Camfil Farr Gold Series Dust Collector Instruction Manual

Farr Gold Series®Customer: IMPACT AIR Location: SHANKS WASTE, PONTEFRACT Purchase Order: 301933 Local rep: JOHN PALMER 07843 630733 Rep. phone: Edition: 1.1 - 17/06-2014 ® Farr Gold Series® Dust Collector ATEX-classified Camfil APC Ltd Unit C, Birch Business Park, Heywood, OL10 2SX United Kingdom Tel: +44 (0)1706 363820 [email protected] www.camfilapc.com/europe FARR GOLD SERIES Instruction Manual AIR POLLUTION CONTROL IOM14027 Farr Gold Series® TABLE OF CONTENTS SECTION 100 - DEFINITIONS 3 SECTION 110 - INTRODUCTION 110.1 Accessories 110.2 Conditions for Safe Use and Start 110.3 Technical Data 110.4 Intended Use 110.5 Understand Your Serial Plate 4 4 5 5 5 6 SECTION 120 - SAFETY PRECAUTIONS 120.1 Flame and Pressure Risk Area 120.2 Understand Signal Words and Symbols 120.3 Warning Decals and Guards 120.4 Lock-out/Tag-out Requirements SECTION 200 - RECEIVING YOUR EQUIPMENT 200.1 The Purchaserʼs Responsibility 200.2 System Components 200.3 Uncrating and Inspection SECTION 320 - FIELD UTILITY CONNECTIONS 320.1 Motor Connections 20 320.2 Solenoids 21 320.3 Differential Pressure (dP) Connections 22 320.4 Compressed Air Connection 22, 23 320.5 Sprinkler Connections 24, 25 SECTION 330 - FILTER INSTALLATION / REPLACEMENT 25 330.1 Step by Step Instructions 25, 26 330.2 Filter Replacement Minimizing Dust Contamination 27, 28 7 7 8 8 8 SECTION 340 - PRECOATING OF FILTERS SECTION 400 - OPERATION OF YOUR EQUIPMENT 30 400.1 System Operation 30 400.2 Filter Cleaning 31 400.3 Cleaning System Components 32 400.4 Fan Operation 33 400.5 Recommended Controller Settings 34 400.6 Shutdown Procedure 35 9 9 10 SECTION 300 - INSTALLATION OF THE EQUIPMENT 300.1 Table, Assembly Tools 11 300.2 Hardware 12 300.3 Hoppers 12 300.4 Support Legs and Brackets 12 300.5 Hopper/Support Structure Assembly 13 300.6 Filter Module 13 300.7 Channel Baffle Inlet 14, 15 300.8 Discharge Accessories 16 300.9 Drum Kit/Butterfly Valve 16 300.10 Platform/Ladder 16 300.11 Earthing Test Procedure 16 SECTION 310 - ATTACHING DUCT WORK 310.1 Inlet Duct Design 310.2 Inlet Flanges 310.3 Remote Mount Fan Discharges 310.4 Top Mount Fan Discharges 310.5 Discharge Hopper Flange 29 SECTION 500 - PREVENTIVE MAINTENANCE 35 500.1 Filter Elements 35 500.2 Hopper 35 500.3 Solenoid and Diaphragm Valves 36 500.4 Control System 36 500.5 Cleaning and Repair 36 500.6 Pressure Vessels 36 500.7 Inspection Log 37 500.8 Suggested Preventative Maintenance Schedule 38 500.9 Safety inspection of Farr Gold Series dust collector 39 500.10 Checking the door seal 40,41 17 18 19 19 19 19 2 SECTION 510 - TROUBLESHOOTING 41, 42 SECTION 600 - REPLACEMENT PARTS LIST 43 Farr Gold Series® SECTION 100 - DEFINITIONS m3/h Emissions Actual m3 of gas per hour. The volume of gas flowing per hour at the operating temperature, pressure, elevation and composition. Particulate that escapes through or around a dust collector into the atmosphere. Air-to-Cloth Ratio A system where the fan is located after the dust collector on the clean air side, pulling air through the system. Negative Pressure System The ratio between air flowing through a dust collector and the m2 of filter area available (m3/m2 h). Sometimes referred to as the velocity (m/h) of air through the cloth. Positive Pressure System A system with a fan located prior to a dust collector on the dirty side, pushing air through the system. Blinding Blockage in a fabric or media by dust that cannot be discharged by the cleaning mechanism, resulting in a reduced gas flow and an increased pressure drop across the media. Once enough material has built up, airflow is severely restricted and the bags have to be cleaned or replaced. Precoat Material added to the air stream at start-up to aid in establishing the initial dust cake on the filter media. Rotary Airlock Valve Device having a star wheel (rotor) designed to provide an air tight seal between the negative or positive pressures of the collector and the outside atmosphere. Bridging Material handling problem characterized by the particulate forming a cavity over the discharge or opening of a hopper or storage vessel. Also, the accumulation of collected dust between two or more filter elements. Screw Conveyor The dust collector area, through which gases are directed, located on the clean side of the filter media. A revolving screw operating in a fixed trough for conveying material from one point to another. Note: Should a screw conveyor be used in a dust collector system, an airlock is still required to ensure ventilation air does not pass through the conveyor. Collection Efficiency Pulse Duration (On-Time) Clean Air Plenum The length of time a pulse lasts, generally described as the length of time the electric signal holds the solenoid pilot valve open (fixed at 150 ms). The measure of a dust collector’s ability to remove particulate from the inlet gas, typically expressed in percent or emission rate (mg per cubic meter). Dew Point Pause Time (Off-Time) The temperature at which condensation begins to form as the gas is cooled. Elapsed time between pulses in a dust collector cleaning system. Differential Pressure Solenoid Valve The change in pressure or the pressure drop across a device. The difference between static pressures measured at the inlet and outlet of a device, Ref. Pressure Drop. An electromechanical plunger device that is either “normally open” or “normally closed”. In use with a dust collector, it is for the relief of air pressure to activate a compressed air device such as a diaphragm valve. Dust Cake A dust build-up on the filter elements that increases the efficiency of the filter media. Tube Sheet A steel plate on which the open end of the filter elements are connected. This wall separates the clean air and dirty air plenums of the dust collector. Diaphragm Valve A compressed air valve operated by a solenoid valve that opens to allow a pulse to a row of filters. Dust Loading The weight of solid particulate suspended in an air stream, usually expressed in mg per cubic meter. 3 Farr Gold Series® SECTION 110 - INTRODUCTION Congratulations on your selection of Camfil Air Pollution Control equipment! As the owner/operator of this equipment you have an important responsibility to see that it is operated and maintained in a safe manner. The unit will require moderate attention to keep it in good operating condition. This manual has been prepared to aid you in that effort. Throughout this manual, reference may be made to various components, which may or may not be part of your particular system. They are included in the interest of fully describing typical systems with all available options. This manual covers the installation, operation and maintenance of the Farr Gold Series dust collector. This air cleaning equipment is used to eliminate dust contaminants from the environment making the facility or plant a healthier and safer work place. 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. Prior to installing your equipment, thoroughly read and understand this manual. Locate all parts and ensure that nothing is missing, suffered shipping damage or has been damaged during unloading. Familiarize yourself with each component of your system and its function using the contents of this manual as a guide. Refer to any local codes or ordinances relating to equipment of this type. They may affect the method or procedure used to install your system. Important! For safe and reliable results, assembling work, electrical installation, use, service and trouble-shooting should be performed by qualified personnel. Special training may also be necessary. Standards relating to the connection and use of dust collectors in hazardous areas must be taken into consideration, especially national standards for installation. Only trained personnel familiar with these standards should handle this type of dust collector. The ATEX-classified Camfil APC Dust Collector is specially designed to comply with official regulations concerning the risk of explosion. If improperly used, badly connected, or altered, no matter how minor, the reliability could be in doubt. N.B. Each ATEX-classified Camfil APC system must be installed and dimensioned individually. To ensure that the system will be safe, a risk analysis must be done for each installation and each intended use. 110.1 Accessories Following is a list of common accessories to Farr Gold Series Collectors that are not covered in this manual. If your collector includes any of the accessories, the documentation will be included with this manual submittal. Fan Fan Silencer Motor Starter Air Lock Screw Conveyor Dust Level Indicator Support Structure Magnehelic Gage Compressed Air Pressure switch Emissions Monitor 4 ..... N..... 9. IP 65 (for Camfil APC Control System)* Relay voltage....................3 Technical Data Filtration....4 Bar depending on model Equipment category...............4 B Weight. Any change with this needs to be approved by Camfil APC..... Cellulose / Polyester Operating temperature.... 0............ If the usage shall be changed contact Camfil APC for a renewed assessment............ Do not discard this manual! It contains information...... To guarantee the correct function and a minimal service the dust collector must only be used according to its intended use and according to the instructions in this manual. • The dust collector is intended to be used as a part of a system................... X: Special conditions If the collector shall be mounted in a zone 2 environment.... 230 V............ 50/60 Hz......... The dust collector must not be used for filtering fume or dust containing sparks or glowing material..Minimum 1” (R25) Voltage supply...... option......... single phase* Protection class...........4 Intended Use 110............ 110 V...... See Sales Information Operating airflow......... • The unit is only approved for it’s intended use and can only be used safely for this..10 kPa PMax red. will insure proper operation...2 B...... after any major changes and at least yearly a safety inspection must be done to verify that the system is safe to operate (see procedure 500.... See project drawing More Technical Data...........................5” valves........... See page 21 Compressed air connection..9). This system may not be started until it has been declared in conformity with relevant safety requirements.................. • Before the unit is started. 