfitters.com
3208 Neil Circle
Jonesboro, AR 72401
Ph: (870) 910-5200
Fax: (870) 910-5201
BY
REVISION
DATE
NO.
OUTFITTERS
315
314
313
312
311
310
309
308
307
306
305
304
303
302
301
L1
L2
L3
480 VAC
to 400
L3
480 VAC
to 400
L2
480 VAC
to 400
L1
L3
from 214
480 VAC
L2
from 215
480 VAC
L1
from 215
300
480 VAC
FIELD WIRED
FACTORY WIRED
AUTOMATION
N04539C01
SHEET #:
4
A11637-004
DWG #:
200729
PROJECT #:
OF
REV:
-
12
04/07/2021
CKD. BY:
DATE:
CUSTOMER #:
SB
DWN. BY:
3-PHASE POWER
DISTRIBUTION
WIRING CONTINUED
DESCRIPTION:
SOUTHERN PERU
COPPER CORPORATION
CUSTOMER NAME:
This drawing and all information
within it is the sole property of
Automation Outfitters, Inc. It
is unlawful and therefore may not
be reproduced or redistributed
without prior written consent of
Automation Outfitters, Inc. or
one of it's representatives.
info@automationoutfitters.com
3208 Neil Circle
Jonesboro, AR 72401
Ph: (870) 910-5200
Fax: (870) 910-5201
BY
REVISION
DATE
NO.
OUTFITTERS
END
1
1 402-3
TB1
*J1
E-STOP
PB406-1 406-1 4
7 A
H1
2L1
TB1
5
404-1
to 500
120 VAC
ATDR-3.5
H2
X1
13 14
406
MASTER
CONTROL RELAY
MCR406-1
CONTROL
POWER ON
PBLT406-1
402-2
to 500
NEUTRAL
402-2
H4
XF401-1
CONTROL
TRANSFORMER
500 VA (480/120VAC)
BLK_12 AWG
RED_14 AWG
120 VAC
H3
480 VAC
2L3
406-2
FU402-1 402-1 X2
MCR406-1 404-1
23 24
406
MASTER
CONTROL RELAY
TB1 TB1 TB1
1
ATQR-4
4 A
L2
L3
from 315
from 314
480 VAC
480 VAC FU400-1
L2
L3
4 A
RED_14 AWG
120 VAC
to 700
402-3
415
414
413
412
411
410
409
408
407
406
405
404
403
402
401
400
L1
from 315
L1 480 VAC
2
2
2
2
406-3
A1
R
A2
NO 407,404,711
NC
MASTER
CONTROL RELAY
NEUTRAL
to 700
402-2
MCR406-1
402-2
TB1 TB1 TB1 TB1 TB1
2
GRY_14 AWG
FIELD WIRED
FACTORY WIRED
NOTES:
·
Remove jumper "J1" to add additional interlocks
to circuit.
AUTOMATION
N04539C01
SHEET #:
5
A11637-005
DWG #:
200729
PROJECT #:
OF
REV:
-
12
04/07/2021
CKD. BY:
DATE:
CUSTOMER #:
SB
DWN. BY:
120 VAC CONTROL.
POWER DISTRIBUTION
WIRING DETAIL
DESCRIPTION:
SOUTHERN PERU
COPPER CORPORATION
CUSTOMER NAME:
This drawing and all information
within it is the sole property of
Automation Outfitters, Inc. It
is unlawful and therefore may not
be reproduced or redistributed
without prior written consent of
Automation Outfitters, Inc. or
one of it's representatives.
info@automationoutfitters.com
3208 Neil Circle
Jonesboro, AR 72401
Ph: (870) 910-5200
Fax: (870) 910-5201
BY
REVISION
DATE
NO.
OUTFITTERS
TB1
3
120 VAC
to 516
404-1
515
514
513
512
511
510
XOX
505-1
504-1
506-1
CLEANING MODE
OFF
DEMAND CONTINUOUS
OOX
SS506-1
M801-143
801
BLOWER44
MOTOR STARTER
503-1
508-1
TB1
6
505-1
506-1
510-1
to 713
PRIMARY DP ALARM
704-1
from 713
24 VDC
704-1
510-1
508-1
GRY_14 AWG
4-20 mA
+
_
L2
L1
CLEAN
ALARM
PDIT510-1
TB1 FDC DIGITAL
DELTA P METER
6
SOL505-1
SOL504-2
SOL504-1
SOL503-2
SOL503-1
SOL502-2
SOL502-1
SOL501-1
513-1 513-1
to 823
PRIMARY DP (-4-20MA)
514-1
514-1
to 822
PRIMARY DP (+4-20MA)
85-120 VAC
Alarm
509
508
404-1
507
506
505
504
503
502
1
L2
L2
L2
501
2
3
4
5
6
7
8
9
10
KY501-1
FDC PULSE
TIMER CONTROL
Δ P Sw.
L1
Offline CLN
G
404-1
from 404
120 VAC
500
NEUTRAL
to 516
402-2
402-2
TB1
2
402-2
from 404
NEUTRAL
120 VAC
to 600
404-1
531
530
529
528
527
526
525
524
404-1
523
522
521
520
519
518
517
404-1
from 515
120 VAC
516
FIELD WIRED
FACTORY WIRED
14 AWG 90° C RATED WIRE ONLY FOR FIELD WIRING
DO NOT DOUBLE SOLENOID OUTPUTS THAT ARE LOCATED ON THE
SAME AIR HEADER.
8 SOLENOIDS PRESENT ON COLLECTOR.
NEUTRAL
to 600
402-2
402-2
from 515
NEUTRAL
N04539C01
SHEET #:
6
A11637-006
DWG #:
200729
PROJECT #:
OF
REV:
-
12
04/07/2021
CKD. BY:
DATE:
CUSTOMER #:
SB
DWN. BY:
120 VAC CONTROL.
PULSE CLEANING
WIRING DETAIL
DESCRIPTION:
SOUTHERN PERU
COPPER CORPORATION
CUSTOMER NAME:
This drawing and all information
within it is the sole property of
Automation Outfitters, Inc. It
is unlawful and therefore may not
be reproduced or redistributed
without prior written consent of
Automation Outfitters, Inc. or
one of it's representatives.
info@automationoutfitters.com
3208 Neil Circle
Jonesboro, AR 72401
Ph: (870) 910-5200
Fax: (870) 910-5201
AUTOMATION
BY
REVISION
DATE
NO.
OUTFITTERS
CANbus
END
615
614
613
612
611
610
609
608
404-1
607
606
605
604
603
602
601
TB1
3
TB1
3
TB1
3
404-1
from 531
120 VAC
600
TB1
3
404-1
AGC-1/4
1/4 A
FU605-1
AGC-1/4
1/4 A
FU601-1
11 14
611
BROKEN BAG
ALARM RELAY
CR611-1
GDL-1
1 A
FU607-1
G
2
1
G
2
LS603-1
HOPPER HIGH
LEVEL SENSOR
731
1
LS601-1
PBLT613-1
(PUSH TO RESET)
BROKEN BAG
A1
C
A2
P-
P+
E
BROKEN BAG
DETECTOR MODULE
BB605-1
HOPPER HIGH HIGH
LEVEL SENSOR
732
607-1
613-1
603-1
601-1
.
.
.
.
.
.
7
TB1
2
A
A2
CR611-1
611-1
TB1 TB1 A1
7
GND
GND
TB1
2
402-2
HHL DEFAULT
SWITCHING
LOGIC DETAIL
FSH
FSL
NO 613,730
NC
BROKEN BAG
ALARM RELAY
END
402-2
402-2
TB1
2
402-2
402-2
402-2
from 531
NEUTRAL
FIELD WIRED
FACTORY WIRED
AUTOMATION
N04539C01
SHEET #:
7
A11637-007
DWG #:
200729
PROJECT #:
OF
REV:
-
12
04/07/2021
CKD. BY:
DATE:
CUSTOMER #:
SB
DWN. BY:
120 VAC CONTROL.
ALARM COMPONENTS
WIRING DETAIL
DESCRIPTION:
SOUTHERN PERU
COPPER CORPORATION
CUSTOMER NAME:
This drawing and all information
within it is the sole property of
Automation Outfitters, Inc. It
is unlawful and therefore may not
be reproduced or redistributed
without prior written consent of
Automation Outfitters, Inc. or
one of it's representatives.
info@automationoutfitters.com
3208 Neil Circle
Jonesboro, AR 72401
Ph: (870) 910-5200
Fax: (870) 910-5201
BY
REVISION
DATE
NO.
OUTFITTERS
TB2 GDL-5
-
+ 703-1
5A
POWER SUPPLY
702-2
1
PWS702-1
TB2
2
707-1
END
739
0 V
to 720
703-1
719
24 VDC
to 720
704-1
738
734
733
718
703-1
732
731
737
NO 729
NC
A1
A2
HIGH DP
ALARM RELAY
CR713-1
703-1
730
704-1
729
728
717
510-1
from 510
PRIMARY DP ALARM
703-1
to 800
0 V
703-1
727
726
725
724
723
736
704-1
to 511
24 VDC
711-1
to 800
24 VDC
TB2
2
BLUWHT_18 AWG
722
721
716
TB2
3
FG
COM
+24VDC
AB
1769-L24ER-QBFC1B
MODULE
COMPACTLOGIX
16-PT DC SOURCE IN, 16-PT SINK OUTPUT, 4 AI, 2 AO
PLC717-1
5 A
TB2
MCR406-1711-1
33 34
406
MASTER
CONTROL RELAY
704-1
GND
FU704-1
1
AGC-1 1/2
1.5 A
FU707-1
GND
L
L2/N
702-1
1
GDL-2-1/2
2.5 A
FU702-1
TB1
2
735
704-1
704-1
704-1
BLU_18 AWG
TB1
1
RED_14 AWG
402-2
704-1
704-1
TB2
1
TB2
1
704-1
704-1
TB2
1
704-1
704-1
704-1
704-1
402-2
704-1
from 415
from 719
NEUTAIRLOCK
24 VDC 704-1
720
402-2
715
714
713
712
711
710
709
708
707
706
705
704
703
702
402-3
701
402-3
from 415
120 VAC
700
M802-1
OOX
AIRLOCK
SS723-1
OFF
HAND AUTO
XOO
PB720-1
21 24
611
BROKEN BAG
ALARM RELAY
CR611-1
23 24
207
ROTARY AIRLOCK
MANUAL MOTOR PROTECTOR
97 98
202
BLOWER MOTOR
OVERLOAD RELAY CB207-1
5 6
603
HOPPER HIGH HIGH
OL202-1 LEVEL SENSOR
5 6
601
HOPPER HIGH
LEVEL SENSOR LS603-1
LS601-1
11 14
713
HIGH DP
ALARM RELAY
CR713-1
COM 1
I/15
TB2 IN 15
19
I/14
TB2 IN 14
18
I/13
TB2 IN 13
17
I/12
TB2 IN 12
16
15 I/11
TB2 IN 11
I/10
TB2 IN 10
14
I/9
TB2 IN 09
13
I/8
TB2 IN 08
12
COM 0
I/7
IN
07
TB2
11
I/6
IN
06
TB2
10
I/5
IN
05
TB2
9
I/4
TB2 IN 04
8
I/3
TB2 IN 03
7
I/2
TB2 IN 02
6
I/1
IN
01
TB2
5
I/0
IN
00
TB2
4
BLU_18 AWG
13 14
ZERO SPEED
802
SWITCH
AIRLOCK MOTOR
PRS727-1
STARTER
13 14
801
BLOWER
MOTOR STARTER
M801-1
OOX
BLOWER
SS721-1
OFF
HAND AUTO
XOO
E-STOP
-
-
-
-
-
-
-
-
-
-
I/15
I/14
I/13
I/12
I/11
I/10
I/9
I/8
I/7
I/6
I/5
I/4
I/3
I/2
I/1
I/0
PLC717-1
SPARE
SPARE
703-1
AIRLOCK MMP
BLOWER
CONTACTOR
OVERLOAD
HIGH HIGH LEVEL
HIGH LEVEL
BROKEN BAG
PRIMARY DP ALARM
703-1
ZERO SPEED
AIRLOCK RUNNING
BLOWER RUNNING
AIRLOCK START IN
AUTO
AIRLOCK START IN
MANUAL
BLOWER START IN
AUTO
BLOWER START IN
MANUAL
E-STOP
END
703-1
703-1
from 719
0 V
AUTOMATION
N04539C01
SHEET #:
8
A11637-008
DWG #:
200729
PROJECT #:
OF
REV:
-
12
04/07/2021
CKD. BY:
DATE:
CUSTOMER #:
SB
DWN. BY:
24VDC POWER
DISTRIBUTION
WIRING DETAIL
DESCRIPTION:
SOUTHERN PERU
COPPER CORPORATION
CUSTOMER NAME:
This drawing and all information
within it is the sole property of
Automation Outfitters, Inc. It
is unlawful and therefore may not
be reproduced or redistributed
without prior written consent of
Automation Outfitters, Inc. or
one of it's representatives.
info@automationoutfitters.com
3208 Neil Circle
Jonesboro, AR 72401
Ph: (870) 910-5200
Fax: (870) 910-5201
BY
REVISION
DATE
NO.
OUTFITTERS
+V
HIGH LEVEL ALARM
ZERO SPEED ALARM
AIRLOCK RUNNING
BLOWER RUNNING
AIRLOCK START
BLOWER START
TB2
3
TB2
3
COM 1
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
+V
COM 0
SPARE
HIGH HIGH LEVEL ALARM
24 VDC
to 820
711-1
819
818
817
816
815
814
813
812
811
810
711-1
809
808
807
806
805
804
803
802
801
711-1
from 711
24 VDC
800
O/9
O/8
O/7
O/6
O/5
O/4
O/3
O/2
O/1
O/0
O/15
O/14
O/13
O/12
O/11
O/10
-
-
-
-
-
-
-
-
-
-
PLC717-1
O/15
OUT 15
O/14
OUT 14
O/13
OUT 13
O/12
OUT 12
O/11
OUT 11
O/10
OUT 10
O/9
OUT 09
O/8
OUT 08
O/7
OUT 07
O/6
OUT 06
O/5
OUT 05
O/4
OUT 04
O/3
OUT 03
O/2
OUT 02
O/1
OUT 01
O/0
OUT 00
TB2
35
TB2
34
TB2
33
TB2
32
TB2
31
TB2
30
TB2
29
TB2
28
TB2
27
TB2
26
TB2
25
TB2
24
TB2
23
TB2
22
TB2
21
TB2
20
BLU_18 AWG
ALARM HORN
AH808-1
A
HIGH HIGH LEVEL
LT807-1
A
HIGH LEVEL
LT806-1
A
ZERO SPEED
LT805-1
R
AIRLOCK RUNNING
LT804-1
703-1
703-1
802-1 CB207-1
13 14
A1
A2
BLOWER RUNNING ROTARY207
AIRLOCK
LT803-1 MANUAL MOTOR PROTECTOR
R
M802-1
BLOWER MOTOR
OVERLOAD RELAY
M801-1
801-1 OL202-1
95 96
A1
A2
202
0 V
to 820
703-1
AIRLOCK MOTOR
STARTER
NO 207,208,209,726
NC
BLOWER
MOTOR STARTER
NO ?,202,203,204,725
NC 504
TB2
703-1
from 711
0 V
703-1
2
I IN 1+
V IN 1+
I IN 2+
V IN 2+
I IN 3+
V IN 3+
SPARE
SPARE
TB3 V/I IN 3-
9
TB3
8
TB3
7
TB3 V/I IN 2-
6
TB3
5
TB3
4
TB3 V/I IN 1-
3
TB3
2
TB3
37 513-1
SHLD TB2V/I IN 0GND
1
TB2
514-1
I IN 0+
TB2
36
V IN 0+
A+1
A+1
A+0
A+0
-
-
-
-
PLC717-1
I OUT 1+
V OUT 1+
I OUT 0+
V OUT 0+
ANLG COM
ANLG COM
SPARE
SPARE
SPARE
PRIMARY DP
TB3
15
TB3
14
TB3
13
TB3
12
TB3
11
TB3
10
*NOTE:
ALL ANALOG SIGNALS TO BE
WIRED WITH SHIELDED CABLE
513-1
from 513
PRIMARY DP (-4-20MA)
514-1
from 514
PRIMARY DP (+4-20MA)
END
839
838
837
836
835
834
833
832
831
830
829
828
827
826
825
824
823
822
821
TB2
711-1
from 819
24 VDC
711-1
820
3
END
TB2
703-1
from 819
0 V
703-1
2
AUTOMATION
SHEET #:
9
A11637-009
DWG #:
200729
PROJECT #:
N04539C01
CUSTOMER #:
SB
DWN. BY:
OF
REV:
-
12
04/07/2021
DATE:
CKD. BY:
24VDC CONTROL
DISTRIBUTION WIRING
CONTINUED
DESCRIPTION:
SOUTHERN PERU
COPPER CORPORATION
CUSTOMER NAME:
This drawing and all information
within it is the sole property of
Automation Outfitters, Inc. It
is unlawful and therefore may not
be reproduced or redistributed
without prior written consent of
Automation Outfitters, Inc. or
one of it's representatives.
info@automationoutfitters.com
3208 Neil Circle
Jonesboro, AR 72401
Ph: (870) 910-5200
Fax: (870) 910-5201
BY
REVISION
DATE
NO.
OUTFITTERS
Clean Air
Low Pressure
Dirty Air
High Pressure
L00070
LEFT
PUERTO DE
PROGRAMCION
PROGRAMMING
PORT
3.00(TYP.)
3.00(TYP.)
4.50
*NOTES
1. ALL DIMENSIONS ARE IN INCHES
2. LEGENDS ARE TO BE WHITE WITH BLACK LETTERS
NEMA 4/12 STEEL
ENCLOSURE
5.00
6.00
2.00
5.00
21.50
10.50
.2
.6
.8
4
1.0
5
1.2
1.4
6
1.6
1.8
R
CONTROL
ENCENDIDO
CONTROL
POWER ON
L00070
L00070
L00070
ENCY S
RG
A
VELOCIDAD
CERO
ZERO SPEED
L00070
AUTOMATICO
OFF
MANUAL
VALVULA ROTATIVA
AUTOMATICO
OFF
L00070
VENTILADOR
AIRLOCK
R
R
L00070
AIRLOCK RUNNING
VALVULA ROTATIVA
FUNCIONANDO
VENTILADOR
FUNCIONANDO
Off
BLOWER RUNNING
www.farrapc.com
Farr Air Pollution Control
3505 Airport Road
Jonesboro, AR 72401, USA
(800) 479-6801 - Fax (800) 222-6891
(870) 933-8048 - Fax (870) 933-8380
Set the high and low pressure
settings on the meter above
to trigger filter cleaning.
MANUAL
9
10
www.farrapc.com
2.4
2.2
8
Replace filters
if pressure
can not be pulsed
back below 5" WC
Time Off:
15 Sec
Time On: 150 mSec
High Limit: 2" WC
Low Limit: 1.5" WC
High Alarm: 6" WC
Low Alarm: 0" WC
FACTORY
PROGRAMMED
SETTINGS:
L00070
L00070
G
L00070
MANGA ROTA
(APRETAR PARA REARME)
BROKEN BAG
(PUSH TO RESET)
A
NIVEL ALTO
HIGH LEVEL
A
NIVEL ALTO ALTO
HIGH HIGH LEVEL
Farr APC is a proud memeber
of the Camfil Farr group
Set the On time, Off Time & Cycle
Delay settings inside this control
panel for continuous cleaning.
Continuous Cleaning
Pulse Cleaning Control Selector
Clean at High Pressure
BLOWER
2.0
7
FILTER PRESSURE DROP
.4
3
Access code
needed to
change DP
pulse settings
0
1
2
Dust Collector Controller
INSTRUCTIONS:
This panel controls
the pulse cleaning of
the Farr APC dust
collector. Use the
switch below to turn
the pulsing off, make
it pulse continuously
based on timed settings, or pulse on
demand only when
the high pressure
setting is reached.
FARR
EME
BOTTOM
FRONT
2222-IO-005A
480 VOLTS
30.00
O
F
F
ON
LINE VOLTS:
PHASE:
FREQUENCY:
F.L.A.:
HORSE POWER:
CONTROL:
Danger
Mfr. By:
Automation Outfitters
3208 Neil Circle,
Jonesboro AR 72401
(870) 910-5200
UL FILE #: E317528
Short Circuit Current:
100kArms Symmetrical
@ XXX VAC Maximum
UL RATING:
TYPE XX
3505 S. Airport Rd
Jonesboro, AR
USA 72401
(800) 479-6801
Hazardous Voltage!
Contact may cause
electrical shock or burn.
Disconnect and lock-out
power before servicing.
WARNING
Arc flash and
shock hazard.
Follow ALL requirements
in NFPA 70E for safe
work practices and for
Personal Protective
Equipment.
XXX VAC
3 Phase
50/60 Hz
XXX Amps
XX HP Max
120 VAC/24 VDC
TBD
TBD
TBD
TBD
XXXXXX-XX-XX
XX/XXXX
AIR POLLUTION CONTROL
PART #:
DWG #:
CAMFIL PO:
CAMFIL SO:
SERIAL #:
MFR. DATE:
42.00
2.50
F2
H2
X1
H4
17.00
Offline Cleaning Delay Time
Offline Cleaning Cycles
Standby
F1
H3
L00069
BACKPANEL
A2
A1
11
14
12
3 L2
A1
6 T3
5 L3
L00069
A2
6 T3 14 NO
5 L3 13 NO
4 T2
3 L2
2 T1 4 T2
1 L1
2 T1
NO
13 14
1 L1
M801-1
M802-1
L00069
4.75
PUERTO DE
PROGRAMCION
PROGRAMMING
PORT
L00070
CAT5
1769-L24ER
COMMUNICATION WIRING DETAIL
Solenoid On Time
Solenoid Off Time
Solenoid Output
Alarm
Cycle Down
Output Pulsing
L00069
Alarm
Run
KY501-1
Output
2.00
3.15A
L00069
9.75
PLC717-1
X2
H1
XF401-1
CONNECT PLANT NETWORK TO PROGRAMMING
PORT FOR ETHERNET COMMUNICATION
NOTE
2.00
1.50
3.50
3.50
4.25
2.50
1.75
3.50
3.50
5.00
2.00
1.50
5.25
15.00
5.25
AUTOMATION
N04539C01
SHEET #:
10
A11637-010
DWG #:
200729
PROJECT #:
OF
REV:
-
12
04/07/2021
CKD. BY:
DATE:
CUSTOMER #:
SB
DWN. BY:
INDUSTRIAL CONTROL
PANEL ENCLOSURE
LAYOUT
DESCRIPTION:
SOUTHERN PERU
COPPER CORPORATION
CUSTOMER NAME:
This drawing and all information
within it is the sole property of
Automation Outfitters, Inc. It
is unlawful and therefore may not
be reproduced or redistributed
without prior written consent of
Automation Outfitters, Inc. or
one of it's representatives.
info@automationoutfitters.com
3208 Neil Circle
Jonesboro, AR 72401
Ph: (870) 910-5200
Fax: (870) 910-5201
BY
REVISION
DATE
NO.
OUTFITTERS
13.43
10.00
P
TO
RED 1
L00070
CONTROL
ENCENDIDO
PUERTO DE
PROGRAMCION
L00070
L00070
VELOCIDAD
CERO
L00070
L00070
AUTOMATICO
ZERO SPEED
MANUAL
OFF
AUTOMATICO
OFF
MANUAL
VALVULA ROTATIVA
AIRLOCK
VENTILADOR
BLOWER
L00070
VALVULA ROTATIVA
FUNCIONANDO
VENTILADOR
FUNCIONANDO
L00070
AIRLOCK RUNNING
CONTROL
POWER ON
L00069
L00069
L00069
L00069
TB1
WHITE 2
WHITE 2
WHITE 2
WHITE 2
WHITE 2
WHITE 2
WHITE 2
WHITE 2
BLOWER RUNNING
PROGRAMMING
PORT
KY501-1
M802-1
M801-1
PLC717-1
RED 1
RED 1
BLUE 1
BLUE 1
BLUE 1
BLUE 1
BLUE 1
BLUE 1
BLUE 1
BLUE 1
RED 3
RED 3
RED 3
RED 3
RED 3
GRAY 4
GRAY 5
GRAY 6
GRAY 6
L00070
GRAY 7
GRAY 7
TB2
L00070
MANGA ROTA
(APRETAR PARA REARME)
BROKEN BAG
(PUSH TO RESET)
NIVEL ALTO
HIGH LEVEL
L00070
NIVEL ALTO ALTO
HIGH HIGH LEVEL
WHITE 2
WHITE 2
WHITE 2
WHITE 2
WHITE 2
WHITE 2
WHITE 2
WHITE 2
WHITE 2
WHITE 2
WHITE 2
WHITE 2
TB3
GRAY 1
GRAY 2
GRAY 3
GRAY 4
GRAY 5
GRAY 6
GRAY 7
GRAY 8
GRAY 9
GRAY 10
GRAY 11
GRAY 12
GRAY 13
GRAY 14
GRAY 15
XXX VAC
3 Phase
50/60 Hz
XXX Amps
XX HP Max
120 VAC/24 VDC
TBD
