Camcorp Pulse-Jet Instruction manual

Installation, Operation,
& Maintenance Manual
Unique Design & Engineering
Approaches for Industrial
Applications
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CAMCORP, INC.
Phone: [phone] Fax: [phone]
www.camcorpinc.com
TABLE OF CONTENTS
Section 1 - SAFETY
Safety Recommendations ............................................................................ 1-1
Section 2 - RECEIVING
Receiving & Inspection of the Unit............................................................. 2-1
Storage Recommendations .......................................................................... 2-2
Section 3 - INSTALLATION
Setting Up Your Unit................................................................................... 3-1
Bag & Cage Installation .............................................................................. 3-5
Electrical Wiring Diagram......................................................................... 3-11
Magnehelic Gauge Connections................................................................ 3-12
Explosion Vent Installation ....................................................................... 3-13
Section 4 - OPERATION
Operating Principle...................................................................................... 4-1
Start-Up Check List..................................................................................... 4-2
Start-Up Dust Control Systems ................................................................... 4-5
Shutdown Procedures .................................................................................. 4-6
Section 5 – COMPONENT INFORMATION
Main Component Listing............................................................................. 5-1
Magnehelic Gauge....................................................................................... 5-3
Timer............................................................................................................ 5-7
National Controls Corp – 120 VAC Standard Timer ............................ 5-7
National Controls Corp – 12-24 VDC (Optional) ................................. 5-9
Dwyer Smart Timer (Optional) ........................................................... 5-11
Diaphragm Valves..................................................................................... 5-19
Goyen #RCA20DD – ¾” Valve........................................................... 5-19
Goyen #RCA25DD – 1” Valve............................................................ 5-20
Goyen #RCA45DD – 1 ½” Valve........................................................ 5-21

CAMCORP, INC.
Phone: [phone] Fax: [phone]
www.camcorpinc.com
Section 6 - TROUBLESHOOTING
Dust Collector.............................................................................................. 6-1
Timer............................................................................................................ 6-5
Compressed Air System .............................................................................. 6-6
Section 7 - MAINTENANCE
Routine Maintenance................................................................................... 7-1
Section 8 – APPENDIX
Dust Collector Terms & Definitions ........................................................... 8-1

CAMCORP, INC.
Phone: [phone] Fax: [phone]
www.camcorpinc.com
Section 1 – Safety Recommendations
Because this unit may be under pressure or vacuum do not attempt to open any
device, doors or panels while fans or blowers are running. The unit has air hoses
and valves with a maximum recommended operating pressure of 100 psig. To
eliminate the danger of bursting care must be taken to insure maximum desired
pressure is not exceeded.
Before servicing any portion of the compressed air system the air supply must be
shut off and any pressure relieved.
If your unit is equipped with a discharge auger or an airlock assure that chain
guards are installed before start-up and servicing is attempted only after
electrical power is locked out.
While servicing the filter it is very important that there are no open flames,
welding or grinding sparks. Dust laden air could be highly explosive and extreme
care must be taken. Most filter bags will burn if exposed to sparks, welding or
open flames.
Before entering any dust collector:
• Run cleaning mechanism 20 minutes with the fan off to clean filter bags.
• Completely discharge dust solids from hopper, if applicable.
• Shut off compressed air supply and relieve pressure in the compressed air
manifold.
• Lock out all electrical power on all equipment especially rotating
equipment.
• On toxic operation, purge collector housing and install a blank in the inlet
duct.
• Install catwalks and safety cables as required.
• Secure access doors in an open position or remove doors.
• Use the buddy system.
• Wear a respirator or appropriate breathing equipment.
• Use common sense.
Follow all current OSHA regulations relative to Lockout / Tag-Out and Confined
Space Entry and any other applicable regulations when servicing your
equipment.
On the following page are examples of safety stickers you will find on Camcorp
equipment. These will help identify potential hazards on the equipment.
1-1

Examples of Safety Stickers
CAMCORP, INC.
Phone: [phone] Fax: [phone]
www.camcorpinc.com
------DANGER------
The DANGER &
CAUTION stickers
indicate serious potential
hazards which may result
in serious injury or
possible death. Extreme
care should be observed
when working in these
areas.
-----CAUTION------
1-2
-------OTHER-------
These stickers provide
instruction or helpful
information.
Serial Number Plate
Important information
contained on these is
needed by Camcorp when
calling for parts or service.

