Camfil DCU OM Manual v1.pdf

ACTION TARGET

3411 Mountain Vista Pkwy

Provo, UT 84606, USA

CAMFIL DCU OPERATION & MAINTENANCE MANUAL

REVISION 1.0

DUST COLLECTION UNIT

CAMFIL DCU OPERATION & MAINTENANCE MANUAL

COPYRIGHT © 2020 Action Target

All Rights Reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, mechanical, electronic, photocopying, recording, or otherwise without the prior written permission of Action Target. For information or licensing, address correspondence to 3411 Mountain Vista Parkway, Provo, Utah 84606, USA.

GENERAL INSTRUCTIONS

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REVISION RECORD

REV DATE BY NEW/REVISED SECTIONS

1.0 07/27/2020 Klay Ashby, Senior Technical Writer

New manual

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TABLE OF CONTENTS

GENERAL INSTRUCTIONS

GETTING HELP

HOW TO USE THIS MANUAL

DOCUMENT CONVENTIONS

ADDITIONAL RESOURCES

TOOLS & EQUIPMENT REQUIRED

TOOLS AND EQUIPMENT

MATERIALS

PRODUCT INFORMATION

ABOUT THE CAMFIL DCU

SYSTEM COMPONENTS

DUST CONTAINMENT UNIT

FILTER BANK

COLLECTION MANIFOLD

BLAST GATE

FILTERS

BROKEN BAG DETECTOR

REMOTE OPERATION SWITCH

SAFETY & LIABILITY

LIABILITY

PERSONAL PROTECTION EQUIPMENT

HEAVY LIFTING

PRECAUTIONS

LOCK-OUT / TAG-OUT REQUIREMENTS

OPERATION

DESCRIPTION AND OPERATION

AIR FILTERING OPERATION

FILTER CLEANING CYCLE

REMOTE START OPERATION

MAINTENANCE

OVERVIEW

RANGE MAINTENANCE SCHEDULE

SERVICE WARNINGS

PURGE COMPRESSOR VALVE

AIR COMPRESSOR OIL LEVEL

DRUM REPLACEMENT

FILTER REPLACEMENT

DUST REMOVAL

SERVICING THE BLOWER AND MOTOR SYSTEM

DIAGNOSING AND FIXING BROKEN BAG ALARMS

TROUBLESHOOTING

TROUBLESHOOTING THE DCU

TROUBLESHOOTING THE INTEGRATED CONTROLLER

TROUBLESHOOTING THE BROKEN BAG DETECTOR

REPLACEMENT PARTS

FILTERS

OTHER ITEMS

HARDWARE

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GETTING HELP

If you have questions or need assistance, please contact Action Target technical support at

(888) 377‑8033.

HOW TO USE THIS MANUAL

Read this manual BEFORE using the product to ensure safe operation. Use this manual in conjunction with range drawings—if questions arise, the drawings prevail in all cases.

DOCUMENT CONVENTIONS

This manual uses the following conventions to highlight important information:

Safety tips offer guidance to help you protect you and others.

Warnings indicate a potential risk of injury or damage to equipment.

Notes call attention to important or helpful information.

ADDITIONAL RESOURCES

Videos of each step of the DCU Assembly and Installation are available on the Camfil website at:

https://camfilapc.com/resources/videos/ https://camfilapc.com/resources/videos/

TOOLS & EQUIPMENT REQUIRED

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TOOLS & EQUIPMENT REQUIRED

TOOLS AND EQUIPMENT

TABLE 1: TOOLS

Cartridge removal tool

MATERIALS

TABLE 2: RECOMMENDED SERVICE PARTS LIST

DESCRIPTION PART NO. QTY

Replacement filters See Table 5 Varies

PRODUCT INFORMATION

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ABOUT THE CAMFIL DCU

The Action Target Camfil Dust Collection Unit (DCU) removes airborne particulates exhausted from the range to prevent them from entering the atmosphere or recirculating back into occupied range areas.

As the owner or operator of this equipment, you have an important responsibility to safely operate and maintain the system. The unit will require moderate attention to keep it in good operating condition.

This manual has been prepared to aid you in that effort. This manual may reference various components that are not part of your system. These references are included in the interest of fully describing typical systems with all available options.

This manual covers the operation and maintenance of your Action Target / Camfil DCU. This air cleaning equipment eliminates lead dust and contaminants from your range, making it a healthier and safer workplace. This unit has been assembled using only quality materials and labor. This machine has been checked to make sure that it is operational for you at the time of installation.

SYSTEM COMPONENTS

FIGURE 1: MAIN COMPONENTS OF DCU

DUST CONTAINMENT UNIT

The Action Target / Camfil Dust Control Unit (DCU) is a primary lead containment system designed to reduce lead particulate emissions in ranges. This system creates a negative net pressure inside the containment chamber, allowing air to flow into the chamber entrance and disturb lead and other particulates. The DCU then filters the particulates from the air, depositing the collected matter in a canister for recycling or disposal. The clean, filtered air is then expelled into the atmosphere. The DCU consists of the following major components (see Figure 1), including:

Blower motor Filter bank Collection canister Collection manifold

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FILTER BANK

Inside the filter bank, air is passed through a group of filter cartridges. These filters are designed to process dry air only. If water is introduced into the filtration system by any means, the filters may be destroyed. Such damage will break or clog the filter. Range owners should maintain a supply of replacement filters on hand in case of a filter failure. If no failures occur, the spare filters can be used at the next regular replacement cycle. Replacement filters are available from Action Target and are not necessarily provided as a part of your original system. Wear appropriate personal protection equipment (Tyvek suit and full-face respirator) when changing filters.

