RG 700YA. DUST COLLECTOR (for normal dust particles) PULSE JET HANDLING INSTRUCTIONS

Transcription

1 PULSE JET DUST COLLECTOR (for normal dust particles) RG 700YA HANDLING INSTRUCTIONS Congratulations on your wise decision to purchase this Hitachi Dust Collector. We suggest that you carefully read this Handling Instructions prior to using the Dust Collector, so that its inherent operating functions can be fully demonstrated. Precautions... 1 Construction... 3 Operation panel... 4 Installation... 5 Before use... 8 After use... 9 Operating display selection switch Contents Indication of alarm lamp Specifications Optional accessories After-sale service Structural drawing, parts list Connection diagram General checklist for maintenance of dust collectors... 22

2 Meanings of WARNING, CATION, NOTE Precautions during use are divided to [ WARNING] and [ CATION] and these meanings are explained respectively along with the meaning of [NOTE] as follows: WARNING : Caution against cases in which possibilities for death of the user or serious injuries to be sustained on the user are assumed when this dust collector is erroneously handled. CAUTION : Caution against cases in which possibilities for injuries to be sustained on the user and only material damages are assumed when this dust collector is erroneously handled. Even a seemingly trivial matter described in [ CAUTION] can lead to serious consequences depending on the situation. Accordingly, make sure that all the tips for safety mentioned above are observed without fail. NOTE : Key points to be noted concerning installation, operation and maintenance of the product. PRECAUTIONS To prevent accidents such as a fire, electric shock, injury, etc., make absolutely sure that the following points are observed. Read these [PRECAUTIONS] in every respect before use and abide by the given instructions. After reading, be sure to keep this manual at a place where anybody can access for reading before use. WARNING 1. Never allow the dust collector to suck in the following substances. Doing so can result in a fire and machine failure. Inflammables such as gasoline, thinner, benzene, kerosene, paints, etc. Dust particles caused by a high-speed cutter, belt sander, grinder, etc. Fumes generated by welding and soldering. Explosive dust particles of materials such as aluminum, zinc, magnesium, titanium, etc. Objects with high temperatures such as smoldering cigarette butts, matches, etc. Carbon powder and fine dust particles of up to 5µm as well as tacky or sticky materials such as chemicals, water, oil, paints, cement powder, etc For power source, use the voltage and frequency specified in the name plate. Use of power source other than what is specified can result in an electric shock, fire and machine failure. 3. Be sure that the dust collector is grounded. Otherwise, there is a risk of an electric shock in case of a machine failure and electric leakage. (For details, refer to the item of (1) Installing ground/earth-leakage breaker in Page 5.) 4. Note that this dust collector is designed for indoor use. Never use this dust collector outdoor.

3 PRECAUTIONS WARNING 5. Ask a repair shop for the repair of this dust collector. Do not remodel this product since this is in conformity with relevant safety standards. Be sure to ask your dealer, where you purchased this product for repair. Repair undertaken by a person without technical knowledge can result not only in a poor machine performance but also in accidents and injuries. CAUTION Be sure to check before applying air pulses Do not turn ON an operation switch and manual pulse switch in a state where clamps are off. This caution must be exercised to prevent accidents caused by scattered dust particles and by the door. Use compressed air with specified pressure For the pressure of compressed air, use the one with 4-7 (kg/cm 2 ). Use of pressure other than what is specified can result in the damage of an air tank and the failure of an electromagnetic valve. Set a regular filter properly Tear, hole Filter Wing bolt Use of the dust collector with a filter having torn sections and holes or without the filter can result in the failure of the dust collector. Set the dust collector at a horizontal place Protect power supply cords Move the main unit properly Otherwise, the dust collector is subject to vibrations or a fall. Do not bring the power supply cords close to heat and oil and into contact with sharp corners. Do not tug the cords. Do not place heavy articles on the cords. Avoid placing the cords between other objects. Be sure to use both of the four hanging bolts and move the main unit quietly to protect it from any possible damage. NOTE The dust collector can come across with unexpected accidents and failures when maintenance is not performed properly. Operate this dust collector safely and effectively by using the list of check points for maintenance provided at the end of this manual. 2

