Clemco ZERO RPH Bedienungsanleitung

RPH DUST COLLECTORSRPH DUST COLLECTORS

Clemco Industries Corp. •One Cable Car Drive •Washington, MO 63090

Phone: (636) 239-4300 •Fax: (636) 239-0788

Email: info@clemcoindustries.com

www.clemcoindustries.com

NOTICE TO PURCHASERS AND USERS OF OUR PRODUCTS

AND THIS INFORMATIONAL MATERIAL

The products described in this material, and the information relating to those

products, is intended for knowledgeable, experienced users of abrasive blasting

equipment.

No representation is intended or made as to the suitability of the products

described herein for any particular purpose of application. No representations are

intended or made as to the efficiency, production rate, or the useful life of the

products described herein. Any estimate regarding production rates or production

finishes are the responsibility of the user and must be derived solely from the

user’s experience and expertise, and must not be based on information in this

material.

The products described in this material may be combined by the user in a variety

of ways for purposes determined solely by the user. No representations are

intended or made as to the suitability or engineering balance of the combination

of products determined by the user in his selection, nor as to the compliance with

regulations or standard practice of such combinations of components or products.

It is the responsibility of the knowledgeable, experienced users of the products

mentioned in this material to familiarize themselves with the appropriate laws,

regulations and safe practices that apply to these products, equipment that is

connected to these products, and materials that may be used with these

products.

ining of operators has

een performed and a safe work environment is provided.

ill utilize

their knowledge and expertise in the safe efficient use of these products.

ining of operators has

een performed and a safe work environment is provided.

ill utilize

their knowledge and expertise in the safe efficient use of these products.

It is the responsibility of the user to insure that proper trat is the responsibility of the user to insure that proper tra

Our company is proud to provide a variety of products to the abrasive blasting

industry, and we have confidence that the professionals in our industry w

Our company is proud to provide a variety of products to the abrasive blasting

industry, and we have confidence that the professionals in our industry w

OWNER’S MANUAL

RPH DUST COLLECTOR Page 1

1.3 Table of Contents

1.0 INTRODUCTION

1.1 Scope: This manual covers the assembly,

installation, operation and maintenance of RPH Reverse

Pulse Jet Dust Collectors. Some equipment may vary

slightly due to size and configuration. Drawings supplied

with this manual apply to the specific dust collector

provided. Use the drawings along with the manual, to aid in

the assembly of the collector and for ordering replacement

parts. The dust collector is one part of a larger system. This

manual is to be used in conjunction with all other manuals

provided with the equipment.

Introduction................................................................... 1.0

Assembly and Installation............................................ 2.0

Operation...................................................................... 3.0

Adjustments ................................................................. 4.0

Preventive Maintenance .............................................. 5.0

Service Maintenance ................................................... 6.0

Troubleshooting ........................................................... 7.0

Replacement Parts ...................................................... 8.0

1.4 Theory of Operation

1.4.1 The exhauster draws dust-laden air through the

ducting from the ventilated area, and through the filter

cartridges. As the air passes through the cartridges,

dust accumulates on the outer surface. Cleaned air

flows through the center of the cartridges, through the

exhaust ducting, and out the exhauster. The

accumulated dust is periodically released from the

cartridges by a pulse of compressed air. A typical

general arrangement with call-outs used in the manual

are shown in Figure 1.

1.2 Hazard Alerts

1.2.1 Clemco Industries Corp. uses signal words, based

on ANSI Z535.2-1991, to alert the user of a potentially

hazardous situations that may be encountered while

operating this equipment. ANSI's definitions of the signal

words are as follows:

This is the safety alert symbol. It is used

to alert the user of this equipment of

potential personal injury hazards.

Obey all safety messages that follow this symbol to

avoid possible injury or death.

1.4.2 RPH Dust Collectors utilize reverse pulse jet

cartridge filters. Compressed air used for the pulse is

released from the pulse manifold by quick-release

diaphragm pulse valves. At regular timed intervals the

sequence timer sends a signal to one of the solenoid

valves, releasing a pulse of air, which in turn opens the

respective diaphragm valve. The momentary opening of

the valve releases a burst of compressed air from the

manifold to the clean air side of the filter cartridges,

thus reversing the air flow to remove accumulated dust.