COLLECTION MANIFOLD

The collection manifold consists of a main collector tube that is fed by individual tubes connecting to each bullet trap chamber module. The number of individual chambers varies according to the range design, so the main collector tube, filter bank, and blower will be sized accordingly.

BLAST GATE

A blast gate is provided where each individual tube enters the main collection tube. These gates are adjustable to vary the amount of air flow drawn off each bullet trap chamber. The gates are adjusted at the time of installation by a factory installer using a flow sensing device inserted at the calibration ports.

Generally, these gates should not require adjustment by the user.

FILTERS

Inside the filter bank, air is passed through a group of filter cartridges. These filters are designed to process dry air only. If water is introduced into the filtration system by any means, the filters may be destroyed. Such damage will break or clog the filter. The user should maintain a supply of replacement filters on hand in case of a filter failure. If no failures occur, the spare filters can be used at the next regular replacement cycle. Replacement filters are available from Action Target and are not necessarily provided as a part of your original system.

BROKEN BAG DETECTOR

Most ATI Camfil DCU’s are equipped with a broken bag detector. This device will alarm and shut the DCU down if there is dust detected in the output stream of the DCU. This will help prevent lead dust contamination of the surrounding area in the event of a failure in the DCU filtering.

REMOTE OPERATION SWITCH

ATI Camfil DCU’s may be equipped with an optional remote start switch. This switch allows the DCU to be started via a remote switch located in a control room or other common area.

SAFETY & LIABILITY

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LIABILITY

Action Target is not responsible for injury or damages caused by the improper use of its products.

Further, Action Target does not claim that the service and repair procedures in this manual are inherently safe. These procedures follow the absolute minimum safety standards you should consider-----depending on your setup, you may need to combine protective measures to protect yourself from lead and/or other contaminants.

PERSONAL PROTECTION EQUIPMENT

Wear protective clothing when replacing product parts, including:

Tyvek suit and full-face respirator: Wear when servicing the chamber or cleaning the trap.

Metatarsal steel-toed shoes: Help prevent a foot injury if you drop a component.

Gloves: Minimize injury associated with pinch points and reduce exposure during cleaning operations.

Eye protection: Wear always.

Hearing protection: Wear when noise exposure exceeds 85 decibels on the A scale (dBA).

HEAVY LIFTING

When lifting heavy product components, practice proper lifting technique:

1. Place your feet shoulder-width apart, with one foot slightly in front of the other.

2. Squat down, bending at the hips and knees only.

3. Maintain good posture by looking straight ahead, keeping your back straight, and pushing your chest out and shoulders back (this helps keep your upper back straight while creating a slight arch in your lower back).

4. Slowly lift by tightening your stomach and straighten your hips and knees (do not use your back).

Keep your back straight and do not twist as you lift.

5. Hold the load as close to your body as possible.

6. Use your feet to change direction and take small steps. Lead with your hips, keeping your shoulders in line with your hips as you move.

7. Squat with your knees and hips when setting down the load.

4.3.1 AVOID THE FOLLOWING

1. Bending forward to pick up heavy objects.

2. Lifting a heavy object above shoulder level.

3. Twisting or turning your body while lifting or holding a heavy object.

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4.3.1.1 FURTHER INFORMATION

For more information about technique of proper lifting of heavy materials, visit the Occupational Safety and Health Administration (OSHA) website:

https://www.osha.gov/SLTC/etools/electricalcontractors/materials/heavy.html

PRECAUTIONS

A blast gate is provided where each individual tube enters the main collection tube. These gates are adjustable. Wear protective clothing and safety glasses when handling collection filters or servicing the dust collector.

Disconnect power before servicing.

Replace all access panels before operating.

Electrical connections and repairs should only be made by qualified personnel and be in accordance with local and national codes and regulations.

Keep flammable materials and vapors, such as gasoline, away from dust collector.

The unit should be inspected frequently, and dirt removed to prevent excessive accumulation which may result in flash-over or fire damage.

The DCU system should not be used to support personnel or material.

Operate only in a safe and serviceable condition.

LOCK-OUT / TAG-OUT REQUIREMENTS

Control of this equipment must be in accordance with OSHA Standard 1910.147 “Control of Hazardous Energy (Lock-Out / Tag-Out)”. This standard “requires employers to establish a program and utilize procedures for affixing appropriate lock-out / tag-out devices to energy isolating devices and to otherwise disable machines or equipment to prevent unexpected energizing, start-up or release of stored energy in order to prevent injury to employees.”

For further information on Lock-Out / Tag-Out requirements, see your company’s Safety Director or refer to OSHA Standard 1910.147.