2 D/G: applicable to the interior of the product 3 D/G X: applicable to the exterior of the product Marking............ This includes risk assessment and an explosion protection plan.......... which when properly used. according to EN ISO 12944 Compressed air requirements.. 0 ºC to +70 ºC (+90 ºC depending on filter media) Environment classes.................. Unless the conditions listed below are fulfilled it is not allowed to start the dust collector................ the control system must be placed outside the zoned area...... EX II 2/3 D/G T2 90 ºC X (see explanation above) Sound power 1”.. 0.. ...... 24 V AC Working pressure........... 110... DuraPleat 20 m2 Filter material....2 Conditions for Safe Use and Start The ATEX-classified Camfil APC Dust Collector is designed for collecting and filtering explosive and non-explosive dry dust...... The unit is only safe to use for the application and dust given in the EX CALC Safety Document........ control system..... See Sales Information Dimensions..2 Bar....... 0 kPa to ........ 5 . The intended use includes dust generating process and materials used.. continued high performance and a long work life to your unit. PolyTech 30 m2. The user is responsible for supplying Camfil APC with relevant information.Farr Gold Series® IMPORTANT! 110.. this is the responsibility of the plant owner/operator.B.. 24 V.......... See Sales Information Filter area / filter cartridge. 1. Please see the controller manual for specific information.. See the Serial Type Plate of the product * This may vary depending on the controller...... 9..........20 ºC to + 40 ºC Process air (dry) temperature.. C3 and C4 on request...... NB! This is a minimum requirement each case must be treated individually. If this is not done the CE-marking of the unit is invalidated............ Here is what your serial plate will show. model.Farr Gold Series® 110. it will be important to have the collector’s serial. If you want to change the use of the system Camfil APC must be consulted or the CE mark of the unit is invalid and the system can no longer be considered safe. Serial # – This represents the sales order number and will link the unit to the prints and engineering documents associated with your unit.5 Understand Your Serial Plate Once you receive your equipment. Model # – This will represent what size unit you have received. Figur 110. This information will be helpful when calling customer service or finding original equipment supplied with the collector. Dust type # – The dust described on the serial plate is the only dust that can be safely handled by the system. You should write this information in this book for easy access. and part numbers. (Example: GS-24). This information should be found on a white plate on the door of your collector see Figure 110.5.5 Serial Plate 6 . Gold Cone Filter P/N # – This field represents the part number of the filters provided with the order. WARNING! Explosion risk! Risk of grave personal injury and/or product damages! A risk area around the ATEX-classified Camfil APC Dust Collector must be marked in an obvious way. Precautions must be taken to ensure that all electrical/air connections and regulation devices are installed and operating properly. in front of the relief panel. W Horizontal venting 120. angled 45°. To reduce the risk area it is possible to fit a deflector. A/2 View from above A A Vertical venting Explosion risk! Risk of grave personal injury! During the operation the roped-off area must only be entered. For detailed information see the Application section of the information binder. for example with a fence and warning lines and signs.Farr Gold Series® SECTION 120 . Within the risk area no inflammable material must be found.1 Flame and Pressure Risk Area L This only applies to units protected by venting. by service technicians to the Dust Collector.SAFETY PRECAUTIONS Camfil APC relies on the skills and expertise of its customer and any consulting engineers and/ or installing contractors hired by that customer to properly design and install the dust collection system of which Camfil APC equipment is a part. Read this manual thoroughly and comply with the precautionary statements relative to worker safety. When the Dust Collector is in operation the risk area must only be entered by service technicians. if absolutely necessary. A A A = approximately height of Dust Collector 7 . A DANGER! A View from above Warning Sign example which can be used to mark the risk area. Indicates hazards associated with rotating machinery. If you do not understand anything in this manual. or by contacting Camfil APC. Before inspecting or servicing this equipment perform an approved Lock-out/Tag-out procedure on the electrical service. Part numbers for these decals are listed in the spare parts list in section 600. 120. which. It is the owner/operator’s responsibility to maintain the integrity of these guards and ensure that they are in place when the equipment is in operation. All such information must be taken seriously. and heed the information that accompanies them. may result in death or serious injury. if not avoided.3 Warning Decals and Guards This piece of equipment contains several warning decals located in many different locations. which. WARNING! Indicates a potential hazardous situation. Indicates hazards associated with compressed air sources. When you see these symbols you must read. WARNING! Do not attempt to operate or maintain this piece of equipment until you have read and thoroughly understood all of the safety information contained in this manual. The symbols shown below appear on the equipment to alert you of potential hazards. Replace damaged guards.4 Lock-out/Tag-out Requirements Employers shall 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. 120. which could result in death. Indicates the presence of an electrical power source. the compressed air (or other gas) supply or any other energy source.Farr Gold Series® 120. DANGER! Indicates an imminently hazardous situation. which can cause serious injury or death. This piece of equipment contains moving parts and potential pinch points. It is the owner/operator’s responsibility to maintain the integrity of these decals and to ensure that all operators of the equipment are aware of them and understand their meaning. DO NOT attempt to operate this equipment without factory-installed guards. 8 . if not avoided. may result in minor or moderate injury and or property damage. This piece of equipment may contain one or more safety guards to protect the operator(s) from injury. may result in death or serious injury. understand. which. start-up or release of stored energy in order to prevent injury to employees”. Replacement decals are available free of charge from your Camfil APC service representative.2 Understand Signal Words and Symbols Indicates a potential hazardous situation. personal and/or property damage. if not avoided. seek assistance from your supervisor before operating this equipment. Your Farr Gold Series dust collection system may consist of one or all of the following components: 1. Dents. Camfil APC should immediately be notified of any structural damage to your equipment. Fan 4. Filter Module 2. a crane. Motor Starter 8. Hopper Section(s) 3. The carrier is responsible for any damage to the equipment while it is in transit unless specific arrangements are made otherwise. with the exception of the electrical and air connections. Screw Conveyor(s) 12.2 System Components A visual inspection of your equipment should be performed before it is removed from the truck. Maintenance Platform 9. Remote mount fan Access Platform Rotary Airlock Support legs Filter module Cartridges are factory installed. Fan silencer The Farr Gold Series dust collector is shipped disassembled and must be reassembled by installation personnel.Farr Gold Series® SECTION 200 . Rotary Airlock 11. forklift and/or chain-fall will be required to position the fan and motor on top of the unit clean-air plenum and lift heavier components into position. Maintenance Ladder 10.RECEIVING YOUR EQUIPMENT 200. Assembly Hardware 7. Hardware is located inside inlet. Manual Cleaning Control 15. can usually be accomplished by anyone with a basic understanding of common hand tools. Support Legs 5. It is the purchaser’s responsibility to file shortage reports and damage claims with the carrier and your Camfil APC representative. The structural integrity of the housing will be adversely affected by large dents. Hopper Figur 200. Besides a common set of hand tools. Butterfly Valve Kit(s) 13.1 The Purchaser’s Responsibility 200. Cross Braces 6. Camfil APC must rely on the skill and expertise of its customers and the customer’s installation contractor to ensure that all electrical connections are made correctly and air connections and regulation devices are installed and operating properly. Unit assembly. Discharge Drum(s) 14. scratches and other damage should be noted and photographed. Automatic Timer Control 16.2 Farr Gold Series Shipment 9 . Typically. Careless handling can damage delicate parts or affect assembly alignments. airlocks and custom accessories. Each Farr Gold Series dust collector is normally shipped on two or more skids. the filter cartridges. support legs. control box and any other user installed components are shipped inside the cartridge area of the bin-vent section.3 Uncrating and Inspection the small parts box located in the inlet of the collector. A copy of this drawing is included with this manual submittal and can also be found in Do not return any damaged components without first contacting your Camfil APC Representative to obtain Returned Goods Authorization (RGA). check all items received against the material list on the project drawing and or the packing list (if any) sent with the shipment. The project drawing has a listing of all loose components shipped with the job. Again. Use extreme care when handling the unit and