CAUTION

Caution used without the safety alert symbol

indicates a potentially hazardous situation

which, if not avoided, may result in property

damage.

1.4.3 Each solenoid and diaphragm valve is opened

in sequence until all cartridges have been cleaned

once, and then the cycle is repeated. If the switch on

the sequence panel is kept in the "on" position, the

sequence control panel energizes when the exhauster

is turned on, and stops when the exhauster is turned

off.

CAUTION

Caution indicates a potentially hazardous

situation which, if not avoided, may result in

minor or moderate injury.

1.4.4 The timers that control the "on" and "off" time of

the air pulse are located in the sequence control panel.

The "on" time should never be adjusted. The "off" time

controls the length of time between each pulse. The

shorter the "off" time, the more frequent the pulse

cycles. See Section 4.2.

WARNING

Warning indicates a potentially hazardous

situation which, if not avoided, could result in

death or serious injury.

1.4.5 The differential pressure gauge shows the

pressure difference between the dirty and clean side of

the filters. The gauge helps determine the proper

setting for the timer "off" time.

DANGER

Danger indicates an imminently hazardous

situation which, if not avoided, will result in

death or serious injury.

RPH DUST COLLECTOR Page 2

Figure 1

High Pressure Line

(Lower vacuum)

Low Pressure Line

(Higher vacuum)

Sequence Panel

Inlet Ducting

Supplied by user

Solenoid Bank

Access Covers

Diaphragm Pulse Valves Pressure Regulator

Com

ressed air inlet

Exhaust Ducting

Supplied by user

Filter Cartridge

Differential Pressure

Panel Assembly

Manifold Drain Petcock

Dust Drums

Dust Drum Lids

Pulse Manifold

2.1 Footing (Foundation)

2.0 ASSEMBLY AND INSTALLATION

2.1.1 The dust collector must be located on a sound

footing.

WARNING

Weight and bulk of the components may require

that erection and placement of the collector be

performed by personnel experienced with

handling structural steel, and able to safely

operate material handling equipment needed to

erect the collector. Failure to recognize and avoid

hazards associated with handling structural steel

could result in serious injury or death.

WARNING

All footings must be designed by a qualified

engineer. Inadequate footing could result in

hazardous shifting of the collector and ducting,

which could result in death or serious injury.

RPH DUST COLLECTOR Page 3

2.2 Assembly

CAUTION

All seams assembled on the job site must be

sealed to weather-tight condition. Use mastic

tape and caulking on all seams as shown on the

assembly drawings.

2.2.1 The degree of assembly depends on the size and

style of the collector. There may be exceptions; but they

are usually as follows:

• RPH-2, RPH-3, RPH-6 & RPH-8: Factory assembled,

each requires locating and anchoring to a sound footing,

and assembly of the exhauster and ducting.

• RPH-4, RPH-10, RPH-12, & RPH-16: Requires field

assembly of the leg/hopper assembly and body, and

assembly of the exhauster and ducting. It must be located

and anchored to a sound footing.

• RPH-20 and larger: Requires field erection of the

structural leg and frame assembly, assembly of the hopper

and body, ladder, hand rail, exhauster and ducting. It must

be located and anchored to a sound footing.

2.2.2 Erect the collector as shown in the enclosed

assembly drawings. Pay special attention to the orientation

of the inlet and outlet duct openings, access doors, ladder,

handrail, and exhauster location. If the collector is part of a

facility, use the general arrangement drawings for the

placement of the components.

2.3 Anchors

WARNING

All anchors must be calculated and specified by

a qualified engineer. Inadequate anchoring to

the footing could result in hazardous shifting of

the collector and ducting, which could result in

death or serious injury.

2.3.1 Anchor modules to the footing with anchors

specified by a qualified engineer.

2.4 Exhauster Assembly

NOTE: 3600 cfm and larger exhausters are floor mounted,

and require ducting from the collector, and an exhaust

stack with a damper adjustable from 0-80% closed.

Smaller exhausters are mounted on the collector body,

and do not require additional ducting.

2.4.1 Anchor the exhauster in position. NOTE:

Positioning of the exhauster must coincide with the

placement of the outlet ducting. Use temporary anchors

until the ducting is in place.

2.4.2 Attach exhaust stack and damper assembly to the

exhauster outlet.

