Amada ADF4 User manual

© 1999 Amada 1IOM-75458-01
Revision1
Amada
Installation and Operation Manual
with Replacement Parts List
Cartridge Filter Dust Collector
Amada ADF4
IncludesInstallation,Operation,ServiceInstructions
andReplacementPartsList
This manual contains specific precautionary statements relative to worker
safety. Read thoroughly and comply as directed. It is impossible to list all
potential hazards of dust control equipment. Discuss the use and application
of this equipment with an Amada representative. Instruct all personnel
involved with this equipment on safe use and maintenance procedures.
IMPORTANT

© 1999 Amada2
NOTE CAUTION
Statementsindicateprecautionsnecessary
toavoidpotentialequipmentfailure. Statementsindicatepotentialsafetyhazards.
CAUTION
APPLICATION OF DUST CONTROL EQUIPMENT:
•Special care must be exercised in the use
of dust collection equipment when
combustiblematerial,suchasbuffinglint,
paper,wooddust,aluminum,and
magnesiumdustarepresent.These
materialsmaypresentafireorexplosion
hazard. A prudent user of Amada
equipmentshouldconsultand must
complywithallNationalandLocalFire
Codesand/orotherappropriate codes
whendeterminingthelocation and
operationofdustcollectionequipment.
•Under no conditions should anyone,
includingthemachineoperator,allow
burningobjectsorlitcigarettestoenter
the hood or ducting of any dust control
system.
•Avoidmixingcombustiblematerialswith
dustgeneratedfromgrindingofferrous
metalsdue to the potentialfire hazard
caused by sparks being pulled into the
dustcollectionequipment.
•When collection equipment is used to
collectflammableorexplosivedusts,the
dustcollectionequipmentshould be
locatedoutsidethebuilding.Also,an
installeroffireextinguishingequipment,
familiarwiththetypeoffirehazard and
localfire codes, should beconsulted for
recommendationsandinstallationofthe
properfireextinguishingequipment.
Amada equipment does NOT contain
fireextinguishingequipment.
•Explosionreliefventsarerequiredon
someapplications.Consultwithan
insuranceunderwriterora NFPA
Manualtodetermineproperventsizing
requirements.Vents installed on dust
collectionequipmentmustrelievetothe
outsideofthebuildingtominimize
chancesofasecondaryexplosion.
Consult the proper authority to
determine proper method of venting the
dustcollectionequipment.Amada
equipmentdoesNOTcontain explosion
reliefvents,exceptonspecialorder.
•Toinsureoptimumcollector
performance,alwaysuseTorit®Ultra-
Web®IIFRreplacementfilters.

© 1999 Amada 3
Notes and Cautions................................ 2
Data Sheet............................................... 3
1.0 Introduction............................................. 5
1.1 Operational Explanation ....................... 5
1.1.1 Normal Operation .................................. 5
1.1.2 Filter Cleaning ........................................ 5
2.0 Quick Start .............................................. 5
3.0 Installation .............................................. 6
3.1 Inspection ................................................ 6
3.2 Equipment/Tools Required .................... 6
3.3 Preinstallation ......................................... 6
3.4 Assembly of Standard Equipment ......... 7
3.4.1 Delta P Control....................................... 7
3.5 Electrical Operation ............................. 10
3.6 Compressed Air Supply Installation ... 11
4.0 Prestart-Up Check ................................ 11
5.0 Start-Up................................................. 12
6.0 Operating Adjustments ........................ 12
6.1 Delta P Control Calibration ................ 12
6.2 Timer Board Adjustment,
NEMA 4 Enclosure .............................. 13
6.3 Airflow Adjustment.............................. 13
6.4 Operating Checks................................. 14
7.0 Service ................................................... 14
7.1 Filter Cartridges ................................... 14
7.1.1 Filter Cartridge Removal..................... 14
7.1.2 Filter Cartridge Installation................. 16
7.2 Dust Removal ....................................... 16
7.3 Original Equipment Filter Cartridge .. 16
7.4 Compressed Air Components .............. 16
8.0 Troubleshooting Guide ........................ 17
Replacement Parts List ........................ 23
Parts Ordering Information ................. 36
Warranty............................................... 36
TableofContents
Figure 1 -Typical Installation ........................ 4
Figure 2 -Operational Schematic .................. 5
Figure 3 -Delta P Display .............................. 8
Figure 4 -Printed Circuit Board ..................... 9
Figure 5 -Filter Cartridge Replacement...... 15
Parts Drawing 1 -ADF4 Dust Collector ........ 24
Parts Drawing 2 -Cover Assembly ................. 26
Parts Drawing 3 -Manifold Assembly............ 27
Parts Drawing 4 -Solenoid Enclosure
Assembly, NEMA 4 ........... 28
Parts Drawing 5 -Delta P Control.................. 29
Parts Drawing 6 -ADF4 Control Box............. 30
Parts Drawing 7 -Venturi................................ 31
Parts Drawing 8 -Dust Bin .............................. 32
Figures
Customer Name
Address
Shipping Date Installation Date
Model Number Serial Number
Filter Medium
Accessories
Other
Data SheetData Sheet

