Donaldson Torit DCE 2000 Series User manual

IPC and IPC (DR) Controllers
(from January 2008)
Installation, Operation and
Maintenance Manual
Publication 2699P (GB) • 0911 1A 3119 8064 (15)
Donaldson reserve the right to alter design without notice.
'MASTER' LANGUAGE
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Installation, Operation and Maintenance Manual
IPC and IPC (DR) Controllers
Indicates information on the efficient operation of the collector.
Indicates important information directed towards preventing damage.
Indicates an important warning, designed to prevent injury or extensive damage.
IMPORTANT
PLEASE READ THIS MANUAL CAREFULLY BEFORE INSTALLATION
THIS MANUAL SHOULD BE READ IN CONJUNCTION WITH THE RESPECTIVE
PRODUCT MANUAL SUPPLIED WITH THE DUST COLLECTOR
FOR IPC CONTROLLERS WITH MOTOR STARTER OPTION,
REFER ALSO TO SUPPLEMENTARY MANUAL ON STARTING EQUIPMENT
AND CIRCUIT DRAWINGS
EXPLANATION OF SYMBOLS USED
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Installation, Operation and Maintenance Manual
IPC and IPC (DR) Controllers
Installation ................................................................................................................4
Dalamatic Insertable ........................................................................................4
Dalamatic Cased..............................................................................................4
Modular Baghouse (MBT) ...............................................................................4
Sintamatic Insertable .......................................................................................4
Unicell Unit.......................................................................................................5
DCE 2000 Series..............................................................................................5
DCE HV500 Series...........................................................................................5
Siloair ...............................................................................................................5
Spotair..............................................................................................................5
PowerCore CPV and CPC ...............................................................................5
DF4 and DF6, DFO, TDS, TDP, DFP ................................................................5
Overload protection .........................................................................................6
IPC Controller connections and set-up ...........................................................6
IPC (DR) Controller connections and set-up....................................................7
Interrupt option ................................................................................................9
Off-line cleaning facility....................................................................................9
Alarm relay – IPC (DR) Controller only...........................................................10
In use relay – IPC (DR) Controller only ..........................................................10
4-20mA output – IPC (DR) Controller only .....................................................10
Minimum Pressure Alarm – IPC (DR) Controller only ....................................10
Operation ................................................................................................................12
Interrupt option ..............................................................................................12
Off-line cleaning facility..................................................................................12
DR control – IPC (DR) Controller only.............................................................12
Alarm relay – IPC (DR) Controller only...........................................................12
In use relay – IPC (DR) Controller only ..........................................................13
4-20mA output – IPC (DR) Controller only .....................................................13
Minimum Pressure Alarm – IPC (DR) Controller only ....................................14
Multi-bank collectors – IPC Controller parallel-linked system.......................14
Multi-bank collectors – IPC Controller serial-linked system..........................16
Maintenance ...........................................................................................................18
Overload protection .......................................................................................18
Replacement PCBs........................................................................................18
IPC (DR) Controller upgrade ..........................................................................19
Fault location..................................................................................................20
Specifications ........................................................................................................23
Controllers for use in hazardous areas .........................................................23
Voltage inputs ................................................................................................23
Voltage outputs..............................................................................................23
Power requirements.......................................................................................23
Spare Parts .............................................................................................................27
Declaration of Conformity ....................................................................................29
Table 1 Incoming power supply.............................................................................6
Table 2 Controller installation settings .................................................................11
Table 3 Terminal/cable identification....................................................................14
Table 4 Switch setting for slave module PCB ......................................................19
Table 5 Fault location ...........................................................................................21
Table 6 Terminal connections...............................................................................24
Appendix A Switch positions for IPC Controllers ................................................28
CONTENTS
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Installation, Operation and Maintenance Manual
IPC and IPC (DR) Controllers
It is a requirement of the Supply of Machinery (Safety) Regulations 1992 to provide
adequate isolation and emergency stop facilities. Due to the varied nature of site
installations this cannot be provided by Donaldson but instead is the responsibility
of the customer.