4 CONSTRUCTION Operation panel For details about individual switches, refer to Page 4. Discharge port Motor Fan Air tank Panel cover Electromagnetic valve Filter cover Pulse pipe Dust cover Air filter Install the air filter attached to the compressed air connecting port of the main unit, and connect the air tube to the air filter. (Pressure 4 7 kg/ cm 2 ) Dust cover Dust box Dust box Clamp Remove the clamp, open the dust cover, draw out the dust box, and discard accumulated dust particles from the dust box at the earliest possible opportunity. Scrape out of the main unit any dust particles spilled to the outside of the dust box. Filter This filter collects sucked-in dust particles quite efficiently. It is necessary to perform cleaning and inspection more than once in every 1-2 months on a periodic basis. Suction port Hose Suction port flange Connect the hose. (Inner diameter 250 mm) 3

5 OPERATION PANEL Display selection switch Digital display Alarm display Press this switch to display the filter s differential pressure, hours till dust discard, hours till filter inspection, and air volume. Contents selected by the display selection switch are displayed. A lamp informs you of abnormality and the period of inspection. 1 If a reverse connection is made on the three-phase power, a reverse rotation of the fan occurs, ending up in an operational failure. 2 Overload applied to the motor stops operation. 3 The lamp informs you of abnormal piping of the pressure sensor. 4 The lamp informs you of the period for filter inspection and dust discard. Alarm reset switch Set/register button Set-value-changing button Manual pulse switch Operation switch When a warning lamp lights up on the alarm display, find out why it lights up and remove the cause of trouble, press this switch and make preparations to start operation. Use this button to change or register set values. For details, refer to Page 12. It is possible to change the set values as desired using the up-button and downbutton. It is possible to eliminate dust particles by applying pulses using hands. After operation is stopped, dust particles can be eliminated more effectively if manual pulses are applied. This switch starts and stops operation of the fan. 4

6 INSTALLATION 1 Installation of ground/earth-leakage breaker WARNING To prevent accidents by electric shocks if electric leakage should occur, Install an earth-leakage breaker on the power source to which this dust collector is to be connected. Make sure before use that this dust collector is grounded. It is recommended that grounding is performed for safety even in case of a dust collector with the power source for which a currentoperating-type earth-leakage breaker is installed. The earth-leakage breaker features less than 15 milliampere (ma) rated sensitivity current and less than 0.1 second operating time. Perform settings according to following procedures: Fasten with screws the grounding terminal of a grounding green wire tip of the power supply cord, and connect it to the grounding wire as illustrated in the right figure. Grounding Be sure that no tension is applied to the grounding green wire. Dust collector Power supply cord Grounding green wire (with terminal) Grounding terminal Specialized work is required for the installation of an earth-leakage breaker as well as grounding according to the technical standards on electric installation and indoor wiring regulations. (An electrician with a diploma is required for the grounding installation, and therefore consult with your electrical work shop. Fee-charging.) For grounding work Installation work s Specify the third class grounding work. s If there is a grounding terminal already installed, check if grounding capacity is sufficient. For earth-leakage breaker work s Install an earth-leakage breaker with a capacity that is above the rated current. (Rated current of the dust collector is indicated in the name plate.) s If there is an earth-leakage breaker already installed, check out the above-mentioned capacity. 5

7 2 Extension of power supply cord WARNING When extending the power supply cord, be sure to replace the whole cord with a completely new one. Because, addition of a new cord to the existing cord can result in a risk for a fire and electric shock. Standard of Maximum Cord Length When the cord is extended in conjunction with installation, a sufficiently thick one is required to prevent malfunction due to a voltage drop. Relation between the maximum length (total length of cord) and the cord thickness is shown on the right table. (The attached cord is 5 meter long.) Cord length Cord thickness Maximum length Nominal conductive cross section of cord (mm 2 ) m 31m NOTE The cord length shown in the above table differs to some extent depending on the power situation. 3 Place for installation WARNNG The construction of this dust collector is not explosion-proof. Do not use this dust collector at a place near inflammables such as gasoline, thinner, etc., to prevent possible accidents. This dust collector is for indoor use. Never use this dust collector outdoor. Use of this dust collector outdoor can result in an electric shock and fire due to electric leakage. Choose a horizontal and flat place on the floor to facilitate operation of the dust collector. Secure a sufficient floor strength in consideration of the product weight (280 kg). 4 Installation of hose Suction port flange Bolt Suction ports are provided on two sides. Use the suction ports as desired in the following manners according to working conditions. s To remove the suction port, remove four bolts on the suction port flange. s To install the suction port, position the suction port flange, and fasten it using bolts. s Fix a suction port cover onto the suction port that is not in use. Bolt Suction port cover 6

