Installation & Service Manual for the Power Booth Module PBM Series Collectors. Models PBM-6

Transcription

1 Installation & Service Manual for Power Booth Module PBM Series Collecrs Models PBM-6 April 2, 2007

2 Power Booth Module Table of Contents Dclaimer...3 Uncrating...4 Description & Operation...4 Optional Equipment...4 Applications - General...5 Installation...6 Installation continued...7 Figure Mor & Transformer Connection Diagram...7 Figure 2 Control Timer...8 Installation continued...9 Ordering Replacement Parts...0 Maintenance... Troubleshooting...2 Specifications...3 Limited Warranty...4

3 Dclaimer Power Booth Module Although instructions and recommendations are included for installation of your Vertical Cartridge Filtration System, manufacturer does not assume responsibility for installation of th equipment nor shall he be held liable for direct or consequential damages resulting from improper installation, application, maintenance or use. The immense variety of contaminants make it impossible lt all of potential hazards that may be encountered with air pollution control systems. It refore important that application of equipment be dcussed with an AER Control Systems representative or application engineer prior use. Additionally, users should consult and comply with all National and Local Fire, Electrical and /or or appropriate codes when determining application, location and operation of any air pollution control equipment. Collection of combustible or explosive materials and collection on flame or spark-generating operations may require specific system configurations (contact AER Control Systems LLC. Applications Engineering Department for questions and/or design asstance). The combined collection of combustible or explosive materials and contaminants from spark or flame generating operations, with a common collecr or duct system, not recommended, unless special design provions have been made system (sparks or flames resulting from such operations may ignite combustible or explosive material). Under no circumstances should anyone be allowed dcard a lighted cigarette, or burning materials, or refuse in an inlet hood or duct of collection system. It responsibility of end user comply with all applicable national, state, and local fire and safety codes. Th manual should be read completely before attempting Operation or Maintenance of th equipment. All work should be performed by qualified personnel according local requirements. WARNING Failure comply fully with following instructions and local code requirements may increase your rk of physical injury due fire, explosion or electrical shock. All data and dimensions in th manual have been thoroughly checked however, we cannot assume responsibility for possible errors or omsions. We reserve right change designs and/or specifications without notice.

4 Power Booth Module SECTION Uncrating. Remove banding and cardboard shipping carn and packing. 2. Plenum Boxes, and Attenuars are typically labeled and packed with unit be installed, Mounting hardware included for mounting se items. Be sure check all boxes for any mcellaneous parts or hardware items before dcarding. 3. Inspect exterior of unit and accessories for shipping damage or shortages that may not have been noticed or recorded when shipment was initially received; you have 30 days notify AER Control Systems LLC. of any dcrepancies. Contact shipping company if any damage or shortages have occurred. Description & Operation The PBM Series Collecrs const of a vertically mounted filter module which houses cartridge filters. Each cartridge has a filter media pack of 2 inch pleated media and formed in shape of a hollow cylinder. The interior of cartridge cylinder open pulse tank module, which periodically cleans cartridges by compressed air, pulse jet flushing.diaphragm valves are mounted a compressed air reservoir tank and activated by a manually operated or solenoid valve. During operation a short blast of compressed air interior of one bank of filters results in media vibration and airflow reversal that back flushes collected contaminants off of exterior surface of filter bank. By alternating compressed air cleaning of filter banks, system can continue collect contaminants while cleaning takes place. The mor/blower module located on clean air side of system after pulse tank. Optional Equipment Special Filters Casters Inlet Plenum Boxes Smart Pulse w/ Downtime Pulse Pre-Filters Spark Trap Filters