components. One skid contains the filter module section.Farr Gold Series® 200. safety monitoring filters. Further inspect the unit and components for hidden damage. A second skid contains the hopper section and other skids will contain fans. 10 . Inspect all items for apparent damage. Compare the number of items received against the carrier’s Bill of Lading. Immediately report any shortages or obvious damage to the carrier and to your local Camfil APC. Carefully inspect all packing material so that small parts are not inadvertently discarded. report any shortages or damage to the carrier and to your local Camfil APC Representative. When all skids are completely unpacked. assembly and installation of the units.5 mm2) Control and lighting electrical connections 21 Safety approved expansion bolts M16 or equivalent suitable for the application Anchoring to floor 22 Electric Motor Starter or Variable Speed Drive * Ventilation Fan *(If not supplied with unit) 23 Transit or Carpenters Level Levelling Unit WARNING! Risk of personal injury and/or product damages! Use approved lifting equipment for unloading. authorized personnel should be permitted to service or maintain electrical or safety components. Farr Gold Series Assembly Tools The following items may be required to install your equipment depending on configuration and installation requirements: Only trained. It is the buyers/installers responsibility to ensure that all applicable electrical and safety codes are met. ITEM DESCRIPTION INTENDED USE 1 SAE Socket Set General tightening of fasteners 2 Common Screwdriver Electrical connections 3 Phillips Screwdriver Electrical connections 4 Electric Drill or Impact Wrench Installation of self-tapping screws and fasteners 5 Hammer Drill Anchoring to floor 6 Masonry Bit Anchoring to floor 7 Hammer Installing anchors 8 Pliers General use 9 Wire Cutters Electrical connections 10 Wire Nuts Electrical connections 11 Electrical Tape Electrical connections 12 Extension Cord General use 13 Conduit Electrical connections 14 ¾” or larger black iron pipe or equivalent Compressed air connections 15 Fittings for items 13 & 14 Compressed air and electrical connections 16 Thread Sealant Compressed air connections 17 Alignment Punch Aligning holes 18 Forklift or Overhead Hoist Moving and positioning components 19 Electrical Cable (5 wire of appropriate cross section area) Fan electrical connections 20 Electrical Cable (3 wire x 1.INSTALLATION OF YOUR EQUIPMENT 300. 11 .1: Table.Farr Gold Series® SECTION 300 . Remove the hopper(s) from the skid(s) and place on a flat. fan mount panel filter module 300. the support legs.3 Hoppers inlet Locate the hopper(s) and support legs.2 for typical assembly points of a standard collector.3.3 for general assembly and your support structure drawing for specific parts. Bolt the hopper(s) together using the corner support brackets and hardware as shown on Figure 300.Farr Gold Series® fan (field install) 300. The carton containing the hardware to be used for the support legs and cross braces will be labelled “hardware kit for structural support”. The carton(s) to be used to bolt the bin-vent to the hopper(s) will contain 3/8-16 thread cutter screws and roll(s) of gray rope caulk. The cartons will be labeled with the part number and are normally located inside the inlet. square the hopper(s) as necessary. Locate the support legs and bolt them to the corner support brackets. foundation dimensions and accessories.2 cross brace support leg knee brace Figure 300. Separate the hardware for ease of location during assembly. If your collector includes multiple hoppers place them in the correct configuration as shown on the General Dimensions drawing. Refer to the General Dimension drawings for specifics. cross braces. and hopper(s) will be shipped sub-assembled for ease of installation to the filter module.2 Hardware Refer to Figure 300. Using a tape measure or string line. such as item part numbers. where the support legs are of standard height. Figure 300. level surface. hopper cross brace butterfly valve support leg drum lid 300. Note: On a GS24 and smaller collectors. Locate the cartons containing the installation hardware. Note: Do not tighten any of the bolts until all bolts have been started.3 (GS32 shown) 12 slot for lifting . inlet and outlet locations. Locate the cross braces and bolt them to the support legs. If your collector contains knee braces.4 Support Legs and Braces drum Refer to Figure 300. bolt one end to the support leg and the other end to the corner support bracket. Ensure that inspection panels or optional device connections are in the desired orientation.4 (GS6 shown) 300. Line the hopper flange with rope caulk as indicated in Figure 300. This will allow you to move and adjust the filter module as necessary. On larger collectors. Clean the filter module flange and set onto the hopper flange. Note: Do not tighten bolts when starting to align hopper. taking care not to damage the flanges or rope caulk. If you have a remote mount fan refer to section 310 (Remote mount fan discharges) for further instructions. lifting lug full module (4 cartridges) upper side panel ~ half module (2 cartridges) ~ lower side panel rope caulk 3/8-16 thread cutter screw “match line” label Figure 300. Note: The slots for lifting in the corner support brackets – Figure 300. Level the hopper flange(s) with a transit or carpenter’s level. 10 & 20 collectors ensure that the “Match Line” label(s) on the filter module. using 3/816 thread cutter screws – Figure 300.5 Hopper/Support Structure Assembly Lift the completed hopper/support structure assembly with a forklift or chain hoist and carefully overturn into an upright position.4. Failure to connect lifting cable to all (4) lifting lugs may result in damage to the collector.4.Figure 300. Hopper Assembly Remove any dirt or other accumulation from the hopper flange. Anchor the support legs to the floor using appropriate concrete anchors (by installing contractor). locate the fan mount panel and clean the area around the fan flange that will be in contact with the rope caulk. Grout the support leg bases as necessary. Bolt the fan to the fan mount panel using the hardware included –Figure 300. using the lifting lugs provided and approved lifting equipment – Figure 300. they are intended only for general hopper to bin-vent orientation – Figure 300. If you have a top mount fan. Clean the fan flange and apply rope caulk. Wait until all bolts have been started before tightening.4.4. Remove any old rope caulk that did not come off with the upper side panel. the collector is in the desired orientation.4. Ensure that the orientation of the collector is as desired for your installation. an “s” (zigzag) pattern is recommended to ensure that there is a continuous seal on the flange. Note: On GS6. Use a drift or alignment pin to align holes as necessary. remove the upper side panel from the side you intend to make your fan duct flanged connection.Farr Gold Series® 300. Turn the hopper/support structure assembly so that when the “Match Line” label(s) on the hopper(s) line up with the “Match Line” label(s) on the bin-vent.3. Move the assembly into final position. ensuring a continuous seal. Note: On GS6. Insert the bolts from the corners to the center of the collector. lift the fan onto the filter module roof. the bin-vent to hopper(s) bolt-holes are not symmetrical. Attach the filter module to the hopper.6 Filter Module Fan Assembly If your collector is equipped with a top-mounted fan. 10 & 20 collectors.2. Lift the filter module. The “Match Line” labels do not have to line up perfectly. Keep the weight of the collector fully supported by the crane or forklift until all hopper bolts have been installed and tightened. If your collector is equipped with a remote mount fan. Insert bolts into each of the four corners without tightening them. 13 . line up with the “Match Line” label(s) on the hopper(s) . adequate cable length or a spreader bar is required to prevent damage to the collector. 5. Use 3/8-16 x 1-1/4” cutter screws in (4) places required for baffle. flanged locknut 3/8-16 x 1/4” cutter screw (4) places per baffle 228. Channel baffle tabs fit to the inside of the frame as shown.6 812. 3. Apply rope caulking to exterior of frame. 2. 4. Attach center baffle channel if required. Position inlet(s) and secure at corners with 3/8-16 x ¾” cutter screws. Bolt inlet(s) in place with remaining 3/8-16 x ¾” cutter screws. Position channel baffle tabs over long bolts and secure with 3/8-16 flanged locknuts on inside of unit. install at this time as follows: 1.7 Channel Baffle Inlet If your filter module is supplied with a louvered channel baffle assembly for the inlet.8 assembly sequence detail assembly detail single inlet configuration 14 . 6.Farr Gold Series® 300. 8 228.Farr Gold Series® flanged locknuts flanged locknut flanged locknut 3/8-16 x 1/4” cutter screw (4) places per baffle 812.6 228.8 assembly sequence detail 3/8-16 x 1/4” cutter screw (4) places per baffle assembled view 15 .6 812. Install the accessory to the hopper discharge flange(s) using the General Dimensions drawing and Section 320 as a guide.9 WARNING! Risk of personal injury and/or severe equipment damages! Use only Camfil APC components. Verify that there is connection between the hopper and the following parts a. 3. Side panels. A good connection between metal parts shall not have more than 10 ohm resistance. Remove the earth connection from a top mounted fan (if present) if it is connected.10 Platform/Ladder Locate the hopper discharge accessory supplied with your collector. This procedure should be performed before the dust collector is put to use. making sure that the butterfly valve is oriented so that there is no inter-ference when the handle is pulled out. Check that the incoming earth from the building is connected to the control system. Frame/-s c. 4. Slip the other end of the flexible hose over the collar of the drum lid and fasten with a hose clamp. regularly (at least once a year) and after any major service or modification of the unit. Re-connect the earth to the fan if it was removed. Be sure that it is right side up. Inlet g. This will be a drum kit/butterfly valve. Slip the drum ring over the top of the drum. 300. 