OWNERS MANUAL. Dust-Pak DUST COLLECTOR MODELS PCH-2, DCH-2, and DTH-1700 (INCLUDES VIBRA-PULSE FILTER CLEANING SYSTEM) DUAL CARTRIDGE DUST COLLECTORS

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1 7LB LB LB LB OWNERS MANUAL Dust-Pak DUST COLLECTOR MODELS PCH-2, DCH-2, and DTH-1700 (INCLUDES VIBRA-PULSE FILTER CLEANING SYSTEM) DUAL CARTRIDGE DUST COLLECTORS Du st Pak DUST COLLECTORS Made in USA Du st Pak Made in USA DUST COLLECTORS PCH-2 DCH-2 Du st Pak Made in USA DUST COLLECTORS DTH-1700 Du st Pak Made in USA DUST COLLECTORS INTRODUCTION UNPACKING INSTALLATION ELECTRICAL OPERATION MAINTENANCE REPLACEMENT PARTS TROUBLESHOOTING MOTOR TROUBLE GUIDE DCH-2 WITH HOPPER ***IMPORTANT*** THIS MANUAL CONTAINS PRECAUTIONARY STATEMENTS RELATING TO WORKER SAFETY. READ AND SAVE THIS MANUAL COMPLETELY AND COMPLY AS DIRECTED. ALL THE POTENTIAL HAZARDS OF DUST AND MIST CONTROL SYSTEMS AND EQUIPMENT ARE IMPOSSIBLE TO LIST; THEREFORE, OBTAIN THE SERVICES OF A PROFESSIONAL INSTALLER. A FIRE PROTECTION EXPERT SHOULD BE OBTAINED IN THE EVENT THE PRODUCT IS INTENDED FOR USES WHICH PRESENT A POTENTIAL RISK OF FIRE OR FIRE PROPAGATION. REFER TO APPROPRIATE AUTHORITIES, AND DISCUSS YOUR INTENDED USE WITH YOUR LOCAL DISTRIBUTOR OR AIRFLOW SYSTEMS, INC. WORKERS HANDLING EQUIPMENT OR SYSTEMS SHOULD BE INSTRUCTED TO CONDUCT THEMSELVES IN A SAFE MANNER. PART # 4KT (REV 1/01/A/# )

2 ALWAYS USE AIRFLOW SYSTEMS, INC. REPLACEMENT PARTS AND FILTERS TO MAINTAIN WARRANTY. TO ORDER SPARE PARTS, PLEASE CONTACT: The Local Exhaust & Ventilation Company Inc Brock Road, Unit Pickering, Ontario L1W 3X4 PHONE (905) FAX (905) INTERNET:

3 TABLE OF CONTENTS 1. Safety Airflow Systems, Inc. Sets the Standard Inspection... 6 INSTALLATION 4. Compressed Air Supply Vibra-Pulse Filter Cleaning System (Manual & Optional Auto Clean) Electrical... 8 Single phase... 8 Three phase Blower Rotation DCH-2 with Hopper Option OPERATION 9. Filter Cleaning - Manual Optional Auto Clean Vibra-Pulse Filter Cleaning System MAINTENANCE 11. Vibra-Pulse Filter Cleaning System Hose and Clamp Replacement Filter Service Filter Replacement Optional AD Module Optional External Afterfilter Maintenance HEPA / D.O.P. / AD Other Service Replacement Parts Vibra-Pulse Filter Cleaning System Optional Auto Clean Vibra-Pulse Filter Cleaning System Filters Motor / Blower Model PCH-2 with 7E10 E-Z Arm Extractor Model DCH Model DTH-1700 Downdraft Table Troubleshooting Notes Appendix... 31

4 READ THIS MANUAL CAREFULLY BEFORE ATTEMPTING TO INSTALL OR OPERATE THE Dust-Pak DUST COLLECTOR SERIES. RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE. SAFETY RULES Follow all electrical and safety codes as well as the National Electric Code (NEC), National Fire Protection Association (NFPA), and the Occupational Safety and Health Act (OSHA). All electrical connections and wiring should be performed by qualified personnel only. National Fire Protection Association (NFPA) standards require specific duct design and dust collector configuration when collecting potentially reactive metal dusts, such as aluminum and magnesium, and other materials. NFPA also covers other dusts such as grain, plastics, etc. A guideline for determining the precautions to be taken can be found thru NFPA. Consult current NFPA standards, available from NFPA, 1 Batterymarch Park, Quincy, MA, 02269, , for applicable safeguards which may required for the Installation, Operation, and Service of this product. Fire suppression equipment provided by others. Additional references are the Uniform Building Code and Uniform Mechanical Code. GENERAL OPERATIONAL WARNING APPLICATION OF DUST CONTROL EQUIPMENT: 1. Do not mix materials being collected by a dust collector unless it is determined that mixing of materials does not cause hazardous conditions to occur or creates a condition of operation for which the equipment was not intended. 2. Under no condition should burning cigarettes or any burning object be allowed into the hood or ducting of any dust control system. 3. When dust collectors are used to collect emissions from steel or combined metal sanding, the dust collector should be located an adequate distance away to minimize the chance of ignition of duct system residue from hot metal chips and sparks. Should further protection from fire be required, adequate duct systems from capture hoods and dust collector should be provided so that a fire protection specialist can install extinguishing equipment. You may also want to contact your insurance underwriter. 4. Always disconnect unit from power source before inspecting or servicing. 4