5 SECTION 2 Power Booth Module Applications - General. Dust & Fume - The Power Booth Module (PBM) designed for capture and removal of DRY dust and/or fumes generated from sanding, grinding, welding and or industrial processes. The PBM collecr a modular system consting of a filter media/cartridge filter module, collection trays and a final module containing air reservoir tank and pulse-jet cleaning system, blower and mor. The unit can be arranged in a variety of configurations and can be equipped with specialized filters for application specific filtration requirements. The floor mounted collecrs are designed primarily for ambient capture applica tions eir inside a booth or sitting on floor in middle of a shop. 2. Size - It important that proper size unit has been selected for application. Too little airflow will not draw contaminant in filter and unit will not be completely effective. Too much airflow may result in loss of efficiency or unit will pick up large or heavy solid particles increasing frequency of maintenance or filter replacement. Questions regarding proper unit sizing should be directed your local AER Control Systems representative or main office (ll free ) 3. Models - Model codes are utilized identify various unit configurations available. The model PBM (Power Booth Module) system uses a direct drive blower (sometimes called a plug fan) along with number 6. The PBM-6 unit has a 7.5 HP direct drive mor and fan. The numeral 6 indicates that th unit has six cartridge filters. An option for a 0 HP Mor and Fan available. 4. Dust Drawers - Three individual dust drawers are available on PBM-6 unit, one under each row of cartridge filters.

6 Power Booth Module SECTION 3 Installation Assembly & Installation PBM Standard Collecrs are pre-assembled. Standard collecrs are free standing and are typically located in a central location near operations needing collection. Floor mounting brackets are provided on unit for shipping and attachment shop floor. Lifting bars are mounted on p side for lifting from skid for placement on shop floor. Do not lift from under dust drawers of unit as th will buckle underside of unit. Assembly & Installation All Models The integral manual mor starter facry wired for 460 volts 3 phase (unless orwe specified on purchase order) requiring only a qualified electrician connect input power unit. Refer electrical section. (Combination mor starters with fusible dconnect packages are available through most local AER Control Systems LLC. dtriburs). A connection for clean, dry, compressed air located outside pulse tank module and connected air reservoir tank. A connection provided on eir side of tank for convenience of air supply line. The or port can be plugged. The supply airline should be purged remove any debr before connecting it unit prevent damage pulse valves on system. The supply compressed air line should be equipped with a manual shut-off valve, a filter/separar, air regular, and a pressure gauge and located close PBM system. If unit be installed in an area where freezing temperatures or high humidity are be expected, an air dryer capable of drying compressed air below dew point must also be provided. If excessive moture present, check drain frequently or install an aumatic drain.

7 SECTION 3 Power Booth Module Installation continued Electrical All three-phase units are wired for input voltage specified on purchase order. Unless specified orwe, standard units are wired for 460 volt, 3 phase, 60 Hz operation. Mors used on PBM collecrs are UL recognized and internal wiring UL rated at 600-volts. Input power line protection required for mor and electrical components. Line load and current requirements are identified on mor nameplate. Unless ordered with machine, power switch for operating machine, any fusible dconnect, mor starter or controller are be provided by cusmer/user and located externally machine. After electrical hook up it important verify that fan rotation correct. Incorrect rotation results in much lower airflow and increased noe. For standard three phase installations, changing connections of any two of three input power lines will usually reverse fan rotation. Rotation direction can be found on side and/or back of mor. If it becomes necessary change input voltage, wiring diagram on mor and transformer nameplates show appropriate wire connections - se diagrams are also shown below: Figure - Mor & Transformer Connection Diagram NOTE A mor starter with overload protection must be provided by User. Thermal overload heaters are installed in external mor starter. Consult starter manufacturer for recommended heater size for installed mor.