2. butterfly valve attach to discharge flange on hopper hose clamp flexible hose hose clamp drum lid drum latch ring 210 litre drum Figure 300. 16 .9. If it does not latch or the latch is too tight. Instructions for this is outside the scope of this instruction. Note the date and result of the test in the service scheme of the user manual. NOTE! It is good practice to also perform a test on the dirty side pipe system. Door/doors f. rotary airlock or screw conveyor. Legs b. Use a calibrated ohm meter.Farr Gold Series® 300. 6. then the ring is upside down – Figure 300. If supplied by Camfil APC please see the special instruction book for Platforms/Ladders. 1.8 Discharge Accessories 300. Measure on at least one bolt / panel 5. Bolt the butterfly valve to the hopper discharge flange. The clamp on the drum lid only goes on one way.11 Earthing Test Procedure IMPORTANT! Earthing of all metal parts is a necessary requirement for ATEX-classified dust collectors. 300. Fasten one end of the flexible hose to the butterfly valve collar with a hose clamp.9 Drum Kit/Butterfly Valve Clean and apply rope caulk to the top surface of the butterfly valve flange. Check that the earth point in the control system is connected to the dust collector hopper. Baffle assembly h. 6 25. GS02 9 PITCHES @ 152.7 Top outlet flange (half panel) .5 Side outlet flange (half panel) 914.6 Top outlet flange (full panel) Figure 310.4 Figure 310.ATTACHING DUCT WORK This section covers and design guidelines for ducting to your dust collector.4 Figure 310.2 Double modul inlet 609.Farr Gold Series® SECTION 310 .3 Triple modul inlet 10 PITCHES AT 101.4 = Figure 310.1 Single modul inlets Figure 310.4 Side outlet flange (full panel) 914.4 Figure 310.6 = Figure 310. The following figures show the different sizes of inlet and outlet flanges. must be horizontal. The air direction will cause the dust to be evenly distributed to all of the filters in the collector.Farr Gold Series® 310.1 Inlet Duct Design When you run ducting to your collector. The straight length of duct entering the inlet should be a minimum of 2 or 5 duct diameters (see figures). resulting in uneven dust loading on the filters.2 Top view 18 Inlet duct dia. (min) Figure 310. The air direction will force dust already in the hopper (previously pulsed off the filters). 2.1 Side view In figure 310. In the “NOT RECOMMENDED” design. . 2 x duct dia. 5 x duct dia. before entering the inlet. the “RECOMMENDED” design shows a straight section of duct that is at least 2 duct diameters long. The transition angle from the duct to the inlet flange should be a minimum of 45°. the duct enters the inlet at an angle.9. (min) Inlet duct dia. Duct dia.1. 1. a 90° elbow and a horizontal length of a least 5 duct diameters before entering the inlet. it is important to follow these guidelines.1. the duct is not long enough to allow the air to straighten out before entering the inlet.8. WARNING! Risk of ignition! If the duct leading to the dust collector is vertical the last 5 x duct dia. (min) Du ct di a. the “RECOMMENDED” design shows a vertical section of duct. 2 x duct dia. The air direction will force the dust to one side of the collector. In figure 310. to be re-entrained into the air stream. Figure 310. The air direction will cause the dust to be evenly distributed to the filters. In the “NOT RECOMMENDED” design. Figures 310. 310. 310. always be sure to caulk or place gasket between the duct and damper outlet before bolting them together. Figure 310.3 show dimensions of the one. is for the half sized side panel. provided by Camfil APC. 19 . The ductwork will be attached to the flange details on Figures 310.6 and 310. while Figure 310. See your General dimensions drawing for the dimensions for your flange. These inlets are configured and classified with the number of modules that the collector uses to support the inlet plenum. When attaching ductwork to these flanges. When attaching ductwork to these flanges always be sure to caulk or place gasket material between the duct and collector before bolting them together.2 and 310.5. 310. or top panels can be removed.4 .2 Inlet Flanges 310. Figure 310. is the bolt pattern for the full sized side panel. are field mounted on the top of the Farr Gold Series collector. provided by Camfil APC. on the upper section of the dust collector. These dimensions are the bolt patterns for the panel and frames.4 Top Mount Fan Discharges Depending on the size and orientation of your Farr Gold Series collector.310.3 Remote Mount Fan Discharges Remote mount fans.1. the inlet will have one or more of three inlet designs. Top mount fans. Larger collectors may have more than one inlet plenum and vary in the size of the inlet.7. respectively. two.7 are for the full and half sized top panels respectively.Farr Gold Series® 310. When attaching ductwork to this flange. Either the side panels. will be ducted to the collector by removing an upper panel and attaching the ductwork to the frame of the Farr Gold Series dust collector.4. and three module inlets.5 Discharge Hopper Flange Accessories will be attached to the hopper discharge flange. always be sure to caulk or place gasket between the duct and collector before bolting them together. Mount the motor starter enclosure in a convenient location for operation. 50/60 Hz Start signal If a Camfil APC Motor Starter is used it will be supplied with inter connection wiring diagrams. motor starter. 6 mm OD Tube RPB-Pilot Box Control system + Low DP (6 mm OD Tube) Second RPB Pilot Box 0. A qualified electrician should only make these connections.2 bar) (min) compressed air (1” NPT) - Air consumption (see table 330. Possible locations include a support leg or plant wall near the collector. It is imperative that all equipment installed complies with your local electrical code.62 MPa (6. WARNING! Failure to perform an approved Lock-out/Tag-out procedure may result in a sudden release of energy resulting in property damage.FIELD UTILITY CONNECTIONS 320. High DP (6 mm OD Tube) + Motor Starter Local isolator for fan if required Figure 320. the customer or Camfil APC representative may elect to supply the fan and other accessories. The wiring diagram for the motor will be either on the motor or inside the motor junction box. and rotary air locks (or other discharge devices) for our dust collectors. Before the system is started the installer shall verify that all metal parts are connected to earth. Serious injury may result if you do not take proper safety precautions! Risk of explosion – The earth connection from the controller must be connected to the metal body of the dust collector.1 Motor Connections Camfil APC can supply the fan.Farr Gold Series® SECTION 320 . Connect the wiring from the motor starter to the fan and from the power source to the motor starter. personal injury or death! Ensure that the circuit you are working with is off before you make these or any other electrical connections. However. Use the enclosure as a template for marking and drilling mounting holes. Check your paper work and information plates to determine electrical specifications for your equipment.1 (field utility connections) 20 .3) 400V 3P 230 V. Run conduit and wiring (supplied by others) from the motor starter to the fan motor and from the power source to the motor starter. The timer outputs are connected to two solenoids each.Timer outputs 21 RPB = Remote Pilot Box . of Model No. Header Air line 6 mm OD tube Control system RPB Second RPB Solenoid Figure 320. of Designation Solenoids/ Designation Solenoids/ Diaphragms Diaphragms GS2 2 GS36 12 GS4 4 GS40 20 GS6 6 GS48 16 GS8 4 GS48L 24 GS10 5 GS56 28 GS12L 6 GS60 20 GS12SQ 4 GS64 32 GS16L 8 GS72 24 GS16 SQ 8 GS84 28 GS20 10 GS96 32 GS24 12 GS108 36 GS32 16 GS120 40 Header Diaphragm Note: On GS 72 through 120 two headers (compressed air reservoir) are used. Do not connect a timer output to two diaphragm valves on the same header. connect the timer outputs to valves on different headers.2 .Farr Gold Series® 320.2 Solenoids SOLENOID/DIAPHRAGM REQUIREMENTS Model No. 1 and your General Dimensions drawing for the location of these taps. plastic plug locate 1/8” NPT (remove plastic and replace with elbow fitting in hose kit) 1935 low pressure tap above tubesheet high pressure tap below tubesheet upper side panel lower side panel Figure 320. Oil or water in the compressed air lines will cause the filter media to fail. 1/8” NPT clean-air and dirty-air pressure taps on the collector.2 bar). Your collector is equipped with an Automatic Pressure Sensing Timer Control or a Magnehelic gauge accessory. The airline should be equipped with a manual shut-off valve. Inspect the header. allowing pressure to build in the tank.62 to 0. valves.4.2 and 7.1 for your compressed air volume requirement. fittings and solenoid valves for air leaks. Tighten all fittings and clamps as required. 22 . Locate the 1/8” NPT brass elbow fittings included in the control package. close the shut-off valve. When the header has reached full line pressure of 0. a filter/separator.Farr Gold Series® 320. an air regulator and a pressure gauge. Re-open the air shut-off valve. Slowly open the shut-off valve. dry compressed air between 0. all located close to the unit. Supply the header (compressed air reservoir) with clean.2 to 7. Connect the dirty-air plenum pressure tap to the HIGH or Dirty Air Plenum connection on the device – Figure 320. Camfil APC recommends that the compressed air supply be kept at a dew point of + 2 ºC or less. Make provisions for draining any condensate from the air reservoir with an automatic tank drain or by other means.2 bar).3.3 Differential Pressure (dP) Connections Using the black ¼” OD black plastic tubing. Total air consumption is variable and is dependent on the type and concentration levels of airborne dust and the set points used for determining the cleaning cycle. connect the clean-air plenum pressure tap to the LO or Clean Air Plenum connection on the device.62 and 0. Refer to Figure 320.3 2591 pamic filter bottom of filter module 320. Install these elbows into the factory supplied. A shut-off valve is recommended between the compressed air source and the header. 