© 1999 Amada4
Figure1
TypicalInstallation
Customer-Supplied
208V,3Ph
PowerSupplyand
DisconnectSwitch
Regulator
Setting:90to100-psi
CoalescingFilter
Customer-Supplied
CompressedAir
Locate as close to
collectoraspossible.

© 1999 Amada 5
1.0 Introduction
The Amada dust collector is used for the
collection of airborne dust and particulate.
Whether in answer to the problem of air
pollution, or as part of a manufacturing process,
this collector provides highly efficient,
continuous, on-line dust collection.
The Ultra-Web II FR filter cartridges are the
heart of the Amada dust collector. These filter
cartridges help ensure that only clean air is
returned to the plant environment.
Technical and field support are always available
from your local Amada representative and
distributors.
Figure2
OperationalSchematic
1.1 OperationalExplanation
(SeeFigure2)
1.1.1 NormalOperation
During normal operation, contaminated air
enters the ADF4 dust collector through the inlet
and passes down and through the filter
cartridges. Dust is collected on the outside
surface of the filter cartridges. The clean,
filtered air flows through the center of the filter
cartridges into the clean-air plenum, where it
exits through the clean-air outlet.
1.1.2 FilterCartridgeCleaning
Filter cartridges are cleaned automatically and
sequentially. The result is that only one filter
cartridge will be off-line at any given time.
Clean-AirOutlet
Dirty-AirInlet
NormalOperation FilterCleaning
High
Pressure
AirSupply

© 1999 Amada6
During the filter cartridge cleaning purge, the
solid-state timer energizes a solenoid valve,
causing the corresponding diaphragm valve to
send a pulse of compressed air through the filter
cartridge from the inside outward, removing the
collected contaminants from the outside surface
of the filter cartridge. The dust falls into the
hopper and then into the dust storage container.
2.0 QuickStart
(SeeFigure1)
This section provides the basic steps to be
completed before operation and is for reference
only. Follow all guidelines in Section 3.0,
Installation.
1. Connect 208-V, 3-Phase power.
2. Check that fan rotation is clockwise.
3. Connect compressed air with pressure
regulator and filter.
4. Connect duct to unit.
5. Ready to start up.
3.0 Installation
(SeeFigure1)
3.1 Inspection
The unit is normally shipped by truck and
should be checked for any damage that may
have occurred en route. Any damage should be
noted and the carrier notified immediately.
3.2 Equipment/ToolsRequired
Typical tools and equipment required to install
and assemble the unit:
•Crane or Forklift
•Slings/Spreader Bars/Clevis Pins
•Drift Pins
•Clamps
•Screwdrivers
•Pipe Wrenches
•Socket Wrenches
•End Wrenches
•Large Crescent Wrench
•Pipe Sealant
•Caulking Gun
3.3 Preinstallation
(SeeFigure1)
The Amada dust collector is usually mounted on
a reinforced concrete foundation; however, roof
mounting is also possible. When calculating for
foundation or roof mounting, the weight of the
dust collector plus the material being collected
and all auxiliary equipment must be considered
together with wind, seismic, and other live loads.
See the Specification Control Drawing for the
dust collector weight.
To avoid delay, install foundation in the proper
location. Pay particular attention to the anchor
bolt size and location. The collector should be
located with consideration for emptying the
hopper storage area, shortest runs of inlet and
outlet ductwork, electrical and compressed air
connections, and convenience of maintenance. In
case of hazardous dust collection, consult with
local authorities for the proper location of the
dust collector.
Location must be free of obstructions, such
asutilitylinesorroofoverhang.See
SpecificationControlDrawing.Acrane
must be used to position the collector.
CAUTION