8 INSTALLATION NOTE Proper work with a minimum loss is essential for the piping of hoses and hoods, considering the surrounding conditions, working environment, etc. Procure separately sold component parts and ask your dealer for installation. When using metal piping parts, be sure to perform complete insulation between a wall surface and the metal piping parts inside the wall surface. Some dust particles may blow out of the discharge port immediately after installation or elimination of dust particles. Installation of an exhaust duct is recommended depending on the working environment. 5 Connection of compressed air Compressed air connecting holes are provided on two sides. Use the compressed air connecting holes as desired in the following manners according to working conditions. 1/4 nipple fixing hole (joint) 1/4 plug 3 Air tube (to be purchased separately) Filter cover 2 Air filter (standard accessory) 1 1/4 nipple (standard accessory) Prevent air leakage using sealing tapes, etc. Dust cover Clamps Sealing agent is coated at the time of delivery s When connecting compressed air, perform connection in order of 1 1/4 nipple, 2 air filter and 3 air tube. s Check and confirm that a 1/4 plug is firmly secured to a joint on the side to which the air tube is not connected. NOTE Before operation of this dust collector, make sure that the above-mentioned connection is completely carried out and that a panel cover, filter cover, and dust cover are all fixed with clamps. Be sure to use specified pressure (4-7 [kg/cm 2 ]) for compressed air. Use of pressure other than what is specified can result in the damage of an air tank and the failure of an electromagnetic valve. (When the 1/4 plug and 1/4 nipple are once removed, prevent air leakage with sealing tapes, etc.) 7

9 BEFORE USE 1 Check the following points at first Check and confirm that the dust box is empty. If dust particles are accumulated, get rid of them by cleaning before use. Make sure that there is no air leakage in the packing, suction hose and other piping parts and that they are all set properly. Make sure that the panel cover, filter cover and dust cover are completely secured with clamps. 2 Connection of power supply cord Connect the power supply cord correctly to the power source specified in the name plate. In this case, connect a grounded phase (S phase) among three power supply wires to the white wire of the power supply cord. 3 Check direction of motor rotation Turn ON the operation switch on the operation panel and check that a [FAN REVERSE] lamp of the alarm display does not light up. In case of a reverse rotation, a lamp lights up and the motor does not rotate. In this case, turn OFF the main power switch of the original installation and switch over the connection of R phase and T phase of the power supply cord. To re-start operation, press the alarm reset switch and then press the operation switch. R phase (red wire) S phase (white wire) Switch connection T phase (black wire) Ground (green wire) 8

10 AFTER USE 1 Elimination of dust particles from filter Manual pulses after the stop of operation can eliminate dust particles more effectively. Remember that a pulse noise is made four times during pulse application. During manual pulse application after the stop of operation, dust particles flow backward and therefore do not look into the suction port, etc. NOTE Before taking actions listed in the following items, make sure that the operation switch is turned OFF, the main power switch is turned OFF and suction is completely stopped. 2 Cleaning of dust box WARNING Discard dust particles accumulated in the dust box every day. Otherwise, there is not only a readhesion of blown-up dust particles to the filter in subsequent operation but also a cloud of dust articles is produced, causing a risk for explosion of dust particles. Wait for more than a minute after eliminating dust particles in the filter, remove one piece of clamp, draw out the dust box, and then discard accumulated dust particles. Try to discard the dust particles at the earliest opportunity, and the dust articles spilled out of the dust box should also be scraped out of the main unit. WARNING Never open the panel cover, filter cover and dust cover while a mark is displayed on the digital display of the operation panel. Do not look into the suction port for dust particles as there is a risk of the dust particles to scatter. 3 Cleaning and inspection of filter Dust eliminating operation by pulse alone is not enough when the filter is heavily clogged up. Under such circumstances, suction power naturally downs. Clean up the filter on a periodic basis (more than once in every 1-2 months). s Extracting filter (1) Remove two clamps and open the filter cover. Filter cover (2) Remove the wing bolt and then quietly extract the filter along with the filter holder. Filter holder Wing bolt Filter Clamp Filter 9

