Camcorp Pulse-Jet Installation, Operation & Maintenance Manual Download

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Installation, Operation,

& Maintenance Manual

Unique Design & Engineering
Approaches for Industrial
Applications

Summary of Contents for Pulse-Jet

Page 1: ...Installation Operation Maintenance Manual Unique Design Engineering Approaches for Industrial Applications ...

Page 2: ...3 11 Magnehelic Gauge Connections 3 12 Explosion Vent Installation 3 13 Section 4 OPERATION Operating Principle 4 1 Start Up Check List 4 2 Start Up Dust Control Systems 4 5 Shutdown Procedures 4 6 Section 5 COMPONENT INFORMATION Main Component Listing 5 1 Magnehelic Gauge 5 3 Timer 5 7 National Controls Corp 120 VAC Standard Timer 5 7 National Controls Corp 12 24 VDC Optional 5 9 Dwyer Smart Time...

Page 3: ...1 0740 Fax 913 831 9271 www camcorpinc com Section 6 TROUBLESHOOTING Dust Collector 6 1 Timer 6 5 Compressed Air System 6 6 Section 7 MAINTENANCE Routine Maintenance 7 1 Section 8 APPENDIX Dust Collector Terms Definitions 8 1 ...

Page 4: ...aden air could be highly explosive and extreme care must be taken Most filter bags will burn if exposed to sparks welding or open flames Before entering any dust collector Run cleaning mechanism 20 minutes with the fan off to clean filter bags Completely discharge dust solids from hopper if applicable Shut off compressed air supply and relieve pressure in the compressed air manifold Lock out all e...

Page 5: ...cate serious potential hazards which may result in serious injury or possible death Extreme care should be observed when working in these areas CAUTION 1 2 OTHER These stickers provide instruction or helpful information Serial Number Plate Important information contained on these is needed by Camcorp when calling for parts or service ...

Page 6: ...e damage Inspection of the Equipment Housing Compressed Air Header and Timer Assembly Particular attention should be paid to the sheet metal housing of your collector The unit should be inspected for dents cracks or rips A dented housing may seriously affect the structural integrity of the unit The compressed air header and timer assembly are very delicate pieces of the unit and must be checked ca...

Page 7: ...water and dirt Ports on diaphragm and solenoid valves must be plugged and taped to keep insects dirt and moisture out For extended storage more than 4 weeks it is recommended to remove the timer panel and solenoid valve assembly if mounted These components should be stored inside a cool dry area along with the copper or black nylon tubing The solenoids should have all ports capped and taped to pro...

Page 8: ...red outside on a pallet or skid to keep them out of water and dirt Fan silencers outlet dampers and inlet boxes should also be tarped and stored on a pallet or skid Reference fan IOM manual for long term storage Ducting Ducting can be stored outside on a pallet or skid to keep it off the ground It should be positioned so that water does not sit on or in the ducting If ducting is unpainted carbon s...

Page 9: ...th product Unit can be stored outside provided it is covered with a tarp and is on a pallet or skid to keep it out of water and dirt Reference rotary valve IOM manual for long term storage Butterfly Wafer Valve All limit switches solenoids and air cylinder ports must be capped and taped to prevent any moisture or dirt from entering Unit can be stored outside provided it is covered with a tarp and ...

Page 10: ... steel for the dust collector level and square Precision at this point will greatly help facilitate erection and bolt hole alignment of the dust collector sections to follow STEP 2 Place the hopper with its girth channel on the supporting steel work Check for squareness and for bolthole alignment between the hopper flange and the girth channel Apply the appropriate RTV silicone caulk around the pe...

Page 11: ...ling of the units during field erection and installation The number and location of these lifting lugs will vary depending on the model size and weight of the dust collector Before attempting to rig and lift your dust collector review the certified general assembly drawing supplied from CAMCORP to verify the number and location of lifting lugs as well as visually checking this information on the a...

Page 12: ...o operate the dust collector s pulse jet cleaning system unless a different voltage for components was requested This timer must be wired according to the wiring diagrams and be provided with a circuit that is free from transient currents The timer has a feature called Demand Pulse that allows the output terminals to be energized and de energized by the high and low set points of a differential pr...

Page 13: ...ided making sure that the solenoids are connected to their corresponding diaphragm valve Valves and Piping After the unit has been installed the diaphragm valves should be checked to make sure that the port marked IN is assembled to the compressed air manifold The IN connection of the solenoid valve is connected to the diaphragm valve by means of nylon or copper refrigeration tubing Each nut on th...