5 7LB LB LB LB AIRFLOW SYSTEMS, INC. SETS THE STANDARD The Airflow Systems, Inc. Dust-Pak dust collector collects dust, welding smoke, and other dry pollutants in industrial plants, shops, schools and factories. Pollutants pass through the top inlet into the dirty air chamber, where the unique baffling system directs heavier particles toward the bottom of the unit. Lighter particles that can follow the air stream turn up behind the baffles where they are filtered from the air by the cartridge filter. (The CLEAN-2 filter is the standard cartridge filter shipped in the Dust-Pak dust collector. Other filters are available and may be used in your specific application.) The CLEAN-2 filter removes particles with a high degree of efficiency. (Contact your local distributor for more information.) The air then moves to the clean air chamber, where it is drawn out of the unit by the fan. Acoustical lining is standard in blower compartment for sound reduction. Filter cleaning utilizing Airflow Systems, Inc. unique Vibra-Pulse filter cleaning system is standard on the Dust-Pak dust collectors and reduces filter-dependent downtime and maintenance. The Vibra- Pulse filter cleaning system uses compressed air to blow collected particles from the filter surface which then fall toward the bottom of the collector into the externally removable dust drawer. IN THIS MANUAL: Dust-Pak dual cartridge dust collectors: Dust Pak DUST COLLECTORS Made in USA Dust Pak Made in USA DUST COLLECTORS PCH-2 DCH-2 Dust Pak DUST COLLECTORS Made in USA Dust Pak DUST COLLECTORS Made in USA DCH-2 WITH HOPPER DTH

6 INSPECTION AND UNPACKING Inspect your Airflow Systems Inc. unit for shipping damage immediately upon receipt, save all packaging materials until unit has been received, inspected and accepted.. Damaged carton(s), broken crate(s), etc. are indications that the unit may have been damaged in shipment. It is also possible shipping damage may be concealed and not noticed until the unit is installed and in operation. If any damage is found, notify your delivery carrier at once and enter a claim. Claims must be filed within 15 consecutive days of receipt of shipment. FREIGHT DAMAGE CLAIMS ARE THE RESPONSIBILITY OF THE PURCHASER, NOT AIRFLOW SYSTEMS, INC. After initial inspection for shipping damage, check the cabinet filter and motor/blower compartments for any packing materials and remove. INSTALLATION COMPRESSED AIR SUPPLY FOR VIBRA-PULSE FILTER CLEANING SYSTEM A. Recommended compressed air supply pressure to the collector is 90 PSI, constant. It is recommended that a 1/2 NPT regulator be used to regulate supplied air pressure to the Vibra-Pulse filter cleaning system. Obtain the regulator locally or contact your local distributor. B. Effective cleaning of the filters in most applications will occur when the pressure at the compressed air connection of the dust collector is maintained, while the filter is cleaning, above 80 PSI. Pressure over 100 PSI is NOT recommended at any time, reduces cleaning performance, and increases Vibra-Pulse filter cleaning system maintenance. A pressure below 80 PSI will decrease cleaning effectiveness. A nominal static (OFF or not cleaning) pressure setting of 90 PSI is usually adequate when using a 1/2 I.D. or larger main compressed air supply line. It is required to use 3/8 I.D. minimum hose and fittings between the regulator and the Vibra-Pulse filter cleaning system. C. Set regulator between 80 and 90 PSI. When the Vibra-Pulse filter cleaning system air valve is open, and compressed air is flowing, confirm that the pressure on the gauge does not go below 80 PSI. If it does, either the inlet supply piping is too small (less than 1/2 I.D.), or the regulator is too small. Compressed air flow rate is 32 SCFM during cleaning with proper pipe size. Each filter cleans for 15 seconds (1/4 minute), using 8 cubic feet of compressed air each. D. Reasonably clean and dry compressed air is required. Oil and/or water in the line will be transferred to the filter, causing shorter than normal life. Check compressed air during installation for oil/water. Add filter/dryer as required. Note: Compressed air filter/dryer is not supplied with the dust collector. 6

7 VIBRA-PULSE FILTER CLEANING SYSTEM INSTALLATION (MANUAL & OPTIONAL AUTO CLEAN) A. To set up the Vibra-Pulse filter cleaning system, simply slide the supplied 3/8 I.D. air hose over the hose barb fitting on the outside of the cabinet and secure it with the 1 hose clamp. (Refer to Figure 1.) Use any standard 3/8 I.D. quick disconnect fitting (as used on an air tool) to attach hose to the supply air. The Dust-Pak dust collector comes with 10 of 3/8 I.D. air line. If a longer run of hose is required, it is recommended to use a continuous piece of hose to avoid splicing, as this will reduce the compressed air available to the unit. Always use minimum 3/8 I.D. air line and 3/8 I.D. connectors with this unit. Once the air is attached to the unit, set the line pressure to 90 PSI at inlet regulator (see Compressed Air Supply section). Compressed air should be as dry as possible, free of moisture and oil. Due to the extreme range of unit application and quality of compressed air, and how the air quality effects unit performance and cleaning, it should be recognized by the user that Figure 1. External hose connection. Use 3/8 I.D. fittings/hose/pipe only. the cleaner and drier the air, the greater chance that compressed air quality will not be a negative factor in unit performance. Compressed air filter/dryer provided by others. B. Test the system by pressing the actuator valve on the side of the unit. (See Figure 7.) Press and hold for 5-10 seconds. The Vibra-Pulse filter cleaning system causes compressed air to flow through the flexible hose with significant force. (See Figure 2.) You should hear vigorous Vibra-Pulse hose oscillations during the entire time. If you don t, your air supply is not maintaining the 32 cfm flow rate required to operate the Vibra-Pulse filter cleaning system at spec. You must determine the reason for low air pressure or flow and resolve. If any problems are found, consult the TROUBLESHOOTING Section in this manual, or contact your local distributor. WHILE THE FILTER IS BEING CLEANED, THE COMPRESSED AIR PRESSURE SHOULD REMAIN ABOVE 80 PSI MEASURED AT THE UNIT. Figure 2. 7