CAMCORP, INC.
Phone: [phone] Fax: [phone]
www.camcorpinc.com
Section 2 - Receiving
Receiving the Equipment
Prior to accepting the shipment(s) care must be taken to inspect all
equipment received both for proper count and for damage. Any and all
irregularities must be noted on the carrier’s copy of the shipping receipt to
assist in settling any claims for damage or shortages. All equipment is
shipped FOB point of origin whether on a prepaid or collect freight basis.
ANY CLAIM FOR DAMAGE IN TRANSIT OR SHORTAGES
MUST BE BROUGHT AGAINST THE CARRIER BY THE
PURCHASER.
Once your claim has been filed with the carrier, contact CAMCORP to
notify us of the problem(s). We will then advise the appropriate repair
procedure or recommend it be returned to our factory, depending on the
extent of the damage.
Inspection of the Equipment
Housing, Compressed Air Header and Timer Assembly: Particular
attention should be paid to the sheet metal housing of your collector. The
unit should be inspected for dents, cracks or rips. A dented housing may
seriously affect the structural integrity of the unit. The compressed air
header and timer assembly are very delicate pieces of the unit and must
be checked carefully for any signs of impact, warpage or loose fittings. If
any of these signs are present note them on the shipping receipt and
notify CAMCORP immediately. The entire unit should be checked against
the certified drawings for correctness. CAMCORP should be notified
immediately if there are any discrepancies. No corrections may be made
without the expressed written consent of CAMCORP.
Components: A count should be made of all pieces received and this
should be verified against the carrier’s manifest. Boxes should be
inspected for rough handling, which may have resulted in hidden damage.
2-1

CAMCORP, INC.
Phone: [phone] Fax: [phone]
www.camcorpinc.com
Storage Recommendations
Baghouse, Bin Vent, Filter Receiver, Dirty Air Hopper and Housing
•Housing can be stored outside.
•Equipment must be blocked up to keep the flanges out of the dirt.
•Most units are supplied with a plain unfinished interior. If storage of more
than two weeks is anticipated the interior should be prime coated before
storage.
•Covering the unit with a tarp is recommended to help keep the interior
from rusting or corroding as well as keeping the outer finish in new
condition.
Baghouse, Bin Vent, Filter Receiver, and Clean Air Plenum
•Unit can be stored outside.
•Compressed air header, diaphragm and solenoid valves must be tarped
for weather protection.
•Position unit so water will not get in or remain inside the tube sheet area.
•Unit must be blocked up to keep the flanges, bag cups, venturis and air
header out of water and dirt.
•Ports on diaphragm and solenoid valves must be plugged and taped to
keep insects, dirt and moisture out.
•For extended storage (more than 4 weeks), it is recommended to remove
the timer panel and solenoid valve assembly (if mounted). These
components should be stored inside a cool dry area along with the copper
or black nylon tubing. The solenoids should have all ports capped and
taped to protect from insects, dirt and moisture.
•The unit should be tarped.
Filter Bags & Cages
•Filter bags must be stored inside a cool dry area protected from moisture,
rodents and insects.
•For extended storage the boxes for the bags should be wrapped with
plastic wrap or stretch wrap to protect from moisture.
•If the bags get wet for any reason, immediately lay them out with plenty of
ventilation to dry in order to prevent mold and mildew.
•It is recommended to store the cages inside a dry area if at all possible.
•If an inside location is not available the cages can be stored outside as
long as they are covered by a tarp.
•Cages are generally stored horizontally on pallets to keep them off the
ground.
2-2