TBD
TBD
TBD
XXXXXX-XX-XX
XX/XXXX
Mfr. By:
Automation Outfitters
3208 Neil Circle,
Jonesboro AR 72401
(870) 910-5200
UL FILE #: E317528
Short Circuit Current:
100kArms Symmetrical
@ XXX VAC Maximum
UL RATING:
TYPE XX
2222-IO-005A
*NOTES
1. ALL DIMENSIONS ARE IN INCHES
2. LEGENDS ARE TO BE WHITE WITH BLACK LETTERS
LINE VOLTS:
PHASE:
FREQUENCY:
F.L.A.:
HORSE POWER:
CONTROL:
PART #:
DWG #:
CAMFIL PO:
CAMFIL SO:
SERIAL #:
MFR. DATE:
AIR POLLUTION CONTROL
3505 S. Airport Rd
Jonesboro, AR
USA 72401
(800) 479-6801
BLUE 3
BLUE 3
GRAY 4
GRAY 5
GRAY 6
GRAY 7
GRAY 8
GRAY 9
GRAY 10
GRAY 11
GRAY 12
GRAY 13
GRAY 14
GRAY 15
GRAY 16
GRAY 17
GRAY 18
GRAY 19
GRAY 20
GRAY 21
GRAY 22
GRAY 23
GRAY 24
GRAY 25
GRAY 26
GRAY 27
GRAY 28
GRAY 29
GRAY 30
GRAY 31
GRAY 32
GRAY 33
GRAY 34
GRAY 35
GRAY 36
GRAY 37
GROUND
AUTOMATION
N04539C01
SHEET #:
11
A11637-011
DWG #:
200729
PROJECT #:
OF
REV:
-
12
04/07/2021
CKD. BY:
DATE:
CUSTOMER #:
SB
DWN. BY:
TERMINAL STRIP &
LEGEND PLATE
DETAILS
DESCRIPTION:
SOUTHERN PERU
COPPER CORPORATION
CUSTOMER NAME:
This drawing and all information
within it is the sole property of
Automation Outfitters, Inc. It
is unlawful and therefore may not
be reproduced or redistributed
without prior written consent of
Automation Outfitters, Inc. or
one of it's representatives.
info@automationoutfitters.com
3208 Neil Circle
Jonesboro, AR 72401
Ph: (870) 910-5200
Fax: (870) 910-5201
BY
REVISION
DATE
NO.
OUTFITTERS
D7-N3R
D7-N3W
CS8-40E-120
PIR6W-1P-24VDC
SPRECHER & SCHUH
SPRECHER & SCHUH
SPRECHER & SCHUH
SPRECHER & SCHUH
SPRECHER & SCHUH
AMETEK NCC
SPRECHER & SCHUH
SPRECHER & SCHUH
ALLEN BRADLEY
WAGO
SPRECHER & SCHUH
SPRECHER & SCHUH
SPRECHER & SCHUH
SPRECHER & SCHUH
SPRECHER & SCHUH
SPRECHER & SCHUH
SPRECHER & SCHUH
SPRECHER & SCHUH
SPRECHER & SCHUH
SPRECHER & SCHUH
SPRECHER & SCHUH
SPRECHER & SCHUH
SPRECHER & SCHUH
SPRECHER & SCHUH
SPRECHER & SCHUH
SPRECHER & SCHUH
AMETEK NCC
SOLA HD
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
E500
DFA-T2610-010
V7-N37
V7-H6
V7-EB3
V7-EA35
V7-W3-W
V7-W3-RE
V7-WG4
V7-W4
V7-W3-B
D7P-SM32
PI84-120AC-M93G
D7-ALF4
D7-ALF0
D7P-LF9
787-1722
1769-L24ER-QBFC1B
CEP7-EEGE
D7P-MT44
DFA-PS700-A10
D7P-P4
D7P-P0
D7-N5W
1
1
METER, DIFF PRESSURE 100-240VAC
PUSHBUTTON, 22MM ESTOP TWIST-TO-RELEASE NON-LIGHTED
7
6
2
1
1
TERMINAL, FUSE BLOCK 1.25 GLASS TYPE NON-INDICATING
TERMINAL, FUSE END BARRIER FOR H-SERIES FUSE BLOCK TERMINALS
TIMER BOARD, 10PT 100-240VAC
TRANSFORMER, IC 500VA - 240/480 X 120VAC
55
TERMINAL, 4MM GREY 30A 22-10AWG
TERMINAL, END BARRIER FOR W3-W4 - GREY
10
TERMINAL, 4MM BLUE 30A 22-10AWG
13
3
SELECTOR SWITCH, 22MM 3-POS MAINTAINED
TERMINAL, END ANCHOR NORMAL DUTY (V7 TYPE)
1
RELAY, INTERFACE 1PDT 24 VDC
20
1
RELAY, 120VAC 4N.O CS8 TYPE
TERMINAL, 4MM WHITE 30A 22-10AWG
5
RELAY, 120VAC 2PDT 8A W/BASE, LED & CLIP
1
1
PUSHBUTTON, LENS FLUSH LGHT RED
8
1
PUSHBUTTON, LENS CAP AMBER
TERMINAL, 4MM RED 30A 22-10AWG
2
PUSHBUTTON, 22MM OPERATOR FLUSH LIGHTED - NO LENS
TERMINAL, 4MM GROUND 30A 22-10AWG
1
POWER SUPPLY, 24VDC @ 5A; 90-264VAC INPUT ECO SERIES
1
1
2
LENS, 22MM PILOT LIGHT - RED
OVERLOAD, RELAY ELECTRONIC 18-90A
FITS CA7-60...97 CONTACTOR
PLC, COMPACTLOGIX 5370 L2 - 24V DC 16 DC IN / 16 DC OUT / 4 UNIV. AN. IN / 2 AN. OUT / 4 HS
COUNTER (2) ETHERNET/IP PORTS 750KB MEM.
1
3
LED, MODULE 24V AC/DC WHITE LATCH MOUNTED SCREW TERMINAL
LENS, 22MM PILOT LIGHT - AMBER
3
LED, MODULE 24V AC/DC RED LATCH MOUNTED SCREW TERMINAL
LED, MODULE 120VAC RED LATCH MOUNTED SCREW TERMINAL
1
2
LED, MODULE 120VAC RED LATCH MOUNTED SCREW TERMINAL
D7-N5R
SPRECHER & SCHUH
25
26
11
LATCH, 22MM MOUNTING - PLASTIC
24
1
ROD, DISCONNECT - 100...200A, 12.6" (320MM)
D7-ALP
SPRECHER & SCHUH
23
1
DISCONNECT, FUSED 100A - 600VAC, J-STYLE, NON-INDICATING, FUSE BOLT ON, uL98, IP20
1
SPRECHER & SCHUH
22
1
ECOMBO STARTER 1.6...2.5A 24VDC COIL 1NO CONTACT
L11-R7
SPRECHER & SCHUH
21
CL7-9E-10-24E-AS2.5A-A10
L11-J100-1753
SPRECHER & SCHUH
20
TA-6-S
L10-HM4E
ILSCO
SPRECHER & SCHUH
19
NA407
1
CUTLER HAMMER
18
GROUND LUG, 2-14 AWG
AJT-80
MERSEN
17
HANDLE, DISCONNECT - 100...400A, ROTARY, LOCKABLE, NEMA 1/3R/12/4/4X, RED/YELLOW, IP66
ATDR-7
MERSEN
16
GDL-5
2
FUSE, 5.0A - GLASS, .25 X 1.25, SLO-BLO
MERSEN
15
GROUND BAR, 5-HOLE KIT
1
FUSE, 4.0A - CC-STYLE, X-FORMER LOAD
ATQR-4
MERSEN
1
1
2
FUSE, 2.5A - GLASS .25 X 1.25, SLO-BLO
GDL - 2 1/2
MERSEN
13
14
3
1
FUSE, 1.5A - GLASS .25 X 1.25, FAST-ACTING
GDL-1 1/2
MERSEN
12
811-411
LPCD06
SCE-42EL3010LP
FUSE, 80A - J-STYLE
1
FUSE, 1.0A - GLASS .25 X 1.25, SLO-BLO
GDL-1
CA7-PA-10
CA7-60D-10-24DD
FUSE, 7.0A - CC-STYLE, MTR LOAD
2
FUSE, 0.25A - GLASS .25 X 1.25, FAST-ACTING
GGC-1/4
MERSEN
11
MERSEN
10
1
FUSE BLOCK, 30A 2P - CC-STYLE, 600VAC, IP20, BLOWN FUSE INDICATION
811-421
WAGO
1
9
1
WAGO
FUSE BLOCK, 30A 1P - CC-STYLE, 600VAC, IP20, BLOWN FUSE INDICATION
LOVATO
8
ETHERNET JACK, 22mm RJ45/RJ45 PLASTIC
7
1
ENCLOSURE, 42 X 30 X 10 ENVIROLINE TYPE 3R/4/12
SCE
1
6
1
SPRECHER & SCHUH
CONTACTOR, 60A 24VDC 1-NO AUX
SPRECHER & SCHUH
4
CONTACT, AUX - 1NO, SIDE MOUNT, FOR CA7
5
7
SPRECHER & SCHUH
3
CONTACT BLOCK, PILOT DEVICE - 22MM, 1NO, FOR D7 & 800F
D7-X01
D7-X10
SCE-42P30
SCE
SPRECHER & SCHUH
1
2
1
Quantity
3
Description
CONTACT BLOCK, PILOT DEVICE - 22MM, 1NC FOR D7 & 800F
A11637 - BILL OF MATERIALS
BACKPLATE, 42 X 30
Mfg. Part Number
Manufacturer
Item Number
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
Unit
AUTOMATION
SHEET #:
12
A11637-012
DWG #:
200729
PROJECT #:
N04539C01
CUSTOMER #:
SB
DWN. BY:
CKD. BY:
REV:
-
12
04/07/2021
DATE:
OF
BILL OF
MATERIALS
DESCRIPTION:
SOUTHERN PERU
COPPER CORPORATION
CUSTOMER NAME:
This drawing and all information
within it is the sole property of
Automation Outfitters, Inc. It
is unlawful and therefore may not
be reproduced or redistributed
without prior written consent of
Automation Outfitters, Inc. or
one of it's representatives.
info@automationoutfitters.com
3208 Neil Circle
Jonesboro, AR 72401
Ph: (870) 910-5200
Fax: (870) 910-5201
BY
REVISION
DATE
NO.
OUTFITTERS
FARR GOLD SERIES
TOUCH SCREEN CONTROLLER
®
User Manual
Software Release 1.0
Camfil APC
3505 S. Airport Road, Jonesboro, AR 72401 | 870-933-8048
www.camfilapc.com | e-mail: filterman@camfil.com | 800-479-6801
AIR POLLUTION CONTROL
Table of Contents
Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Electrical Data and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Terminal Board for Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Terminal Board for Three Phase Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Terminal Board for Digital Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Terminal Board for RPB Output and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Terminal Boards for RP612 Output and Connections . . . . . . . . . . . . . . . . . . . . . . . . 7
Button Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Help Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Password Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Home Screen, Data and Measure, and Analog Input Values . . . . . . . . . . . . . . . . . . . 10
Home Screen (Primary Filter Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Home Screen (Primary and Secondary Filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Run Mode Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
On Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Continuous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Autocleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Alarm Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data and Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analog Input Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Menu, Alarm Setup Analog Input, and Function Menu . . . . . . . . . . . . . . . . . . .
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Menu Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Menu Value Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Language Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Menu Solenoid Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarms Setup Analog Input Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reset Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Time and Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reset Default . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data Logger Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B
13
14
14
15
15
16
16
17
18
19
20
20
21
21
22
23
The Gold Series Controller
This controller is designed for ease of use and offers full monitoring and control of all functions
of your dust collector and equipment associated with it. The device is equipped with a touch
screen user interface that allows access to all of the functions. A built in differential pressure
sensor monitors the primary filter pressure drop and 4 analog inputs can be used to monitor the
secondary filter along with other devices like leak detectors, flow meters and compressed air
pressure. Six digital inputs are also contained in this unit for inputs such as hopper level, smoke
detection, remote cleaning and many other pertinent inputs. Four relay outputs are provided
that can be used to signal faults from any of the digital or analog inputs and from internal device
faults. The 4-20 milliamp output can be used to remote monitor the air flow or pass through
any analog input to a remote location. The device also has the ability to monitor the power
consumption of your fan.
Four cleaning modes are available, On Demand, Continuous, Autocleaning and Remote cleaning.
The device controls up to 30 remote pilot boxes (solenoid trays). These are referred to as RPB
modules. The controller recognizes the pilot valves, counts them and monitors their operation.
Performance data is logged to an internal storage chip and can be accessed with a usb jump
drive. This jump drive can also be used to backup and restore interval settings.
1
Electrical Data and Connections
General Data
Power Supply
90 – 27 0 Vac, 50/60 Hz
Max Power
10 VA @ 230 Vac
6.5 VA @ 115 Vac
Dimension (mm / inches)
200 W x 100 H x 70 D / 7.87 W x 3.94 H x 2.75 D
Temperature (°C / °F)
-40 +60 / - 40 + 140
Display
480 x 272 pixels; 65,636 colors
Analog Input
Inputs
4
Input Type
2 Voltage and 2 Current
Voltage Range Type
0 – 5 V , 0 – 10 V , 1 – 5 V , 2 – 10 V
Current Range Type
4 – 20 mA
Digital Input
Inputs
6
Input Type
Positive
Input Maximum Voltage
30 Vdc
Other Input
Input Type
Three Phase Voltage
Voltage Limit
500 Vac
Input Type
One Phase Current
Current Limit
6 A ac
Analog Output
Outputs
1
Output Type
Current
Output Range Type
4 – 20 mA
Relay Output
Outputs
4
Contact Type
2 relay two-way switch (N.O., Com); (SPST)
2 relay three-way switch (N.O., N.C., Com) (SPDT)
Rated Maximum Voltage
230 Vac, 30 Vdc
Rated Current (115 Vac)
2A
Ports
2
Port Type
USB
Ports
1
Port Type
RS232
Ports
1
Speed
9600, 19200, 38400 bps
Port Type
RS485
Ports
1
Speed
9600, 19200, 38400 bps
Ambient Condition
Operating Temperature (°C / °F)
-10 + 60 / 14 to 140
Storage Temperature (°C / °F)
-30 – 80 / -22 + 140
Relative Humidity
< 90%
Housing
Material
ABS V0
Front Protection
IP 65
Weight
0.65 kg
Electrical Connections
Terminal Board
Connections
1–3
Power Supply
4, 5
Analog Output
6, 7
Output RPB
8 – 10
RS232
11 – 13
RS485
14, 15
Ammeter Input
16 – 19
Three Phase Current
20 – 27
Analog Input
28 – 35
Digital Input
36 – 45
Relay Output
3
Relay Outputs Terminals
Relay Outputs
Output relays can be used to
pass internal or input events
out to external devices. Relays
1 and 2 are SPDT, Relays 3
and 4 are SPST.
Analog Input Terminals
Analog Input
Default Settings
The analog inputs are voltage
and current. Analog Input 1 and
2 are set for 0 – 10 V input.
Analog Input 3 and 4 are set
with 4 – 20 mA input.
Digital Input Terminals
4
Three Phase Sequence Terminals
The controller is capable of monitoring your three phase voltage and triggering alarms if there
are voltage or phase deviations. If a current transmitter is installed the device will monitor
current and set an alarm based on programmed current data. With both of these inputs
combined the controller can monitor, log and display the power consumption of your fan.
The advanced IO and voltage monitoring functions of this device are only available factory
wired. The schematic of this wiring will be inside the integrated control panel. Access to these
advanced program features is not permitted by end users without factory guidance and are
password protected.
5
RPB Output Connections
Note: the difference between RPB and RP612 remote pilot boxes is the material of
construction. The RPB is constructed from ABS plastic and the RP612 box is aluminum.
6
RP612 Output Connections
RPB #1
Farr Gold Series
Touch Screen
Controller
RPB #2
Output RPB
RPB #Last
Farr Gold Series
Touch Screen
Controller Output
Input
RPB612
Output
Next RPB612
7
Button Index
NOTE
The Configuration Menu button
“C”, accesses advanced
configurations of the device.
Advanced configurations are
generally not adjustable by
the end user. You will need
to contact Camfil Farr if you
suspect a problem with the
preset advanced features.
The system will automatically
return to the Home Screen if
idle for 90 seconds.
8
Button
Letter
Name
Function
A
Home Page
Shows the Home Page
B
Main Menu
Shows the Main Menu
C
Configuration
Shows the Configuration page,
accessible only with a password
D
Info
Shows the Help page
E
Time and Date
Shows the Time and Date page, where
the time and date can be set
F
Date Format
Change the date format to MM/DD/YY
(US flag) or DD/MM/YY (EU flag)
G
Confirm
Used to confirm the password in the
password entry page
H
Program
Language
Used to set the menu language
I
Zero Calibration
Shows the Zero Calibration page
J
OK
Used to start the calibration process (for
primary or secondary pressure gauge)
K/L
Yes / No
Used to answer the security question
before the Zero Calibration process
M/N
Value Arrows
Used to change parameter values
O/P
Shift Screen
Arrows
Used to shift screens left or right, or go
back
R
Password
Used to set or change the password
S
Default
Used to set all parameters to the default
T
USB
Shows the USB Data Logger menu
U
Download
Parameters
Used to download parameters to USB
V
Upload User
Parameters
Used to upload user parameters
from USB
W
Download Data
Logger
Used to download system data to USB
X
Upload All
Parameters
Used to upload all parameters to USB
Password Menu
The device is equipped with two password fire walls. One protects the advanced configuration
settings that are factory programmed. The other protects user settings so unauthorized
personnel cannot change the cleaning and alarm settings. This password is set in the Main
Menu section, page 3. If you program a password please record it in a safe place. If you lose
this password you will have to contact Camfil APC for assistance.
Home Screen, Data, and Analog Input Values
Switch between these screens by selecting the back and next buttons.
9
Home Screen (Primary Filter Only)
When the dust collector does not have a secondary safety filter such as Camfil’s safety
monitoring filter the home screen will display the operating status of the filter current pressure
drop, the type of clean cycle operating and any alarms that have occurred.
E
A
F
B
C
D
Name
Function
A
Stop Cleaning Setpoint
During “ON DEMAND” and “AUTO” cleaning this setpoint stops the
cleaning.
B
Pressure Gauge
Shows the filter pressure level as an analog pressure gauge
C
Filter Pressure Drop