All electrical work should be carried out by competent personnel.
Always isolate power before opening the controller.
Special precautions/procedures are required for installation of IPC Controllers in
hazardous areas (refer to page 6).
Each dust collector may be supplied with either an IPC or an IPC (DR) Controller, which
is used to operate the reverse jet cleaning.
Dalamatic Insertable:
Attach the controller and make connections in accordance with the installation instructions
in the dust collector product manual, Publication 1730.
Dalamatic Cased:
The controller is supplied fitted to the manifold assembly. For 'multi-bank' collectors, connect
controller to the solenoid valve enclosures in accordance with the installation instructions
in the dust collector product manual, Publication 1731. Refer also to 'Multi-bank Collectors
– IPC Controller Parallel-linked system' in the 'Operation' section.
Modular Baghouse (MBT):
Attach the controller to the support structure of the dust collector using the brackets supplied.
Connect the controller to the solenoid valve enclosures as described under 'Multi-bank
Collectors – IPC Controller Parallel-linked system' in the 'Operation' section.
Sintamatic Insertable:
Open the plastic bag, supplied with the filter, containing fixing bolts, tubing and controller
mounting brackets. Fix the brackets to the controller using 4 x M4 fixing bolts and nuts (see
fig. 1). Attach the controller to the preferred side of the filter body using 4 x M8 fixing bolts
and nuts. Cut tubes to length and push-fit to the diaphragm valves under the compressed
air manifold, in the order according to the installation instructions in the dust collector product
manual, Publication 1726. Pass the tubes through the holes in the side of the filter body,
and push-fit to the corresponding solenoid pilot valves projecting from the controller (valves
are numbered in sequence from the left, see Fig. 2 for typical arrangement). Ensure each
tube is firmly connected to the valve.
INSTALLATION
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Installation, Operation and Maintenance Manual
IPC and IPC (DR) Controllers
Unicell Unit:
On C10-30 hopper type collectors, C10-30 venting type collectors and C10-30 venting type
collectors with dust container, the controller is supplied fully fitted to the base section.
On C40-90 collectors the controller is supplied fully fitted to the controls section.
On C10-30 standard collectors with dust container or rotary valve and C10-30 venting type
collectors with rotary valve, the controller is supplied fitted to the base section. Connect the
tubing in accordance with the installation instructions in the dust collector product manual,
Publication 2711.
DCE 2000 Series:
The controller is supplied fully fitted to the controls section of the collector.
DCE HV500 Series:
The controller is supplied fully fitted below the compressed air manifold of the collector.
Siloair:
The controller is supplied fully fitted to the filter body, below the compressed air manifold.
Spotair:
When the Spotair filter is supplied with an optional IPC (DR) Controller, it is fully fitted to the
top of the filter body, adjacent to the compressed air manifold.
PowerCore CPV and CPC:
The controller is supplied fully fitted to the collector body.
DF4 and DF6, DFO, TDS, TDP, DFP:
The controller is supplied fitted to the collector. Connect the controller to the solenoid valve
enclosure.
INSTALLATION
Figure 1 Fixing brackets to controller Figure 2 Typical connection to controller
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
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Installation, Operation and Maintenance Manual
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Refer to fig. 17 in 'Specification' section for typical wiring arrangements.
All terminal blocks are removable for ease of connection.
For installation in hazardous areas, all work must be carried out with the electrical
supply isolated or only when the potentially explosive atmosphere is not present.
Checks should be made to ensure the category of equipment is suitable for the
zone in which the installation is made.
Overload protection
A fused isolator, fitted with either a 4A fuse for 24V supply or a 1A fuse for 110/240V supply,
should be fitted between the controller and incoming supply. A high rupturing capacity
(HRC) cartridge-type fuse must be used.
IPC Controller connections and set-up
Remove the lid of the controller by unscrewing the six retaining screws. Connect the
incoming supply to the terminal block (see fig. 3 and Table 1).