CAMCORP, INC.
Phone: [phone] Fax: [phone]
www.camcorpinc.com
Storage Recommendations (continued)
•If cages can be stored horizontally do not stack over three boxes high.
•If the job site is in an area that may receive a significant snow load the
cages must be stored vertically in order to prevent being crushed by the
weight of the snow. Do not stack more than one box high.
Accessory Parts
•This includes all gauges, bag clamps, nylon or copper tubing, valves,
gaskets and other parts not specifically called out.
•These items should be stored inside a cool dry place protected from
moisture, insects, and rodents.
Fan and Fan Accessories
•Fans can be stored outside on a pallet or skid to keep them out of water
and dirt.
•Fan silencers, outlet dampers, and inlet boxes should also be tarped and
stored on a pallet or skid.
•Reference fan IOM manual for long-term storage.
Ducting
•Ducting can be stored outside on a pallet or skid to keep it off the ground.
It should be positioned so that water does not sit on or in the ducting.
•If ducting is unpainted carbon steel it should be at least primed coated
before storage.
•If ducting is already finish coated, it should be tarped to protect the finish.
Knife Gate
•All limit switches, solenoids, and air cylinder ports must be capped and
taped to prevent any moisture or dirt from entering.
•Equipment can sit outside provided it is covered with a tarp and is on a
pallet or skid to keep it out of water and dirt.
•Reference knife gate IOM manual for long-term storage.
2-3

CAMCORP, INC.
Phone: [phone] Fax: [phone]
www.camcorpinc.com
Storage Recommendations (continued)
Isolation Dampers
• All limit switches, solenoids, and air cylinder ports must be capped and
taped to prevent any moisture or dirt from entering.
• Equipment can sit outside provided it is covered with a tarp and is on a
pallet or skid to keep it out of water and dirt.
Rotary Valve
• Rotor and interior of valve should be well oiled with vegetable oil to
prevent rust and to maintain compatibility with product.
• Unit can be stored outside provided it is covered with a tarp and is on a
pallet or skid to keep it out of water and dirt.
• Reference rotary valve IOM manual for long-term storage.
Butterfly (Wafer Valve)
• All limit switches, solenoids, and air cylinder ports must be capped and
taped to prevent any moisture or dirt from entering.
• Unit can be stored outside provided it is covered with a tarp and is on a
pallet or skid to keep it out of water, dirt and sunlight.
• Reference butterfly valve IOM manual for long-term storage.
Level Indicators
• Store these items inside a protected cool dry area.
AC Inverters
• Store these items and all other electrical controls inside a protected cool
dry area.
2-4

CAMCORP, INC.
Phone: [phone] Fax: [phone]
www.camcorpinc.com
Section 3 - Installation
Setting Up Your Unit
CAMCORP dust collectors are shipped either in one piece, fully assembled,
or in two or more sections depending on the unit size and weight. Before
attempting to move the dust collector or any of its sections review both the
certified general assembly drawing supplied from CAMCORP and the
rigging and lifting guidelines included in this manual. Become familiar with
the size and number of sections to be assembled, the orientation of inlet(s),
outlet(s), access door(s) and compressed air header(s), as well as the
number and location of lifting lugs.
Dust collectors of this type are manufactured from steel sheets or plate and
are quite flexible. Therefore, even though care has been taken to maintain
dimensional accuracy and squareness, some difficulty should be anticipated
and temporary bracing in the field may be required.
The following sequential procedure will help to minimize any assembly
difficulties:
STEP 1: Set up the supporting steel for the dust collector level and square.
Precision at this point will greatly help facilitate erection and bolt hole
alignment of the dust collector sections to follow.
STEP 2: Place the hopper with its girth channel on the supporting steel
work. Check for squareness, and for bolthole alignment between the hopper
flange and the girth channel. Apply the appropriate RTV silicone caulk
around the periphery of the hopper flange with one bead on each side of the
boltholes.
STEP 3: Lift the dirty air plenum, with the tube sheet, into place. DO NOT
LOWER THE PLENUM ONTO THE HOPPER FLANGE UNTIL
ALIGNMENT IS ACCOMPLISHED. The silicone caulk makes horizontal
movement very difficult once a load is applied. With the plenum suspended
over the hopper ½” to 1”, begin bolt hole alignment starting at the center of
the plenum and working toward the ends by using tapered drift pins. If the
wall(s) has flexed out of square it will be necessary to pry or pull it back into
alignment. Depending on the size of the unit and the degree of difficulty
hydraulic jacks and come-alongs may be required. When the mating holes
are properly aligned, finish lowering the plenum. Install the remaining bolts,
washers, and nuts and torque to the appropriate specifications.
3-1