Before inspecting or servicing this equipment perform an approved Lock-Out/Tag-Out procedure on the electrical service, the compressed air (or other gas) supply, or any other energy source.

https://www.osha.gov/SLTC/etools/electricalcontractors/materials/heavy.html

OPERATION

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DESCRIPTION AND OPERATION

The Action Target / Camfil DCU is a high-efficiency cartridge dust collector designed to eliminate airborne dust as it is generated. Contaminants are captured at the source(s), then conveyed through ducting to the cartridge filter section (dirty air section) where the dust is collected. Clean air is then discharged from the unit through the clean air discharge.

Incoming dust-laden air enters the inlet plenum through a baffle that forces large and heavy particles to drop out of the air stream and fall into the hopper. The clean air passes through the filter media from the outside to the inside of the filter cartridge and exits through the open top of each filter cartridge.

The air then flows from the filters into the clean-air plenum, where it enters the fan inlet and is exhausted. The dust is captured on the outside surface of the filter media. There are two primary modes of operation—the air filtering operation and filter cleaning cycle. Both modes of operation are shown in Figure 2.

FIGURE 2: DCU OPERATION MODES

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AIR FILTERING OPERATION

The filter media can be made of several different fabrics and materials depending on the application.

However, the high efficiency of these cartridges is due to the dust layer or “cake” formed on the surfaces of the media. The media primarily provides a surface on which dust particles collect a combination of these mechanisms results in formation of the dust cake on the filter and eventually increases the resistance to air flow. The filter must be cleaned periodically. A balance must be maintained between having some dust cake formation to improve efficiency and an acceptable increase in pressure drop. A timer controller or Magnehelic gauge, monitoring the differential pressure (DP) and pulsing accordingly, can maintain the dust cake with minimal increase in pressure.

Clean, filtered air rises from the center of the Gold Cone cartridge, through the clean air plenum and into the fan, where it is exhausted. Dust laden air enters the inlet of the collector. The baffle forces large or heavy particles to drop into the hopper. Dust collected on the cartridges drops into the hopper and is collected in a discharge device.

If your DCU is not equipped with a remote start switch, all DCU operations are done from the control on the door of the control box. The settings for the controls on the box for normal operation should be (see Figure 3):

1. Master Control Switch (1 on Figure 3): This should be in the ON position for normal operation.

Turn this to OFF for servicing of the control box (see lock-out / tag-out requirements above.)

2. Pulse Cleaning Control Selector (2 on Figure 3): This should be set to the CLEAN AT HIGH PRESSURE setting for normal operation.

3. Filter Pressure Drop Display (3 on Figure 3): This display shows the pressure across the filters of the DCU unit. This indicates the efficiency of the system and state of the filters. Under normal operation the pressure drop should be between 0.5 and 3.0 in of water (WC). See Filter Cleaning Cycles below for more information.

4. Blower Switch (4 on Figure 3): This should be set to HAND or MANUAL for normal operation of a DCU not equipped with a remote start switch. For DCU’s with a remote start switch, the blower switch should be set to AUTO or REMOTE.

5. Control Power ON Push-Button Switch (5 on Figure 3): Push this switch to turn the DCU and begin normal filtering operation.

6. Blower Running Light (Item 6 on Figure 3): This light should be illuminated when the blower is in operation.

7. Broken Bag (Push to Reset) (Item 7 on Figure 3): This light should be OFF under normal operation. If the light illuminates, the broken bag detector has detected dust particles in the exhaust stream. Follow the procedures in section 6.10 below to diagnose and repair broken bag alarms before resetting this switch.

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FIGURE 3: DCU CONTROLS

FILTER CLEANING CYCLE

The Gold Cone cartridge elements are sequentially cleaned by back flushing with air. This momentary airflow reversal is induced by a short burst of compressed air. The air is released from the compressed air reservoir by a fast-acting, high-flow diaphragm valve. This “pulse” of air dislodges the accumulated dust from the filter element. The dislodged dust then drops into the hopper or collection drawers. Each pulse cleans a series of filter cartridges leaving the remaining cartridges available to continue filtering the ventilation air. This allows the cleaning to take place without the need to stop the ventilation system.

The filter cleaning cycles are controlled by the settings on the pulse cleaning control. These are normally set to start performing cleaning cycles if the pressure goes above 3.0 in of water. The DCU will continue to operate cleaning cycles at a set interval until the pressure drops below 2.5 again. If your DCU continues to perform cleaning cycles for an extended period (i.e., more than a few hours) and the pressure doesn’t drop below 2.5, replace the DCU filters.

REMOTE START OPERATION

If your DCU is equipped with a remote start / stop switch, the day to day operations of the DCU will be controlled by this switch. For the remote start switch to operate the DCU correctly, the blower switch on the DCU control panel (See Figure 3 above) needs to be set to the AUTO or REMOTE setting. Once this is done, the DCU can be started by simply pushing the start button on the remote start switch. The light on the switch will illuminate when the fan motor is running. To turn the DCU off, push the off button (on 2-button switches) or push the start button a second time (on single button switches) on the remote start switch.

4 6 5

MAINTENANCE

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OVERVIEW

Establish routine inspection and maintenance of the DCU to ensure ongoing maximum operating performance.

RANGE MAINTENANCE SCHEDULE

Perform the maintenance procedures listed in the Dust Collection Unit (DCU) section of the Range Maintenance Schedule and record maintenance performed in the Range Maintenance Log.

Maintenance procedures listed in the Range Maintenance Schedule that require supplementary information have been included in this section.