11 NOTE It is recommended that some spare filters be stocked since the filters are expendable. Try to maintain the performance of the filter and restore its suction capacity by brushing and washing the filter with water and eliminating clogged dust particles as illustrated below. After washing the filter with water, dry it completely in the shade before use. Depending on the kind of dust particles, think about how to treat waste fluid while washing the filter with water. * Wash off dust particles under running water. Filter Filter * Scrape out dust particles using a brush and other effective tools. s Installing filter 1 To begin with, insert the filters into the filter holder. Insert two filters into one filter holder. Be sure to insert the filter vertically. Filter holder Filter 2 Mount the filters on the left and right filter guiding plates and thrust them in until they contact the filter stop. Filter cover Filter guiding plate (left) Filter stop Filter holder Wing bolt Filter guiding plate (right) Filter 3 Then, lift the front of the filter holder up and fasten it scurely with the wing bolt until it hits the filter support plate. If a male screw and a female screw of the wing bolt do not engage well each other when fastening the filter holder, the filter holder is not pushed in sufficiently. Be sure to push it in completly. WARNING Install the filter properly before use. Do not use the dust collector with the filter removed or at an erroneously installed position. Avoid the use of a torn filter, too. Otherwise, dust particles can enter into the motor and can result in the machine failure and damage of motor by a fire. 10

12 AFTER USE 4 Drain-out of air filter WARNING Air tube Wear protective glasses during work since drain liquid scatters. Drain s upper limit mark After completion of work or before working, perform drain-out of the air filter more than once a day on a periodic basis with the drain s upper limit mark. Air filter Drain-out button 5 Drain-out of air tank NOTE After completion of work, make sure that the fan rotation is stopped. Remove the air tube, and perform drain-out after discharging compressed air filled in the air tank. When removing the 1/4 plug, provide a tray underneath, and then perform drain-out. Drain-out is necessary on a periodic basis of more than once a year. Caution must be exercised not to expose the filter to the drained liquid. Air tank 1/4 plug Pulse pipe 11

13 OPERATING DISPLAY SELECTION SWITCH When the main power switch is turned ON, the following character or numeric appears on the digital display. Abbreviation of model name (RG700YA) is displayed Two seconds later Then, press the button, and when the dust collector starts to operate, the current filter s differential pressure value is displayed. For individual names of switches, refer to Page 4. 1 Operating filter s differential pressure switch Filter s differential switch The filter gets clogged gradually as it continues to suck in dust articles. The degree of clogging exhibited in numerical values is the filter s differential pressure. This dust collector is designed to apply pulses to the filter automatically upon reaching the differential pressure values set in advance and to discard the dust particles adhered on the filter. The differential pressure values set at the time of factory shipment is 180 mm H2O. To change the set value, follow the instructions described below. Press the filter s differential pressure switch Display the current filter s differential pressure Press (starts to set) 1 2 value. 3 4 a lamp on the upper left of the switch [ lights up ] Display the current set value. It is possible to set the value, ranging from 50 to 300 mm H2O. [ ] The numeric of set value flashes, indicating completion of registration. Press The set value changes. 8 (setting is completed) Press the setadjusting switch (up/down) and adjust the set value. When registration is completed, the set value flashes and notifies the user to that effect. Several seconds after the completion of registration, the digital display automatically turns to filter s differential pressure display. If dust particles of particularly high adhesive power are sucked in, lower the set value and eliminate the dust particles at the earliest opportunity. 12