8 Power Booth Module Figure 2 - Control Timer

9 SECTION 3 Power Booth Module Installation continued Control Systems WARNING Permanent damage mor will be sustained if connected voltages or than normal operating voltage for which unit pre-wired. The PBM standard with manual push butn controlled air operated valves. Push butn briefly which located on each valve clean filters. AUTOMATIC CONTROLS,are optional, an integrated, electrically operated pilot solenoid valve for each diaphragm valve. The solenoid valves are controlled by a solid-state sequential control timer that determines order in which solenoid valves are operated, length of time that valves remain open, and time interval between each valve opening. The compressed air tank and valves are fully enclosed and located between cartridges and blower. The sequential control timer, input power connection, transformer and indicar light are contained in electrical box mounted on unit. WARNING Take special care when electrical box opened. When power ON, full line voltage can appear from any electrical point on circuit board metal enclosure or ground. Compressed Air Requirements Air reservoir pressure should be between 90-psig ( minimum pressure which will assure truly effective cleaning of cartridges) and 05-psig ( maximum recommended working pressure of valves and air reservoir). Note: Watch Air Pressure Guage make sure reading does not exceed 20 PSIG. The tal consumption of compressed air variable and dependent upon points of ON and OFF time of timer and air pressure in reservoir at time of air pulse. When ON timer at its recommended time of 0. second and air reservoir pressure at 00-psig, approximately 0.9 cubic feet of free air will be used per pulse. While cartridges are being cleaned, average usage rate in CFM of free air depends upon ting of OFF timer. If at 30-second intervals (2 pulses per minute) average usage rate during a cleaning cycle would be (0.9 cu. ft./pulse) x (2 pulses/minute) =.8 CFM of free air.

10 Power Booth Module SECTION 4 Ordering Replacement Parts Information required for prompt delivery of replacement parts will be:. Model and Serial Number 2. Part Number and Description Contact your local AER Control Systems LLC. dtribur for replacement parts. Use eir our ll free telephone number or our website obtain nearest AER Control Systems LLC. dtribur s name and telephone number Par art Numbe umber D escription Qy Qt t PBM- BM BlowerInletCone, 6" BlowerWheel BlowerWheel 6-00(Optional) Mor, 7.5HP Mor, 0HP(Optional) Cartridge, 80/20 30" L Diaphragm Valve.5" Diaphragm Valve.5", Solenoid(Opt) ControlTimerBoard(Optional) 0-0 Pushbutn Valve -0 DiffusionNozzle Transformer, 50W(Optional) ampfuse(optional) /2ampFuse(Optional) 22-0 DelayRelayTimer(optional)

11 SECTION 5 Power Booth Module Maintenance Operation & Maintenance Lubrication or or routine periodic preventative maintenance not required. All that needed an occasional check of fasteners, hoses and clamps and an overall vual check of unit. Periodic replacement of cartridges required when necessary and check/ draining of condensation from air reservoir. Draining can be done aumatically if drain opened (slowly) while tank under pressure. Always empty dust srage drum before it fills completely. Do NOT allow dust collect point where it begins fill flexible hose and enter botm of hopper, since th would result in dust being re-entered in air stream, re-depositing on cartridges and shortening ir life. Do NOT use hopper as a dust srage device! Cartridge Replacement The pressure drop across cartridges will eventually reach a point at which airflow and suction are o low. At th time, cartridges should be replaced as follows:. Shut off electrical power blower and control box. 2. Open cartridge access door (if supplied) on front of filter cartridge mod ule. 3. Remove handknobs on threaded rod that supports cartridge lift bars and drop down two cartridge lifting bars, lower bars enough slide out both of filters. 4. Slide cartridges out on track by grabbing cartidge header and pulling ward you. Remove cartridges for inspection or replacement. 5. Reinstall cartridges by sliding cartridges in cabinet on track and swing lift bars up and turn handknobs compress gasket on p of cartridge. The gasket requires a good tight seal on cartridges eliminate any blow-by of filters. 6. Close cartridge access doors (if supplied).

12 Power Booth Module Troubleshooting roblem P m roble P m roble P m roble P m roble P e aus C e aus C e aus C e aus C e aus C n olutio S n olutio S n olutio S n olutio S n Solutio Start Fails Mor Unit To Power No starter in heaters overload if re or replace fuses, and wire proper for necessary. starter from and connections collecr. and unit Power box electrical from input wires mor. collecr on mor if see wiring. mor faulty. suction Low airflow and/or backwards running Blower running If blower. of rotation 3 2of interchange backwards, mors (3 phase leads power input only). cleaned being not are Cartridges it if see system pulse air pressure. air correctly. working of out blowing Contaminant exhaust collecr cartridge in ole H. cartridge Replace installed properly not Cartridge cartridge correct for gasket, cartridge orientation. in hole around seal must gasket cabinet. cartridge of sheet tube mor but pulsing, not Unit running (Optional) board timer power No if replace fuses, blown for transformer. necessary. board timer getting Power (Optional) on, air compressed if see wiring unit. connected and assembly. valve from board opening. are valves if see mor but pulsing, not Unit or timer delay with (units running option) pulse Phohelic (Optional) properly Not be time Off points. timer you than period longer a for low pressure and high expect. gauge. Phohelic on points be may point pressure High high. o time of all pulses Unit o be may time Off short.(optional) Timer tings, board timer intervals pulse for designed board 3minutes. 8.5 sec every Gauge Phohelic on times Set (Optional) properly not are option Low Pressure and/or Pressure High low. o be may points