The maintenance schedule (high or standard) that a range should follow is determined by the number of days it takes to fill the lead collection containers (drums or canisters) as outlined in Table 1 below.

FIGURE 3: DCU MAINTENANCE SCHEDULE

FOLLOW MAINTENANCE SCHEDULE HIGH STANDARD

Ranges with a BCS Auto 55 (screw conveyor system): Average time to change a 55-gallon lead collection drum (change when 2/3 full)

1-10 days 11+ days

Ranges with a BCS Basic 3 (“bucket” system): Average time to change a 3.5-gallon lead collection canister (change when filled to 2-gallon mark):

1-20 days 21+ days

Ranges with a BCS Deluxe 20 (20-gallon drum): Average time to change ALL 20-gallon lead collection drums (change when 80% full or when lead is at a depth of 16 inches):

1-90 days 90+ days

Adjust maintenance schedule if range use varies. New ranges should follow the high maintenance schedule until use is determined.

SERVICE WARNINGS

Read and follow all the caution instructions below before servicing the DCU.

1. Airborne lead is generally present in the area surrounding the bullet trap. Always wait a minimum of 15 minutes after rounds have been fired and collection or ventilation systems have been turned off before entering the trap area. This allows lead dust to settle on the ground where it is easier to collect.

2. Wear appropriate personal protective equipment (PPE) designed for lead protection (e.g. Tyvek suits, full face respirators, eye protection, and foot/hand/head coverings). See Section 2 for personal protection equipment information.

3. Disconnect and lockout electrical power to the unit and control panel.

4. Close off and slowly bleed the compressed air supply from the air manifold reservoir. Air manifold reservoir pressure should be reduced to 0 PSIG (0 BAR).

5. Collected dust may be hazardous. Consult proper authorities for handling and disposal.

6. Collected dust may be a potential fire hazard. Do not perform welding, grinding, or operations involving open flames without fire protection measures in place. Disposal of collected dust must be according to federal, state, and local regulations and all appropriate authorities before servicing your unit.

A wet wash down procedure is not recommended on ranges equipped with a DCU as direct introduction of water into the DCU would damage the filters. Water droplets on the broken bag detector can also cause broken bag detector alarms.

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PURGE COMPRESSOR VALVE

There is generally an air compressor which provides pressure for the filter cleaning cycle. Check to see that the air pressure is in the range of 90 to 100 psi. There should be a purge valve on the bottom of the compressor, somewhere in the air line, or both. Each day, prior to use of the system, open this purge valve momentarily to see that compressed air blows out. If water comes out, continue purging until all water has been blown out.

AIR COMPRESSOR OIL LEVEL

To check the oil level in the air compressor:

Remove the plug at the base of the cylinder head. Oil should be clearly visible near the base of the threaded hole.

Add oil if necessary. If oil needs to be added more frequently than once per month, the rings on the compressor may be worn. This may be blowing oil into the filtration system and compromising the integrity of the filters. Repair the unit as soon as possible

DRUM REPLACEMENT

Do not let the dust storage drum overfill. This can cause poor dust collector performance and require extensive clean-up due to the overflow of dust when removing the collection container(s).

Turn off the dust collector (power to fan system and compressed air to cleaning system) and empty the dust storage drum as necessary to prevent dust from accumulating in the hopper(s). Empty the dust storage drum(s) when two-thirds full. If the hopper has a slide gate, close the slide gate before servicing the dust storage drum(s). The dust collector fan and compressed air cleaning systems do not have to be turned off if the hopper slide gate is closed prior to servicing storage drums. Remember to open the slide gate when the dust storage drum is replaced.

FILTER REPLACEMENT

Filters should be replaced with Gold Cone filters only. The Gold Cone filters have an expanded capacity due to the patented inner cone of filtration media. The inner cone provides uniform dispersion of back-pulsed air and opens more useable space for airflow in the dust collector. To order filters, contact ATI Customer Service at +1 (877) 852-2418 or visit the Action Target store at www.shop.actiontarget.com.

If the pressure drop readings on your DCU main display are above 5.0 in of water (WC) or your DCU continues to perform cleaning cycles for an extended period, replace the filters.

6.7.1 REPLACE CARTRIDGE FILTERS

Disconnect electrical power to the fan and control box. Disconnect compressed air service from the compressed air header. Perform an OSHA approved lock-out/tag-out procedure on these and any other energy sources.

Wear appropriate protective clothing when servicing dust collector. Before servicing dust collector:

Wear appropriate protective clothing when servicing dust collector.

Disconnect and lockout electrical power to the unit and control panel.

Close off and slowly bleed the compressed air supply from the air manifold reservoir. Air manifold reservoir pressure should be reduced to 0 PSIG (0 BAR).

Collected dust may be hazardous. Consult proper authorities for handling and disposal.

Collected dust may be a potential fire hazard. Do not perform welding, grinding, or operations involving open flames without fire protection measures in place. Refer to SECTION 3: of this manual for additional precautions.

Disposal of collected dust must be according to federal, state, and local regulations and all appropriate authorities before servicing your unit.

http://www.shop.actiontarget.com/

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1. Open the access doors at the front of the unit, swinging them out of the way.