14 OPERATING DISPLAY SELECTION SWITCH 2 Using dust-discard hours This switch displays remaining hours till dust discard. Although this is set for 25 hours at the time of factory shipment, lower the setting to the smaller number [ ] of hours in case there are many dust particles accumulated. To display the remaining hours till dust discard, carry out the following. Press the dust discard switch a lamp on the upper left 1 [ of the switch lights up ] 2 The remaining hours till dust discard is displayed. NOTE If the alarm reset switch is pressed while the remaining hours till dust discard are being displayed, the remaining hours are reset, returning to the initial set value. Be careful. Try to discard the dust particles accumulated in the dust box at the earliest opportunity. The accumulated dust particles can result in the reduced air volume due to the clogged filter, declined suction power, etc. To change the remaining hours till dust discard, carry out the following. Press the dust-discard switch a lamp on the upper left Display the current Press (to start setting) 1 [ of the switch lights up ] 2 hours till dust discard. 3 4 Display the current set value. It is possible to set, ranging from 1 to 99 hours. [ ] The numeric of the set value flashes, indicating completion of registration. Press The set value changes. 8 (to complete setting) Press the setadjusting switch (up/down), and adjust the set value. Set/register When registration is completed, the set value flashes and notifies the user to that effect. In several seconds after the completion of registration, the digital display automatically turns to the filter s differential pressure display. 3 Using filter inspection hours This switch displays how many hours are still left till filter inspection. Press the filter inspection switch a lamp on the upper left 1 [ of the switch lights up ] 2 The number of hours till filter inspection is displayed. 13

15 NOTE If the alarm reset switch is pressed while the hours till filter inspection are being displayed, the remaining hours are reset, returning to the initial set value. Be careful. The hours till filter inspection are set to 200 hours at the time of factory shipment, but it is necessary to inspect torn parts and holes of the filter depending on the accumulated quantity and the kind of dust particles. To change the hours till filter inspection, carry out the following. Press the filter inspection Display the current switch hours till filter Press (to start setting) a lamp on the upper left 1 2 inspection. [ 3 4 of the switch lights up ] Display the current set value. It is possible to set, ranging from 10 to 1000 hours. [ ] The numeric of the set value flashes, indicating completion of registration. Press The set value changes. 8 (to complete setting) Press the setadjusting switch (up/down), and adjust the set value. When registration is completed, the set value flashes and notifies the user to that effect. In several seconds after the completion of registration, the digital display automatically turns to the filter s differential pressure display. 4 Using air volume switch To display the air volume, carry out the following. Press the air volume switch a lamp on the upper left of 1 [ the switch lights up ] 2 Air volume is displayed. NOTE Note that there can be instances where some errors occur in the displayed values. 14

16 INDICATION OF ALARM LAMP 1 Reverse rotation of fan... When a motor rotates reversely, the motor automatically stops, and a fan-reverse-rotation lamp lights up. Refer to the procedures mentioned in Page 8 and re-connect the power supply cords. Abnormal lamp 2 Overload... When a motor is overloaded, the motor automatically stops and at the same time an overload lamp lights up. If the dust collector is operated with an open-phase connection, the overload lamp lights up. 3 Pressure sensor... A pressure-sensor lamp lights up when there is some abnormality in the piping of the pressure sensor. When abnormality lamps of 2 and 3 above light up, consult with your dealer. Inspection lamp 1 Filter inspection... A filter-inspection lamp lights up when the set inspection time for the filter comes. When the filter s differential set value is not restored even after the dust-eliminating operation of 4-5 cycles is continuously performed by pulse application, a filter-inspection lamp lights up. 2 Dust discard... Upon reaching the set dust-discard hour, a dust-discard lamp lights up. Even when an abnormality lamp lights up, the dust collector can be operated again if the alarm reset switch is pressed and the operation switch is turned ON after the cause of abnormality is removed. Even when an inspection lamp lights up, if the alarm reset switched is pressed, the dust collector can be operated again. If the alarm reset switch is pressed while the hours till filter inspection and the hours till dust discard are being displayed, the remaining hours are reset, returning to the initial set value. When the alarm reset switch is pressed before an inspection lamp lights up, do not forget the inspection work for the filter and the job to discard the dust particles from the dust box. 15

