CARTRIDGE DUST COLLECTOR BASIC STARTUP AND OPERATIONS MANUAL
CONSOLIDATED STRIPPING & DERUSTING, INC.
942 INDUSTRIAL PARKWAY
PLAINWELL, MI. 49080-0120
Basic installation and operations manual for manual pulse cartridge dust collectors
Important note: It is not possible to list all of the potential hazards of dust control equipment or systems. It is imperative that this equipment be used by trained persons familiar with the potential for fire and explosion hazards associated with specific applications such as buffing lint, paper, wood, aluminum, magnesium dust, etc. Special care must be exercised in the installation, operation and use of all dust collection equipment where combustible or explosive materials are present. Under no circumstances should anything that could cause direct ignition be allowed to enter the collector such as a lit cigarette, or other ignited objects. Allowing live sparks or other red hot metal embers, such as those created by grinding or cutting ferrous metals, to be pulled into the dust collector has the potential to create a fire hazard.
Improper operation of a dust control systems may contribute to conditions in a work area that could result in severe personal injury and/or property damage. It is the customers responsibility to make certain that the selected equipment is appropriate for the intended purpose for which it is employed.
The dust collector will require electrical and compressed air connections before startup. All electrical connections must be done by a qualified electrician in accordance with all local codes. Motor rotation should be clockwise as viewed from the top of the motor looking down and towards the opening of the dust collector outlet. Proper rotation is required to achieve proper function of the unit. If the rotation is reversed suction will be substantially reduced.
Important note: These units require substantial startup power. At startup the motor may draw up to 10 times the rated load listed on the motor nameplate. It is important to size the electrical wire appropriately to prevent low voltage starving of the motor upon startup. Failure to follow these instructions will result in premature motor failure. If high startup voltages are undesirable or unavailable, it is recommended that an inverter drive or soft start motor starter be used. This will substantially reduce initial electrical requirements. As of Jan. 2008 all new models are now equipped with an inverter drive, soft start, variable speed electrical package as standard equipment. This makes the above warning only applicable to units purchased before Jan. 2008.
A motor starter is not required with these units. All new systems come complete with an inverter drive, soft start, and variable speed electrical package as standard equipment. No additional fusing or shutoff is required unless necessary to meet your local electrical codes. We suggest a manual knife blade type shut-off located directly at or near the unit to aid in maintenance of the dust collector if the main breaker is in excess of 50 feet from the unit.
All our auto pulse dust collectors require 90 -125 psi of clean and dry compressed air. Compressed air that contains large amounts of oil and or water will reduce the life expectancy of the filter cartridge(s). It is advisable to install a condensate trap at or near the unit to insure clean compressed air, free of oil and water. The air tank(s) can be located on either side of the unit as one stands in front of the dust collector. Each dust collector has one or more solenoid valves used to clean the filters. The solenoid valves are actuated via programmable sequential timer board system located on the upper clean air box. Compressed air enters the storage tank thru a 1/4 inch female ntp fitting located at the very bottom of the compressed air storage tank or a larger direct line can be added for faster tank filling if necessary.
Unless otherwise noted all units are indoor dust collectors. Do not install any unit outside unless it is necessary to do so. All outdoor units may require the addition of heat tape to the air tanks and supply lines to prevent water condensate from freezing during winter months. Unless it is absolutely required we recommend that units be placed outside only as a last resort and after much consideration. An auto pulse system will still require periodic attention to insure proper function. Placing a system in an area that is hard to access will hamper required periodic attention, especially during adverse weather conditions. Also, be sure to check with your local government for any required permits when placing any unit outside of a building. Careful consideration to these matters should be observed before installing an exterior unit.
Once electrical and compressed air connections have been completed, the unit is ready for test operation. The dust collector should power-up to full speed within 30 seconds. If the motor is lagging or laboring, the electrical connections or power supply should be double checked. Recheck all electrical motor connections and power supply.
Long runs of duct work with many 90 degree bends will reduce the capacity of the system. We recommend that the unit be placed as close to the source of dust as possible and that as few 90 degree elbows be used as necessary. If distances over 50 feet and/or with several elbows are required, the diameter of the main duct line to the dust collector may be increased by two inches to help prevent reduced capacity. It is important not to increase the diameter of the duct work to the point that the velocity in the duct will no longer support dust movement. This may cause the dust to settle in the duct work creating an increased risk of fire.
The dust collection unit will begin to loose suction as the filter load increases and the dust cake becomes thicker. The filter cartridges should be pulse cleaned as often as required to restore system air flow to optimal levels. Over pulsing of filters will reduce life expectancy. As factory set, the auto pulse package will handle most high loading applications. For light applications it may only be necessary to trigger the pulse system once per day or less your circumstances may dictate.
Filter cartridge replacement should be done if visible dust is seen coming out of the outlet at any time. A sure sign a filter has developed a rupture is a fine haze visible around lighting fixtures near the dust collector. When working properly, no visible dust should be airborne and a crystal clear condition should exists around lighting fixtures around the unit. As standard equipment, all cartridges have a minimum 99.7% efficiency @ 0.5 microns. Thus for every 100 pounds of 0.5 micron dust collected, less than 0.3 lbs would be dispensed into the air, at 1 microns 0.2 lbs and at 2 microns 0.0 lbs. This is often referred to as grain loading. This system is not 100% efficient against particles below 0.5 microns.
On average, filter replacement is normally required every 1 to 3 years with regular daily use. Filter replacement will require approximately 1/2 hour per filter. When filters will no longer support acceptable air flow, after appropriate pulse cleaning, then filter replacement is required. Filtration of oil or mist laden air will degrade filters and dirty or wet compressed air will also decrease the life expectancy of the filters.
Important note: Lockout procedures must be followed before filter replacement can be done safely.
Disconnect power from unit
Remove outlet silencer if present
Depressurize and then remove air tank(s)
Unbolt top scroll from filter box (10-26) bolts
Remove the scroll housing
Remove the filter mounting plate
Unbolt filters and replace with new filters
Inspect and replace filter gasket material if necessary
Inspect and replace filter mounting plate gasket if necessary
Reverse order and reassemble
ONE YEAR LIMITED WARRANTY
Consolidated Stripping & Derusting, Inc. warrants that it will, at its option, repair or replace the goods, or return the purchase price thereof, which are found to be defective in material or workmanship for a period of one year from the date of purchase, provided that the Purchaser gives written notice of such defects and returns the goods to Consolidated Stripping & Derusting, Inc. with transportation charges prepaid by the Purchaser and an examination by Consolidated Stripping & Derusting, Inc. discloses to its satisfaction the existence of such defect.
In no event shall Consolidated Stripping & Derusting, Inc. be liable for any incidental, special or consequential damages resulting from said defects. The foregoing does not apply to components which were not manufactured by Consolidated Stripping & Derusting, Inc. and is expressly in lieu of all other warranties expressed or implied, including any warranty of merchantability or fitness for a particular purpose or use.This unit comes with a 1 year warranty against defect in workmanship or materials.
We offer an 85% return of the purchase price, excluding freight, for the return of the collector within 60 days after receipt of delivery if this unit fails to perform as described.