2.5 Ducting

2.5.1 Clemco Industries Corp. does not usually supply

ducting, but does provide a general arrangement drawing

for suggested ducting.

2.5.2 The illustration in Figure 2 shows a typical ducting

and exhauster arrangement. The illustration is not to be

used to fabricate ducting.

CAUTION

All ducts, joints, and connections must be tight.

Any leaks will affect the overall performance of

the system.

The joint between the duct and exhauster

housing must be flexible, such as canvas or

rubber with band clamps. The ducting must be

self supporting. NO LOAD IS TO BE APPLIED TO

THE EXHAUSTER BY THE DUCTING.

Ducting must be supported sufficiently to place

no load on connecting equipment.

2.5.3 All duct work must be performed by qualified

licensed contractors familiar with industrial ventilation

practices, and must conform to local codes. Where state or

local codes conflict with each other or with specifications

by Clemco Industries Corp., the more stringent regulation

shall be followed.

RPH DUST COLLECTOR Page 4

Figure 2

Motor

Fan Housing

Flex Joint

Ducting Support

Exhaust Stack

with Damper

Dust Collector Outlet

Inlet Ducting

Supplied by user

Exhaust Ducting

Supplied by user

2.6 Electrical Connections

WARNING

Shorting electrical components could result in

death, serious electrical shocks, or equipment

damage. All electrical work, or any work done

inside an electrical panel, must be performed by

qualified electricians, and comply with

applicable codes.

NOTE: Wiring schematic for the sequence panel,

exhauster motor, control panel and other electrical

accessories are included when accessories are

furnished by Clemco Industries Corp. Refer to the Table

of Contents for the locations of the electrical wiring

schematics.

2.6.1 The dust collector should be controlled by a

separate switch to enable operation before and after all

other components in the system. Wire all other

components to start in series to prevent the overloading

of any component. The last segment in the system that

the abrasive reaches should start first and stop last. A

complete blast and recovery facility will have the dust

collector start first; followed by the abrasive cleaner,

bucket elevator, and floor recovery. Shutdown is in

reverse order.

2.6.2 Electrical connections are required for the

exhauster motor and sequence control panel. Unless the

collector is operated in conjunction with a Clemco-

provided system control panel, a customer supplied

starter is also required. When the exhaust fan is

connected, make sure it rotates in the direction of the

scroll.

2.6.3 Sequence panel wiring must enter through the

bottom of the panel to avoid potential leakage.

2.7 External Grounding

2.7.1 To dissipate static electricity, attach an external

grounded wire from an earth ground to the grounding lug

located next to the sequence panel.

RPH DUST COLLECTOR Page 5

2.9 Dust Containers

2.8 Compressed Air Connections

2.9.1 Attach a flex hose and dust drum lid to the bottom

of the dust hopper.

CAUTION

The air source for the filter pulse must be 35 to

50 degrees Fahrenheit dew point and be free of

any oil contaminants. If line air does not meet

this requirement, an optional air dryer is

recommended. Moisture or oil contaminants in

the pulse system will decrease cartridge life

and filtering efficiency

2.9.2 Place a dust drum under the dust lid and

securely attach the lid to the drum.

CAUTION

All flex hose connections made at the bottom of

the hopper and the lid must be air tight.

2.8.1 An air line must be supplied to the pressure

regulator located on the pulse manifold inlet. The size of

the line depends on the size of the collector. The

compressor and piping supplying air to the pulse

manifold must be large enough to provide at least 3 cfm

per cartridge. The air line should not be smaller in

diameter than the manifold inlet at the regulator.

3.0 OPERATION

WARNING

All persons operating this equipment must be

made aware of the hazards of abrasive blasting,

and handling toxic materials, including red lead

and silica dust. Toxicity and health risk vary

with the type of media, and dust generated by

blasting. Identify all material being removed by

blasting, and obtain a materials safety data

sheet for the blast media.

2.8.2 Purge the air supply line to remove moisture or

other foreign material before connecting it to the pulse

manifold.

2.8.3 Connect tubing to the differential pressure

indication panel as shown in Figures 1 and 3.