8 ELECTRICAL SPARKING IN THE PRESENCE OF AIRBORNE DUST WARNING DO NOT OVER-EXTEND THE UNIT POWER CORD REACH. DISCONNECTING THE POWER SOURCE WHILE UNIT IS IN OPERATION CAN CAUSE SPARKING. All 115V AC Dust-Pak dust collectors have an ON/OFF switch and cord with plug. The 230 volt, single phase and all three phase units have wiring terminated inside the junction box located on the side of the unit. Motor starters and disconnects are not supplied with the unit (unless purchased as an option), and must meet local and National Electric Code. Motors are typically multiple voltage type (e.g. 115/230, 1 or 208/230/460,3 ). Make sure connections in motor junction box correspond to the line voltage you plan to use. Single phase motors have built-in thermal overload protection. Three phase motors do not have built-in thermal protection. Motor starters are required. Three phase motor starters (manual or magnetic type) must have properly sized thermal overloads for the voltage and current required at the motors. All units are required to have a motor voltage and current check performed at startup and recorded on the data page at the end of this manual, just prior to the Appendix. Motor checkout should be performed with the unit running, all filters in place, and end cap closed. Measured motor current readings should be equal to or below motor nameplate rating. These specifications can be found on the motor nameplate. If the motor amp draw does not fall within the Full Load Rating (FLA) of the motor refer to the TROUBLESHOOTING Section of this manual. SINGLE PHASE MOTOR BASIC CONNECTION The single phase 115V AC motors supplied in the Dust-Pak dust collectors have an internal thermal overload protection built in as noted in Figure 3, and have an ON/OFF switch mounted on the side of the cabinet. Figure 3 is the 115V AC electrical schematic without any other electrical options. On some but not all 1 motors motor rotation may be changed, if required, by reversing two internal motor leads located under the wiring cover. The motor cover plate shows an internal schematic of the motor and should be consulted for this operation. Figure 3. Basic 1 motor wiring schematic. 8

9 THREE PHASE MOTORS THREE-PHASE CAUTION MOTOR ROTATION IN LARGE PLANTS, WHEN ROLLING UNITS FROM ONE BUILDING TO ANOTHER, YOU MAY BE ON A DIFFERENT SUBSTATION TRANSFORMER. UNITS USING A THREE PHASE BLOWER MOTOR MAY RUN BACKWARDS. CHECK ROTATION IN EACH LOCATION WHERE THE UNIT WILL BE USED TO ENSURE THAT BLOWER MOTOR ROTATES IN PROPER DIRECTION. REVERSING SWITCHES ARE AVAILABLE IF REQUIRED. GENERAL OPERATION CAUTION THE FILTER COVER (END CAP) MUST BE IN PLACE WHEN OPERATING THE BLOWER. MOTOR WILL BE SEVERELY OVERLOADED IF RUN WITH THE FILTER END CAP OFF. Three phase motors do not have overload protection included in the standard configuration and starters must be supplied by the end user, see Figure 4 or page A3 of the Appendix. They are also available from the factory as a pre-installed option. If these protective circuits are not ordered from the factory, use equipment as specified by the National Electric Code or other applicable authority. Figure 4. Typical 3 connection w/details of main disconnect & motor starter shown. 9

10 7LB BLOWER ROTATION THREE-PHASE A. On the three phase models, the motor can operate in either direction, and the fan will pump air in either direction although output is reduced and noise increases when run backwards. However, for proper suction and airflow, the blower/motor should be turning in a COUNTER-CLOCKWISE direction when viewed from the filter end of the unit, see Figure 5. B. To verify the correct rotation, remove the filter end cap and bump start motor (turn on briefly then turn off). Look at the blower wheel, using an inspection mirror if necessary, and make sure the motor is turning counter-clockwise, or corresponds to the arrow on the blower housing. CAUTION: Do not insert fingers or foreign objects into filter area when wheel is turning. C. Rotation can be changed by re-wiring the internal motor hookup. This can be done by reversing any two of the 3 incoming electrical wires at either the junction box on the outside of the unit or at the motor junction box. Refer to the motor nameplate before attempting to reverse motor rotation. D. Check motor current with unit running, all filters in place, and end cap in place. The current should be at or below nameplate full load amp rating. If not, refer to Troubleshooting Guide in Appendix. Figure 5. View into cabinet from filter end. DCH-2 HOPPER OPTION INSTALLATION Figure 6 illustrates the hopper option for the Dust-Pak dust collector model DCH-2, which is shipped completely assembled. A. Locate the unit in place. Shims may be required to compensate for an uneven foundation. Using suitable anchors, secure the unit in place. One-inch diameter holes have been provided in the leg pads for this purpose. B. Attach dust container. It is very important that any container and container connecting system to the hopper outlet be air tight. If air is allowed to leak, dust that would normally fall into the container will be swept back into the filters, requiring frequent filter cleaning and shortened filter life. Hoppers are not intended to be storage devices. Dust Pak Made in USA DUST COLLECTORS Figure 6. 10

11 OPERATION FILTER CLEANING MANUAL The filters have been charged with pre-coat (an inert white mineral dust) at the factory. This pre-coat material will increase initial filter efficiency and help to extend the cartridge filter life. Upon initial unit start up, go through one cleaning cycle (see filter cleaning below), most of the pre-coat will be removed from the filter and fall into the dust pan. The remaining pre-coat will stay on the filters. Save any material that falls into the pan for treating replacement filters. (A Material Safety Data Sheet (MSDS) will be furnished upon request. Please contact your local distributor.) Operation of the Dust-Pak dust collectors is straight-forward. Place the unit in the desired work area and arrange it so that no equipment will come into contact with the unit. For the Dust-Pak dust collector PCH-2, pull the arm into a position so that the hood is approximately from the source of smoke or dust. Switch the unit ON, allowing the contaminated air to be drawn into the collection unit. As the filters get dirty, airflow volume will decrease. Once the airflow has dropped off sufficiently that capture of contaminates is not adequate, the Vibra-Pulse filter cleaning system needs actuated. Refer to the steps below and Figure 7 for details. 1. Turn unit OFF and let motor/blower come to a complete stop. 2. Close the arm hood damper, PCH-2 unit only. 3. PRESS and hold the pulse cleaning button in for 5-10 seconds. Repeat this process 2 or 3 times. (See Figure 7.) 4. Remove, empty, and replace the dust tray in the bottom of the unit. This will prevent the dust from recollecting on the filter when the unit is restarted. 5. Turn the unit ON and check suction and/or pressure gauge. If additional cleaning is needed repeat the steps listed above. (During multiple cleanings, some dust may come out of the hose or blower outlet. This is normal.) 6. If the filter is overloaded or contaminated with wet debris, in-place cleaning may not dislodge all of the collected dust. The filter will need to be replaced. Any moisture such as oil or water on the filter will cause shortened filter life. If the filter plugs with dirt due to oil or water, it may not pulse clean. (See Note below.) 7. If shop air is not clean and dry, it may be necessary to install an airline filter/dryer to prevent premature filter replacement. You must use 3/8 I.D. minimum components; 1/2 NPT is recommended for filter/dryer. Figure 7. WET CONTAMINANT NOTE Not all applications will self-clean. Sticky or oily dust may not dislodge from the filter. In this case, the filter must be cleaned manually or replaced. DO NOT BLOW OFF WITH COMPRESSED AIR DUE TO POSSIBLE OVER- EXPOSURE OF WORKERS AND POTENTIAL FILTER DAMAGE. AUTOMATIC AIRLINE OILER CAUTION IT IS IMPORTANT TO USE ONLY CLEAN AND DRY COMPRESSED AIR TO CLEAN THE FILTER. OTHERWISE, CONTAMINATION TO CARTRIDGE FILTER ELEMENT WILL RESULT. DO NOT HOOK UP TO A COMPRESSED AIR LINE THAT HAS AN AUTOMATIC OILING DEVICE ON IT. OIL OR WATER WILL MAKE CLEANING DIFFICULT AND SHORTEN FILTER AND VALVE LIFE. 11