Page 14: ...pinc com Auxiliary Equipment All auxiliary equipment must be installed according to its manufacturer s specifications and interlocked with the entire system as needed Direction of rotation of each item must be checked prior to start up of the entire system 3 5 ...

Page 15: ...lds inside the top of the cage Slip the assembled filter bag and cage over the outside of the bag cup mounted on the tube sheet making sure to mate the male groove of the cage roll band top to the female groove of the bag cup If you try to move the assembly up and down you will be able to tell if the grooves are properly aligned Install the worm gear bag clamp on the assembly and tighten around th...

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Page 17: ...oove of the snap band to the I D of the tube sheet hole and allow it to expand and audibly snap into place If the band will not snap into place initially do not push on the dimple as doing this will permanently damage the snap band Instead kidney shape the snap band from the opposite side of the dimple Then you can allow the band to expand and audibly snap into place Check the fit of the snap band...

Page 18: ...tubesheet holes must be inspected carefully to ensure that proper sealing will result The surface finish on the inside diameter must be relatively smooth Any deep grooves or protrusions will cause leakage A hole that was flame cut but not ground smooth is one example The tubesheet holes must be consistent in circumference from one hole to another If the circumference difference is determined by me...

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Page 22: ...ned on the filter media surface D Cleaning cycle consists of a momentary blast of 90 100 psig compressed air 1 Momentarily taking a row of bags off stream through pressure reversal 2 Flexing filter bags 3 Solids are released to fall towards hopper and through rotary valve or other discharge equipment CAMCORP INC Phone 913 831 0740 Fax 913 831 9271 www camcorpinc com 4 1 ...

Page 23: ...indicator if so equipped should be connected below the material inlet s to avoid over filling the hopper Interior of Clean Air Plenum The blowholes in the blowpipes must be centered over the filter bags On top bag removal collectors verify that bags and cages are properly installed On top bag removal collectors the bulkhead fittings must be checked for proper tightness and that the blowpipes are s...

Page 24: ...in its enclosure in a suitable location All the copper or nylon tubing connections between the diaphragm and the solenoid valves must be tight and the tubing must not be crimped The plugs when used must be removed from the exhaust ports of the solenoid valves and the tubing from the diaphragm valves must be connected to the IN port on the solenoid valves The compressed air supply system must be eq...

Page 25: ...olenoid valve in the firing order noting any valves that do not fire or are stuck open causing a continuous airflow out of the exhaust port of the valve At this time note the quality of the compressed air It should be clean dry and oil free Allow the compressed air system to operate as long as possible to clear the system of dirt rust scale welding slag and metal chips that can cause the diaphragm...

Page 26: ...e closed and latched or bolted The main exhaust fan can now be started and brought up to speed Start the dust laden air through the collector The collector should be started under partial load to allow the bags to become slowly and evenly coated with dust particles On pneumatic conveying systems watch the differential pressure gauge closely for the first hour or so If unstable the collector discha...

Page 27: ...crease Readings up to 6 w g are acceptable however we recommend operating at 3 4 w g for maximum filter bag life The timer off time may be decreased when lower differential pressure readings are desired When adjusting the off time interval proceed in small steps allowing the differential pressure to stabilize for several hours between adjustments Check the main airflow with a pitot tube or equival...

Page 28: ... not include pressure module Camcorp P N 400028 Dwyer DCT 1006 6 Outputs Camcorp P N 400029 Dwyer DCT 1010 10 Outputs Camcorp P N call Dwyer DCP100 0 10 Pressure Module Diaphragm Valves Compression Coupling Ends Goyen Camcorp P N 400001 Goyen RCA20DD 3 4 Valve Camcorp P N 400002 Goyen RCA25DD 1 Valve Camcorp P N 400003 Goyen RCA45DD 1 1 2 Valve Camcorp P N 400008 Repair Kit Goyen G 20 3 4 Valve Ca...

Page 29: ...orp P N 400105 18 x35 Domed Vent 1 5 PSI Burst Camcorp P N 400067 36 x36 Flat Vent 1 5 PSI Burst Camcorp P N 400096 36 x36 Domed Vent 1 5 PSI Burst The parts above are supplied as standard components on a Camcorp dust collector If you require high temperature components NEMA 7 9 electrical components 24VDC or 220VAC components etc please contact Camcorp for the correct parts 5 2 ...