Figure 3

To Pulse manifold

Manifold Pressure Gauge

Differential Pressure Gauge

Low Pressure

High Pressure

In-Line Filter

1/4″Tubing

Snubber Fitting

Clean side of collector

Dirty side of collector

Snubber Fitting

3.1 The dust collector access covers must be

closed, and the dust drums secure when the dust

collector is in operation.

3.2 Initial Start-up

WARNING

Do not look into the exhauster outlet while the

fan is turning. Injury to the eye or face could

occur from objects being ejected from the

exhauster.

3.2.1 Check motor rotation by jogging the starter

(momentarily turn switch on and off). This will cause the

motor to rotate slowly. Look through the slots in the fan

housing on the end of the motor where rotation of the

fan can easily be observed. Proper rotation is indicated

by the arrow on the exhauster housing. The fan should

rotate toward the scroll.

RPH DUST COLLECTOR Page 6

CAUTION

Do not pulse new dust collectors or

replacement cartridges until the cartridges are

properly seasoned. See Section 6.2. Pulsing

unseasoned cartridges could cause premature

cartridge failure or decrease the efficiency of

dust collector.

3.2.2 With the sequence switch off, pressurize the

pulse manifold to 100 psi and check pneumatic

connections for leaks.

3.2.3 Turn pulse pressure to 20 psi and switch the

pulse sequence on. Check the air pulse and sequence

of the diaphragm pulse valves, solenoids, and panel

timer. After all items are checked, adjust the pulse

pressure to 70 psi, and turn the sequence switch off.

Do not switch the sequence panel on until the

cartridges are seasoned per Section 6.2.

3.3 Operational Start-Up

3.3.1 Make sure access doors are closed, and dust

drums are secure.

3.3.2 Check to make sure the sequence switch is "on".

CAUTION

Do not turn the sequence switch on until the

cartridges are seasoned. See Section 6.2.

3.3.3 Start the exhauster at the control panel.

3.3.4 Pressurize the pulse manifold and check the

manifold pressure.

3.4 Shutdown

3.4.1 Allow the system to run until all system

components are empty (see the accessory components

operation manual) and all areas ventilated are free of

airborne dust.

3.4.2 Turn off the exhauster.

3.4.3 Shut off the air supply to the pulse manifold.

3.4.4 Drain the pulse manifolds. The drain cock is

mounted at the bottom of each manifold. See Figure 1.

Drain whenever the air supply is turned off.

3.4.5 Empty all dust receptacles.

4.0 ADJUSTMENTS

4.1 Pulse Manifold Pressure

4.1.1 A pressure regulator and gauge is provided on the

manifold inlet to adjust pressure to 70 psi. An additional

manifold pressure gauge is mounted on the differential

pressure gauge panel to enable monitoring pressure from

ground level. The panel is usually mounted on one of the

dust collector legs. See Figure 3.

4.2 Pulse Sequence Control Panel and Timer

4.2.1 A toggle switch mounted on the sequence control

panel cover (located on the dust collector stand), enables

or disables the sequencer. If the switch is "on", the pulse

sequence will automatically start whenever the dust

collector exhauster is started. If the switch is "off", the pulse

sequence will not occur. The switch should be left "off" (no

pulse) until the cartridges are seasoned. See Section 6.2.

4.2.2 The timer is factory set at 40 seconds "off" and

15/100 of a second "on". Every 40 seconds, one filter bank

is pulsed in sequence until all filters have gone through a

cycle.

4.2.3 As the filters cake with dust, the pulse may not

clean them well enough to bring the differential pressure

gauge below the recommended changeover pressure of

4". A constant reading higher than 4" is an indication that

more frequent pulse cycles or higher pressure are needed.

When the differential pressure gauge shows a constant

pressure difference greater than 4", adjust the "off" time

setting by half. DO NOT ADJUST "ON" TIME. Increasing

on time will consume more air, but will NOT increase

cleaning efficiency.

4.2.4 When the frequency of the pulse cycles will not

lower the differential pressure to less than 4", or if a

decrease in the efficiency is noted, increase pulse

pressure in increments of 10 psi until the maximum of 100

psi is reached.

4.2.5 When the frequency of the pulse cycles and

higher pulse pressure will not lower the differential

pressure below the changeover pressure of 4" w. c., the

filter cartridges should be replaced, and the timer "off" time

should be reset to 40 seconds, and pressure set to 70 psi.

See Section 6.1.