12 OPTIONAL AUTO CLEAN VIBRA-PULSE FILTER CLEANING SYSTEM Operation of Dust-Pak dust collectors equipped with the Auto Clean option is straight-forward. Place the unit in the desired work area and arrange it so that no equipment will come into contact with the unit. See Installation Section to ensure proper connection of air and electricity. For the Dust- Pak dust collector PCH-2, pull the arm into a position so that the hood is approximately from the source of smoke or dust. Switch the unit ON, allowing the contaminated air to be drawn into the collection unit. As the filters get dirty, airflow volume will decrease. Once the airflow has dropped off sufficiently that capture of contaminates is not adequate, the Dust-Pak dust collector needs to be turned off, which automatically initiates the Auto Clean Vibra-Pulse filter cleaning system. In many applications, cleaning once-a-day is enough; some applications require multiple cleanings per day, hence, multiple shutdowns. Adjustment of the control board may be required to optimize cleaning. Refer to the steps below and Figure 8 for details. 1. The cleaning system is initiated by loss of fan pressure, i.e., when fan is turned off. 2. When the timer/power board is energized, the "power on" LED light comes on. 3. The individual output lights come on one at a time, in sequence, to indicate that power is being applied to the electric air valves. In a cleaning cycle, each valve is actuated one time. 4. The length of time the valves are open (energized by the timer board) is controlled by the 5/8" diameter white knob, identified as the "ON" knob. Its time is factory set to 15 seconds (using 8 Cu. Ft. of compressed air per filter). The cleaning duration can be increased up to 60 seconds: however, after 20 to 30 seconds of proper cleaning, an increase in time rarely has any effect except to increase compressed air consumption. WHILE THE FILTER IS BEING CLEANED, THE COMPRESSED AIR PRESSURE SHOULD REMAIN ABOVE 80 PSI. If it does not, check your compressed air supply piping, 1/2 minimum is preferred. Also, check all post-regulator fittings for properly sized fittings. All post-regulator fittings must be 3/8 I.D. or larger. If the air pressure falls below 80 PSI, the Vibra-Pulse cleaning system becomes less effective and overall unit performance will suffer. To reduce compressed air consumption, set the ON time as short as possible (7 to 10 seconds). For best filter cleaning, set at seconds. 5. The dial for the "OFF" time is preset to the minimum setting of 5-10 seconds. This "rest" time between the cleaning of each filter can be increased to as long as 10 minutes. The only purpose for an increase in the "OFF" time is to allow the compressed air to be replenished. 6. Prior to restarting the unit, remove the dust pan, discard collected dust, and replace pan. It is important that collected material be emptied after every cleaning before fan restart; failure to do so will cause collected dust to be swept back into the filters significantly reducing your dust collector s performance. Figure 8. Timer board. 12

13 MAINTENANCE ENERGY-SOURCE WARNING ALWAYS DISCONNECT THE UNIT FROM ALL ENERGY SOURCES BEFORE WORKING ON OR NEAR THE MOTOR OR WIRING ASSEMBLIES. LOCK OUT DISCONNECTS TO PREVENT UNEXPECTED APPLICATION OF POWER OR COMPRESSED AIR. VIBRA-PULSE FILTER CLEANING SYSTEM HOSE & CLAMP REPLACEMENT The 7 Vibra-Pulse hose that is used to clean the filter will eventually wear reducing cleaning performance. Check for signs of excessive wear when doing normal filter service or if a decrease in filter cleaning effectiveness is observed. A hose should be replaced when it has worn to a length of 6. Replacement of the hose is a simple operation. Proceed as follows to accomplish the hose replacement. 1. Turn unit off. Disconnect power and lock out. 2. Disconnect air supply before working on unit and lock out. 3. Remove filter access door(s). 4. Remove dust tray(s) and dispose of material in accordance with local, state, and federal regulations. 5. Remove cartridge filter(s) from unit. 6. The Vibra-Pulse actuator mechanism consists of 2 replaceable parts: See Figure 16. a. 1 - Hose clamp (7HG3-1008) b. 1 - Hose (2VP2-3009) 7. Remove the old Vibra Pulse hose in one of two ways: a. Remove the old Vibra Pulse hose, spring, and clamp. This is sometimes easiest to do by cutting the hose at the top, where it fits over the hose barb, to allow free removal. Discard old hose, spring, and clamp after removing. b. Cut tie wrap, remove old hose assembly and discard. (a.) (b.) 13

14 8. Slide the double hose assembly onto the air cleaner s hose barb until fully seated against brass hex on barb, see Figure Install the Nylon Snap Grip Clamp 1/4 from edge and compress clamp, see Figure 9. Figure 9. Figure 10. Assembled view. 10. Reconnect air line and power. 11. Test the Vibra Pulse system for operation manually or electrically as appropriate for your unit s configuration to verify that hose(s) is oscillating vigorously. Call your local distributor with any questions. 12. Replace filter(s) into unit. Note: Make sure NOT to pinch hose - position Vibra Pulse hose into the center of the cartridge filter. Engage filter locking mechanism if required. 13. Reinstall dust tray(s), if equipped. 14. Reinstall filter access door(s). 14