1” supply line for anything larger than a GS10).4 Compressed Air Connection Connect an air hose or hard plumbing from the compressed air source to the 1” NPT coupling on either side of the header (¾” minimum air supply line for GS2 – GS10. See Table 320.72 MPa (6.72 MPa (6. 8 6.1 10.0 15.5 15. GS56 and GS64 through GS120 based on diaphragm size On Time 1” Diaphragm Valve 1-1/2” Diaphragm Valve 150 msec 150 msec On Time 5 10 15 20 25 30 35 40 45 50 55 60 54.8 9.8 9.2 .4 13.0 18.5 20.4 .2 48.2 40.5 12.0 27.0 36.2 bar).2 23 108.6 12.0 10.4.9 4.6 18.5 22.7 6.0 21.6 61.6 27.8 30. • Quick couplings restrict the air too much and are not recommended.7.6 24.1 5 10 15 20 25 30 35 40 45 50 55 60 Table 320.3 13. • The compressed air shall have a dew point (+2°C is recommended) below the minimum temperature at which the system is meant to be used.5 1-1/2” Diaphragm Valve 150 msec 150 msec Compressed Air Consumption (m3/h) 122.1 54.2 20. • Turn off and bleed off compressed air supply before doing any service work.0 13. • Improper air pressure or contamination in the compressed air can result in cleaning valve failure.8 35.0 27.4. • Do not pressurise the system if the air temperature is below the minimum operating temperature.5 10.0 30.0 244.0 5.2 24.Farr Gold Series® IMPORTANT! • The compressed air supply pressure has to be 0.9 40. poor cleaning and filter performance.62 .8 9.7 122.4 4. • The compressed air supply must be both oil and water free. • Purge compressed air lines to remove debris before connecting to the compressed air manifold. Dust Collector Air Consumption Dust Collector Air Consumption for GS2 through GS48 and GS60 based on diaphragm size for GS48L.72 MPa (6.3 61.0.0 7.4 17.2 11.2 Off Time (sec) Off Time (sec) Compressed Air Consumption (m3/h) 1” Diaphragm Valve Table 320.3 81. Figure 320. welded near the bottom of a lower side panel. locate the sprinkler connection coupling(s).5.2 shows an internal sprinkler system.1 shows a single sprinkler head system. sprinkler 1/2” flange sprinkler connection (1/2” NPT) 3/8-16 bolted flange Figure 320. which are connected to a pipe that runs along the bottom of the filter module.5 Sprinkler Connections If your collector is equipped with a sprinkler system. The plate can be unbolted in order to replace the sprinkler.2 sprinkler head (see table for quantity) 24 see table for size and no. Two or more sprinkler heads connect to vertical pipes. which is used on large GS collectors.5.1 Figure 320. A single ½” orifice sprinkler is screwed into a ½” coupling.5. of connections . which is bolted to a lower side panel.Farr Gold Series® 320. There is one pipe connection for each sprinkler head. Figure 320.5. All sprinkler heads are supplied through a single coupling. The coupling is welded to a circular plate. Refer to the General Dimensions drawing for locations. where necessary. GS20 2 161 √ Pw 1/2” BSP (2) GS12L. 5. Model Designation No. 2. 320.FILTER INSTALLATION/REPLACEMENT New units ship with filter cartridges installed. taking care not to cut or otherwise damage the filter media. until it is clear of the cartridge removal path also – Figure 330. until its locking tab clears the rectangular cut-out on the left-hand clamp bar. GS12S. 320. Remove the dirty filter cartridges by sliding them off the clamp bar channels.B: If the collector is installed in a location where sub zero temperatures can occur. GS24 3 161 √ Pw 1-1/2” BSP (1) GS32 4 242 √ Pw 1-1/2” BSP (1) GS40 5 323 √ Pw 1-1/2” BSP (1) GS48 6 403 √ Pw 1-1/2” BSP (1) GS56 7 564 √ Pw 1-1/2” BSP (1) GS64 8 645 √ Pw 1-1/2” BSP (1) GS72 9 725 √ Pw 1-1/2” BSP (1) Pw .5. • Rotate the left-hand clamp bar clockwise or 25 down. of Connections GS02.4 shows the cartridges ready to be removed. 3. • Make sure the clamp bar handles are fully opened and will not interfere with the cartridge during installation .1 to determine the water flow rate and the size and number of couplings required for your system. GS08 1 81 √ Pw 1/2” BSP (1) GS10.B: If you are supplying more than one sprinkler connection coupling with a single supply pipe. N.1-330. See fig. Clean the surface of the tube sheet in the areas where the filter gasket forms a seal. GS06. until it is clear of the cartridge removal path – Figure 330. 330.Figure 330.2. • Push the cartridge in just far enough to leave room for the next cartridge to rest on the clamp bar channels. Apply Teflon tape to the supply pipe and connect it to the sprinkler connection coupling(s). • Rotate the right-hand clamp bar counterclockwise or down. 4.Replacement Parts List for replacement filter and various parts identification. • Grasp the new cartridge by the top metal pan and set it onto the clamp bar channels.1. N. do not push the media.1. Disconnect compressed air service from the compressed air header. Please contact Camfil APC for genuine replacement parts. the supply pipe must be sized to accommodate the required flow rate. Turn on water supply and inspect all connections for leaks.B: Water leaks in the collector will cause cartridge failure and hopper flow problems. Sprinkler Heads Flow Rate (litre/min) Size & No. We have many types of replacement filters available for a wide range of applications. See fig. rotate the left-hand clamp bar counter-clock-wise or up and push it away from you until its locking tab clears the rectangular cut-out on the right-hand clamp bar.6√Pw Table 320. k factor for vert mount sprinkler is 80. Disconnect electrical power to the fan and control box. • Holding the cartridge level. Bleed all air from the air header.1 for GS2 through GS24 sprinkler instructions. . • With your right hand. GS18. slide it forward.5.6 lpm/bar 1/2 80.Farr Gold Series® Refer to Table 320. GS04.5. please contact Camfil APC for advice on installation. taking care not to drag the gasket along the tube sheet.1. pushing on the cartridge pan. • Figure 330.1 Step by Step Instructions 1.4. Open the access doors at the front of the unit.3 of this manual for more information). rotate the right-hand clamp bar clockwise or up and pull it toward you.5.1.1 SECTION 330 . Perform an OSHA approved lock-out/tag-out procedure on these and any other energy sources (Refer to Section 100. Care should be taken to make sure the correct Camfil APC original equipment replacement filters are used to insure continued satisfactory performance of the unit. Refer to section 600 .2 for GS32 through GS120 sprinkler instructions. Remove a new cartridge from the shipping carton. N. Unlatch the clamp bars as shown in Figures 330. swinging them out of the way.1. • Repeat steps 4 and 5 until the row is full. GS16.5.Water Pressure (bar) at sprinkler. Check local codes for requirements.3.1. • With your left hand. rotate the left-hand clamp bar counter-clock-wise or up to between 80° and 90°. The clamp bars must be bent slightly if the locking tabs do not stay inserted in the rectangular cut-outs.1 – Clamp bars Figure 330. repeat the instructions in step 3 in reverse order.3 Figure 350. To seal the new cartridges.3 Figure 330. With your left hand.Clamp bars closed Figure 350.2. With both hands rotate the right-hand clamp bar clockwise or up and pull it toward you.1. While pushing the left.3 Figure 350.1.1. until the locking tab inserts into the rectangular cut-out on the left-hand clamp bar – Figure 330.5 Figure 26 350.1. Insert the locking tab on the left-hand clamp bar when it lines up with the rectangular cut-out on the right-hand clamp bar. Repeat the above procedure until all the rows of cartridges are full.4 . Release the left-hand clamp bar.2 Figure 330.Farr Gold Series® 6.4350.5 Fi Open . rotate the right-hand clamp bar clockwise or up.Clamp bars open Figure . 7.hand clamp bar away from you.1.1 .Clamp Bars closed Figure 350. Figure 330.1.2 Figure 330. with your right hand. 2.Pull the bag up over the cartridge Figure 330.1 . Figure 330.4 .2.2.2 Filter Replacement Minimizing Dust Contamination If you wish to reduce dust contamination around the unit it is possible to use the following procedure. Wear suitable personal protection and acquire plastic bag to fit the cartridges (610 x 1020 mm).2 .Open door Figure 330.Open the clamps 27 .2.3 .Put the plastic bag under the used cartridge Figure 330.Farr Gold Series® 330. Close the box Figure 330.Place the used cartridge in the box that came with the replacement cartridge 28 .7 .2.2.2.5 .Farr Gold Series® Figure 330.Pull out the cartridge Figure 330.6 . By applying a suitable precoat dust. 10. Pre-coating Procedure 1. 29 .1. This is normal and should stop when all the precoat dust is applied. 2.26 32.54 195.95 Note: Expanded perlite is only product Camfil APC provides.82 GS-12 10.1 . pre-coating of the filters is not required.14 81. Table 340. The system is now ready for operation. Airflow can be measured by means of a Pitot tube.51 65. 11.63 16. it must first be removed from the system. Discard according to local codes and procedures. maximum efficiency can be attained in a few hours. Weigh out the appropriate amount of pre-coat dust according to Table 340.1.49 GS-8 7. The dust can be fed into any suction hood in the duct system or through the hopper discharge. This is desirable if the air is to be recirculated through Safety Monitoring Filters (SMF). 5. the life of the filters can be greatly increased by pre-coating. Start the collector and feed the pre-coat dust into the collector. which may take weeks without pre-coating. Re-enable the collector by either opening the compressed air line or turning on the power to the timer control (see step 4). 7.81 8.5 microns).98 GS-36 32. pre-coating will result in a higher initial efficiency and extended filter life. Install a clean. When all the dust has been applied.Cartridge Pre-coat Data Model Designation Pre-coat Amount Expanded Perlite (kg) Pre-coat Amount Limestone (kg) GS-2 1. SMF housing and discharge container.99 GS-16 14. 9. Also. Dust will be observed from the fan outlet.96 GS-48 43. In applications where the dust concentration is low and/or the dust particles are small (less than 0.07 40. 6.33 GS-6 5. 15.66 GS-10 9.65 GS-24 21. anemometer or similar device.32 GS-20 18. Ensure the filter cartridges are correctly installed. 