Installation & Service Manual for VCF Series Collectors. Models VCF-1 VCF-2 VCF-4 VCF-6

Transcription

1 Installation & Service Manual VCF Series Collecrs Models VCF-1 VCF-2 VCF-4 VCF-6 September 18, 2007

2 Vertical Cartridge Filtration Collecrs Table of Contents Dclaimer...3 Uncrating...4 Description & Operation...4 Optional Equipment...4 Applications - General... Installation...6 Installation continued...7 Figure 1 Mor & Transmer Connection Diagram...7 Figure 2 Control Timer...8 Installation continued...9 Ordering Replacement Parts...10 Maintenance Troubleshooting...12 Specifications...13 Limited Warranty...14

3 Dclaimer Vertical Cartridge Filtration Collecrs Although instructions and recommendations are included installation of your Vertical Cartridge Filtration System, manufacturer does not assume responsibility installation of th equipment nor shall he be held liable 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 ree 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 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 bee attempting Operation or Maintenance of th equipment. All work should be permed 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 possible errors or omsions. We reserve right change designs and/or specifications without notice.

4 SECTION 1 Vertical Cartridge Filtration Collecrs Uncrating 1. Remove banding and cardboard shipping carn and packing. 2. Floor stand, Hoppers, Plenum Boxes, and Attenuars are typically labeled and packed with unit be installed, Mounting hardware included mounting se items. Be sure check all boxes any mcellaneous parts or hardware items bee dcarding. 3. Inspect exterior of unit and accessories 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 VCF 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 med 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 solenoid valve or manual push butn control 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 module and provides airflow collection system. Optional Equipment Special Filters Drum Kit Hopper and stand Mor Starters Mechanical Arms Smart Pulse w/ Downtime Pulse Delay Pulse Timer Casters Inlet Plenum Boxes

5 SECTION 2 Vertical Cartridge Filtration Collecrs Applications - General 1. Dust & Fume - The Vertical Cartridge Filtration System (VCF) designed capture and removal of DRY dust and/or fumes generated from sanding, grinding, welding and or industrial processes. The VCF cartridge 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 application specific filtration requirements. The floor mounted collecrs are designed primarily direct ducted, source capture applications 2. Size - It important that proper size unit has been selected 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 VCF (Vertical Cartridge Filtration) system uses a direct drive blower (sometimes called a plug fan) along with number 70 and 100. The 70 unit has a 1. HP direct drive mor and 100 unit has a 3HP direct drive mor and fan. The 70 has one cartridge filter and 100 equipped with two cartridge filters. 4. Hopper and Drum Kits - Hopper and Drum kits are available on Vertical Cartridge Filter units applications that require greater dirt srage capacity.. Collars & Inlet Plenums - Ducted source capture units are provided with inlet collars and / or inlet plenum boxes attaching ductwork or direct mounting of mechanical arms. 6. Portable Units - The 70 and 100 available with four casters portability and an extraction arm can be added as an option.