The mains cables should not exert any undue stress on the terminal block. The
use of multistrand conductors is advised. Ensure that socket is fully engaged
into the plug on the PCB.
Ensure that the switch for the pulse duration and the interval between pulses (see fig. 4) is
set in accordance with Table 2.
Replace the controller lid using the six screws. Switch on the mains supply. The green
power-on LED will flash, indicating normal operation and the cleaning sequence will
commence.
Refer to dust collector product manual for start-up procedure of equipment.
INSTALLATION
Figure 3
Incoming supply connection
Incoming supply
terminal block
L230
L110
N
PE
+
-
TABLE 1 – INCOMING POWER SUPPLY
Power supply Connection
220-240V AC Terminals 1 and 3
110V AC Terminals 2 and 3
24V DC Terminals 5 and 6
The protective earth (PE), terminal 4, should be connected in all cases.
For IPC Controllers installed in potentially hazardous areas, the earth
connection to the solenoid valve bodies must also be connected to terminal
4. For systems employing slave solenoid enclosures, the earth connection
must be made to these solenoids also.
For Modular Baghouse (MBT) collectors, use only the 230V (AC) or 110V
(AC) input. Using the 24V (DC) input will result in a significantly reduced
cleaning efficiency.
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Installation, Operation and Maintenance Manual
IPC and IPC (DR) Controllers
IPC (DR) Controller connections and set-up
Remove the lid of the controller by unscrewing the six retaining screws. Remove retainer
and lift up the hinged top PCB assembly. Connect the incoming supply to the terminal
block (see fig. 3 and Table 1).
The mains cables should not exert any undue stress on the terminal block. The
use of multistrand conductors is advised. Ensure that socket is fully engaged
into the plug on the PCB.
Ensure that the switch, on the base PCB, for the pulse duration and the interval between
pulses (see fig. 4) is set to the 'F' position. (For controllers fitted with optional heater, set
switch to '0' position).
In order to utilise the DR cleaning option of the IPC (DR) Controller, the cleanside (coloured
blue and labelled P1) and dirtyside (labelled P2) tapping points on the controller (see
fig. 5), need to be fitted to the cleanside and dirtyside tappings on the casing of the collector
using the tubing supplied.
For Dalamatic Insertable and Sintamatic Insertable filters, only the cleanside
tapping point is located on the casing. The customer will need to make provision
for fitment of the dirtyside tapping point to the equipment (typically on the silo or
mounting flange).
Incorrect connections of the cleanside and dirtyside tapping points will be
indicated by flashing LEDs on the DR scale of the controller when the collector
is operating.
To avoid ingress of dust into the controller pressure transducer, it is recommended
that a filter is fitted between the dirtyside of the collector and the controller
connection. For collectors handling explosive dusts this filter must be used.
Close the hinged top PCB back into position and secure. Switch on the mains supply. The
green power-on LED will illuminate.
INSTALLATION
Pulse duration and
interval setting switch
Figure 4 Pulse duration
and interval setting
Cleanside and
dirtyside tapping
points
Figure 5 DR connections
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Installation, Operation and Maintenance Manual
IPC and IPC (DR) Controllers
To set up the IPC (DR) Controller use the select button to scroll through the set-up options
available (a flashing LED will indicate the parameter being set). Use the + and - buttons
to adjust the settings (see fig. 6).
The options available are as follows:
High DR alarm set point. Single LED illuminates to indicate set point; +and -buttons cycle
through 10-260 daPa scale. To turn alarm function off, press -button until function off ∅is
illuminated.
DR high limit set point (point at which cleaning will commence when DR cleaning is used).
Single LED illuminates to indicate set point; +and -buttons cycle through daPa scale.
It is not possible to set the DR high limit below the DR low limit setting. When re-
setting the DR high limit, the controller will, if necessary, automatically reduce the
pre-set low limit to 1 point below the new high limit.