Page 30: ...ing adapters with screws Caution For use with air or compatible gases only For repeated over ranging or high cycle rates contact factory Hydrogen Gas Precautionary Note The rec tangular rare earth magnet used in the standard gage may not be suitable for use with hydrogen gas since a toxic and explosive gas may form For hydrogen service consult the factory for an alter nate gage construction B U L ...

Page 31: ...th adaptors Part No 360c firmly secured in place To mount gage on I 1 4 2 pipe order optional A 610 pipe mount ing kit 5 To zero the gage after installation Set the indicating pointer exactly on the zero mark using the external zero adjust screw on the cover at the bottom Note that the zero check or adjustment can only be made with the high and low pressure taps both open to atmosphere Operation P...

Page 32: ...7 Zero gage and compare to test instrument Make further adjustments as necessary Caution If bezel binds when installing lubricate threads sparingly with light oil or molybdenum disulphide compound Warning Attempted field repair may void your warranty Recalibration or repair by the user is not recommended For best results return gage to the factory Ship prepaid to Dwyer Instruments Inc Attn Repair ...

Page 33: ...mping shoe 2 req d e Clamp plate screw f Spacer 2 req d g Clamp plate 14 Range Spring with magnet 150 Wishbone Assembly consists of a Front jewel b Locking nut c Wishbone d Pointer e Mounting screws 2 req d f Helix assembly not shown g Pivots 2 req d not shown h Rear jewel not shown 230 Zero adjust assembly consists of a Footscrewswithwashers 2req d b Adjust screw c Foot d Finger 260 Scale Assembl...

Page 34: ...rough all selected outputs until the high and low pressure switch contacts are opened If the pressure switch contacts open dur ing the ON TIME the output will complete the active ON cycle The next time the high pressure switch is closed the next output in the sequence is fired Pressure monitoring with no hysteresis is achieved by using only a high pressure switch Placing a jumper across the high p...

Page 35: ...5 4 25 250 8 X 6 X 3 5 DNC T2006 020 6 6 75 4 75 6 25 4 25 250 8 X 6 X 3 5 DNC T2010 020 10 6 75 4 75 6 25 4 25 250 8 X 6 X 3 5 DNC T2020 020 20 8 75 7 00 8 25 6 25 375 10 X 8 X 4 DNC T2032 020 32 8 75 7 00 8 25 6 25 375 10 X 8 X 4 DNC T2006 R20 6 8 75 6 875 8 25 6 25 313 10 X 8 X 4 DNC T2010 R20 10 8 75 6 875 8 25 6 25 313 10 X 8 X 4 DNC T2020 R20 20 10 75 8 875 10 25 8 25 312 12 X 10 X 5 DNC T20...

Page 36: ...rol As with traditional Dwyer products the Dwyer DCT1000 was designed so that it is easy to use thus allowing for a quick and easy start up for your dust control applications The con tents inside this installation and operating manual will guide you through the features of the DCT1000 and how they can be applied to get the most out of your dust control require ments DWYER INSTRUMENTS INC P O BOX 3...

Page 37: ...operation on 120 VAC to 240 VAC power lines The input voltage must be between 85 VAC and 270VAC either 50 or 60 Hz No circuit changes are required when switching between these voltages The solenoid loads however must be sized to accommodate the line voltage selected 1 2 DCT1000 Terminal Connections The line and solenoid connections are located at the lower edge of the board below the plastic guard...

Page 38: ...000 Dust Collection Board for on demand cleaning requirements These series of modules are available in 10 w c 2 49 kPa or 20 w c 4 98 kPa ranges which allow for differential process pressure measurement as indicated on the display of the master controller An isolated 4 20 mA readout chan nel is provided for remote pressure display The 4 20 mA output may be wired either for use with an external pow...

Page 39: ... 3 2 Alarm Reset Switch Connection The alarm may be reset either by pressing the Alarm Reset button on the control panel or by an external switch con nected between the alarm reset terminal and one of the common terminals The alarm reset will only operate if the pressure module is installed and the pressure has returned to a normal condition 2 3 3 Connecting the 4 20 mA Loop The pressure module pr...

Page 40: ...of channels installed typically 10 or 22 This value becomes more important when multiple modules are installed The last output value flashed will be the sum of all channels available in the system After the last available channel indication has completed the currently programmed last channel value is displayed This value may be changed using the Up and Down buttons The minimum value is one while t...