13 Power Booth Module Specifications S pecifications PBM- 6 Nominal Airflow-CFM 5000 AvailableExternalpressure -IN. H2O 3 Filters-Qty. 6 TotalFilterArea-Sq. Ft. 644 Mor-HP 7. 5 MorTemp. Max-C 40 Compressed Air psig TankQty. TankVolume-Cu. Ft D iaphragm Valve (3).5in. Program Timer: Off On TIme Time SolidState 8.5 sec.80 sec 0.05 sec.50 sec Timer Input Power 0 VAC, 60Hz, PH Blower/Mor Type PlugFan Inlet Open-wiremeshspark prefilters filter - Wheel Diameter 6 inches Speed Drive 3450 RPM Direct HP Voltage 90/380//230/460 Frequency-Hz 50/60 Phase 3 Frame - NEMA 84TC PowerFacr 94 Efficiency StrartCurrentAmps(60Hz) 52/76 FullLoadAmps(60Hz) 7.2/8. 6 Insulation Class- Min. B Enclosure TEFC ServiceFacr. 5 Duty Cycle Continuous Bearing Grease Exxon POLYEXEM Specification UL&CSA Approved

14 Limited Warranty AER Control Systems LLC warrants all products sold only purchasers for use in business or for resale, against defects in workmanship or materials under normal use, for one () year after date of purchase from AER Control Systems LLC. Mapplication of product, decomposition by reaction or chemical action and wear caused by abrasion will not constitute, or be considered as a defect. Warranty void if product has been subject damage, unreasonable use, neglect, improper service, improper installation, or or causes not aring from defects in original materials or workmanship. Any part that determined be defective in material or workmanship and returned an AER Control Systems LLC dtribur or authorized service facility, as AER Control Systems LLC designates, shipping costs prepaid, will be, as exclusive remedy, repaired or replaced at AER Control Systems LLC s option. AER Control Systems LLC shall not be liable for any incidental or consequential cost, expenses, or damages resulting from any failure, defect, or malfunction of th product, liability expressly dclaimed. AER Control Systems LLC s liability in all events limited and will not exceed, purchase price of product. Title and rk of loss pass buyer on delivery common carrier. If a product damaged in transit, recipient MUST make note of damage upon receipt of product and file a claim with carrier. AER Control Systems LLC will make a good faith effort for prompt correction or or adjustment, with respect any product that proves be defective within warranty period. Collection of combustible or explosive materials and collection on flame or spark-generating operation any require specific system configurations (contact AER Control Systems LLC s Applications Engineering Department for questions and/or design asstance). The combined collection of combustible or explosive materials and contaminants from spark or flame generating operations, with a common collecr or duct system, not recommended, unless special design provions have been made system (sparks or flames resulting from such operations may ignite combustible or explosive material). Under no circumstances should anyone be allowed dcard a lighted cigarette, or burning materials, or refuse in an inlet hood or duct of collection system. It responsibility of end user comply with all applicable national, state, and local fire and safety codes. AER Control Systems LLC s liabiltiy for consequential and incidental damage resulting from a fire or explosion expressly dclaimed. Installation of suitable overload protection such as a mor starter, according NEC guidelines, required. Failure provide proper overload protection will void warranty coverage on electrical components in system. (Combination mor starters with fusible dconnect packages are available through your local AER Control Systems LLC representative). To ensure optimum collecr performance, always use AER Control Systems LLC replacement filters.