DR low limit set point (point at which cleaning will cease when DR cleaning is used). Single
LED illuminates to indicate set point; +and -buttons cycle through daPa scale from 1 point
below current DR high point to 10 daPa.
Continuous cleaning. To achieve continuous cleaning, set the DR high limit and DR
low limit set points to off by pressing the -button until function off ∅is illuminated.
To reactivate DR cleaning both the DR high limit and DR low limit set points must
be reset.
Off-line cleaning time. Single LED illuminates to indicate number of cycles (1-26); +and
-buttons cycle through 10-260 daPa scale. To turn off-line cleaning function off, press
-button until function off ∅is illuminated.
Pulse duration. Ensure that the pulse duration is set in accordance with Table 2. Single LED
illuminates to indicate pulse duration (60-260 ms); +and -buttons cycle through daPa scale
(60-260 only). Pulse duration of less than 60 ms is not possible.
Pulse interval. Ensure that the interval between pulses is set in accordance with Table 2.
Single LED illuminates to indicate pulse interval on small scale 5s to 30s; +and -buttons
cycle through scale.
(Optional: 4-20mA versions only). Low DR alarm set point. Single LED illuminates to
indicate set point; +and -buttons cycle through 10-240 daPa scale. To turn alarm function
off, press -button until function off ∅is illuminated.
Selection of the above parameters will only be enabled, provided that the switch
on the base PCB (see fig. 4) is set to the 'F' position. (For controllers fitted with
optional heater, set switch to '0' position).
Once each setting has been entered, the new value will be stored by pressing the select
button once more. To change one setting only, the select button can be used to scroll
through to the appropriate option. After a period of 5 seconds without any buttons being
pressed, any new settings will be stored and the controller will operate normally. The
controller settings are retained in memory even if the power is switched off.
Replace the controller lid using the six screws.
Refer to dust collector product manual for start-up procedure of equipment.
INSTALLATION
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Installation, Operation and Maintenance Manual
IPC and IPC (DR) Controllers
Interrupt option
For a description of this option, refer to 'Operation' section. In order to utilise this function,
a volt free contact should be connected across terminals 7 and 8 on the base PCB (see
fig. 7). Closing the contact stops the cleaning cycle, opening the contact restarts the cycle.
When the interrupt signal is received, the green power-on LED will illuminate continuously
on the IPC Controller, or, on the IPC (DR) Controller, the ' ' LED will illuminate on the
front panel.
Off-line cleaning facility
For a description of this facility, refer to 'Operation' section.
IPC controller
In order for this function to operate, remove the bridging link between terminals 9 and 10
on the base PCB (see fig. 7) and connect a normally open contact on the fan starter across
terminals 9 and 10. Set the off-line cleaning switch on the base PCB to the 'on' position
(see fig. 8). The power to the controller must be permanently connected. When the fan
starts and contacts 9 and 10 are closed, the controller will operate normally. When the
fan stops and the contacts are opened, the controller will continue to pulse for 7 complete
cycles and then stop. Off-line cleaning can be switched on or off as desired, by setting
the switch to the appropriate position.
The interrupt function will override the off-line cleaning function.
IPC (DR) Controller
Off-line cleaning on the IPC (DR) Controller can be activated with a hard-wired connection
as described above. However, the controller will off-line clean automatically, based on
the pressure drop reading. Therefore, connections to terminals 9 and 10 are not required
and the bridging link should be left in place. Power must be permanently connected
to the controller (i.e. not switched off with the fan). The controller will operate normally
(continuous or in DR mode as selected) as long as the pressure drop is above 10 daPa. If
off-line cleaning is selected during set-up and the pressure drop falls below 10 daPa (i.e.
the fan is stopped) the controller will switch to off-line clean mode and the valves will fire
INSTALLATION
Figure 7 Interrupt and
Off-line cleaning connection
Interrupt and
Off-line cleaning
terminal block
Selecting
option button
Setting option
buttons (+/ -)
Figure 6 set-up buttons
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Installation, Operation and Maintenance Manual
IPC and IPC (DR) Controllers
for a complete number of cycles stored in memory. When the pressure drop rises above
10 daPa (either during or after the off-line cleaning period) the controller will return to its
normal operating mode.