Page 41: ...alues 1 Return the master controller to the process mode 2 Press and hold both UP and DOWN buttons The display will indicate a 10 second countdown at the end of which all parameters will be restored to factory defaults Releasing the switches prior to the end of the count will stop the process and no modification will be made Likewise in each of the parameter setup modes pressing and holding the UP...

Page 42: ...addi tional solenoids on larger dust collection systems It can be recognized easily as it does not have the on board display panel or the power supply present A master controller may also be used as a slave board Display Meaning Action Required This is a watchdog reset that is enabled when the master con troller isn t able to cycle through its operation The pressure module has failed to respond to...

Page 43: ...NUAL OVERRIDE PROCESS IN 0 LAST OUTPUT TIME OFF SEC TIME ON MSEC HIGH LIMIT LOW LIMIT HIGH ALARM LOW ALARM CYCLE DELAY MIN DOWN TIME CYCLES MIN AUTO ALARM RESET SEC 6 1 4 158 75 6 7 8 174 62 HIGH LOW LIMIT COM LIMIT ALARM MAN DT ALARM COM MODE OVR CLN RESET COM Figure 2 Dimensional Specifications for the DCT1000 shown with optional module DCP200 DWYER INSTRUMENTS INC P O BOX 373 MICHIGAN CITY INDI...

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Page 47: ... is zeroed or that the manometer is level zeroed and contains the correct fluid Compressed Air System Inspect the compressed air system as follows to make sure that all of the filter bags are being cleaned If none of the solenoid valves are operating check the timer using the Troubleshooting the Timer section Check the air pressure at the compressed air manifold It should recover to 90 100 psig be...

Page 48: ... from the filter bags and the rest of the system before measuring the main air flow volume Visually inspect the bags for heavy caking If caking is evident see the note below and take the necessary action to clean the bags Next measure the main airflow with a pitot tube or equivalent device and compare with the original volume for which the unit was designed If the flow is too high cut back the mai...

Page 49: ...as been reset to specifications prior to re start Information pertaining to filter bag cleaning may be obtained by calling your CAMCORP sales representative Extremely Low Pressure Drop Differential Pressure Gauge Check the differential pressure gauge or manometer and the tubing leading to the dust collector Holes in Filter Bags or Bags Incorrectly Installed Inspect the filter bags for holes rips t...

Page 50: ...ilter bags for wear Thin worn bags may not stop fine dust when flexed by a compressed air pulse Residual dust If dust has migrated into the clean air plenum because of a dropped filter bag torn filter bag or a hole in tube sheet etc the pulsing air may stir up the dust and allow it to escape into the clean air exhaust after each pulse Residual dust may also be driven down inside the filter bags by...

Page 51: ... inlet of the dust collector Filter bag cages failure Corroded rusted or broken filter bag cages can cause excessive bag wear Stainless steel or coated cages are available Troubleshooting the Timer Check for mechanical damage If the Power On indicator is not on check for 120 VAC power input The hot line connection must be connected to terminal L1 as this is the fused terminal Check for a blown fus...

Page 52: ...d exhaust port Remove and discard plug Ruptured diaphragm Disassemble valve in question and inspect diaphragm s Replace with a repair kit if necessary Pinched or plugged tubing between solenoid and diaphragm valve Inspect tubing and replace if necessary Continuous passage of compressed air through one of more blowpipes O D tubing or fittings disconnected leaking or broken Inspect and repair as req...

Page 53: ...ck for dust accumulation in clean air plenum Repairs Filter bags Generally replacement although some applications can be laundered Solenoid Valves Repair kits are available if a valve is stuck open or fails to operate Diaphragm Valves Repair kits are available if a valve is stuck open or fails to operate due to a ruptured diaphragm Rotary Valves Usually a matter of periodic seal and blade replacem...

Page 54: ...sses through after being filtered by the filter media Diaphragm Valve A compressed air valve that provides a volume of high pressure air to clean the filter media Differential Pressure The variance in pressure between two measured points On a dust collector this is generally measured on each side of the tube sheet to indicate the condition of the filter bags This is typically measured in inches of...

Page 55: ...iaphragm valve It does this by venting compressed air from the backside of the diaphragm which allows the diaphragm to open Smart Timer Board A timer that senses the differential pressure and only cleans pulses the filter media when differential pressure is high when the bags cartridges are dirty This provides for more economical use of compressed air The Smart Timer also provides additional featu...

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