17 SPECIFICATIONS Item Model name RG700YA Motor (KW) 3.7 Maximum air volume (m 3 /min.) 70 Maximum static pressure (mm H2O) 300 Filter area (m 2 ) 18 Dust elimination system Clog-detecting automatic pulse jet Compressed air pressure (kg/cm 2 ) 4~7 Standard consumption of compressed air (Nr /min.) 28 Volume of dust box ( r ) 46 Diameter of hose (mm) 250 Length of power supply cord (m) 5 Weight (kg) 280 <Approximate dimensions> Width x Depth x Height (mm) NOTE Note that the maximum air volume and static pressure differ largely depending on the length and thickness of the pipes to be connected. 16

18 OPTIONAL ACCESSORIES ASK YOUR DEALER FOR INFORMA- TION ABOUT THESE PARTS Names Code No. Hose ø150 Hose ø200 Hose ø250 Hose Round hood ø200 Round hood ø250 Round hood Breeches pipe with flange ø250 Breeches pipe with flange Discharge port ø300 discharge port ø100 caster (containing 4 pieces)

19 AFTER-SALE SERVICE For abnormality during use WARNING Before you ask for repair, read this instruction manual carefully and check according to the table below. If abnormality still persists after checking and taking necessary measures, do not try to repair by yourself and be sure to consult with your dealer. Contact your dealer for any questions about troubles. Troubles Motor does not run. (Absolutely no suction power) Rotation of a motor stops during operation and an overload lamp lights up. Check and remedy Check if the power supply cord is properly connected. If an overload lamp lights up, turn OFF the main power switch immediately and ask your electrician for a complete checkup as it may be caused by open-phase operation or other faults. Remove two M6 bolts, roll the controller box to your front, and you will find the electromagnetic switch. Red button Electromagnetic switch Bolts Controller box Check if a thermal relay of the electromagnetic switch is functioning. If the thermal relay is functioning, find out why it is functioning and remove the cause, and press a red reset button provided on the electromagnetic switch. Suction power is weak. Blowout of dust particles coincides with exhaust. Get rid of dust particles in the filter and discard the dust particles from the dust box. If dust particles are clogged up in the hose and wire nets of the discharge port, eliminate them. Check if there are some defective joints (gaps, etc.) on the hose and if the front door is firmly fixed with clamps. Check if the filter is not broken or if it is installed properly. 18

20 19 STRUCTURAL DRAWING ( RG700YA)

21 PARTS LIST Item No. Parts Name Q'ty Remarks KW motor KW fan 1 3 Tube connector (B) 2 4 1/4 plug 2 5 D10 tube 2 6 Filter holder 4 7 Filter 8 8 Suction port cover 1 9 PB assembly 1 10 Eyenut 4 11 Controller box assembly 1 12 Motor case plate assembly 1 13 Tube (W) 1 14 Tube (R) /4 nipple 1 16 Air filter 1 17 Tube (W) 1 18 Tube connector (A) 1 19 Clamp 5 20 Panel cover 1 21 Pulse pipe 4 22 Filter cover 1 23 Dust cover 1 24 Electromagnetic switch 1 25 Diaphragm valve 4 26 Electromagnetic valve 4 27 Air tank 1 28 Suction port flange 1 29 Dust box 1 for 50 Hz for 60 Hz 20

22 CONNECTION DIAGRAM Magnet SW Noise suppressor assembly Power source Green Black White Red Transformer Black Black White Operation panel PB assembly White Blue Yellow Green Black White Red Motor for dust collector Electromagnetic valve Red White Black Black Red Brwon Yellow White Red Red Red Red Red Red Red Red Controller box assembly 21

23 GENERAL CHECKLIST FOR MAINTENANCE OF DUST COLLECTORS Month/Date Checkup items for maintenance Check if the dust box (drawer) is empty. Check if the grounding is proper. Before use Drain-out of air filter Daily inspection Discard dust particles from the dust box. After use Extract the filter and clean up (washing with water) Check if the filter is not torn. Measurement of insulation resistance (check if there is more than 1 MΩ insulation resistance between the power supply wire and the frame body of the dust collector) Elimination of dust particles deposited on pipes, hoses, wire nets of discharge port, etc. Monthly inspection Filter replacement. Interior cleanup. Drain-out of air tank. Annual inspection 1. Put [ ] mark on every item that was checked. 2. Read this instruction manual carefully before inspection. 3. In case something abnormal is detected, notify a responsible individual in charge of maintenance. 22

24 612 Code No. C N Printed in Japan