© 1999 Amada 7
3.4 AssemblyofStandardEquipment
(SeeFigure1)
Remove all crating and strapping from the unit.
Remove all miscellaneous parts such as bolts,
nuts, or loose components before lifting the unit
off of the truck. Check the parts received
against the packing slips. If there are parts
missing, the carrier and your local Amada
Representative should be notified immediately.
NOTE
NOTE
3.4.1 DeltaPControl
•Connect the lifting sling to the four (4)
cabinetliftinglugs.
•Use clevice pins, not hooks, on the
liftingsling.
• Do not lean unit on legs.
A crane or forklift is recommended for
unloading,assembly,andinstallationof
thedustcollector.
Each item to be attached to the collector is
accompaniedby a drawing thatshows the
attachment process. Refer to both the
drawingandthismanual to install the unit.
CAUTION
CAUTION
•Allelectricalworkmustbeperformed
byaqualifiedelectricianaccordingto
allapplicablenationalandlocalcodes.
•TurnelectricalpowerOFFduring
installation.
•Donotapplyinclassifiedhazardous
atmosphereswithoutanappropriately-
ratedenclosure.
NOTE
•Donotmountcontrolsinhigh-vibration
areaswithoutshockmounts.
•Donotmount controls incorrosive
atmosphereswithoutanappropriate
enclosure.
•Do not operate with enclosure open.
CAUTION
Static-FreeElectronicAssembly
•Usepropergroundingandhandling
procedurestopreventpermanent
damagetothisdevice.
•Handleprintedcircuit board bythe
edgesonly.
•Avoid touching the socketed E2PROM
pins.
NOTE
Ingroundedsystems, connect neutralto
control box to terminal L2 of the solid-state
controltimer.

© 1999 Amada8
1. Using the wiring diagram provided with the
control, wire the alarm circuit labeled
AUXILIARY, if desired. When the pressure
drop reaches the preset alarm value, the
relay will actuate and the LED light
ALARM, on the user interface, will
illuminate. The relay can be used to actuate
visual/audible alarms (by others).
2. Check the tubing to the high and low
pressure ports on the control enclosure. The
high-pressure connection goes to the dirty-
air, or filter side of the collector. The low-
pressure connection goes to the clean-air
side of the collector.
Figure3
DeltaPControlDisplay
3. Apply power to the Delta P Control and
timer. Adjust the setpoints for the high- and
low-pressure drop. These are the pressure
drop setpoints that start and stop the
cleaning process, and the alarm setpoint.
NOTE
Do not attempt to adjust the ON or OFF
time.Thesevaluesarefactorysetfor
maximumperformanceofpulsingsystem
andminimumcompressed-airuse.

© 1999 Amada 9
determine the current settings, but will not
allow any changes until the jumper wire is
removed. Installing a key-operated normally
closed switch through the door of the
enclosure that interrupts the jumper wire,
will provide temporary access to the setting
function without opening the control
enclosure.
3.External Alarm reset
Locate the ARM RESET (TB2) terminal
block in the lower right quadrant of the
printed board. Wire this terminal block to a
key-operated normally open switch. Closing
the switch will turn off the alarm. If the
alarm conditions still exist, the alarm relay
will latch on again in 10 seconds.
OptionalSettings
(SeeFigure4)
1. Change from English to metric units
Locate the jumper block labeled J1, just
above the PROG DISABLE terminals at the
bottom edge of the printed circuit board.
Remove the jumper from the center and left
pins (2 and 3), and reinstall on the center
and right pins (1 and 2).
2.Disabling the setpoint adjustments
To restrict the ability to change the
setpoints, install a jumper wire across the
PROG DISABLE terminals on Terminal
Block 2 (TB2). This will allow the operator
to press the appropriate set keys to
Figure4
PrintedCircuitBoard
Alarm Disable
Alarmor
AuxiliaryRelay
Hi/Lo Timer
ControlRelay
{ {
{ {
Remote Alarm Reset
DisableProgramming
Units ("wg or mm wg)
PowerConnections
VoltageChoiceJumpers

© 1999 Amada10
4.Disable the alarm
Locate the MODE (J5) jumper block in the
lower right quadrant of the printed circuit
board. Remove the jumper from the alarm
position. Disabling the alarm relay reduces
the alarm function to lighting the LED on
the user interface.
1. Reinstalling the jumper in the SLAVE
position—upper and middle pins—causes
the AUXILIARY relay to operate in
parallel to the HI/LO CONTROL relay.
2. If the jumper is not installed in either
position, the AUXILIARY relay does not
function.
5.Analog Output
Locate the SENSOR (TB4) terminal block in
the upper left quadrant of the printed circuit
board. This connector provides a 1 to 5
VDC output proportional to the 0 to
maximum span of the pressure sensor,
10K ohm load minimum.
3.5 ElectricalOperation
Each dust collector comes equipped with 115-
VAC solenoid valves that control the pulse
cleaning valves, which clean the filter
cartridges.
Make the proper electrical and pneumatic
connections to the collector and motor starter
per the diagrams and instructions supplied with
the control panel.
Verify proper blower rotation by pushing the
start-stop button on and off very quickly. The
rotation should be clockwise when looking
down at the top of the motor. Also reference the
rotation sticker on the fan housing. Proper fan
rotation is extremely important.