The interrupt function will override the off-line cleaning function.
Alarm relay – IPC (DR) Controller only
For a description of this function, refer to 'Operation' section. Connection to the relay contact
is made using terminals 15, 16 and 17 (15 and 16 normally open; 15 and 17 normally closed)
on the underside of the top PCB (see fig. 9).
This relay is energised in the non alarm state.
In use relay – IPC (DR) Controller only
For a description of this function, refer to 'Operation' section. Connection to the relay contact
is made using terminals 18, 19 and 20 (18 and 19 normally open; 18 and 20 normally closed)
on the underside of the top PCB (see fig. 9).
4-20mA output – IPC (DR) Controller only (optional)
For a description of this function, refer to 'Operation' section. Output connection is made
using terminals 23 (+) and 24 (-) on the underside of the top PCB (see fig. 9).
When a 110/230V AC input supply is used for the controller, the "-" signal should
be connected to GND of the PLC. When a 24V DC input supply is used, an
isolation amplifier should be connected between the 4-20mA output and the PLC
input.
Minimum Pressure Alarm – IPC (DR) Controller only (optional)
For a description of this function, refer to 'Operation' section. Connection to the relay contact
is made using terminals 21 and 22 (normally open contact – contact will close when DR is
above alarm set point) on the underside of the top PCB (see fig. 9).
INSTALLATION
Figure 8 Off-line cleaning switch
Off-line cleaning switch
Position ON
= off-line cleaning on
Position 1
= off-line cleaning disabled
ON
1
ON
1
Alarm and
In use
terminal block
4-20mA and Min.
Pressure Alarm
terminal block
(optional)
Figure 9 Alarm relay, In use relay, 4-20mA output
and Minimum Pressure Alarm relay connection
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Installation, Operation and Maintenance Manual
IPC and IPC (DR) Controllers
Dalamatic Insertable
Models: V3/7, V4/7, V5/12,
V6/10, V7/7, V7.5/12, V8/7,
V9/15, V10/10, V12/10, V13/12,
V14/7, V15/12, V15/15, V18/15
and V20/10 (5-valve version) 9 F* 100 ms 25 sec.
Models: V20/10 (10-valve version),
V21/7, V25/12, V30/10, V30/15,
V38/12, V45/15, V50/12 and V60/15 3 F* 60 ms 12 sec.
Dalamatic Cased (series DLM 15)
2- to 5-tier models 3 F* 60 ms 12 sec.
6- to 8-tier models 4 F* 100 ms 12 sec.
Modular Baghouse (series MBT)
All models 4 F* 100 ms 12 sec.
Sintamatic Insertable
All models 3 Not applicable Not applicable Not applicable
PowerCore
All models Not applicable F* 100 ms 12 sec.
Unicell Unit
All models 4 F* 100 ms 12 sec.
DCE 2000 Series
Models: F2012 and F2018 6 F* 60 ms 18 sec.
Models: F2024, F2030,
F2036 and F2045 3 F* 60 ms 12 sec.
Models: S2021, S2026, S2031,
S2040, S2053, S2066, S2080
and S2100 3 Not applicable Not applicable Not applicable
DCE HV500 Series
Models: F504, F506, F508, F510,
F514 and F520 9 F* 100 ms 25 sec.
Models: F530, F538 and F545 3 F* 60 ms 12 sec.
Models: C508, C510, C516, C520,
C524, C530, C540 and C548 4 F* 100 ms 12 sec.
Siloair
All models 4 F* 100 ms 12 sec.
Spotair
All models Not applicable F* 200 ms 25 sec.