2. Unlatch the clamp bars as shown in FIGURE 4 below. With your left hand, rotate the right clamp bar up and pull it toward you, until its locking tab clears the rectangular cut-out on the left clamp bar. With your right hand, rotate the left clamp bar up and push it away from you until its locking tab clears the rectangular cut-out on the right clamp bar. Rotate both clamp bars down until they are vertical and clear of the cartridge extraction path.

FIGURE 4: UNLATCH FILTER CLAMP BAR

3. Remove all dirty filter cartridges by sliding them off the clamp bar channels. Clean the surface of the tube sheet in the areas where the filter gasket forms a seal. To reach the inside cartridges, Camfil APC provides a telescoping extraction pole with a hook on the end (see Figure 5).

FIGURE 5: USE THE FILTER REMOVAL TOOL

4. Remove a new cartridge from the shipping carton, taking care not to cut or otherwise damage the filter media. Make sure the clamp bar handles are fully opened and will not interfere with the cartridge during installation. Grasp the new cartridge by the top metal pan and set it onto the clamp bar channels. Holding the cartridge level, slide it forward, pushing on the cartridge pan, do not push the media, taking care not to drag the gasket along the tube sheet. Push the cartridge in just far enough to leave room for the next cartridge to rest on the clamp bar channels. Repeat steps 4 and 5 until the row is full.

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5. To seal the new cartridges, repeat the instructions in Step 3 in reverse order. With your left hand, rotate the left clamp bar counterclockwise or up to between 80° and 90°. While pushing the left clamp bar away from you, rotate the right clamp bar clockwise or up, with your right hand. Insert the locking tab on the left clamp bar when it lines up with the rectangular cut-out on the right clamp bar. Release the left clamp bar. With both hands rotate the right clamp bar clockwise or up and pull it toward you, until the locking tab inserts into the rectangular cut-out on the left clamp bar (see Figure 28). The clamp bars must be bent slightly if the locking tabs do not stay inserted in the rectangular cutouts.

FIGURE 6: LATCHING FILTER CLAMP BAR

6. Repeat steps 2 through 5 until all the rows of cartridges are changed.

DUST REMOVAL

Do not let the dust storage drum overfill. This can cause poor dust collector performance and require extensive clean-up due to the overflow of dust when removing the collection container(s).

Turn off the dust collector (power to fan system and compressed air to cleaning system) and empty the dust storage drum as necessary to prevent dust from accumulating in the hopper(s). Empty the dust storage drum(s) when two-thirds full. If the hopper has a slide gate, close the slide gate before servicing the dust storage drum(s). The dust collector fan and compressed air cleaning systems do not have to be turned off if the hopper slide gate is closed prior to servicing storage drums. Remember to open the slide gate when the dust storage drum is replaced.

SERVICING THE BLOWER AND MOTOR SYSTEM

ELECTRIC SHOCK HAZARD! All electrical work should be performed by a qualified electrician in accordance with local electrical codes. Disconnect electrical power before installing or servicing any electrical component.

Refer to blower assembly Installation and Operation Manual provided with blower assembly for servicing requirements.

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DIAGNOSING AND FIXING BROKEN BAG ALARMS

The broken bag detector on your DCU will alarm and shut the DCU down if there is dust detected in the output stream of the DCU. This will help prevent lead dust contamination of the surrounding area in the event of a failure in the DCU filtering. If your DCU suddenly shuts down during normal operation, a broken bag detector alarm is the most common reason. Before resetting the alarm, you need to determine the cause for the alarm. Most broken bag detector alarms are due to a punctured or dislodged filter. Steps to diagnose the cause of a broken bag detector alarm are:

1. Remove the filters from the unit one at a time. See section 6.7 for filter removal steps and follow all safety guidelines. Pay close attention to the filter orientation prior to removing it. Make sure the filter was properly seated and the filter clamping bars were properly locked.

2. Examine each filter for signs of a puncture. Dust on the inside of the filter is good indication that the filter has a hole or puncture.

3. Check the lead level in the hopper. If the lead collection drum is not emptied when full lead can collect in the hopper and dislodge filters. Clean the lead out of the hopper either into the collection drum or into an empty drum if the attached drum is full.

4. Examine the clean sheet area of the DCU for any damage. This is the steel section between the bottom section of the DCU (the “dirty side”) and the top section of the DCU (the “clean side”).

Damage to this steel sheet is rare.

5. Replace all the DCU filters and ensure they are all seated correctly.

6. Remove any lock-out / tag-out items from the DCU and turn the master power switch back on.

Push the “Push to Reset” switch on the broken bag detector and start the DCU in normal operation mode.

7. Observe operation of the DCU for a minimum of 10 minutes to ensure the broken bag detector does not alarm again.

8. If the broken bag detector alarms again, you may have an equipment failure in the broken bag detector circuit. Contact Action Target or Camfil customer service for repairs.

Although moisture in the air will not affect the broken bag detector performance, actual moisture droplets on the broken bag detector probe located it the exhaust stream can affect the signal and cause the detector to set off an alarm. If you have reason to believe water has entered the exhaust side of the DCU (for instance, a hose was used to wash-down the DCU) this could be the cause for an unresolved broken bag detector alarm. Normally allowing the probe to dry for several hours will prevent further alarms.