CAMCORP, INC.
Phone: [phone] Fax: [phone]
www.camcorpinc.com
Setting Up Your Unit (continued)
Step 4: Check the top of the dirty air plenum for squareness and bolthole
alignment between the dirty air plenum and the tube sheet. Make sure that
the silicone caulk has been applied between the top flange of the dirty air
plenum and the underside of the tube sheet flange. Next, apply the caulk
around the periphery of the topside of the tube sheet flange one bead to
each side of the boltholes.
STEP 5: Lift the clean air plenum into place and assemble in the same
fashion as in STEP 3. Again, do not lower the clean air plenum completely
until preliminary alignment is accomplished. Start drift pin alignment at the
center of the plenum on the compressed air header side since the header
makes access to the flange more limited. When alignment is complete install
the remaining bolts, washers, and nuts and torque to the appropriate
specifications.
All CAMCORP dust collectors are provided with lifting lugs for ease in
handling of the units during field erection and installation. The number and
location of these lifting lugs will vary depending on the model, size, and
weight of the dust collector. Before attempting to rig and lift your dust
collector review the certified general assembly drawing supplied from
CAMCORP to verify the number and location of lifting lugs as well as visually
checking this information on the actual unit. Large units are frequently
shipped in several sections so check the lifting lugs provided on each
section. If these cannot be used or there is some question about lifting lug
location consult the engineering staff at CAMCORP for proper location since
proper care must be taken to prevent damage to housing or its components.
Rigging and Lifting Guidelines
Do not lift the dust collector by any attachments other than the lifting lugs
provided.
Use all of the lifting lugs provided on the dust collector or a section of the
dust collector when making a lift.
If the lifting lugs are located below the roofline of the dust collector or
below the top of the section of the dust collector a vertical pull must be
made to avoid crushing the top of the unit. Use spreader beams to
accomplish this vertical pull.
3-2

CAMCORP, INC.
Phone: [phone] Fax: [phone]
www.camcorpinc.com
Setting Up Your Unit (continued)
Attach tag lines at several locations to help in controlling the unit when
lifted and to prevent spinning or swinging.
The dust collector should be lifted and lowered at a slow, uniform rate
and not allowed to bounce or joggle since this can cause excessive
impact stresses at the lift points.
Compressed Air Manifold: Typically, CAMCORP ships the compressed
air manifold installed complete with diaphragm valves and solenoid
enclosure(s), except when units are over legal shipping width with them
in place.
Doors and Flanges: Hold-downs on doors should only be hand
tightened. Excessive pressure can distort the door panel itself resulting
in leakage. All bolts on flanges should be tight. All ports in the dust
collector not being used must be plugged prior to start-up.
Electrical: A 120 volt 60 Hertz circuit is required to operate the dust
collector’s pulse-jet cleaning system (unless a different voltage for
components was requested). This timer must be wired according to the
wiring diagrams and be provided with a circuit that is free from transient
currents. The timer has a feature called “Demand Pulse” that allows the
output terminals to be energized and de-energized by the high and low
set points of a differential pressure switch such as a Dwyer Photohelic
Series 3000. The “Demand Pulse” terminals are marked “Pressure
Switch”. Do not over fuse.
The NCC pulse timer boards have adjustable pulse duration and interval
(time between valves firing) settings. Before applying power to the timer
always check these settings according to the table below. Since there are
many variances in operations and conditions these are presented only as
initial start-up guidelines. If you experience problems in cleaning of the
filter bags, please contact CAMCORP.
TIMER BOARD ADJUSTMENTS
(Recommended at start-up)
VALVE SIZE PULSE DURATION INTERVAL
¾” .10 to .12 seconds 20 to 25 seconds
1” .10 to .12 seconds 20 to 25 seconds
1-½” .06 to .08 seconds 20 to 25 seconds
3-3