3. 8. collect the dust from the discharge container and repeat the above procedure. Disable the dust collector so that it does not pulse while the pre-coat is being applied.1.5 microns). Remove any remaining pre-coat dust from the outlet ducting. This can be done by shutting off the compressed air and bleeding the compressed air reservoir or turning off the power to the timer control. If a Safety Monitoring Filter (SMF) is installed. empty discharge container under the unit.44 24.16 GS-4 3.66 146.77 97. or if the dust is toxic. Maximum efficiency of the filter is not achieved until a dust cake is formed on the media.89 48. if the collected dust contains a considerable content of hydrocarbons or similar substances. Record the Magnehelic gauge reading and set the fan damper to correspond to the system design airflow. 4.Farr Gold Series® SECTION 340 PRECOATING OF FILTERS In applications where the dust concentration is high and/or the dust particles are large (more than 0. through through the clean air the clean air plenum and into the fan. metal. may cause unsatisfactory results. The Farr Gold Series dust collector described in this manual is designed for the capture of airborne particles generated from mixing. Dust laden air enters the inlet of theladen collector. plastics.Farr Gold Series® SECTION 400 . 400. the Gold Cone cartridge. fiberglass.OPERATION OF YOUR EQUIPMENT and cutting operations involving wood. Variations in environment. 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. Figure 400. The baffle forces or heavy particles to drop large heavy particles to drop intoorthe hopper. The the baffle Dust air enters inletforces of thelarge collector. it expressly disclaims responsibility for the results obtained or for any consequential or incidental damages of any kind incurred. grinding Clean. It is intended that personnel having specialized training in accordance with currently accepted practice and normal operating conditions use this manual. Camfil APC has prepared this proprietary user’s manual for the exclusive use of its customers.1 . plenum and into the fan. where it is exhausted. The recommendations contained herein are based on proven techniques and on test data believed to be reliable. sanding. Since Camfil APC has no control over the conditions of service. Dustcollected collected cartridges Dust on on thethe cartridges drops into the hopper and is collected drops into the hopper and isin a discharge device.GS Operation 30 . The dust is captured on the outside surface of the filter media. where it enters the fan inlet and is exhausted. into the hopper. collected in a discharge device. The air then flows from the filters into the cleanair plenum. advanced composites or similar materials. filtered airGold rises Cone from the center ofcartridge. filtered air rises from the center of the Clean. changes in operating procedures or extrapolation of data.1 System Operation Incoming dust-laden air enters the inlet plenum where a baffle forces large or heavy particles to drop out of the air stream and fall into the hopper. high-flow diaphragm valve. can maintain the dust cake with minimal increase in pressure. A timer controller monitoring the differential pressure (DP) and pulsing accordingly.Normal Gold Cone Operation 31 . Figure 400.Farr Gold Series® 400. you can increase initial efficiency of your collector (see Section 340 – Precoating of filters). the high efficiency of these cartridges is due to the dust layer or “cake” formed on the surfaces of the media. Figure 400. • Interception – Particles that do not cross the fluid streamlines come in contact with fibers because of the fiber size. increasing the probability of contact between the particles and collecting surfaces. This “pulse” of air dislodges the accumulated dust from the filter element. Each pulse cleans one row of filter cartridges leaving the remaining cartridges available to continue filtering the ventilation air. Figure 400. The media primarily provides a surface on which dust particles collect through the following four mechanisms: The Gold Cone cartridge elements are sequenti-ally cleaned by back flushing with air.2 . • Brownian Movement – Sub-micron particles are diffused. The filter must be cleaned periodically. • Inertial Collection – Dust particles strike the fibers placed perpendicular to the airflow direction instead of changing direction with the air stream.2 Filter Cleaning The filter media can be made of several different fabrics and materials depending on the application. • Electrostatic Forces – The presence of an electrostatic charge on the particles and the filter can increase dust capture. The dislodged dust then drops into the hopper or collection drawers.2 shows a Gold Cone cartridge in normal operation. However. which eventually increases the resistance to air flow. This allows the cleaning to take place without the need to stop the ventilation system. By pre-coating your filter with a special dust at start-up. This momentary airflow reversal is induced by a short burst of compressed air. A balance must be maintained between having some dust cake formation to improve efficiency and an acceptable increase in pressure drop.3 demonstrates the pulse of compressed air cleaning a cartridge. The air is released from the compressed air reservoir by a fast-acting. A combination of these mechanisms results in formation of the dust cake on the filter. This allows the air in the header to be released into the pulsejet blowpipes. These nozzles are positioned above.2 and 7. The resulting difference in air pressure between the upper chamber and the compressed air reservoir allows the diaphragm valve to open.62 and 0.2 bar). the opening of the filter cartridge. dislodging the dust from the filter cartridge. Diaphragm valves on the collector operate one (1) pulsejet blowpipe each. dry compressed air between 0. As the pulse of air reaches the nozzle. The size of the diaphragm valves is 1” or 1-1\2”. Supply the header with clean. an air regulator and a pressure gauge. all located near the unit. a filter/ separator. See Section 600 .3 . The automatic timer control energizes the solenoid. SOLENOID/DIAPHRAGM VALVES Solenoid-operated valves on the collector operate one (1) diaphragm valve each. The air supply line should be equipped with a manual shut-off valve. and directed into. depending on the size of the collector. NPT coupling at each end.72 MPa (6. When the plunger moves.Pulse jet cleaning components 32 . creating the potential for eye injury. WARNING! Risk of personal injury! Use caution when working near an operating collector. which causes the plunger in the solenoid to move. air in the upper chamber of the solenoid is released to the atmosphere. HEADER (COMPRESSED AIR PRESSURE RESERVOIR) A header is provided with a 1 in. The resulting shock wave travels down the length of the inside of the filter cartridge. Wear appropriate ear and eye protection! Hearing damage can result from high noise levels generated during filter cleaning or “pulsing” and collected debris. Do not operate with access doors open! control system remote pilot box diaphragm valve header (compressed air reservoir) puls-jet blowpipe nozzle pulsing air filter cartridge dust dust Figure 400. near the diaphragm valve discharge.Farr Gold Series® 400.3 Cleaning System Components PULSEJET BLOW PIPE Each pulsejet blowpipe contains one (1) nozzle for each cartridge. it is accelerated through the smaller diameter. may become a projectile.Replacement Parts Lists for the size of diaphragm valves on your collector. refer to Section 340 of this manual. Air to cloth ratio m3/m2 h Figure 400. Refer to your General Dimensions drawing for the Air to Cloth Ratio (ACR) for your collector. Power requirements may vary and will depend on what equipment was provided with the collector.2 bar). Lock the damper in position. Be sure to follow all lock-out/tag-out procedures. Close the fan damper to approximately 25% of its designed operational setting. cartridges and compressed air connections. cfm/sqft Pressure loss (Pa) Initial pressure loss vs. even if the collector is insulated. For processes generating hot or moist gases. electrical wiring. Compressed air should be regulated Perform a routine system check to be sure all systems and components are operational.4 33 . ductwork.2 and 7. Adjust the damper until the pressure gauge registers the pressure drop obtained from the graph. Trained and experienced personnel should make the selection of the fan that you require. Make a routine check of the fan.4) to determine the pressure drop. The selection of fan size is usually made from a fan performance table or a fan curve published by the fan manufacturer.62 and 0. Make sure the fan rotates in the direction indicated by the wheel rotation arrows on the fan. Use the graph (Figure 400. If your fan does not include an information packet contact the fan supplier. Restore compressed air and electrical power to the collector.4 Fan Operation between 0.72 MPa (6. Note: Operating the collector above the designed airflow will cause the collector to plug. discharge devices. If the elements are to be pre-coated. The system is now ready for operation. Activate the collector fan and dust removal devices. Make sure the collector doors are closed and latched and the butterfly valve is in the open position. Refer to your General Dimensions drawing to determine the airflow rate and static pressure required for your application. If Camfil APCsupplied your fan.Farr Gold Series® 400. preheat the collector to prevent moisture condensation. contact Camfil APCCustomer Service. Consult the information packet attached to your fan before proceeding with installation and wiring. Adjusting the settings above would only be necessary on the most aggressive applications. shorter cartridge life. These settings represent a recommended starting point and the optimum operation settings may vary for your application. these adjustments may have to be reversed as the filters age.37 kPa Stops differential pressure cleaning. 