TROUBLESHOOTING

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TROUBLESHOOTING THE DCU

TABLE 3: DCU

PROBLEM POSSIBLE CAUSES RECOMMENDED SOLUTIONS

Motor/blower won’t start or won’t stay running.

Blower rotation is reversed Reverse blower rotation

No voltage to system Check primary voltage to motor circuits for proper voltage on all legs.

Improper electrical wiring Check and correct internal motor wiring for proper connections based on the incoming line voltage at the motor junction box. check control voltage power (i.e., fuses, transformer, etc.).

Starter overloads are tripped Check for proper motor starter overload rating against full load amps on motor nameplate. adjust or replace overloads as required.

Hopper discharge open to atmosphere

Ensure drum is properly sealed against drum lid package. ensure drum lid package is properly installed.

Blower damper not properly adjusted

Check motor current draw and close volumetric control damper or silencer damper until amperage FLA is below full load rating of motor.

Low system static pressure Close dampers to increase static pressure or install orifice plate in a branch duct.

Dust emissions from clean air discharge.

Filters not installed properly Inspect and reinstall cartridge filters, gasket end first.

Filters are damaged Replace damaged filter(s) with new cartridge filter(s).

Filter access doors not installed properly

Remove and reinstall filter access door assembly.

Insufficient airflow Blower rotation is reversed Reverse blower rotation

Loose or open access. Remove filter access door assembly, verify filters are properly installed, gasket end first. Verify drum lid is installed properly

Volumetric duct dampers or blower outlet damper is not positioned properly

Adjust dampers to permit increased air volume

An inlet(s) is obstructed Inspect and clean all hoods and other machine connections.

Filter plugged Refer to troubleshooting procedures for continual pressure drop.

High Pressure Drop Cleaning mechanism not properly adjusted

Increase cleaning frequency Perform off-line cleaning Check performance of diaphragm and solenoids

(repair) Check performance of timer controller (adjust or repair) Check compressed air supply (should be 90 - 105 psi

Control Timer failure See actions following Integrated Controller Trouble shooting

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PROBLEM POSSIBLE CAUSES RECOMMENDED SOLUTIONS

Pulse Valve failure Check wiring between controller and solenoid valves

Check tubing between solenoid valves and diaphragms

Check diaphragms (replace or repair) Check solenoid valves (replace or repair

Blinding of Filter Media Check designed airflow against actual airflow, adjust damper accordingly

Check collection point vs. suggested collection points adjust

Minimize excess airflow, use appropriate ducting Change filter media type ( consult Technical

Services) Install overbags to prevent blinding Perform off-line cleaning Add more compartments or modules and filter media Evaluate dust to find correct Air-to-Cloth Ratio

(Camfil APC lab)

End of Cartridge service life Replace cartridges (service life is determined by the application)

Improper start-up of collector

Restart collector using suggested procedure in manual

Open damper fan slowly as system starts up Preheat the collector before start-up Use pre-coat dust to season the cartridges

Moisture in collector See section on moisture in collector

Temperature too high Measure air temperature in collector and compare to design

Use dilution air to reduce temperature in collector Install alternate media that can tolerate higher temperature

Inlet baffle plugging, causing high velocities

Check to find type of baffle (channels, abrasion resistant inlet velocities, inlet velocities plate, or none)

Remove plugged baffle Replace baffle with the appropriate style for application Reduce moisture in the collection system-see above

Moisture in collector Leaks in the collector and ducting

Check ductwork on inlet and outlet to assure good caulking

Check ductwork on inlet and outlet to assure tightened bolts

Check frame and panels caulking (re-caulk if necessary)

Check frame and panels for tightened bolts (replace or tighten)

Leaks in the collector Check ductwork for any leaks or punctures (repair or replace) Check door gasket for leaks (repair or replace) Install moisture resistant or washable cartridges Check hopper flange at corners and seam of module Check double or triple inlet where bolted to seam on multiple frames

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Water or moisture in compressed air supply

Open drain valve on air header to see if water comes out

Check to see if compressed air supply has an air dryer installed

Verify air dryer is rated for -40° dew point Replace desiccant in the dryer Replace dryer Install timed drain valve on header.

System is not purged after shutdown

Keep fan running for 5 to 10 minutes after process is shut down

Insulate the collector if it is to be located outside Install a bypass line to allow pre-heating of the collection system Install a heating system inside the collector Install moisture-resistant or washable cartridges

Wall temperature below dewpoint

If the collector is located outside, it must be insulated

Preheat collector before operation Purge collector after process shutdown Install a bypass line to allow heating of the system while off-line Install a heating system inside the collector Install moisture resistant or washable cartridges

Cold spots through insulation

Locate cold spots and repair insulation Eliminate direct metal line through insulation Install moisture resistant or washable cartridges

Low Air Pressure Regulator set too low Adjust regulator to 90-105 psi of compressed air Install a regulator or gauge on the air header if possible

Compressor too small (for total plan requirements)

Check Pulse Timer off setting. If currently set to 60 seconds, extend to 90 seconds

Repair leaks and reduce unnecessary loss of air Replace compressor with larger unit Add another compressor to system

Compressed air consumption too high

Look for leaks in the compressed air system (repair) Check to make sure air header drain valve is closed Check to make sure diaphragm is not stuck in open position

Restrictions in compressed air piping

Check compressed air line to be sure it is clean If a hose is run to the air header, be sure there are no kinks Check all valves in the line to be sure they are opened completely