6 SECTION 3 Vertical Cartridge Filtration Collecrs Installation Assembly & Installation VCF-1, VCF-2, VCF-4, and VCF-6 Standard Collecrs are pre-assembled VCF-1 with exception optional items such as inlet plenum boxes, hopper/stand, and drum kits. The VCF-2 assembled in two pieces. One piece cartridge cabinet and or piece pulse tank/blower cabinet. The pulse tank/blower cabinet can be bolted p of cartridge cabinet at cusmer s facility. The VCF-4 and VCF-6 are usually supplied with a floor stand, hopper, and inlet plenum section. These three sections are shipped separately from p VCF cartridge and blower section. Standard collecrs are free standing and are typically located in a central location near operations needing collection. Weldnuts permanent mounting (bolt frame or hang with threaded rod) are welded in corners of each module on p of cabinet. Eyebolts lifting, assembly, and mounting are provided. The VCF-4 and VCF-6 floor stand shipped assembled with hopper and inlet plenum on p of hopper and stand. The cartridge filter and blower cabinets will ship loose and can be mounted and bolted ger in field. The integral junction box facry wired 460 volts 3 phase (unless orwe specified on purchase order) requiring only a qualified electrician connect input power unit. Suitable overload protection such as a mor starter required. Refer electrical section. (Combination mor starters with fusible dconnect packages are available through most local AER Control Systems LLC. dtriburs). A connection clean, dry, compressed air located outside pulse tank module and connected air reservoir tank. A 120-PSI relief valve prevent tank over-pressurization and a condensate drain (check periodically) are provided and are pre-connected reservoir tank. The supply airline should be purged remove any debr bee 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 VCF 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 Vertical Cartridge Filtration Collecrs SECTION 3 Installation continued All three-phase units are wired input voltage specified on purchase order. Unless specified orwe, standard units are wired 460 volt, 3 phase, 60 Hz operation. Mors used on VCF collecrs are UL recognized and internal wiring UL rated at 600-volts. Input power line protection required mor and electrical components. Line load and current requirements are identified on mor nameplate. Unless ordered with machine, power switch 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 transmer nameplates show appropriate wire connections - se diagrams are also shown below: Figure 1 - Mor & Transmer 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 recommended heater size installed mor.

8 Vertical Cartridge Filtration Collecrs Figure 2 - Control Timer

9 SECTION 3 Vertical Cartridge Filtration Collecrs Installation continued Control Systems WARNING Permanent damage mor will be sustained if connected voltages or than normal operating voltage which unit pre-wired. AUTOMATIC CONTROLS VCF series with exception of VCF-1 include an integrated, electrically operated pilot solenoid valve 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, transmer and indicar light are contained in electrical box mounted on p of unit. The VCF-1 uses a manual push-butn control operating diaphragm valve pulse clean cartridges. 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 10-psig ( maximum recommended working pressure of valves and air reservoir). Note: The air reservoir system has a 120-psig-relief valve. 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 0.1 second and air reservoir pressure at 100-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) = 1.8 CFM of free air.

10 SECTION 4 Vertical Cartridge Filtration Collecrs Ordering Replacement Parts Inmation required prompt delivery of replacement parts will be: 1. Model and Serial Number 2. Part Number and Description Contact your local AER Control Systems LLC. dtribur 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 Qt t y V CF-1 V CF- 2 V CF- 4 VCF Inlet Cone Inlet Cone Inlet Cone 1" Inlet Cone 16" Wheel Wheel Wheel 1" - HP Wheel 16" - 7. HP Wheel 16" - 10 HP Mor, 1.HP Mor, 3HP Mor, HP Mor, 7.H P Mor, 10HP Cartridge One End Open 30" L Diaphragm Soleniod Valve 1" Diaphragm Air Valve 3/4" Diaphragm Soleniod Valve 1." Control Timer Board Diffusion Nozzle Pushbutn Relief Pressure Relief Valve Transmer, 0W amp Fuse /2 amp Fuse Louvre, Exhaust 14 x Delay Relay Timer (optional)

11 SECTION Vertical Cartridge Filtration Collecrs 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 bee 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 VCF-1 and VCF-2 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: 1. Shut off electrical power blower and control box. 2. Open cartridge access door on front of filter cartridge module. 3. Remove thumbscrews on cartridge lift bars and drop down two cartridge lifting bars by lifting m off support tab and swing bars back in cabinet. 4. Slide cartridges out on track by grabbing cartidge header and pulling ward you. Remove cartridges inspection or replacement.. Reinstall cartridges by sliding cartridges in cabinet on track and swing lift bars up on support tabs and lock in place using thumbscrews. The lift bars compress gasket on cartridges sealing purpose. 6. Close cartridge access doors. Cartridge Replacement VCF-4 and VCF-6 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: 1. Shut off electrical power blower and control box. 2. Open cartridge access door on front of filter cartridge module. 3. Remove aded knob on cartridge lift bars and drop down cartridge lifting bars and swing bars back in cabinet. 4. Slide cartridges out on track by grabbing cartidge header and pulling ward you. Remove cartridges inspection or replacement.. Reinstall cartridges by sliding cartridges in cabinet on track and swing lift bars up and lock in place using threaded knobs. The lift bars compress gasket on cartridges sealing purpose. 6. Close cartridge access doors.