CAMCORP, INC.
Phone: [phone] Fax: [phone]
www.camcorpinc.com
Setting Up Your Unit (continued)
The firing sequence of the diaphragm valves on the dust collector should
be set so that no two adjacent rows of bags fire in succession to insure
maximum cleaning and life of the filter media. This can only be achieved
when wiring the pulse timer board to the solenoid valves. If you are
experiencing a high-pressure drop across the filter bags in your dust
collector the pulse interval should be reduced.
Apply electrical power to the timer and make sure that it is cycling
completely through all rows of the unit. In some cases the timer panel
may have more “positions” than required in which case the position
selector cable needs to be attached to the proper numerical value
corresponding to the number of diaphragm valves on the unit.
If your dust collector was shipped via common carrier rather than a
contract hauler there is a possibility that the solenoid enclosure was not
shipped installed on the unit. If this is the case, there is a mounting plate
welded on the housing or the air header with the bolt pattern of the
enclosure already drilled. Bolt the enclosure and install the nylon (or
copper) tubing with the fittings provided making sure that the solenoids
are connected to their corresponding diaphragm valve.
Valves and Piping: After the unit has been installed the diaphragm
valves should be checked to make sure that the port marked “IN” is
assembled to the compressed air manifold. The “IN” connection of the
solenoid valve is connected to the diaphragm valve by means of ¼” nylon
or ¼” copper refrigeration tubing. Each nut on the compression fittings
should be checked for tightness before the compressed air manifold is
pressurized. In most cases a slip fit fitting has been used. The integrity of
the nylon tubing inside each fitting should be checked by pulling gently on
each tube. If the tube pulls out, simply push it back into the fitting until it
will not go any further. The solenoids are shipped with a plastic plug in
the discharge side of the valve. These plugs must be removed for proper
operation.
Gauges: The differential pressure gauge, mounting bracket, fittings and
tubing are usually shipped loose in a box with the dust collector. When
installing these make sure that the high-pressure port of the gauge is
connected below the tube sheet and the low-pressure port is connected
above the tube sheet on the dust collector. There are pipe couplings
welded on the side of the dust collector for these connections. After the
differential pressure gauge is permanently mounted the gauge needs to
be zeroed prior to connecting the tubing to the gauge.
3-4

CAMCORP, INC.
Phone: [phone] Fax: [phone]
www.camcorpinc.com
Auxiliary Equipment: All auxiliary equipment must be installed
according to its manufacturer’s specifications and interlocked with the
entire system as needed. Direction of rotation of each item must be
checked prior to start-up of the entire system.
3-5

CAMCORP, INC.
Phone: [phone] Fax: [phone]
www.camcorpinc.com
Bag and Cage Installation
Installation of Bag and Cage Assembly – Bottom Loader
Inspect the filter bag cages for any signs of damage, warping, bent wires
or missing welds. Inspect the filter bags for any signs of mold, mildew,
ripped seams or holes.
Be sure the wire cage has a bottom pan. Slip the filter bag over the cage,
centering the seam 1-½” or 2” on either side of the split at the top of the
cage roll band. Seam must be straight (not corkscrewed). Make sure that
the filter bag bottom is tight against the cage bottom pan.
Pull the bag up and over the full length of the cage and fold the entire
extra length over and down inside the top of the cage. Smooth out any
filter bag folds inside the top of the cage.
Slip the assembled filter bag and cage over the outside of the bag cup
(mounted on the tube sheet) making sure to mate the male groove of the
cage roll band top to the female groove of the bag cup.
If you try to move the assembly up and down you will be able to tell if the
grooves are properly aligned.
Install the worm gear bag clamp on the assembly and tighten around the
bag and cage at the point just above the groove on the cage. The clamp
head should be located in the best position for ease in tightening.
Tighten the clamp until secure. You should not be able to rotate the bag-
cage assembly by hand if it is tighten properly.
Close the access door and tighten accordingly. You are ready to begin
start-up procedures if all other preceding tasks and connections are
completed.
It is recommended to double check the tightness of the bag and cage
assembly approximately one month after the initial start-up.
3-6