Shows the current pressure level
D
Cleaning Mode
Shows the current cleaning mode
E
Start Cleaning Setpoint
F
Alarm Pressure Setpoint
Shows the High Pressure Alarm setpoint
Alarm Display
Shows the alarm status. When no alarm is active, it reads “No
Alarm” and is green. When an alarm is active it becomes red and
shows the alarm name. If there are more than one alarms active,
touch the button to see an alarm list.
Letter
G
10
G
During “ON DEMAND” and “AUTO” cleaning this setpoint starts the
cleaning
Home Screen (Primary and Secondary Filter)
If the system has a secondary filter it would be shown on the Home Screen as shown below.
The pressure drop of the secondary filter is displayed by the analog gauge and digitally. In this
picture you can also see what a high pressure alarm looks like on the alarm button.
A
B
C
Letter
Name
Function
A
Pressure Gauge
Shows the filter pressure level as an analog pressure gauge
B
Alarm Pressure Threshold
Shows the High Pressure Alarm setpoint
C
Filter Pressure Drop
Shows the current pressure level for the secondary filter.
Help Menu
The help menu is accessed by touching the question mark in the top right corner of any
screen. This menu provides contact information to call for help and a web link to the Camfil
APC website where this manual is available along with a quick start guide.
11
Run Mode Menu
Touching the Cleaning Mode button will open the Run Mode Menu. There are five cleaning
options as show in the graphic to the right. On Demand and Autoclean are controlled by the
internal differential pressure of the primary filters
On Demand
On Demand cleaning only operates when the start cleaning setpoint is crossed. The filter will
continue to pulse clean the filters until the pressure drop falls below the stop cleaning setpoint.
On demand cleaning saves energy by only cleaning when the pressure drop demands it.
Factory default start and stop setpoints are 1.5 and 2.0 in wg. As the filters age and the
system can not achieve the low setpoint these settings are progressively increased.
Continuous
In continuous cleaning mode the controller pulses the valves continuously based on the on
time and off time settings
Autocleaning
Autocleaning operates similar to the on demand cleaning cycle. It starts and stops based
on the start and stop setpoints. However, autoclean will decrease the off time settings if
the pressure does not drop during cleaning. When the lower setpoint is reached the off time
setting is restored to the programed value.
Remote
The Remote cleaning mode allows the user to start and stop the cleaning operation by an
external contact connected to the Remote Cleaning Input. Close the circuit to activate remote
cleaning. Any of the digital inputs can be used for remote cleaning.
Off
12
Off stops the controller cleaning functions while the controller stays on.
Alarm Page
The alarm button on the home page displays the current alarm if an alarm exists. If multiple
alarms occur the controller will log them. The controller retains the last 16 alarm conditions
and are displayed on two pages. To access the alarm history touch the alarm button. If the
alarm is red it means the alarm condition is still active.
13
Data and Measure
This page displays pressure, power, and operating time. No information can be changed.
Analog Input Values
This page displays analog inputs and their alarm values. No information can be changed.
14
Name
Function
n. EV
Last solenoid work
kWatt
Instantaneous FAN consumption
kWatt h
Total FAN consumption
Volt
FAN voltage
Ampere
FAN current
Primary
Primary gauge pressure
Secondary
Secondary gauge pressure
Time (h) Total
Total elapsed time of cleaning
Time (h) Service
Service time of cleaning
Main Menu, Alarm Setup Analog Input, and Function Menu
Home Button
Switch between these screens by selecting the back and next buttons
Main Menu
This page shows the user parameters that control the unit. These are all active buttons.
Touching them will take you to a screen that allows you to change the value.
15
Main Menu Buttons
Symbol / Name
ON
Box
Description
Range
Default
1
Pulse on time
0.10 – 0.30 sec
0.15 sec
OFF
2
Pulse off time
5 – 300 sec
15 sec
Start Set Point
3
Start cleaning set point
0.0 – 10.0 inwg
2.0 inwg
0.0 – 10.0 inwg
1.5 inwg
1 – 60 sec
60 sec
Stop Set Point
4
Stop cleaning set point
Delay
5
Offline cleaning delay
Cycles
6
Number of times each valve is pulsed
during the shut down cleaning cycle
0 – 10
0 (disabled)
n. EV
7
Number of electric valve boxes
(solenoids)
0 – 360
0
EV Tot
8
Total number of valves on system
0 – 360
0
Primary
9
Alarm setpoint for primary filter
0.0 – 10.0 inwg
6.0 inwg
Secondary
10
Alarm setpoint for secondary filter
0.0 – 10.0 inwg
4.0 inwg
Units
11
Unit of measure
Eng, SI
Eng
Language
12
Language of the unit
English, French,
Swedish, Italian, German,
Programmable
English
Main Menu Value Setting
Touching boxes 1 – 6, 9, or 10 will open a screen like the one seen above. Adjust the settings
using the up and down buttons.
16
Language Setting
Touching box number 12 will open the Language Setting screen. Adjust the settings using the
flag buttons. When you select a language, its flag is surrounded by a blue rectangle.
17
Main Menu Solenoid Setting
NOTE
The number of valves for
your system will be factory
set. However, this needs to
be check and the auto detect
function must be activated
after the valves are connected
and if any valves are replaced.
18
Touching the box number 7 or 8 will open a
screen like the one seen here. Push the button
“Total Ev” and insert the correct total number
of valves present in the system using the red
arrow buttons. Then push the button “AutoDetect EV” and the system will start a scan of
all valves in the system. The automated count
should match the total you entered. If it does
not the controller will show an “EV” error.
Alarms Setup Analog Input Page
The top row of this screen displays analog inputs set up in your controller. Touch the buttons in
the middle row to change the alarm settings.
The following screen appears and the alarm values can be changed using the up and down
buttons.
19
Function Menu
The Function Menu opens a screen that allows you to zero the pressure gauges , set the time
and date, create or reset the Main Password and to reset the Default parameters.
Reset Pressure
To reset the pressure of the unit:
1. Touch the “Reset Pressure” button to enter the
internal and external pressure gauges page.
2. Disconnect the two connection pipes of the
pressure gauge that you want to reset.
3. Touch the “OK” button for the gauge you want
to reset. A confirmation page opens.
4. Touch “Yes” button to confirm.
5. After resetting, 0.0 should be visible.
20
Time and Date
Touch the Time and Date button to go to that page.
If you want to change the date or the time push on the value that you want to change.
Press this button to change
the time and date format
(MM/DD/YY or DD/MM/YY)
It will begin to blink. Use the red arrows to change the value. The new value will be save
automatically when you exit from the page.
Main Password
To set or reset the password:
1. Touch the password button to enter the
page.
2. Inset the old password (if necessary).
3. Insert the new password with the red
arrow buttons and save with the Confirm
button.
21
Reset Default
Touch the “Default” button to enter in the reset default page.
Touch the “Yes” button if you want to confirm or “No” button to exit. If you confirm the reset
default, all parameters will be reset to their factory values. To complete the reset, power the
controller off then on.
22
Datalogger Menu
When you connect a USB key in the USB port, the USB symbol will appear on the Home
Screen.
Touch the USB Button to enter in the USB Datalogger page.
In this menu there are 4 buttons:
1. Touch the “Download Parameters” button to download all the parameters list in real time.
2. Touch the “Upload User Parameters” button to upload the new user values.
3. Touch the “Download Datalogger” button to download system data in real time.
4. Touch the “Upload All Parameters” button to upload the new value of all values (operation
permitted only to authorized persons).
The system uses the .csv extension file for Microsoft Excel.
Below shows the progress of an upload.
23
850 – Explosion/Fire Protection
Equipment
PROCESS MOUNT
PROCESS TEMPERATURE
PROCESS PRESSURE
PROBE ENCLOSURE
ALARM
POWER INPUT
RESOLUTION
RANGE
ELECTRONICS ENCLOSURE
REMOTE ELECTRONICS
2 RELAYS
UNIVERSAL AC/DC (20 TO 250 VAC/VDC)
5.0 pA
0pA ‐ 5,000 pA
NEMA 7/9
REMOTE PROBE
1/2"NPT
‐40F TO 250F (‐40C TO 121C) MAX
0 TO 10 PSI (0.69 Bar) MAX
NEMA 7/9
Particulate Monitor
Model DynaCHARGE™ PM 1
INSTALLATION & OPERATING MANUAL
T: (978) 927-4304 | 800 Cummings Center, 355W Beverly, MA 01915 USA | www.filtersense.com
Table of Contents
1
Notifications .................................................................................................................................. 4
1.1
1.2
1.3
1.4
1.5
2
Introduction .................................................................................................................................. 8
2.1
2.2
2.3
2.4
3
Terminal Connections ............................................................................................................................................................. 21
Operation .................................................................................................................................... 23
5.1
5.2
6
Location ........................................................................................................................................................................................ 13
Process Mounts.......................................................................................................................................................................... 15
Mounting ..................................................................................................................................................................................... 16
Test Port ........................................................................................................................................................................................ 18
Wiring .......................................................................................................................................... 19
4.1
5
PM 1 Overview ............................................................................................................................................................................. 8
Components ................................................................................................................................................................................. 9
Technical Data............................................................................................................................................................................ 10
Model Configuration ............................................................................................................................................................... 12
Installation .................................................................................................................................. 13
3.1
3.2
3.3
3.4
4
Technical Support Contact...................................................................................................................................................... 4
Disclaimer ...................................................................................................................................................................................... 5
Symbols and Conventions ...................................................................................................................................................... 5
Safety ............................................................................................................................................................................................... 6
Associated Documentation .................................................................................................................................................... 7
User Interface ............................................................................................................................................................................. 23
Settings ......................................................................................................................................................................................... 24
Commissioning ........................................................................................................................... 27
6.1
6.2
6.3
Signal Smoothing ..................................................................................................................................................................... 27
Alarms (PM 1-A) ......................................................................................................................................................................... 28
Analog Output (PM 1-T) ......................................................................................................................................................... 29
7
Alarm Setpoint Guidance ........................................................................................................... 30
8
Functional Verification ............................................................................................................... 32
8.1
8.2
8.3
8.4
9
Power-Up Check ........................................................................................................................................................................ 32
System-Zero Check .................................................................................................................................................................. 32
Response Testing ...................................................................................................................................................................... 33
Factory Testing .......................................................................................................................................................................... 33
Troubleshooting ......................................................................................................................... 34
10 Maintenance................................................................................................................................ 35
11 Spare Parts .................................................................................................................................. 36
11.1
Electronics Module Replacement ....................................................................................................................................... 36
PM 1 Installation and Operating Manual v1.2
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FilterSense © 2016
1 Notifications
1.1
Technical Support Contact
FilterSense provides industry leading Engineering and Technical Support for all product lines. The Technical
Support department is staffed with a team of engineering professionals. Areas of assistance provided by the
Technical Support department include:







Pre-Installation Site Analysis
Product Installation
General Operation
Application-Specific Review
Routine Calibration
EPA Compliance
Performance Upgrades and Add-On Features
To assure the best and most efficient technical support, please be prepared with the following information prior
to contacting FilterSense. If it is determined that the component must be returned for evaluation/repair, a
Return Material Authorization (RMA) number will be issued. You must include the RMA number on the packing
slip and mark the outside of the shipping container.





Company Name
Product Model Number
Product Serial Number
Date of Installation
Reason for Return
FilterSense Technical Support may be reached by:
Phone: (978) 927-4304
Fax: (978) 927-4329
E-Mail: info@filtersense.com
Hours of Operation: 8:00AM 5:00PM U.S. Eastern Time




Any control unit or particulate sensor that was exposed to hazardous materials in a process must be
properly cleaned in accordance with OSHA standards and a Material Safety Data Sheet (MSDS) must be
completed before it is returned to the factory.
All shipments returned to the factory must be sent by prepaid transportation.
All shipments will be returned F.O.B. factory.
Returns will not be accepted without an RMA number.
PM 1 Installation and Operating Manual v1.2
4
FilterSense © 2016
1.2
Disclaimer
This document contains important information necessary for proper operation of the product. It is
strongly urged that all users of the product read this manual in its entirety. All instructions should be
followed properly and any questions that arise should be discussed with FilterSense (A Division of Impolit
Environmental Control Corp.).
Any use or distribution of this document without the express consent of FilterSense is strictly prohibited.
Any reproduction is prohibited without written permission.
In no event will FilterSense be liable for any mistake, including lost profits, lost savings, environmental
compliance costs, or other incidental or consequential damages or injury arising out of the use or
inability to use this manual, even if advised of the possibility of such damages, or any claim by any other
party. Terms and conditions supplied with each order contain additional liability limitations related to
this product.
1.3
Symbols and Conventions
Identifies information about practices or circumstances that can lead to personal injury
or death, property damage, or economic loss.
Warning statements help you to:



Identify a hazard
Avoid a hazard
Recognize the consequences
Identifies information that is critical for successful application and understanding of
the product.
Identifies information, sections or statements in this manual that apply to approved
hazardous area systems, regulations, or installation.
PM 1 Installation and Operating Manual v1.2
5
FilterSense © 2016
1.4
Safety
AREA CLASSIFICATION
Before installing any device, confirm area classification requirements as specified on
the product label. Do not install any device that is not tagged as suitable for the
required area classification.
ENVIRONMENT
Before installing any device, confirm ambient temperature, process temperature, and
process pressure requirements. Do not install any device that is not tagged as suitable
for the required temperatures and pressures.
NOT A SAFETY RATED DEVICE
This model must not be used independently for safety or as a critical input signal to a
safety system. This model is designated for general process control, diagnostics, and
environmental monitoring. Safety must be addressed with the detailed engineering,
redundancy, and safety certified components where applicable. Consult factory for
critical safety applications.
GROUNDING
Before turning on the instrument, you must connect the protective earth terminal of
the instrument to a proper earth ground. Grounding to the neutral conductor of a
single-phase circuit is not sufficient protection.
INSTALLATION AND SERVICE PERSONNEL
Only appropriately licensed professionals should install this product. Always
disconnect power before servicing.
Personnel must be familiar with operational hazards, such as those caused by hot,
pressurized, or toxic gases, liquids, or particulates.
Service of individual electronics is limited to replacement of the electronics module. Do
not attempt to disassemble electronics. Any components that are not operating
properly should be returned to FilterSense for service.
PM 1 Installation and Operating Manual v1.2
6
FilterSense © 2016
1.5
Associated Documentation
This manual is to be referenced in conjunction with the following FilterSense documentation:
Product Information
Publication Number
Title
228-1077
FilterSense Particulate Monitoring Application and Alarm Guide
EXXXX
Project Specific Drawings if Applicable
PM 1 Installation and Operating Manual v1.2
7
FilterSense © 2016
2 Introduction
2.1
PM 1 Overview
a single-point/basic functionality particulate monitor employing charge induction
sensing for reliable continuous monitoring of particulate in stacks, ducts, and pipes. Applications include filter
leak detection, cyclone overflow, and powder flow/no flow. The PM 1 is available in two versions.
PM 1