15 FILTER SERVICE Filter service is required when a reduction of airflow (suction) is observed. The optional pressure gauge is used to judge the amount of particulate collected on the filter. As the worker gets accustomed to the units effectiveness of capture, and the associated gauge reading, the gauge can then become an indicator of filter condition. The optional pressure gauge is subjectively calibrated as follows: In most applications, with clean filters, turn unit on and mark or record the pressure reading on the gauge. Make a second mark at 2.0" higher than initial reading (i.e. if initial reading is 3.0" the second mark should be at 5.0"). Note that a reading of 5.0 is typical of when the filter should be cleaned in most normal Vibra-Pulse filter cleaning system applications. Auto Clean applications clean every time the unit is switched off. On these units, use pressure gauge observations to judge when these switch-offs should occur. At some point, however, all filters will retain enough non-removable dust such that even Vibra-Pulse cleaning becomes ineffective. Filter replacement is required at that point. FILTER REPLACEMENT 1. Confirm unit has completed any cleaning cycle. 2. Follow lock-out/tag-out procedures preventing unit operation. 3. Loosen knob in center of filter cover. Remove filter cover (Note: knob stays with cover, see Figure 11). 4. There are two filters located behind the filter cover. If required, a plastic bag can be used to slide over each filter as they are removed from the filter housing. CAUTION: Dirty filters can be extremely heavy and awkward to handle. WEAR PERSONAL PROTECTIVE EQUIP- MENT AS REQUIRED. 5. While the filter is out, inspect the Vibra-Pulse hoses for cracks, splits or degrading. Conical end wear is normal. All hoses should be approximately 7 long. Replace any hose that does not appear normal or which is worn to less than 6. (Refer to the Vibra-Pulse System Hose Replacement Section above.) 6. Install new filters. *Small diameter gasket to be installed first (large diameter toward cap, see Figure 12). 7. Inspect perimeter gasket on cabinet opening for damage and replace as necessary. Remove any debris accumulations. 8. Locate and install filter cover assembly. Hand tighten securely, but do not over-tighten. 9. PCH-2 unit only - follow the procedures below for application of pre-coat. Figure 11. Figure

16 Note: It is best to isolate your dust generating process from the PCH unit when applying pre-coat to avoid possible contamination of your process. The procedure for applying pre-coat to a replacement filter is: 1. Start blower 2. Slowly feed pre-coat (supplied in ½ lb. bags with replacement filter) into the duct system at the rate of 1/4 pound per minute. 3. Allow the unit to operate for 3-5 minutes. 4. Turn the blower off. 5. Allow the Vibra-Pulse system to clean the filters. 6. Remove any excess pre-coat which is in the dust drawer. Save for future use. OPTIONAL AD MODULE The adsorption material (activated carbon or other) can be emptied from the module and refilled with fresh adsorber. Refer to the Figure 13. Use the large opening to fill the majority of the module. After as much material can be put in as possible, use the small filler hole on top of the large cover plate. It is important to get the AD module as full as possible as any low spots or air gaps will allow the air being filtered to by-pass or be exposed to a reduced amount of scrubbing. Always dispose of the spent adsorption material in accordance with local, state and federal regulations. Follow the instructions below to fill the AD Module. When filtering flammable materials, it may be necessary to have the unit meet Class I, Group D electrical requirements. 1. Remove module and take to a well ventilated area: DUST IS RELEASED DURING THE REFILLING OPERATION. 2. Remove the poly pre-filter and after filter pads and discard properly. (The screen securing the inner afterfilter and the rod securing the outside pre-filter pad are to be set aside for re-use.) 3. Remove large cover plate and empty module contents into a plastic bag or other approved container. WEAR ADEQUATE PERSONAL PROTECTIVE DEVICES. Figure 13. Vibra-pulse is not available on units equipped with these internal AD Modules. 16

17 4. Refill with the new adsorber material. After refilling, shake module to pack granules tightly before replacing cover plate to make sure module is full. Remove the small cover plate and top off any void in the module. 5. Install new afterfilter poly pad, (2AZ10013, the shorter length), by pressing into place on interior of module cylinder and securing in place using the screen removed in step #2. 6. Install new poly pre-filter pad, (2AZ10012, the longer length), around outside of the AD Module and secure in place. Figure 14. Vibra-pulse is not available on units equipped with these internal AD Modules. 7. Vacuum any excess carbon dust that occurs from settling during handling. After re-installing, stay clear of the unit outlet area as some dust may be expelled when unit is first turned on. 8. Dispose of or recycle used material in accordance with applicable laws. 17

18 OPTIONAL EXTERNAL AFTER FILTER MAINTENANCE HEPA / 95% D.O.P. FILTER / AD MODULE: A. The external HEPA / D.O.P. filter cannot be cleaned. See your local distributor for replacement. B. The adsorption material (activated carbon or other) in the external AD module can be emptied from the module and refilled with fresh adsorber, see Figure 15. It is important to get the AD module as full as possible, as any low spots or air gaps will allow the gas being captured to by-pass or be exposed to a reduced amount of scrubbing. Always dispose of the spent adsorption material in accordance with local, state and federal regulations. When filtering flammable materials, it may be necessary to have the unit meet Class I, Group D electrical requirements. Follow the instructions below to refill the AD Module. WEAR ADEQUATE PERSONAL PROTECTIVE DEVICES; AIRBORNE CARBON DUST IS RELEASED DURING THIS OPERATION. 1. Unhook latches and remove external filter end cap, refer to Figure 18 in the Replacement Parts section of this manual. 2. Remove 2 polyester afterfilter and discard. 3. Remove AD module and take to a well ventilated area: DUST IS RELEASED DURING THE REFILLING OPERATION. 4. Remove cover plate and empty module contents into a plastic bag or other approved container. WEAR ADEQUATE PERSONAL PROTECTIVE DEVICES. 5. Refill with the new adsorber material. After initial refilling, shake module to pack granules tightly and top off any void in the module before replacing cover plate. 6. Vacuum any excess carbon dust that occurs from settling during handling. Re-install both the AD module and new polyester afterfilter. 7. Install external filter end cap and re-hook latches. Stay clear of the unit outlet area when unit is first turned on as some dust may be expelled. 8. Dispose of or recycle used material in accordance with applicable laws. Figure 15. OTHER SERVICE Most other components of your Dust-Pak dust collector require little or no routine servicing. Items such as motors, blower wheels, friction joints of arms, pickup-hose and gaskets should be checked twice a year under normal usage (more frequently under severe 24hr-per-day usage). Clean, repair, or replace parts as necessary. Check for dirt build-up on blower wheel and other rotating parts which can cause imbalance and resultant vibration, noise, and short bearing life, and clean as necessary. An occasional drop of oil on the caster wheel bearings will help keep them moving freely. Replacement parts are available from your local distributor. The following section lists replacement parts for the dual cartridge Dust-Pak dust collectors. 18