4.5 kPa after this period. To optimize the cleaning system operation for continuous cycle cleaning. If your system is set to operate on differential pressure cleaning then the cleaning system will automatically use the minimum amount of compressed air to maintain stable operation of the dust collector. You would decrease this value if your application involves high dust loads and dust that does not easily release from the cart- ridge.75 kPa. perform the following procedure: CAUTION: Over cleaning the cartridges will result in higher emissions. 1.5 kPa Initiates differential pressure cleaning. This will also result in longer cartridge life.Farr Gold Series® 400. the cleaning system can be adjusted to reduce air consumption. and higher energy costs. If the pressure is less than 0. 2. Increase the pulse frequency by 2 seconds or 1 step.5 to 0. If your system is set to clean continuously then it would be beneficial to take the time to adjust the settings to achieve stable operation with the least amount of compressed air consumption. High Alarm 1. Low dP Set Point 0. Repeat steps 2 and 3 until the dust collector stabilizes at 0. 3. Make sure the timer is set at the recommended settings above at start up. Monitor the pressure on the collector for 4 weeks. Decreasing this value will increase compressed air consumption. 34 . High dP Set Point 0.5 Recommended Controller Settings The following settings apply to any model timer that is shipped with a Farr Gold Series Dust Collector.5 kPa This value will protect the cartridges from damage due to high differential pressures. Pulse Frequency (off time) 15 seconds Increasing this value will decrease compressed air consumption. On applications with light dust loads this value can be increased to conserve compressed air. Note. breathing mask and gloves when doing servicing and repairing work inside the system. Dispose of any waste accumulation according to federal. The collector is now ready for replacement of the cartridges. Empty and replace full collection containers frequently. • Before doing any service work. MIE. Under no circumstances should the hopper be used to store collected material. but then climbs much more slowly throughout the rest of their service life.5 kPa water gauge or greater. it will be necessary to continue to pulse the collector for an additional 20 minutes after the fan is shut down. check the hopper or discharge container at the bottom of the unit. as this will inhibit performance of the collector. high heat or other perilous conditions. 8.2 Hopper At the start/end of each shift. The following items should be periodically serviced: WARNING! Risk of personal injury! • Use protective goggles.6 Shutdown Procedure not pulse the unit after the fan is turned off. 3. • Avoid contact or exposure to dust as much as possible during servicing or maintenance. Perform the necessary lock-out/tag-out procedures. In that case the boxes must be cleaned. Tools used for service works on the dust collector then also must be approved for explosion hazardous areas. Do not over fill containers. Check the tracks located on either side of the gate for dust accumulation. If the cartridges are going to be replaced with this shutdown. especially when replacing the filter cartridges and emptying the dust container. • Disconnect electrical power before servicing. the gate should remain open allowing the collected material to flow freely into the discharge container. This will assure that the cartridges are clean and much lighter for removal. install a heater or allow a warm air stream to flow through the collector while it is shutdown. maintenance. This will also purge much of the process moisture that may be still in the collector. • If the Minimum Ignition Energy. If the collector is located outside or is subject to condensation formation. and cleaning mechanisms for at least 20 minutes to assure good removal of the collected dust. they have reached the end of their service life and require replacement. Turn off power to the controller. 6. 500. clean the working place and all surrounding areas. • The Control Box must not be opened or be disconnected from cables if there is explosive dust in the atmosphere or dust cover on the boxes. Continue operation of the fan. Locate the handle on the front of the butterfly valve (if equipped) and pull to ensure that the gate is open. or other electrical equipment. state and local environmental regulations. or storage. the service personal must use shoes and other clothes specially designed to be used in explosion hazardous areas. of the dust is less than 10 mJ. During operation.1 Filter Elements Pressure drop across Gold Cone filter elements normally increases rather rapidly when the filter elements are new and clean. 7. 5. (Note – if the cartridges are not to be removed do SECTION 500 . dust removal device. as this will remove the filter cake already formed on the cartridges). discharge devices. Shut off the fan and perform the necessary lock-out/tag-out procedures. 2. Other indications for replacement are cartridges that have been in service over 2 years or cartridges that have been damaged by moisture. when the Gold Cone elements cannot be cleaned below a differential of 1. 35 . 1. Shutdown the process or dust generating operation to which the dust collector is installed. • Shut-off and bleed compressed air supply before servicing any compressed air components. Close the compressed air line valve and perform the necessary lock-out/tag-out procedures. Typically. Remove any build-up to maintain free operation of the gate. 500. 4.PREVENTIVE MAINTENANCE Your Farr Gold Series Dust Collection system requires very little maintenance to achieve maximum life and efficiency.Farr Gold Series® 400. in Farr APC Dust Collection Systems. Misuse of the reservoir may cause injury or death. Check periodically to verify that the board is operating properly and the userdefined settings have not been tampered with. This is strictly forbidden! Doing so may cause irreparable damage and weaken the integrity of the vessel.2 and 7. Check the enclosure periodically to ensure that no condensation is forming on the inside and that dust has not collected on the circuit board or inside the enclosure. If you find significant damages or corrosion replace the tank. Verify periodically that the operating pressure is between 0. Periodic application of a quality automotive wax will prolong the life of painted surfaces and make them easier to clean. 500. 36 .2 bar) in pressure.72 MPa (6. Examine the unit for any damage to the surface coating and repair as necessary.2 bar). • Use the reservoir for its intended purpose only. Check each valve periodically to see that it is operating properly and if required. Dirt and moisture can damage the timer board.62 and 0. add to. • Do not alter. Inspect the reservoir for damage or corrosion.6 Pressure vessels Drain condensate periodically.5 Cleaning and Repair The external and internal surfaces of the unit should be treated as any other painted metal surface subject to corrosion. Keep the external surfaces clean to prevent the possibility of hidden damage occurring. as moisture will damage the filter media.3 Solenoid and Diaphragm Valves SAFETY AND WARNING! The solenoid and diaphragm valves may require periodic maintenance depending on the quality of the compressed air supplied to the unit. • In case of fire. thus causing an explosion hazard. (Compressed air tank(s)) Risk of personal injury! • Never attempt to disconnect or remove any connecting component of the pressurized system before bleeding off pressure and performing lockout / tag-out procedures on the pressure source. Refer to separate instruction manual regarding the Control System. 500. or weld on to the reservoir. • Do not exceed 0. • A damaged reservoir must not be pressurized until it has been appraised by a qualified pressure vessel inspector. Never attempt to repair a damaged reservoir.82 MPa (8. • Replace reservoir if it has been exposed to temperatures above 93.4 Control System (if equipped) The automatic timer control does not require any routine maintenance. 500.3 ºC (200 ºF). immediately depressurize reservoir.Farr Gold Series® 500. 7 Inspection Log Copy and use this inspection log. ( Semi-Annually ) ) ) ( ( ( Record pulse duration. Safety inspection (See section 500. Check all bolts and welds. Clean compressed air filter tap. It should be maintained to assure that a proper maintenance routine is followed.9) ) ) ) ) ) ( ( ( ( ( KPa Y/N Y/N Y/N Y/N Y/N KPa Y/N Y/N Y/N Y / N Y / N KPa Y/N Y/N Y/N Y/N Y/N ( ( ( KPa ) ( ) ( ) ( KPa ) ( ) ( ) ( KPa ) ) ) ) ) ) ( ( ( ) ) ) ( ( ( ) ) ) ( ( ( ) ) ) ( ( ( ( ) ) ) ) ( ( ( ( ) ) ) ) ( ( ( ( ) ) ) ) ( ( ( ( ) ) ) ) ( ( ( ( ( ) ) ) ) ) ( ( ( ( ( ) ) ) ) ) ( ( ( ( ( ) ) ) ) ) ( ( ( ( ( ) ) ) ) ) Notes/Comments 37 . ( Check pulse pipe alignment. etc. ( Annually ) ) ) ) Check case/support for corrosion. ( Record pulse delay. ( Check that hopper is empty. ( Monthly KPa ) ( ) ( ) ( KPa ) ) ) Are there leaks in access doors? ( Check door seals for deterioration. Check ductwork for build up of dust. ( *Check fan.Farr Gold Series® 500. ( Check tube sheet for filter leaks. ( Check air lines & fittings for leaks. Date Time Inspector Daily Record Differential Pressure (dP) KPa Is timer sequencing. row by row? Y / N Are solenoids operating? Y / N Are Diaphragm valves firing? Y / N *Hopper discharge device operating? Y / N Any visible stack emissions? Y / N Weekly KPa Y / N Y / N Y/N Y / N Y / N Record compressed air pressure. Bag dye penetrate test. belt tension. Check screw conveyor and/or airlock for wear or abrasion Check fan belts Check welds Annually Inspect hopper for wear Check explosion vents.8 Suggested Preventative Maintenance Schedule Frequency Procedure Daily Check controller and pressure drop Observe stack (visual or with opacity meter) Walk through system. listening for proper operation Check for unusual occurrences in process Observe control panel indicators Assure that dust is being removed from system Weekly Inspect screw conveyor/airlock bearings for lubrication Check packing glands Operate damper valves Check compressed air lines.9 38 .Farr Gold Series® 500. including line filters and dryers Check that valves are opening/closing properly in sequence Spot-check cartridge appearance