All of the following products:
DF4 and DF6, DFO, TDS, TDP, DFP 4 F* 100 ms 12 sec.**
Interval
Pulse
duration
Base PCB
switch setting
Pulse duration and
interval switch setting
IPC CONTROLLER IPC (DR) CONTROLLER
TABLE 2 – CONTROLLER INSTALLATION SETTINGS
Dust collector type
These figures apply to collectors built from February 2007. For collectors built prior to this date
refer to product manual.
* For controllers fitted with optional heater, set switch to '0' position.
** The pulse interval should be set at 25 sec. for products supplied with a serial-linked control system.
For a complete listing of available pulse intervals/durations see Appendix A.
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The controller is fully automatic and ensures that the diaphragm valves of the dust collector
it serves are operated in sequence, at regular intervals, to facilitate the efficient cleaning
of the filter elements. The pulse duration and the interval between pulses must be set
according to the specific dust collector model (see Table 2). These figures should not be
altered without prior consultation with Donaldson.
Interrupt option
The controller offers the facility to interrupt and restart the cleaning cycle at any point. This
is particularly useful on venting applications where the actual filter operates over a short
period of time (e.g. pneumatic conveying of small quantities of product) where a complete
cleaning cycle may not take place. Under normal circumstances if the power to the controller
is switched off the cleaning cycle is reset to the first element position when the power is
reapplied. The interrupt option can be used to start and stop the cleaning without the
controller resetting, provided that the power is left on, ensuring that all filter elements are
cleaned. When the interrupt signal has stopped the cleaning cycle, the green power-on
LED will illuminate continuously on the IPC Controller, or, on the IPC (DR) Controller, the
' ' LED on the front panel will illuminate.
Off-line cleaning facility
This function (when enabled) allows the cleaning cycle to continue for a period of time after
the fan has been switched off. For the IPC Controller, the off-line cleaning will operate for
7 complete cycles. For the IPC (DR) Controller, the off-line cleaning will operate according
to the parameters entered by the buttons on the top PCB (refer to 'Installation' section). On
the IPC (DR) Controller, the ' ' LED on the front panel will illuminate when the controller
is operating in off-line cleaning mode.
DR control – IPC (DR) Controller only
The principle feature of the IPC (DR) Controller is the DR control system, which ensures
effective and economical use of the dust collector's reverse-jet cleaning system. Under
normal operation a dust coating on the filtration medium can enhance the filter's overall
efficiency but this 'dust cake' will become detrimental if allowed to build up to such an extent
that it becomes a barrier to the air flow.
The DR control system monitors this build-up of dust by measuring the Differential Pressure
(known as the 'DR') across the filtration medium and dust cake. The IPC (DR) Controller
will activate the cleaning system when an adjustable preset high level limit is reached and
maintain cleaning until the differential pressure has returned to a second adjustable preset
low limit, when the cleaning system will be switched off (refer to 'Installation' section). This
process is repeated every time the pressure rises to the high level limit.
This system ensures that a combination of both efficient filter performance and minimum
compressed air consumption is maintained.
Alarm relay – IPC (DR) Controller only
The alarm relay provides a volt free changeover contact to indicate an alarm condition. The
alarm condition is either a power fail or high filter pressure drop. The pressure drop level at
which the alarm is triggered is entered by the buttons on the top PCB (refer to 'Installation'
OPERATION
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Installation, Operation and Maintenance Manual
IPC and IPC (DR) Controllers
section). When the alarm is active due to high filter pressure drop the large red alarm light
and the ' ' LED, on the front panel, will illuminate.
This relay is energised in the non alarm state.
In use relay – IPC (DR) Controller only
This provides a volt free changeover contact which indicates whether the cleaning system is
active or inactive. This can typically, be used to provide information to a PLC/Scada system.
When the cleaning system is active the ' ' LED, on the front panel, will illuminate.
On multi-bank collectors, do not connect an external 'in use' lamp to the controller
when using the in use relay in combination with a 24V DC supply. Instead, replace
a solenoid valve enclose with another IPC (DR) Controller and use the in use relay
on this controller to connect an external 'in use' lamp.