19 REPLACEMENT PARTS The following section lists typical replacement parts for the Vibra-Pulse filter cleaning system of the Dust-Pak dust collectors. If a part is not listed in Table 2, contact your local distributor. Refer to Figure 16 for parts illustrations. TABLE 2 VIBRA-PULSE ITEM PART NUMBER QTY DESCRIPTION 1 2VP Hose 2 7HG Speedyclamp 3 7TB /8 O.D. Nylon tubing Figure

20 REPLACEMENT PARTS Listed below are common replacement parts for the optional Auto Clean Vibra-Pulse filter cleaning system. If a part is not listed in Table 8, consult your local distributor for ordering replacement parts. Refer to Figure 17 for parts illustrations. TABLE 8 AUTO CLEAN ITEM PART # QTY DESCRIPTION 1 7EG Auto clean controller board 2 7ER Pressure switch 3 7ET Transformer (230/1 and all 3 phase) 4 7VA Valve, solenoid, less coils 5 7VA Coil, 115V for above valve Figure

21 7LB REPLACEMENT PARTS Refer to the following section for filter replacements for the Dust-Pak dust collectors. If a part is not listed in Table 3, contact your local distributor. Refer to Figure 18 for filter illustrations. TABLE 3 FILTERS ITEM PART NUMBER QTY DESCRIPTION 1 7FR Cartridge, Clean-2, Std. 1a 7FR Cartridge, FiberDust, Opt. 1b 7FR Cartridge, Spunbond, Opt. 1c 7FR Cartridge, Spunbond with PTFE film, Opt. 1d 7FR Cartridge, Ultraclean-Plus, dbl treated fire retardant, Opt. 2 1AC External filter cabinet, Opt. 3 1AC External filter end cap, Opt. 4a 7FJ External HEPA filter, 99.97%, Opt. 4b 7FJ External HEPA filter, 95%, Opt. 5 2AF External AD module, Opt. 6 2AF polyester afterfilter (used with AD), Opt. Du st Pak DUST COLLECTORS Made in USA Assembled view - optional external HEPA/AD module. Figure

22 REPLACEMENT PARTS The following section lists typical replacement parts for the motor/blower assembly of the dual cartridge Dust-Pak dust collectors. If a part is not listed in Table 4, contact your local distributor. Refer to Figure 19 for parts illustrations. TABLE 4 MOTOR / BLOWER ITEM PART NUMBER QTY DESCRIPTION 1 7MP HP Motor, single phase, Std. 1a 7MP HP Motor, 3 phase, Opt. 1b 7MT HP Motor, 3 phase, Opt. 2 7BW Blower wheel, 10 radial, Std. 2a 7BW Blower wheel, 12 radial, Opt. 3 2AB Blower assembly, Std. 3a 2AB5-173P 1 Blower assembly, (3 HP, High pressure), Opt. 3b 2AB5-173F 1 Blwr assembly, (3 HP, High flow, DTH-1700 only), Opt. Figure

23 REPLACEMENT PARTS PCH-2 The following section lists typical replacement parts for the Dust-Pak dust collector model PCH- 2. If a part is not listed in Table 5, contact your local distributor. Refer to Figure 20 for parts illustrations. TABLE 5. ITEM PART NUMBER QTY DESCRIPTION 1 1AC Exhaust panel 2 7AC Handle, push 3 1AC Dust drawer 4 2AX Filter cover 5 2KB Assembly, knob / stud 6 7HG Wheel, 8 x 2, rubber / steel 7 7HG " Caster, Swivel w/brake 8 7ER Power switch, rocker (115V only) 9 7VA Vibra-Pulse control valve, push (manual) 10 7PC Power cord, 115 VAC, yellow, E10-DD 1 10 E-Z ARM with damper, Std.* 11a 7E10-DD 2 Dual E-Z ARM, 10 arms with dampers, Opt.* 11b 7E14-DD 1 14 E-Z ARM with damper, Opt.* 12a 7NT Dial pressure gauge, flush mounted, Opt. 12b 7NT Pressure gauge, surface mounted, Opt. N/S 7PN Regulator, ½ NPT full flow, adjustable, Opt. USE ONLY AUTHORIZED AIRFLOW SYSTEMS REPLACEMENT PARTS AND FILTERS TO PREVENT VOIDING THE WARRANTY. (*) - See separate manual for these arms (included). 23

24 7LB LB Dust Pak DUST COLLECTORS Made in USA Du st Pak DUST COLLECTORS Made in USA Dual 10 arm option. Figure 20. Model PCH-2 general assembly. 24