Compressed air dryer plugging

Replace desiccant in the dryer Bypass dryer temporarily Replace dryer

Dust Bridging in Hopper Dust Stored in hopper Always keep the slide gate or discharge open Remove dust continuously Store collected dust in drums, bags, or bins instead of hopper Install bin - level indicator

Moisture in collector See sections following Moisture in Collector

Discharge opening too small Install compressed air purge (air sweep) equipment Install hopper with larger discharge opening Install bin-level indicator

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Media Failure End of cartridge service life Replace cartridges (service life determined by application)

High pressure drop See sections following High Pressure Drop

Moisture / Water Present See sections following Moisture in Collector

Temperature too high Measure air temperature in collector and compare to design

Use dilution air to reduce temperature in collector (change fans)

Install alternate media that can tolerate higher temperatures

Conveying velocity too great Reduce airflow, damper fan if possible Confirm appropriate location of pickup points and hoods Minimize excess air flow, use appropriate ducting Change media area or media type Perform off-line cleaning Change inlet baffle design (solid strike plate, perforated, etc.)

Add more compartments or modules

Compressed air too high during pulsing

Regulate pressure to 90-105 psi of compressed air Install a pressure gauge on air header to monitor supply pressure

Inlet air not properly baffled Install correct baffle (channel, abrasion resistant plate)

Replace channel baffle with abrasion resistant material

Channel baffle worn or missing

Replace channel baffle Replace channel baffle with abrasion resistant material

Poor Efficiency End of cartridge service life Replace cartridges (service life determined by application)

Insufficient filter cake formation

Use pre-coat dust for start-up Check for adequate airflow at collection points and hoods (adjust) Allow more time for collector to build dust cake; it may take weeks Reduce cleaning frequency Change media type or surface area in filter cartridge Use pre-coat to assist in the capture of other forms of dust

Wrong filter media used Replace cartridges with correct filter media for application

Cleaning cycle too frequent Check programming on controller and adjust accordingly

Check and calibrate Photohelic or Magnehelic gauge Increase the amount of time between pulse events Increase the “high” set point on the collector Refer to the appropriate section in manual for your type of controller

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Leaking of cartridges Check for puncture in media, see sections following Media Failure

Perform a colored trace dust test to discover the source of leak

Check for leaking gaskets, clean tube sheet to assure good seal

Check temperature, use appropriate media or use dilution air

Change media type or total area in cartridges Check for abrasion

Temperature too high Measure air temperature in collector and compare to design

Use dilution air to reduce temperature in collector Install alternate media that can tolerate higher temperature

Leaking gaskets Confirm correct placement of cartridges, prevent ramping of filters

Confirm locking mechanism is in the closed position Remove filters and clean tube sheet to assure a good seal If cam-bars are not bent, replace support brackets for cam-bars Replace cartridges

Cartridge cam-bars not sealing

Confirm correct placement of cartridges, prevent ramping of filter

Confirm locking mechanism is in the closed position If cam-bars are bent, replace cam-bars

Poor Airflow Fan malfunction Check to see if the fan is turned to the “on” position Check required fan power requirement vs. what is supplied Check that power supply is “hot” Incorrect wheel rotation, correct motor wiring Damage to fan wheel - replace wheel Wheel mounted backwards on shaft, rotate wheel orientation Temperature too high, replace motor for one better suited Bent shaft, replace shaft Broken or damaged belt; adjust, repair, or replace belt Build-up of dirt or dust, clean fan Bad or damaged bearings; lubricate, repair, or replace bearings Confirm correct motor starter is used Check condition and repair the motor starter Check that all fuses and switches are operational Check for faulty wiring or shorts in wiring Consult the fan manufacturer Replace fan/motor if necessary Refer to appropriate fan manual

Fan sized incorrectly Take airflow readings and compare to the design of application

Evaluate fan performance (fan curve) vs. design of application

Replace fan with larger or smaller unit, depending on application

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Motor Overloads Speed set too high on motor, slow motor down Fan over capacity, replace with larger fan Density of gas/dust above design, replace with larger fan Wrong direction of wheel rotation, rotate wheel orientation Shaft bent, repair or replace Poor alignment, realign motor and housing Bind on wheel in housing, repair and realign motor and housing Bearing wear; lubricate, repair, or replace bearings Temperature too high, replace motor for one better suited Build-up of dirt or dust, clean fan Short in wiring, repair or rewire fan Defective motor, replace Consult fan manufacturer

Air leaks in the collection system

Repair or replace any damaged ductwork or collection hoods

Replace missing screws, bolts, gaskets, or caulk Seal any holes or punctures in the system Damper any unused collection points

Plugged cartridges See sections following High Pressure Drop End of cartridge service life, replace cartridges Check and clean pulsing mechanisms Increase compressed air pressure or volume Eliminate moisture in collector Check and repair the timer / controller Inspect and clean inlet baffles Perform off-line cleaning of filter cartridges Install overbags Add more compartments or modules and filter media Increase filter media area or change filter media type

Duct sized incorrectly Perform a system balance to discover possible problems

Review duct design, adjust blast gates to designed settings

Rework ducts to achieve desired performance Poor inlet or outlet design, redesign for optimal performance Install new blower to compensate for poor airflow

Collection point incorrectly positioned

Reference: Industrial Ventilation — A Manual of Recommended Practice

Resize duct according to industrial standard Change hood type to improve collection performance Reposition collection point or hood to improve performance

Abnormal Noise Normal noise level of fan operation

Most Camfil APC provided fans range from 89 to 99 decibels to reduce sound levels, install a fan silencer

- Call Customer Service for a Quote.