PM 1-A
o Basic Particulate Monitor with Alarm
Relay Outputs
o Integral Electronics Only
PM 1-T
o Basic Particulate 4-20mA Transmitter
o Integral Electronics Only
The PM 1 is also available in a PRO version for demanding process control and EPA compliance applications.
Refer to separate manual for the PM 1 PRO.
PM 1 PRO



PM 1 PRO-A
o Advanced, High-Performance
culate Monitor with Alarm
Output
o Integral or Remote Electronics
o Graphical Display/Keypad
PM 1 PRO-AT
o Advanced, High-Performance
culate Monitor with Alarm
Outputs and Analog Output
o Integral or Remote Electronics
o Graphical Display/Keypad
PM 1 PRO-T
o Advanced, High-Performance
culate 4-20mA Transmitter
o Integral or Remote Electronics
o Graphical Display/Keypad
PM 1 Installation and Operating Manual v1.2
PartiRelay
PartiRelay
Parti-
8
FilterSense © 2016
Principle of Operation
As particles flow near or around the electrically
isolated sensing probe, minute charge is continuously
induced into the probe. The charge flows through a
measurement circuit to ground.
The induced charge signal is digitally analyzed and
processed to provide an output that is reasonably
linear to mass. The unit of measure is picoamperes
(pA). For highest accuracy and linearity to mass, refer
to model PM 100 PRO.
For best understanding of particulate levels, 4-20 mA
analog outputs should be converted to pA at remote
recording devices or remote displays.
2.2
Components
The PM 1 consists of the following main elements:
①
②
③
④
Electronics Module
Electronics Enclosure
Process Mount
Sensing Probe
PM 1 Installation and Operating Manual v1.2
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FilterSense © 2016
2.3
Technical Data
Electronics Module
Parameter
Model Code
Specifications
Measurement
Technology
Charge Induction
Measurement Units
Picoamperes (pA)
Input Voltage
Notes
1 x 10-12 A
-A-U
-A-D
Universal 20-250 VAC/VDC, 47-63 Hz
18-60VDC
Fuse: 1.0A, Slo-
-T
12-32 VDC Loop Power
Input Power
-A
3 Watts Max.
Electronic Resolution,
Range
-R1
-R2
-R9
0.5pA, Range 0 to 5,000pA
5.0pA, Range 0 to 5,000pA
10.0pA, Range 0 to 100,000pA
Minimum Detection
Level
-R1
-R2
-R9
Powder Flow Only
3
~1-5 mg/m
~5-10 mg/m3
~10 mg/m3
Minimum Particle Size
0.3 Micron
Temperature Ambient
-13F to +160F (-25C to +71C)
Operating
-40F to +185F (-40C to +85C)
Storage
Form A (SPST)
Type
250 VAC / 5A (Resistive), 2A (Inductive)
30 VDC / 5A (Resistive), 2A (Inductive)
Max Rating
Relay Outputs
4-20mA Output
-A
-T
@ 24 VDC
Rating
Loop Power
Adjustable via Keypad
Enclosure
-N4
NEMA 4/IP 66 Aluminum, Powder
Coated
Area Classification
-G
Ordinary/General Purpose Only, CE
Approved (CSA/UL Approval Pending)
Optional Hazardous Location, CSA
Approved, Class II, Division II, Groups EG, ATEX, IECEx (Approval Pending)
-H2
PM 1 Installation and Operating Manual v1.2
10
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FilterSense © 2016
Sensor Probe
Parameter
Detail/Code
Specifications
Mounting
-N05
-B10
-Q15
NPT Male 0.5 in
BSPT Male 1.0 in
Quick Clamp, 1.5 in
316L Stainless Steel
Optional Fully Insulated Probe (Teflon
Coating)
Probe
-C
316L Stainless Steel, Teflon
Nipple/Mount
Wetted Materials
Process Temperature
Operating Range
-T12
-T14
Process Pressure
Operating Range
PM 1 Installation and Operating Manual v1.2
Notes
-13F to +250F (-25C to +121C) Max.
-13F to +450F (-25C to +232C) Max.
Full Vacuum to 10PSI (0.69 Bar) Max.
11
FilterSense © 2016
2.4
Model Configuration
Order
Code
DynaCHARGE™ PM 1 Particulate Monitor
Base Unit
Transmitter (4-20 mA), 2-Wire Loop Power
Alarm (2 Relays)
PM 1-T
PM 1-A
Power Supply (PM 1-A Only)
Universal AC/DC Power (20 to 250 VAC/VDC)
DC Power Only (18-60 VDC)
U
D
Resolution and Range
Resolution: 0.5 pA, Range: 0 to 5,000 pA
Resolution: 5.0 pA, Range: 0 to 5,000 pA
Resolution: 10.0 pA, Range: 0 to 100,000 pA
R1
R2
R9
Probe Length
Length - 1.5 in (3.8 cm)
Length - 3.0 in (7.6 cm)
Length - 6.0 in (15.2 cm)
Length - 12 in (30.5 cm)
Length - 18 in (45.7 cm)
Length - 24 in (60.9 cm)
Length - 30 in (76.2 cm)
Length - 36 in (91.4 cm)
L1.5
L3
L6
L12
L18
L24
L30
L36
Process Mount
NPT Male 0.5 in (1.3 cm) with Mounting Coupling
Optional - Remove NPT Mounting Coupling
BSPT Male 1.0 in (2.5 cm) with Mounting Coupling
Optional - Remove BSPT Mounting Coupling
Quick Clamp, 1.5 in (3.8 cm) with Mounting Kit (Z= Mount Extension Size in Inches)
Optional - Remove Quick Clamp Mount Kit
N05
R
B10
R
Q15(Z)
R
Process Temperature
-13 °F to 250 °F (-25 °C to 121 °C) Max.
-13 °F to 450 °F (-25 °C to 232 °C) Max.
T12
T14
Process Pressure
Full Vacuum to 10 PSI (0.69 Bar) Max.
P0
Additional
Fully Insulated Probe (Teflon Coating)
C
Enclosure
NEMA 4/IP 66 Aluminum, Powder Coated
N4
Area Classification
Ordinary/General Purpose Only, (Approval Pending), CE Mark
Hazardous Location, Class II, Division II, Groups E-G, CSA/FM, ATEX, IECEx (Approval
Pending)
PM 1 Installation and Operating Manual v1.2
12
G
H2
FilterSense © 2016
3 Installation


3.1
Only trained professionals should install/maintain this product.
Shutdown processes that include high temperatures, high pressures, toxic
gases, hazardous particulate, or explosion risks prior to installing or removing
equipment.
Location
Temperature, Pressure, and Area Classification