RPH DUST COLLECTOR Page 7

5.0 PREVENTIVE MAINTENANCE

WARNING

Make sure the following conditions are met

before performing any maintenance on the

collector.

•Turn off compressed air supply and drain air

from pulse manifolds.

•Turn off sequence control switch.

Failure to observe the above warnings could

result in serious injury from the sudden release

of trapped compressed air or the operator

loosing balance.

•Always wear a properly fitted and

maintained, NIOSH approved respirator, eye

protection and safety clothing when

servicing dust laden areas of the dust

collector.

Failure to do so could result in serious eye

irritation and lung disease or death. Toxicity

and health risk vary with type of media, and

dust generated by blasting. Identify all material

that is being removed by blasting, and obtain a

materials safety data sheet for the blast media.

5.1 Daily

5.1.1 Empty dust drums.

NOTE: Check dust drums daily until the dust collection

rate is determined. At that time setup a program to

empty the drums before they are 2/3 full. Dust should

never accumulate in the hoppers.

5.1.1.1 Empty and/or replace the drums, ensuring that

the drum lids are secure.

5.1.2 Check the exhaust air during a pulse cycle.

5.1.2.1 If dust is emitting from the exhauster, filters are

leaking or damaged. Check immediately. To determine

which cartridge in leaking, turn the sequence switch off,

open the top access door and check the inside of the

collector for dust trails. NOTE: A small amount of dust

egress is normal for a short period when cartridges are

new.

5.1.3 Check the differential pressure gauge at least

once daily, and more often under dusty conditions. Turn

the sequence switch "on" or "off" as necessary to

maintain optimal differential pressure of 2" to 4". If the

reading is continually high (greater than 4"), adjust

pressure and/or sequence timing per Sections 4.1 and

4.2.

5.2 Weekly

5.2.1 Check the inside of the collector for moisture. If

moisture is caused by leaks, repair immediately.

5.2.2 Clean the differential pressure gauge in-line dust

filter located behind the gauge panel. See Figure 3.

6.0 SERVICE MAINTENANCE

6.1 Replacing Filter Cartridge

WARNING

Make sure the following conditions are met

before performing any maintenance on the

collector.

•Turn off compressed air supply and drain air

from pulse manifolds.

•Turn off sequence control switch.

Failure to observe the above warnings could

result in serious injury from the sudden release

of trapped compressed air or the operator

loosing balance.

•Always wear a properly fitted and

maintained, NIOSH approved respirator, eye

protection and safety clothing when

servicing dust laden areas of the dust

collector.

Failure to do so could result in serious eye

irritation and lung disease or death. Toxicity

and health risk vary with type of media, and

dust generated by blasting. Identify all material

that is being removed by blasting, and obtain a

materials safety data sheet for the blast media.

6.1.1 Lock out and tag out the compressed air supply

and electrical power.

6.1.2 Empty the dust receptacles.

6.1.3 Open the top access door.

6.1.4 Remove the wing nuts securing the filter hold-

down plate.

6.1.5 Remove the hold-down plates and venturi tubes.

RPH DUST COLLECTOR Page 8

6.1.6 Remove all filter cartridges. A small amount of

force may be necessary to loosen the seal of the filter

gasket.

7.0 TROUBLESHOOTING

WARNING

6.1.7 When all filters are removed, clean the inside of

the collector to remove loose dust or hardened dust clods,

particularly from the cartridge sealing surface, and the

clean-air side (top side) of the cartridge sheet.

Shut down the collector immediately when dust

emits from the exhauster. Check to make sure

filters are correctly seated and not worn or

damaged. Prolonged breathing of abrasive dust

and blasting by-product dust could result in

serious lung disease or death. Short term

ingestion of toxic dust such as red lead, poses an

immediate danger to health. Identify all materials

that are to be removed by blasting, and obtain a

material safety data sheet for the blast media.

6.1.8 Install new filter cartridges; center each cartridge,

install venturi tube, and secure with hold-down plate as

each cartridge is installed.

6.1.9 If necessary, replace the gasket on the access

door. Close the access door and secure.

6.1.10 Reset timer "off" time to 40 seconds, and set

pulse pressure to 70 psi.