Enclose fan in a foam lined housing Enclose the entire collector inside a separate room Relocate the collector away from production areas Consult manufacturer of fan

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Vibrating or resonance of ductwork

Support and brace ductwork, or improve existing supports

Tighten flanges between the collector and the ductwork

Tighten flanges between the fan and the ductwork Re-apply gaskets or caulk all the flanges Place rubber padding between ductwork and support structures Adjust fan speed and setting to minimize vibrations Consult ductwork installer

Housing of fan vibrating Damaged wheel, replace or repair wheel Damaged housing, replace or repair housing Broken or loose belt, repair or replace belt Worn coupling, replace coupling Broken or loose bolt or screws, replace or tighten bolts and screws Unstable foundation or supports, tighten or shim housing

Fan impeller hitting the inlet of the fan

Balance or adjust fan wheel Consult manufacturer of fan

Bad bearings in the fan Lubricate bearings Replace bearings Consult manufacturer of fan

Constant “Hissing” sound Compressed air being lost, check compressed air line connection

Diaphragm stuck open, check and repair diaphragm Check for air leak into system Check drain valve on air header, close if necessary

Electric “Humming” sound Defective starting relay, replace relay Replace motor starter Consult manufacturer of motor starter

Installation Problems Missing Parts Reference packing slip and inventory items (report missing items)

Loose parts will be shipped in a box placed inside the inlet plenum

Thoroughly check all boxes before discarding

Legs & cross-braces do not match holes

Consult manufacturing drawings for correct arrangement

Re-drill braces to match leg bolt holes Re-drill legs to match cross-brace bolt holes Contact Camfil APC to replace cross-braces

Bin vent flange doesn’t match hopper

Bin vent or hopper misaligned, rotate plenum 180°, install per match line stickers Wrong assembly procedure, insert bolts in corners, work to center Use alignment pins to match flanges during assembly Drill and tap new holes to match corresponding flange Flange bent during shipping, replace hopper

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Fan flange does not match top panel bolt pattern (top-mount fans only)

Wrong top panel, replace panel (if Camfil APC provided fan)

Drill or cut flange into blank top panel (if other than Camfil APC fan)

Use alignment pins to match flanges during assembly

Fan misaligned, rotate fan until flanges match

Hopper flange doesn’t match discharge device flange

Discharge device misaligned, rotate to match hopper flange

Wrong assembly procedure, insert bolts in corners, work to center

Use alignment pins to match flanges during assembly

Drill and tap new holes to match corresponding flange

Flange bent during shipping, replace hopper

Controller does not operate See section following Controller Failure Check for correct power supplied to control board

(correct) Check for off switches, breakers, or blown fuses

(replace or correct) Check for improper wiring, correct as needed Bad control board, replace if necessary Consult Customer Service (1-800-479-6801)

Collector leaks dust Locate and seal any dust leakage points in the collector

Caulk any leaking flanges or panels Insert any missing bolts or fittings Replace door gaskets if leaking Check and repair door lock mechanism if necessary Weld or caulk any holes or gaps in welded seems

Air header leaks Check drain plugs, close if open Check and repair diaphragm valves Check connection to compressed air supply line, repair if necessary

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TROUBLESHOOTING THE INTEGRATED CONTROLLER

TABLE 4: INTEGRATED CONTROLLER

PROBLEM RECOMMENDED SOLUTIONS

Lack of power Confirm that power is supplied to board, correct if necessary Confirm that power supplied matches board requirements Confirm all breakers and switches are in the ‘on’ position Check fuse, replace if necessary Check controls ‘ on / off switch, turn it to ‘on’ Replace control board

Fuse blown Replace Fuse Replace control board

Improper wiring Check to see if timer is indexing to all contacts Check output on all terminals Check wiring between controller and solenoid valves (repair) Check power connections to board (correct if necessary) Confirm the type of controller used and refer to appropriate section in this manual or the controller manual

Improper programming Confirm the type of controller used and refer to appropriate section in this IOM manual or the controller manual Confirm accurate number of terminals wired into the control board Confirm designed High and Low set points (adjust accordingly)

Bad control board Replace board; consult replacement part list for correct part number Consult Aftermarket (1-866-639-7151)

Bad magnehelic gauge (if applicable)

Confirm accuracy of the gauge, adjust as necessary Sensor hoses are backwards, switch connections of tubing Replace Magnehelic gauge; see replacement parts list for correct part number Consult Aftermarket (1-866-639-7151)

Moisture or contamination in control box

Confirm that the controller housing door is shut Confirm NEMA rating of housing and upgrade if necessary Remote mount controller away from the dust collector

Vibrations causing failure Locate controller indoors Consult Customer Service (1-800-479-6801) Remote mount controller away from the dust collector

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TROUBLESHOOTING THE BROKEN BAG DETECTOR

The ATI Camfil DCU is equipped with two different…