4-20mA output – IPC (DR) Controller only (optional)
This output provides a 4-20mA output signal proportional to the measured pressure drop
(0-260 daPa). This can be used to provide information to a PCL/Scada system or enable
remote display of the dust collector operating pressure drop. The external resistance of
the connected circuit should be in the range 150-250W. (The output is protected against
short-circuit).
When a 24V DC input supply is used the 4-20mA signal is not potential free.
The 4-20mA signal will be switched off when the controller is in off-line cleaning
mode.
Applying an external voltage to the 4-20mA output may damage the controller.
Figure 10 IPC (DR) Controller front panel
LED bar graph display
of pressure drop
Power-on LED
In use LED
(cleaning system active)
Off-line cleaning LED
DR alarm LED
Interrupt LED
Alarm warning light
OPERATION
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Installation, Operation and Maintenance Manual
IPC and IPC (DR) Controllers
Minimum Pressure Alarm – IPC (DR) Controller only (optional)
The alarm relay provides a volt-free contact to indicate an alarm condition. The alarm
condition is a low filter pressure drop or power supply failure. The pressure drop level at
which the alarm is triggered is entered by the buttons on the top PCB (refer to 'Installation'
section). When the alarm is active due to low pressure drop, the relay contacts will open.
This alarm will not illuminate the large red alarm light.
This relay is energised in the non alarm state.
Multi-bank collectors – IPC parallel-linked system
(Standard supply for DLM Cased, MBT and DFO 2-16 to DFO 4-96 collectors)
Where controllers are supplied separately for multi-bank collectors which use a number
of separate solenoid valve enclosures, connections should be made as shown in
figure 11 and Table 3, using the cables supplied. One IPC Controller can operate up to
88W per output (i.e. up to 4 solenoid valves). Refer to dust collector product manual for
controls assembly sequence.
When connecting the controller to the solenoid valve enclosures the maximum
length of cabling that can be used is 25m when using the 230V or 110V AC input,
or 15m when using the 24V DC input.
The solenoid valve enclosures will require a separate power supply for controllers
with optional heater.
TABLE 3 – TERMINAL/CABLE IDENTIFICATION
Cable colour Cable number
Terminal number /
Valve number
1 Red 1
2 Yellow 2
3 Blue 3
4 Green 4
5 Grey 5
6 Pink 6
7 Brown 7
8 Purple 8
9 White 9
10 Orange 10
11 – 11
12 – 12
+ common Black Highest number
OPERATION
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Installation, Operation and Maintenance Manual
IPC and IPC (DR) Controllers
Figure 11 IPC parallel-linked multi-bank connection details (5-bank shown)
10987
V10V9V8V7V6V5V4V3V2V1+
V10V9V8V7V6V5V4V3V2V1+
151617181920
IPC (DR) Controller Solenoid valve
enclosure Solenoid valve enclosure Solenoid valve enclosure
IPC Controller
To next
controller
(if applicable)
Connection for collectors
larger than 4-banks
Connection to
solenoid valve
enclosure
10987
V10V9V8V7V6V5V4V3V2V1+
151617181920
IPC (DR)
Controller
Solenoid valve
enclosure
IPC Controller
To next
controller
(if applicable)
Connection for
collectors larger
than 4-banks
Connection to
solenoid valve
enclosure
Plastic solenoid valve enclosures
Aluminium solenoid valve enclosures
Solenoid valve
enclosure
Solenoid valve
enclosure
Solenoid valve
enclosure
Solenoid valve
enclosure
1
C
1
2
3
4
5
6
7
8
9
10
23
C
1
2
3
4
5
6
7
8
9
10
45678910
Solenoid valves
OPERATION
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16
Installation, Operation and Maintenance Manual
IPC and IPC (DR) Controllers
Multi-bank collectors – IPC serial-linked system
(Standard supply for DFO 4-104 to DFO 4-128 collectors)
The IPC serial-linked control system allows the IPC (DR) Controller to operate up to 96
valves in modules of 8, 10 or 12. This is achieved using a single master controller and up
to 8 slave control modules.