Verify accuracy of temperature-indicating equipment Check pressure drop indicating equipment for plugged lines Monthly Inspect fans for corrosion and material build-up Check drive belts for wear and tension Inspect and lubricate appropriate items Spot check for filter cartridge leaks Check hoses and clamps Check accuracy of indicating equipment Inspect housing for corrosion Quarterly Inspect inlet baffle for wear Inspect filter cartridges thoroughly Check duct for dust build-up Observe damper valves for proper seating Check gaskets on doors Inspect paint. etc. see Section 500. see Section 340 Safety inspection. insulation. If the panel is in any way damaged it must be replaced.9 Safety inspection of Farr Gold Series dust collector NOTE: This inspection must be performed by a competent person familiar with explosion safety and dust collection systems. a mechanical isolation valve or a burst detector on an explosion vent panel. • If the system is protected by an explosion suppression system. • If the unit is protected by venting.10).Farr Gold Series® 500. The stop signal can come from several sources such as a suppression system. • Check that all metal parts in the collector are electrically bonded (See procedure 300. There shall be no significant obstructions in the vent area and no combustible or loose material shall be stored in the area. Test each installed detector individually and ensure that the pulse controller. Check that the hose is undamaged and properly attached in both ends. 39 . If the hose or the clamps are damaged they must be replaced with Camfil APC original parts. adapted to the cable diameter and tightened. check that this has been inspected and approved by a competent person according to the instructions from the fan manufacturer. Additional checks for yearly inspection • Verify that the units use (Dust/-s and application) is the same as the originally stated intended use. • Check that the electrical system is correctly installed according to the system manual.11). • If the filter unit is equipped with an ATEX approved fan. verify that the risk area is clearly marked and if required in the risk assessment fenced off. verify that this has been inspected and tested by an approved service engineer from the supplier. Verify by testing that the system stops in case of an explosion. Verify that this has been inspected by a competent person. Pay special attention to cable glands that should be of the correct ATEX approved type (if required). if this is required to maintain the approval. • Check that the units doors seals (See procedure 500. If this has changed the unit should not be used until Camfil APC technical support has verified that the new use is safe. • If the system is protected by venting check that the vent panel is undamaged. • If the unit is equipped with a hose connecting the unit to a collecting drum. fan and any other accessories stop directly. • If the system is equipped with an explosion isolation valve. • Emergency stop in case of explosion. 4 . Increase door gasket compression only when test fails.10.5 . A properly compressed gasket should not allow paper to be removed.10.Loosen bolts and insert one shim 40 .Use either 1.5 mm.10 Checking the Door Seal Door Adjustment Instructions Check door gasket compression by consecutively closing and clamping door gasket onto a 100 x 200 mm strip of standard copy paper.10.3 Instructions for Increasing Door Gasket Compression Figure 500. Or 3 mm shim (the unit comes with 2 of each) Figure 500. Do not use excessive force. as this will cause the paper to tear and/or the gasket to roll. Make sure paper is inserted so that gasket compresses against paper.10.10. first at the top. and then lower section of the handle side.2 Figure 500.Farr Gold Series® 500. then middle. Figure 500. when pulling paper laterally with moderate force.1 Figure 500. Check when the last one was made. clean it. Re-test all areas after adding shims. E. SECTION 510 . • Please note that in heavy use it might be necessary to replace cartridges earlier then 6000 h. Listen for the cleaning pulses from the system Are all valves pulsing normally? . • If it is blocked.No D. Check the designed air flow against the actual airflow Measure the air flow. • When the system is stopped the control system will show number of hours in operation. Inspect the cartridges • Check if the surface of the cartridges is blocked by firbrous dust. • If the cartridges have been running for more than 6000 h replace them.7 . Is the actual flow higher than the design air flow? . F. please contact Camfil APC for advice. You may need another type of inlet and overbags. new additives. Check if the process the filtered air is comming from has been changed.Farr Gold Series® Figure 500. contact Camfil APC for advice. . • If the dust/fume generating process is changed significantly the performance of the dust collector can be affected. increasing the power of a machine or working more intensely.10. 41 . • Significant changes can for example be.Yes --------> If it is not possible to adjust the flow back to the intended value. • If inlet blockages from the product being filtered re-occurs. working with another material. • If you suspect that there has been a significant change contact Camfil APC for advice.Add additional shims for any other areas that require gasket compression.Verify shim is in place and retighten bolts Figure 500.No --------> Go to cleaning system section of this guide. C. Inspect the inlet.Yes B. . We recommend that overbags are installed. • All cartridge changes should be noted in the user manual. Check how long the cartridges have been used.TROUBLESHOOTING High pressure drop / Low air flow A.10.6 . Verify that the supply has sufficient capacity. • If the problems continue we recommend that the unit is moved to a heated space or insulated. • Bleed of the pressure. Check that the compressed air drier is working and that the dew point is 2 C or less. B.Farr Gold Series® G. D.7 Bar). 42 . • This problem is typically caused by contaminated compressed air. See page 21 for data.62 . • If one or more valves does not clean at all. If the dust collector is sited outside or in an unheated space. Air consumption depends on valve size and pulsing frequency. Check that the compressed air supply is connected and supplying 0. Examine the membrane for damage and if necessary remove any contaminants.0. • Remove the pilot valve body from the RPB and disassemble the valve. • If the problem re-occurs it may be necessary to clean tanks and pipes by blowing them with compressed air. in the duct leading to the collector. C. A. • We also recommend that the collector is flushed with clean air a while before shut down. • Carefully reassemble the cover. • Check if the dust inside the collector is agglonomerating. Go to the control system problems section. Make sure that the air supply is filtered. • We recommend that the collector is pre-heated with clean air for a short while at the start up before dust load is applied.72 MPa (6 . especially from the bleed hole in the membrane. Verify that the supply pipe is at least 1” (R25) and that no restrictions for example quick couplings are used. If one or more valves are closing slowly or making abnormal noise. E. • It is recommendable to install an off line damper. This will close when the collector is out of operation and prevent natural draft that can cause condensation. making sure that the closing spring is in place. Remove the cover from the pulse-jet valve. • Clean the inside in the same way as the pulse-jet valve. Cleaning system problems WARNING! Risk of personal injury! Close supply valves and bleed the pressure from the compressed air tanks before any components of the cleaning system are removed or opened. PTFE Membrane B DPO-225EG .Hi Eff. 10m cable GS Controller main board GS Controller complete GS ATEX Controller complete GS ATEX Controller cover GS Controler Cover Self cutting GS Bolt 15 + 10 RPB-5 Way Pilot Box ExII 3D/G RPB-3 Way Pilot Box ExII 3D/G RPB-2 Way Pilot Box ExII 3D/G RPB-6 Way Pilot Box ExII 3D/G DP Transducer-Gold Controller Pressure Switch Compressed Air RPB-4 Way Pilot Box ExII 3D/G BIBO replacement kit GS 10. always refer to your bill of lading or original packing slip.Hi Efficiency BIBO HMPTC-325EG . * 84416016 * 84416012 * 84404000 * 50032 * 50029 212443001 208721001 204574001 74492000 50031 50030 50028 50026 50025 50024 50023 50022 50021 50020 50014 50013 50012 50011 50010 50009 50005 * 212055010 * 212055008 * 212055006 * 212055004 * 212055002 Description Camfil APC Part no.Durapleat Oleiphob B DPA-225EG .Durapleat BIBO HMPTC . FR 30 m2 HMPTU325 . To know what specific filters and components match your specific collector and application.Carbon 30 m2 HMPTS325 .Fire Retardant 30 m2 HMPTC325 . 12 BIBO replacement kit GS 8 BIBO replacement kit GS 6 BIBO replacement kit GS 4 BIBO replacement kit GS 2 212492005 212492002 212492001 211497014 211497006 211497005 211497004 211497002 211497001 207087001 205637004 205637003 205637002 205637001 212500004 212500003 212500002 212500001 212492008 212492007 212492006 212492004 HMPTU-325EG . 21 m2 DPO–Durapleat Oleophobic 21 m2 DPA–Durapleat Antistatic 21 m2 DPS – Durapleat Standard 21 m2 DPT-225EG .STANDARD REPLACEMENT PARTS LIST This list is meant to be a general listing of common replacement parts and equipment that you will need to keep your dust collector operational long into the distant future.Carbon BIBO HMPTS-325EG .Polytech Std 30 m2 Overbag for Gold Cone cartridge DPT–Durapleat PTFE Mem.325EG-Fire Retardant BIBO 43 . Description Filter Cartridges Diaphragm Repair Kit 1 1/2” DD Diaphragm Repair Kit 1” DD APC GS Pamic Filter GS Controller fuse kit Solenoide valve RPB BIBO Bag tool kit Cartridge Removal Tool Door gasket Rope Caulk Pulse valve 1 1/2” DD Pulse valve 1” DD Door gasket 1/2 size door Level sensor ATEX.Hi Eff.Hi Eff 30 m2 HMPTF325 . Carb.325EG W/GrndStrp-HiEff B HMPTUF .Durapleat AntistaticB DPS-225EG .325EG-HiEff Fire Ret BIBO HMPTF . * Recommended spare parts Camfil APC Part no. 30 m2 HMPTUF325 .325EG SST Screen-Carbon HMPTU .Farr Gold Series® SECTION 600 .Polytech Std BIBO HMPTUC325 . Farr Gold Series® AIR POLLUTION CONTROL .