CAMCORP, INC.
Phone: [phone] Fax: [phone]
www.camcorpinc.com
Bag and Cage Installation (continued)
Installation of Bag and Cage Assembly – Top Loader
Inspect the cages for any signs of damage, warping, bent wires or
missing welds. Inspect the filter bags for any signs of mold, mildew,
ripped seams or holes.
Remove the blowpipes inside the clean air plenum by loosening the
bulkhead fitting on the air header end of the blowpipe and then slide the
pipe out of the bulkhead fitting. Some CAMCORP dust collectors use a
retaining clip on the opposite end of the blowpipe and it must be removed
before removal of the blowpipe is possible.
Lower the closed end of the bag through the hole in the tube sheet and
carefully feed the bag in. Assure that the bag doesn’t scrap against the
sides of the tube sheet hole. Excessive scraping can damage filter bags
with special coatings or finishes.
With your hands, “kidney shape” the snap band bag top in order to fit and
align it within the tube sheet hole. Fit the groove of the snap band to the
I.D. of the tube sheet hole and allow it to expand and audibly snap into
place. If the band will not snap into place initially, do not push on the
“dimple” as doing this will permanently damage the snap band. Instead,
kidney shape the snap band from the opposite side of the dimple. Then
you can allow the band to expand and audibly snap into place.
Check the fit of the snap band in the tube sheet hole. It should be even in
height above the tube sheet around the entire circumference, which will
confirm to the installer that the filter bag is centered and well secured in
the tube sheet.
Lower the cage into the bag and press that cage top down into the bag’s
snap band I.D. When in position the rolled flange of the cage top will rest
on the tube sheet and the bag and cage assembly will be rigidly mated.
Replace the blowpipes in the opposite order stated above. Make sure
that the orifices in the blowpipes are properly oriented to blow straight
down the center of the bag and cage assembly before tightening the
bulkhead fitting.
Replace access doors and tighten accordingly. You are ready to begin
start-up procedures if all other preceding tasks and hook-ups are
completed.
3-9

PRODUCT HIGHLIGHT
BEADED SNAPBAND FILTER BAG DESIGN FOR FLAT TUBESHEET HOLE
The snapband was developed to improve sealing efficiency. This design eliminates multiple parts, minimizing labor
expenses. Camcorp provides a uniform double beaded gasket in the cuff assembly. This assures a leakproof seal for flat
plate tubesheet holes. When installing the bags, follow instructions provided.
PROPERINSTALLATIONOFTHECUFF
1. Form the snapband into the shape of a kidney.
The vertical seam in the cuff should be on the
outer radius of the kidney shape.
2. Seat the seam of the cuff into the hole first with
the tubesheet fitting between the beads, with
one above and one below it .
3. Release the band and it will spring securely into
place. Use caution, and ensure all fingers are
out of the tubesheet opening when the snap-
band is released. Make sure the snapband fits
squarely in the hole and there are no kinks in
the metal band.
NOTE:If you are converting to a snapband bag from some other type of sealing method, the tubesheet holes must
be inspected carefully to ensure that proper sealing will result. The surface finish on the inside diameter must be
relatively smooth. Any deep grooves or protrusions will cause leakage. Ahole that was flame cut, but not ground
smooth is one example. The tubesheet holes must be consistent in circumference from one hole to another.
If the circumference difference is determined by measuring, the holes should be checked to the nearest 0.001 in.
Slight out-of-roundness is acceptable. Take three measurements for each hole and record the average of these three
measurements. Compare all the hole averages. The difference between the largest average and smallest average hole
size should not exceed 0.020 in. Try sample cuff in largest and smallest hole to confirm proper fit.
When checking the sample snapband in the hole for fit, push on the edge of the snapband slightly with your thumb
to try and move it inward. If a gap occurs easily between the snapband and the edge of the tubesheet hole, leakage
may result. If the inside surface of the hole is smooth, check the cuff fit by trying to spin the cuff in the hole. If it
spins easily, it may leak.
Flat Plate Tubesheet Hole
Snapband
Top View
Seam