Enclosure Label Example
Do not install any device that is not tagged as
suitable for the required area classification.
Confirm compatibility of sensor ratings with
process and installation area.
Check label for the following:
o Process temperature rating
o Process pressure rating
o Wetted materials
o Enclosure rating
o Area classification
Installation must be in grounded metal
duct/pipe. Consult factory for non-metallic
duct/pipe solutions.
Filter Outlet Locations
① Ensure good access.
② Avoid locating too close to stack exit.
③ Straight runs and laminar flow best for
measurement.
④ Short straight runs are acceptable for basic
leak detection.
⑤ Accessible negative pressure locations may be
preferred to prevent exposure to toxic gases
and particulate.
PM 1 Installation and Operating Manual v1.2
④⑤
②
①③
③⑤
13
FilterSense © 2016
Straight Run Considerations




Install in straight run if possible (not required).
Three (3) duct diameters upstream.
Two (2) duct diameters downstream.
Straight run can be horizontal or vertical.
Powder Flow Locations
① Best installed in pneumatic section (positive
or negative pressure).
② For gravity feed, consult factory.
 Grounded metal duct required.
o Consult factory for nonmetallic duct/
pipe solutions.
 Follow straight run considerations.
②
①
Horizontal Pipes/Ducts



Side or top mount recommended.
Bottom mount not recommended.
Proper mount and installation location will
prevent buildup.
PM 1 Installation and Operating Manual v1.2
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FilterSense © 2016
3.2
Process Mounts
The following types of process mounts are available:
Threaded


①
②
NPT Standard
G/BSPT Optional
Threaded Nipple
Threaded Half-Coupling Process Mount
①
②
Quick-Clamp



①
②
-Clamp
Allows quick and easy removal from process
Allows rotation to easily align
Quick-Clamp Nipple
Quick-Clamp Process Mount
①
②
PM 1 Installation and Operating Manual v1.2
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FilterSense © 2016
3.3
Mounting
Mounting Considerations
① Process mount should protrude into process
0.125 in (3.175 mm) to 0.5 in (12.7 mm).
② Sensor probe should extend approximately
1/2 of the duct diameter for filter outlet
applications and 1/4 to 1/2 of the pipe
diameter for powder flow applications.
 In smaller pipes, the probe should be 1 in
(25.4 mm) minimum from the opposing side.
①
②
①
②
Welding and Clearance
①
-clamp
mount to ensure proper clearance and to
prevent particulate buildup in mount. Process
mount should protrude into process 0.125 in
(3.175 mm) to 0.5 in (12.7 mm).
② Do not face weld.
 Weld in center of the duct/pipe,
perpendicular to the flow.
 Air and water tight seal.
①
Threaded
①
PM 1 Installation and Operating Manual v1.2
Quick-Clamp ②
16
②
FilterSense © 2016
Improper Extensions
① Do not use an extended or improper mount.
② Longer mounts can cause the nipple not to
protrude into the process.
③ Extended mounts can cause particulate
buildup on the insulator and sensing probe.
 Contact the factory for custom sensor nipple
extensions for proper installation in an
existing port.
 Do not use non-stainless steel mounts that
may corrode and cause corrosive residue to
drip on the sensor.
①
③
②
PM 1 Installation and Operating Manual v1.2
17
FilterSense © 2016
3.4
Test Port
Installation of a sensor test port is for introducing particulate upstream of the sensor as a method for checking
the response to an increase in particulate. Some applications are required by EPA regulations to include a sensor
test port for Response Testing.
Location and Mounting







Non-hazardous areas only.
Negative pressure location.
Install at least 3 ft upstream of the particulate
sensor.
In line with sensor on the same side of the
duct.
If possible, locate the test port at ground level
and/or a location with easy access.
If the test port must be located at an
inaccessible location, a length of tubing can
be used to improve access.
Typical test port is a
with a cap or shutoff valve.
PM 1 Installation and Operating Manual v1.2
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FilterSense © 2016
4 Wiring
Conduit Entries



One (1)
and two (2)
NPT entries
provided.
Conduit fittings should be tight.
Conduit should be routed downward to
prevent moisture from entering enclosure.
Recommended Service Loop



Flex conduit and ground cable should be
sufficient length to allow removal of the
sensor.
Recommended service loop is 1 to 2 times the
sensor probe length.
Service loop should extend downward to
prevent moisture from entering enclosure.
PM 1 Installation and Operating Manual v1.2
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FilterSense © 2016
Grounding





Required for reliable operation and safety.
PM1-T: Earth ground connection is made
through the process mount. Grounding to the
enclosure ground studs is not required.
PM1-A: Earth ground connection should be
made to one of the three ground locations:
o External enclosure ground screw.
o Internal enclosure ground screw.
o Electronics module earth ground
terminal.
Analog wiring cable shield should be
terminated to earth ground in PLC/DCS
cabinet or at panel meter (terminate at one
end only).
Ground wire should not impede service loop.
GROUNDING IN HAZARDOUS AREAS


For hazardous area applications, an external sensor earth ground cable is
required to maintain sensor grounding during installation and maintenance.
The ground cable must remain attached when the sensor is temporarily
removed from the process. Do not disconnect the ground cable.
PM 1 Installation and Operating Manual v1.2
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FilterSense © 2016
4.1
Terminal Connections
PM 1-A



Terminal connections for power and two
alarm relays.
All wiring must be rated for 250V minimum.
Always disconnect power before connecting/
removing wiring from the terminal
connectors.
PM 1 Installation and Operating Manual v1.2
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FilterSense © 2016
PM 1-T





Terminal connection for loop powered analog
output.
All wiring must be rated for 250V minimum.
Always disconnect power before connecting/
removing wiring from the terminal
connectors.
Analog 4-20mA wire should be 22 AWG
stranded shielded twisted pair, Belden 88761
or equivalent.
Analog wiring cable shield should be
terminated to earth ground in PLC/DCS
panel/cabinet (terminate one end only).
PM 1 Installation and Operating Manual v1.2
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FilterSense © 2016
5 Operation
5.1
User Interface
The user interface consists of two navigation keys and a digital readout. The PM 1-A also includes status LEDs for
power and alarms. Upon power up, the particulate measurement is shown, from which the user can view live
values or choose to access the Settings.
Keypad
Description
Key
① Up/Next

② Right/Enter
Key

Next reading or
setting
Increment value



Enter setting
Move cursor right
Accept value
①
Display and LEDs
Description
③ Digital Readout
④ Status LEDs
User Interface
②
③

6-Character display
with decimals


PM 1-A only
Alarms and power
indications
④
Status LEDs (PM 1-A Only)
LED
State
A1
Red
Off


Alarm 1 active
Alarm 1 inactive
A2
Red
Off


Alarm 2 active
Alarm 2 inactive
PWR
Green
Off


Power
No power
PM 1 Installation and Operating Manual v1.2
Meaning
23
FilterSense © 2016
5.2
Settings
Live Particulate Reading
Upon power up, the Live Particulate Reading is shown in picoamps (pA) (the actual measured value from
particulate charge). Pressing the NEXT key will cycle from the Live Particulate Reading (pA), to the
corresponding Live 4-20mA Reading (PM 1-T only), and the Setup display. Pressing the ENTER key on Setup
will enter the Login display.
Next
Live Particulate Reading
Live Analog Output Reading
(PM 1-T Only)
Setup Menu
Enter
25 pA
408 mA
5ETUP
LOGIN
User Login
Login is required to access the Settings and is valid until power is removed, or after 5 minutes without keypad
activity. Default passwords cannot be changed.
User Level
Password
Permissions
Operator
0
View live process readings and all settings, no changes allowed.
Engineer
55
View and change all settings.
Numeric Entry
Next
123456
223456
123456
Enter
123456
Exit & Accept
Numeric Entry
PM 1 Installation and Operating Manual v1.2
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FilterSense © 2016
Settings (PM 1-A)
Next
Enter
A1 SETPOINT
pA
A1 Setpoint Entry
NUMERIC ENTRY
A1 DELAY
SECONDS
A1 Delay Entry
NUMERIC ENTRY
A1 LOGIC
A1 Logic Selection
HI / LO
A1 FAIL-SAFE
A1 Fail-Safe Selection
YES / NO
A2 SETPOINT
pA
A2 Setpoint Entry
NUMERIC ENTRY
A2 DELAY
SECONDS
A2 Delay Entry
NUMERIC ENTRY
A2 LOGIC
A2 Logic Selection
HI / LO
A2 FAIL-SAFE
A2 Fail-Safe Selection
YES / NO
SMOOTHING
SECONDS
Smoothing Entry
NUMERIC ENTRY
LANGUAGE
Language Selection
ENGLISH / DEUTSCH / FRANCAIS / ESPANOL
INFO
PM 1 Information
SERIAL NUMBER / FIRMWARE VERSION /
HARDWARE VERSION
EXIT
Exit Settings
PM 1 Installation and Operating Manual v1.2
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FilterSense © 2016
Settings (PM 1-T)
Next
RANGE pA
Enter
Range Selection
0-100 LINEAR / 0-500 LINEAR / 0-1000 LINEAR / 0-5000
LINEAR / 0-100K LINEAR / 0.5-500 LOG / 5-5000 LOG
FORCING mA
Analog Output Forcing Selection
YES / NO
SMOOTHING
SECONDS
Smoothing Entry
NUMERIC ENTRY
LANGUAGE
Language Selection
ENGLISH / DEUTSCH / FRANCAIS / ESPANOL
INFO
PM 1 Information
SERIAL NUMBER / FIRMWARE VERSION /
HARDWARE VERSION
EXIT
Exit Settings
PM 1 Installation and Operating Manual v1.2
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FilterSense © 2016
6 Commissioning
6.1
Signal Smoothing
Alarms and ranges should be adjusted after changes are made to Smoothing
Seconds.