25 REPLACEMENT PARTS DCH-2 The following section lists typical replacement parts for the Dust-Pak dust collector model DCH- 2. If a part is not listed in Table 6, contact your local distributor. Refer to Figure 21 for parts illustrations. TABLE 6. ITEM PART NUMBER QTY DESCRIPTION 1 1AC Exhaust panel 2 1AC Dust drawer 3 2AX Filter cover 4 2KB Assembly, knob / stud 5 1PL Plate with 8 inlet collar 6 7ER Power switch, rocker (115V only) 7 7VA Vibra-Pulse control valve, push (manual) 8 7PC Power cord, 115 VAC, yellow, 25 9a 7NT Dial pressure gauge, flush mounted, Opt. 9b 7NT Pressure gauge, surface mounted, Opt. 10 1AC Leg, Opt. 11 1AC Hopper, Opt. 12 1PN Panel, dust can retainer, Opt. 13 1PN Panel, pivot, left side, Opt. 14 1PN Panel, pivot, right side, Opt. 15 1AN Angle, lift, right side, Opt. 16 1AN Angle, lift, left side, Opt. 17 7AC Handle, quick release latch, Opt. 18 1AC Dust can, Opt. N/S 7PN Regulator, ½ NPT full flow, adjustable, Opt. USE ONLY AUTHORIZED AIRFLOW SYSTEMS REPLACEMENT PARTS AND FILTERS TO PREVENT VOIDING THE WARRANTY. 25

26 7LB LB Dust Pak DUST COLLECTORS Made in USA Standard DCH-2. Dust Pak Made in USA DUST COLLECTORS Standard DCH-2. DCH-2 with hopper. Dust container and lift parts. Figure 21. Model DCH-2 / DCH-2 with hopper general assembly. 26 Dust container lift assembly.

27 REPLACEMENT PARTS DTH-1700 The following section lists typical replacement parts for the Dust-Pak dust collector model DTH If a part is not listed in Table 7, contact your local distributor. Refer to Figure 22 for parts illustrations. TABLE 7. ITEM PART NUMBER QTY DESCRIPTION 1 1AC Exhaust panel 2 1AC Downdraft table 3 1PN Grill channels, steel, Std. 4 1PN Baffle 5 1AC Dust drawer 6 2AX Filter cover 7 2KB Assembly, knob / stud 8 7ER Power switch, rocker (115V only) 9 7VA Vibra-Pulse control valve, push (manual) 10 7PC Power cord, 115 VAC, yellow, PL Back fence (BF-1), Std. 12 1AC BF-3 with light, Opt. 13a 7NT Dial pressure gauge, flush mounted, Opt. 13b 7NT Pressure gauge, surface mounted, Opt. N/S 7PN Regulator, ½ NPT full flow, adjustable, Opt. USE ONLY AUTHORIZED AIRFLOW SYSTEMS REPLACEMENT PARTS AND FILTERS TO PREVENT VOIDING THE WARRANTY. 27

28 7LB Du st Pak DUST COLLECTORS Made in USA Figure 22. Model DTH-1700 general assembly. 28

29 TROUBLESHOOTING The troubleshooting guide included in this manual is for qualified personnel only. A Motor Trouble Guide is included in Appendix A. If the unit does not function properly after following the guidelines in this manual, consult your local distributor for further help. PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION 1. Motor won't operate Motor overload Failed motor Starter failure No input voltage Too much airflow. Be sure arm, hose (or ducts),and doors are installed before running. Replace motor. Check amps to ensure proper operation. Check overload reset. Check magnet coil for failure Check circuit breaker 2. Motor runs, then trips out overload or blows fuses Voltage source inadequate Static load on blower too low Check voltage at motor with motor running. Voltage should be +/- 10% of motor rating. If not, check: 1. Power source 2. Wire size from source Check running amps of motor. If at or below amps indicated on unit nameplate, check fuse size or overload sizing/adjustment. Increase system duct inlet resistance (more air) 3. Low air flow Duct disconnected Pre-filter/filter plugged Motor running backwards (3 phase only) Motor running slow Inspect and repair Clean filter Check rotation. Check line voltage Check motor current 4. Vibra-Pulse not effective The main cause of low performance is failure to observe the minimum 3/8 I.D. throughout the entire air supply circuit. A single ¼ hose barb will severely compromise performance. Air pressure too low Air hose too small Air hose blocked/leaking Air valve plugged Vibra Pulse hose loose/damaged Vibra Pulse hose pinched in filter Quick disconnect too small Minimum 80 PSI (see Compressed Air Supply section) Use 3/8 I.D. hose (supplied) Check hose. Flush valve and install filter / dryer Inspect or replace Inspect and correct Use minimum 3/8 I.D. size 29

30 NOTES RECORD START UP DATA HERE MODEL: PCH-2 DCH-2 DTH-1700 SERIAL NO.: DATE PURCHASED: DATE INSTALLED: MOTOR VOLTAGE (MEASURED): MOTOR CURRENT (MEASURED): MOTOR FLA (FROM NAMEPLATE): MOTOR VOLTAGE (FROM NAMEPLATE): ALWAYS USE AIRFLOW SYSTEMS REPLACEMENT PARTS AND FILTERS TO MAINTAIN WARRANTY TO ORDER SPARE PARTS, CONTACT YOUR LOCAL REPRESENTATIVE OR LEV-CO 1050 Brock Road, Unit Pickering, Ontario L1W 3X4 CANADA Phone (905) FAX (905) INTERNET: APPENDIX 30