12 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 light (indicar Unit To Power No lit.) not starter in heaters overload if re or replace fuses, and wire proper necessary. starter from and connections collecr. and lit.) light (indicar unit Power box electrical from input wires mor. collecr on mor if see wiring. mor faulty. suction Low airflow and/or backwards running running If blower. of rotation 3 2 of interchange backwards, mors (3 phase leads power input only). cleaned being not are Cartridges it if see system pulse air pressure. air correctly. working ducting in Obstruction blockage. ducting y system, duct in dampers duct Improper closed. be may design. of out blowing Contaminant exhaust collecr cartridge in ole H. cartridge Replace installed properly not Cartridge cartridge correct gasket, cartridge orientation. in hole around seal must gasket cabinet. cartridge of sheet tube knob door, access cartridge and door proper tight be should sealing filter mor but pulsing, not Unit running board timer power No if replace fuses, blown transmer. necessary. board timer getting Power 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 properly Not be time Off points. timer you than period longer a low pressure and high expect. gauge. Phohelic on points be may point pressure High high. o time of all pulses Unit short. o be may time Off Timer tings, board timer intervals pulse designed board 3 minutes. 8. sec every Gauge Phohelic on times Set properly not are option Low Pressure and/or Pressure High low. o be may points

13 Specifications S pecifications V CF- 1 V CF- 2 V CF- 4 VCF- 6 Nominal Airflow - CFM / /00 0 Available External pressure - IN. H2O 2 3 4/ / 4 Filters - Qty Total Filter Area - Sq. Ft Mor - HP /7. 7./1 0 Mor Temp. Max - C Compressed Air psig psig psig psig Tank Qty Tank Volume - Cu. Ft D iaphragm Valve ( 1).7 in. ( 2) 1 in. ( 2) 1. (3) 1. Program Timer: Off TIme On Time Timer Input Power Manual - Pushbutn N/ A Solid State 8. sec.80 sec Solid State 8. sec.80 sec Solid State 8. sec.80 sec 0.0 sec.0 sec 0.0 sec.0 sec 0.0 sec.0 sec 110 VAC, 60 Hz, 1 PH 110 VAC, 60 Hz, 1 PH 110 VAC, 60 Hz, 1 PH /Mor Type Plug Fan Plug Fan Plug Fan Plug Fan Inlet 1 std. up 2 available 1 std. up 4 available 1 std. 1 std. Wheel Diameter Speed 11 inches 12 inches 1"/ 16" 16" 340 RPM 340 RPM 340 RPM 340 RPM Drive Direct Direct Direct Direct HP /7. 7./ Voltage 190/380//230/ /380//230/ /380//230/ /380//230/46 0 Frequency - Hz 0/60 0/60 0/60 0/60 Phase Frame - NEMA 6C 6C 184TC 21T C Power Facr /94 94/90 Efficiency / /87. Strart Current Amps (60Hz) 22/11 6.8/ /47 // 12/76 12/76 // 174/8 8 Full Load Amps (60Hz) 3.6/ / /6 // 17.2/ /8.6 // 23.8/11. 9 Insulation Class - Min. B F F/ F F/ F Enclosure TEFC TEFC TEFC TEFC Service Facr / /1.1 Duty Cycle Continuous Continuous Continuous Continuous Bearing Grease Exxon POLYEX EM Exxon POLYEX EM Exxon POLYEX EM Exxon POLYEX EM Specification UL & CSA Approved UL & CSA Approved UL & CSA Approved UL & CSA Approved

14 Limited Warranty AER Control Systems LLC warrants all products sold only purchasers use in business or resale, against defects in workmanship or materials under normal use, one (1) 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 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 eft 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 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 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 permance, always use AER Control Systems LLC replacement filters.