A signal smoothing adjustment is provided to
fine tune the real-time output.
Adjust for reasonably stable baseline readings,
while response to peaks remains dynamic and
fast.
Adjusting too high may limit setting an alarm
based on peaks.
Adjusting too low may result in an output that
is too dynamic to easily interpret.
Smoothing Seconds example. Actual response is
application dependent.
Setting
Default
Notes
Smoothing Seconds
3
Signal smoothing. Increase for smoother reading, decrease for more
dynamic.
PM 1 Installation and Operating Manual v1.2
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FilterSense © 2016
6.2
Alarms (PM 1-A)
Two alarms are available in the PM 1-A. An alarm will be activated when the particulate measurement increases
above (HI Alarm Logic) or decreases below (LO Alarm Logic) the Alarm Setpoint continuously for a period
longer than the Alarm Delay setting. The LED status will correspond with the associated alarm. The default
alarm configuration is listed below.
ALARM LEVELS
Appropriate alarm levels will vary by process and user needs. Default alarm levels
should not be relied on without careful review of each process.
Alarm Settings
Setting
Default
Notes
A1 Setpoint pA
30
Limit for alarm 1 activation
A1 Delay Seconds
10
Amount of time reading must be in alarm condition to activate alarm 1
A1 Logic
HI
Activation logic (HI or LO)
A1 Fail-Safe
No
Determines relay state of alarm 1 output (closed/open)
A2 Setpoint pA
100
Limit for alarm 2 activation
A2 Delay Seconds
5
Amount of time reading must be in alarm condition to activate alarm 2
A2 Logic
HI
Activation logic (HI or LO)
A2 Fail-Safe
No
Determines relay state of alarm 2 output (closed/open)
Alarm Logic
Alarm Logic defines how the particulate alarms are activated. When the Alarm Logic setting is set to HI, the
alarm is activated when the input rises above the Alarm Setpoint continuously for a period longer than the
Alarm Delay. When Alarm Logic is set to LO, the alarm is activated when the input falls below the Alarm
Setpoint continuously for a period longer than the Alarm Delay. LO Alarm Logic is used for loss of flow
applications.
Fail-Safe Relay State
Fail-Safe Mode
Power Off/Removed
Normal Operation
Active Alarm
Normal (No)
Open
Open
Closed
Fail-Safe (Yes)
Open
Closed
Open
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6.3
Analog Output (PM 1-T)
The PM 1-T is a 4-20mA transmitter, which can be used for trending live particulate readings in external devices.
The selectable Range can be set to one of five linear ranges or two logarithmic ranges. After selecting the
desired Range, the output can be forced to verify proper wiring and scaling in the connected device.
Analog Output Settings
Setting
Default
Notes
Range pA
0-1000 Linear
Range selection for the analog output. Available ranges include 0-100
Linear, 0-500 Linear, 0-1000 Linear, 0-5000 Linear, 0-100K Linear,
0.5-500 Log, 5-5000 Log.
Forcing mA
No
Stepwise simulation of analog output (YES or NO)
Analog Output Range Selection
 Range selection recommendations:
① Baseline is 0-10% of range.
② Peaks are 30-50% of range.
②
①
Analog Output Forcing





Set Forcing mA to Yes to force a step-change
output for testing the analog output in a
stepwise manner.
Output will follow the pattern shown.
Each step will last for 10 seconds from 4mA to
20mA and back down in a cyclic pattern.
Forcing cycles will either end automatically
after four (4) cycles (5 minutes 30 seconds) or
can be stopped before completion by setting
Forcing mA to No.
Once simulation has ended, the analog output
will continue with normal operation.
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7 Alarm Setpoint Guidance
Alarms should be set based on observing the output over the full range of normal operating conditions. For
fabric filter applications, monitor the readings when the filter media is in good non-leaking condition and with
cleaning both disabled and enabled. For filter applications, baseline and peak particulate readings following
cleaning cycles should be noted.
Once a good set of readings is observed, alarms should be set based on the alarming objective. In all cases recall
the output of a
particulate monitor is reasonably linear/proportional to mass. This means that if
the readings increase by a factor of 3, for example, the amount of particulate will have increased by a factor of 3.
If during normal operation the baseline is always 0pA, contact the factory for a model with lower detection
capabilities.
The following are the main approaches to setting the alarms.
Leak Alarming (focus is on detecting leaks in filter media)



Adjust Smoothing Seconds for good response to cleaning cycles while keeping the baseline fairly
stable.
Set a HI (peak) alarm to capture increasing cleaning cycle peak readings at 1.5x to 5x typical peak height
with a 1- to 5-second delay. This provides an early warning alarm.
Set a HIHI (baseline) alarm to capture increasing baseline readings at 2x to 10x average baseline
reading with a 30- to 180-second delay.
Proportional Alarming (focus is on detecting a relative change in the mass concentration)



Adjust Smoothing Seconds for relatively stable particulate readings.
Set a HI (peak) alarm at a desired multiple over the average baseline reading with a 1- to 60-second
delay.
Set a HIHI (baseline) alarm at a desired multiple over the average baseline reading with a 30- to
360-second delay.
Powder Flow Alarming



Adjust Smoothing Seconds for relatively stable particulate flow readings.
Set a HI (increased powder flow) alarm above the desired powder flow rate.
Set a LO (loss of powder flow) alarm below the desired powder flow rate.
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Example of Typical Baghouse/Dust Collector Readings
① Normal baseline.
② Normal peaks from cleaning cycles.
③ Filter wear causes an increase in the cleaning
peak. Early warning alarm of filter leak-through
(HI alarm).
④ Filter leak increases, causing a baseline shift.
HIHI alarm triggered.
⑤ Filter replaced.
⑥ Baseline and cleaning peaks return to normal
levels.
③
②
⑤ ⑥
④
①
Typical Readings for Modern Efficient Fabric Filters
Average Baseline
Peaks (After Cleaning Cycles)
Filter Condition
1 to 10pA
Less than 50pA
No significant leaks
10 to 100pA
50 to 500pA
Onset of leaks
100 to 1000pA
500 to 5000pA
Significant leaks present
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8 Functional Verification
To verify operation after commissioning or otherwise as needed, the following 3 checks should be performed:
1.
2.
3.
8.1
Power-Up Check
System-Zero Check
Response Testing
 As needed the device can be returned to the factory for full electronics testing and mechanical
checkout.
Power-Up Check
A Power-Up Check can be initiated to check the general functionality of the particulate monitor. The check
occurs each time the instrument is powered up. A failed status result will remain until power is cycled and the
error has cleared. Follow the steps below to run a Power-Up Check:
Power-Up Check Procedure
1.
2.
8.2
Cycle power to the PM 1.
If ERR 1 or ERR 2 is displayed on the digital
readout, follow the steps outlined in the
Troubleshooting section of this manual.
System-Zero Check
A System-Zero Check is an in situ (fully installed) test of the entire system when there is no airflow. A SystemZero Check confirms proper installation and zeroing of the electronics and sensing probe when fully installed.
System-Zero Procedure
1.
2.
Shut down the process and fan. Ensure process flow has completely stopped. The slightest amount of
flowing particles can create a signal.
Monitor the particulate reading for a system zero.
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8.3
Response Testing
Response Testing is performed to verify response to an actual increase in particulate.
Response Testing Procedure
1.
2.
Introduce particulate upstream of the sensor using one of the following methods:
a. Pulse filters while process is running and collecting particulate.
b. Inject particulate using sensor test port (1 tsp of talc powder or actual process dust
recommended).
c. Increase particulate flow by changing process.
Monitor the particulate reading for an increase in particulate.
RESPONSE TESTING


8.4
Particulate injections should only be performed in non-hazardous areas.
A response test can trigger alarm activation depending on alarm setpoints and
the amount and type of particulate injected.
Factory Testing
Contact FilterSense to request an RMA in order to return the device for full factory testing. NIST traceable
calibration certificates are available on request. The following parts can be returned for calibration:
1.
2.
PM 1 (Electronics Module)
PM 1 (Electronics Module & Sensor Probe)
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9 Troubleshooting
Issue
Action
Display reads ERR 1


Replace electronics module.
Return faulty electronics module to factory for evaluation/repair.
Display reads ERR 2

Inspect the electronics enclosure to check that water has not entered the
enclosure.
o If water is found, contact Technical Support.
Inspect the particulate sensor and process mount for particulate buildup,
moisture, and/or damage.
o Clean the sensor of all particulate and moisture.
o If damage is found, contact Technical Support.
After performing the above inspections, cycle power to the particulate monitor.
If the issue remains, contact Technical Support.


Zero Reading
(with process
running)



Elevated Flat-Lined
Reading
(with process
running)






Perform a Response Test.
If response is confirmed, baseline detection level may not be suitable for the
application. Contact factory for PM 1 electronics module with lower detection
capabilities.
If response is not confirmed, contact Technical Support.
Perform a Power-Up Check to verify the electronics module.
Confirm correct scaling between 4-20mA output and PLC.
Inspect the electronics enclosure to check that water has not entered the
enclosure.
o If water is found, contact Technical Support.
Perform a Response Test.
Perform a System-Zero Check.
If the issue remains, contact Technical Support.
Low Reading (with
process running)


Confirm correct scaling between 4-20mA output and PLC.
Perform a Response Test. If the system responds properly, reevaluate the
selected Alarm Setpoints.
High Dynamic
Reading (with
process running)

Check to make sure the particulate has not increased. Leaking filters and filter
cleaning cycles can cause high dynamic readings. The particulate sensor detects
very low levels of particulate. Small leaks can cause alarms.
Verify PM 1 is grounded to earth
specifications in the Grounding section.
Check the Signal Smoothing adjustment.
Confirm correct scaling between 4-20mA output and PLC.
If nothing is found, perform a System-Zero Check.




Relay Not
Responding

Verify alarm LED status. Remove all wiring from the output and connect the
output to an ohmmeter. Check continuity across relay output circuit.
Analog Output Not
Responding

Use a multimeter in series to verify that the milliamps match the milliamp
measurement on the digital readout.
Force the analog output.

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10 Maintenance


Only trained professionals should install/maintain this product.
Shutdown processes that include high temperatures, high pressures, toxic
gases, hazardous particulate, or explosion risks prior to installing or removing
equipment.
Electronics Module
normally drift free and require no periodic maintenance or electronics calibration
by the user. Electronics calibration is automatically confirmed with PRO models equipped with device health
checks or EPA automatic self tests. As desired or required for quality programs or regulations, the entire device
or the electronics module may be returned to the factory for NIST traceable calibration certification.
Particulate Sensor
not require periodic
maintenance other than an annual inspection. This should be verified by conducting functional verification
checks of the electronics and manually inspecting the sensor after one and six months of operation. After these
two initial checks, if no need for sensor maintenance is observed, an annual inspection is recommended. For EPA
compliance and critical measurement applications, PRO models with device health checks and EPA automatic
self tests are recommended to provide added assurance between annual inspections and to automate
regulatory inspection requirements.
Particulate Monitor Inspection
Each inspection should consist of the following:





Visually inspect inside the sensor enclosure.
Remove the sensor from the process and inspect the probe and insulator for buildup and/or moisture.
o The sensor probe and insulator may be wiped down with a damp rag.
o Fully insulated probes are recommended for processes with moisture and most conductive
particulates.
Inspect the inside of the process mount for buildup and/or moisture.
Check the outputs.
Perform Functional Verification checks.
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11 Spare Parts
Spare parts for the PM 1 include the following:


PM 1 Electronics Module
PM 1 Enclosure and Sensor/Nipple/Probe Assembly
Please see the Model Configuration section for spare parts configuration and examples. Add SP to a part
number to specify a spare part.
11.1 Electronics Module Replacement
The PM 1 is designed so that the electronics module can
be easily replaced. An electronics module can be
replaced by following the steps below:
1.
2.
3.
4.
5.
6.
7.
8.
Remove the cover to the PM 1.
Record all settings from the existing electronics
module.
Disconnect all power to the PM 1.
Remove all wiring (power and outputs) from the
terminal connections.
Remove the entire device from the process.
Remove the two 9/64" hex screws that connect
the electronics module to the enclosure.
Remove the electronics module from the
enclosure and replace with spare electronics
module.
Follow the above steps in reverse to complete
the replacement.
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