31 1. BRANCH WIRING... A1 2. MOTOR TROUBLE GUIDE... A2 3. TYPICAL INSTALLATION WIRING DIAGRAM 3 PHASE... A3 31

32 MOTOR WIRING GUIDE (BRANCH CIRCUIT) WIRING To connect motor for proper voltage and rotation, refer to connection diagram on nameplate or inside terminal/conduit box. If power factor correction capacitors are used for individual motor power factor correction, do not exceed maximum recommended value. All aspects of the installation must conform to the requirements of the NEC, including Article 430 (Motor Circuits and Controllers), and all local codes. Wherever possible, each motor should be powered from a separate circuit of adequate capacity to keep voltage drop to a minimum during starting and running. Increase wire size where motor is located a distance from the power source. Wire size must be adequate to minimize voltage drop during starting and running. Refer to Tables A and B for suggested wire sizes. Distances shown are one-way between source and load. Portable cords, if used, should be as short as possible to minimize voltage drop. Long or inadequately sized cords, especially on hard starting loads, can cause motor failure. Insulate and protect motor lead connections to prevent cut-through from sharp edges and vibration. Tape wire nuts to prevent loosening. All electrical connections in system must be secure to prevent voltage drop and localized heating. Determine direction of rotation before connecting driven equipment to prevent damage. Remove shaft key if motor is to be operated at no-load. On three phase motors, interchange any two line leads (not motor leads) to reverse rotation. On air compressors, rotation of flywheel should direct air towards the cylinders. Look for rotational arrow on flywheel. All motors must be securely and adequately grounded by wiring with a grounded, metal-clad raceway system, using a separate ground bond wire connected to bare metal on the motor frame, or other suitable means. Refer to NEC Article 250 (Grounding) for additional information. Explosion-proof motors incorporating over temperature thermostats should be controlled with a magnetic starter. The thermostat circuit must be wired in series with the holding coil circuit, as shown on tag or nameplate on motor, to remove power from the starter coil if motor overheats. TABLE A - MINIMUM WIRE SIZES FOR THREE-PHASE MOTORS MOTOR 25 FT TO 50 FT 100 FEET 150 FT TO 200 FT HP 200V 230V 460V 200V 230V 460V 200V 230V 460V 1/8 14(18)* 14(18)* 14(18)* 14(18)* 14(18)* 14(18)* 14(16)* 14(18)* 14(18)* 1/6 14(18)* 14(18)* 14(18)* 14(18)* 14(18)* 14(18)* 14(16)* 14(16)* 14(18)* 1/4 14(18)* 14(18)* 14(18)* 14(16)* 14(18)* 14(18)* (18)* 1/3 14(18)* 14(18)* 14(18)* 14(16)* 14(16)* 14(18)* (18)* 1/2 14(16)* 14(18)* 14(18)* (18)* (18)* 3/ (16)* 14(18)* (18)* (16)* (16)* 14(18)* (18)* ½ (18)* (16)* (18)* (16)* (18)* [*]Type S, SO, SJ, SJO, etc. flexible cable wire sizes. See NEC Article 400 for ampacity. Note: Above wire sizes based on approximate 5% voltage drop during starting; copper conductors; and 75 C type TH, THW, RH, RHW, etc. insulation. For aluminum wire, increase two wire size steps minimum. See NEC Article 310 for ampacities of aluminum conductors and 60 C type RUW, T, etc. insulation. TABLE B - MINIMUM WIRE SIZES FOR SINGLE-PHASE MOTORS MOT0R 25 FT 50 FT 100 FT 150 FT 200 FT HP 115V 230V 115V 230V 115V 230V 115V 230V 115 V 230 V 1/8 14(16)* 14(18)* 14 14(18)* 10 14(16)* 10 14(16)* / (18)* 12 14(18)* 10 14(16)* / (18)* 12 14(18)* / (18)* 10 14(16)* / (18)* 10 14(16)* / (18)* (16)* ½ 10 14(16)* / /0 6 2/0 4 Note: Above wire sizes based on approximate 5% voltage drop during starting; copper conductors; and 75 C type TH, THW, RH, RHW, etc. insulation. For aluminum wire, increase two wire size steps minimum. See NEC Article 310 for ampacities of aluminum conductors and 60 C type RUW, T, etc. insulation. A1

33 MOTOR TROUBLE GUIDE The purpose of this guide is to suggest common answers to electrical problems. The information is not all-inclusive and does not necessarily apply in all cases. When unusual operating conditions, repetitive failures, or other problems occur, consult an electric motor service firm for assistance. TROUBLE CAUSE WHAT TO DO MOTOR 1. Blown Fuses. 1. Replace with time-delay fuses FAILS or circuit breakers. Check for TO START grounded winding. 2. Low voltage. 2. Use higher voltage tap on transformer terminals, increase wire size. Check for poor connections. 3. Improper line 3. Check connections against connections. diagram supplied with motor. 4. Overload (thermal protector) 4. Check and reset overload tripped. relay in starter. Check heater rating against motor nameplate current rating. Check motor load. If motor has manual reset thermal protector, check if tripped. 5. Motor may be overloaded. 5. Reduce load. Increase motor size. 6. If permanent split capacitor 6. Indicated by humming sound. motor, capacitor may Replace run capacitor. See be open. nameplate for correct value. 7. Defective motor or starter. 7. Repair or replace. MOTOR 1. Overloaded motor. 1. Reduce load or increase STALLS motor size. 2. Low motor voltage. 2. See that nameplate voltage is maintained. MOTOR 1. Not applied properly. 1. Consult motor service firm for DOES NOT proper type. Use larger motor. COME UP 2. Voltage too low at motor 2. Use higher voltage tap on TO SPEED terminals due to line drop. transformer terminals, increase wire size. Check for poor connections. 3. Load too high. 3. Check load motor is carrying at start-replace with larger motor. MOTOR 1. Excess Loading; high 1. Reduce load. Increase TAKES TOO inertia load. motor size. LONG TO 2. Inadequate wiring. 2. Increase wire size. Check for ACCELERATE poor connections. 3. Applied voltage too low. 3. Reconnect to a higher transformer tap. Increase wire size. Check for poor connections. 4. Defective motor. 4. Repair or replace. 5. Inadequate starting torque. 5. Replace with higher horsepower motor. MOTOR 1. Motor mis-aligned. 1. Realign. VIBRATES 2 High voltages 2. Check wiring connections, OR IS transformer. EXCESSIVELY 3. Worn, damaged, dirty or 3. Replace, check loading and NOISY overloaded bearings. alignment. 4. Loose or defective or 4. Tighten set screw(s); repair or out-of-balance air mover. replace. INSUFFICIENT 1. Insufficient motor load. 1. Use a lower horsepower motor. SPEED 2. Reduce system restrictions CHANGE (blower). Increase system restriction (propeller fan). MOTOR 1. Overload. 1. Reduce load; increase motor size. OVERHEATS 2. Dirt preventing ventilation. 2. Clean motor. WHILE 3. Faulty connection. 3. Clean, tighten or replace. RUNNING 4. High or low voltage. 4. Check voltage at motor, should UNDER LOAD not be more than 10% above or below rated. 5. Defective motor. 5. Repair or replace A2

34 TYPICAL INSTALLATION WIRING DIAGRAM 3 PHASE A3