7.1 Collector Not Pulsing

6.1.11 Turn the sequence panel off and season

cartridges per Section 6.2. 7.1.1 Check the manifold pressure gauge. If low,

check the compressed air supply; look for a closed

supply valve.

6.2 Seasoning Cartridges

7.1.2 Check function of the pressure regulator located

on the pulse manifold inlet.

6.2.1 New cartridges must be seasoned. Cartridges are

seasoned by letting a dust cake develop on the filter media

before starting the pulse cycle.

7.1.3 Make sure the sequence switch located on the

panel cover is "on".

6.2.2 Operate the dust collector without pulsing

(sequence switch turned off) until the differential pressure

gauge reads the recommended changeover pressure of

4". At that point turn on the sequence switch to start the

pulsing cycle.

7.1.4 Check the fuse in the sequence control panel.

Replace as necessary.

7.1.5 Have a qualified electrician check for electrical

malfunction; check the supply voltage to the pulse

sequence board. Check outlet voltage to solenoids.

6.3 Tube fittings

7.2 Some Cartridges Not Pulsing

6.3.1 If it becomes necessary to remove or replace the

tubing between quick-release valves and panel, be sure

the tubing does not bottom out in the fitting. If the tubing is

inserted too far into the fitting it will block the air passage,

and cause the pulse to malfunction.

7.2.1 Solenoid defective. Have a qualified electrician

check for electrical malfunction.

7.2.2 Check the diaphragm pulse valves.

7.2.3 Check for blockage in the tubing between the

diaphragm pulse valve and solenoid assembly.

7.3 Pulse Is A Steady Stream Of Air Instead Of A

Quick Pulse.

7.3.1 Check for a leak or split in the tubing between

the diaphragm pulse valve and solenoid assembly.

RPH DUST COLLECTOR Page 9

7.3.2 Solenoid remaining in open position. Have a

qualified electrician check for electrical malfunction, clean,

or replace.

8.0 REPLACEMENT PARTS

Refer to the enclosed assembly drawings for replacement

parts for specific dust collectors. Any replacement parts

that do not have a stock number should be ordered by

referencing the Job Order Number, drawing number, part

description, location, and quantity

7.4 Exhauster Not Running

7.4.1 Exhauster overload could be tripped. Have a

qualified electrician reset and check for overload. 8.1 Differential Pressure Panel Assembly, Figure 4

Item Description Stock No.

7.4.2 Make sure that the main disconnect is in the

"on" position.

1. Gauge, pressure .......................................... 19150

2. Gauge, differential pressure ........................ 10188

7.4.3 Motor faulty. Have a qualified electrician check for

electrical malfunction. 3. Snubber fitting .............................................. 15786

4. Filter, in-line dust ......................................... 23415

5. Fitting, 1/8" NPT straight x 1/8" barb ........... 11732

6. Fitting, 1/8" NPT-F x 1/4" tubing .................. 15703

7.5 Excessive Differential Pressure

7. Elbow, 1/8" x 90obrass st. ........................... 03993

8. Fitting, 1/8" NPT elbow x 1/8" barb .............. 11733

7.5.1 Valves may not be pulsing properly. See 7.1.

9. Fitting, 1/4" NPT elbow x 1/4" tubing ........... 03428

10. Tubing, 1/8" urethane, Specify ft. req. ......... 12475

7.5.2 The differential pressure gauge lines may be

plugged with dust. Check and clean. 11. Fitting, 1/4" NPT female bulkhead ............... 05605

12. Bushing, 1/4" NPT x 1/8" NPT brass ........... 02010

13. Tubing, 1/4" OD, specify feet required ........ 15892

7.5.3 Make sure the tubing has not been inserted so far

into the tube connection to block the tube ends.

7.5.4 The in-line dust filter may be blocked. Check and

replace.

7.5.5 Snubber fitting blocked with dust. Clean or

replace. See Figure 3.

7.5.6 The sequence "off" time may need adjusting. See

Section 4.2.

7.5.7 The filter cartridges may need to be replaced. See

Sections 4.2. and 6.1.

7.6 No Reading on Differential Pressure Gauge.

7.6.1 Check to make sure the low and high pressure

lines have not been reversed. See Figure 3.

7.7 Dust Emitting From Exhauster.

7.7.1 Check for loose or damaged filter cartridge.

1512

Figure 4

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