The IPC serial-linked master controller has all the features of the standard IPC (DR) Controller
and the individual pulse and DR control parameters should be set up as described in the
'Installation' section.
The system uses a 4-wire serial data link between master controller and slave modules,
which carries both power and pulse signals (see fig. 12).
The valves in a serial-linked control system will fire sequentially as shown in figure 13.
The interval between individual pulses will be the overall interval, as set up on the master
controller, divided by the number of slave modules (see fig. 13). The number of slave
modules is detected automatically by the master controller. The master controller will also
detect the number of valves fitted to the slave modules and will set the cycle according to
the module with most valves connected, e.g. for a combination of 8 and 12 valve modules,
all modules will act as for a 12 valve module, resulting in a gap in the pulsing on the module
with 8 valves (see Table 4). The cycle will therefore always be completed in the overall
interval time, multiplied by the maximum number of valves per module.
Serial-linked slave modules will operate in order of connection to the master controller, closest
first. Pulse parameters (i.e. interval and duration), will be as set in the master controller.
The slave modules will require a separate power supply for controllers with
optional heater.
Master controller Slave modules
4-wire serial links
Figure 12 IPC serial-linked control system arrangement
Terminals
11 to 14
Terminals
X1 to X4
Terminals
B1 to B4
Terminals
X1 to X4
Terminals
B1 to B4
Terminals
X1 to X4
Terminals
B1 to B4
Terminals
X1 to X4
OPERATION
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Installation, Operation and Maintenance Manual
IPC and IPC (DR) Controllers
Time
Slave module
1 (closest
to master
controller)
Figure 13 IPC serial-linked control system operating sequence
Slave module 2
Slave module 3
Slave module 4 Valve n Valve 1 Valve 2
Valve 2
Valve 2
Valve 2Valve 1
Valve 1
Valve 1
t1 =Pulse duration (as set in master controller)
t2 =Pulse interval (as set in master controller)
t3 =t2 ÷Number of slave modules fitted
4 slave module system shown.
Arrangements possible up to 8 slave modules in total, with 8, 10 or 12 valves per module.
OPERATION
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18
Installation, Operation and Maintenance Manual
IPC and IPC (DR) Controllers
Always isolate power before opening the controller.
For controllers installed in potentially hazardous areas, suitable precautions should
be taken to ensure no ignition sources are introduced or that the atmosphere is
not hazardous during any maintenance operations or when making adjustments
to operating parameters when the controller is energised.
Overload protection
A fused isolator, fitted with either a 4A fuse for 24V supply or a 1A fuse for 110/240V supply,
should be fitted between the controller and incoming supply. A high rupturing capacity
(HRC) cartridge-type fuse must be used.
Protection of the controller against an output current overload is achieved by
2 small HRC cartridge fuses mounted on the PCB (see fig. 14). These fuses are 0.4A for
110/240V supply and 2.5A for 24V supply. In an emergency a quick-acting fuse could
be used as a temporary alternative but a time delay fuse must not be used under any
circumstances.
Two spare fuses are supplied inside the controller.
Replacement PCBs
Isolate supply to controller and, where applicable, ensure connections to Alarm
and In use relays are also isolated.
All terminal blocks are removable for ease of connection.
The fitment of replacement PCBs is relatively simple. However, when fitting a new base
PCB, the controller will automatically detect the number of solenoid valves connected, so
it is necessary that the solenoid valves are connected in the same order as on the PCB
being replaced.
Valve setting switch
Figure 15 Slave module switch setting
HRC cartridge fuses:
2.5A
0.4A
Figure 14 HRC cartridge fuse location
MAINTENANCE
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19
Installation, Operation and Maintenance Manual
IPC and IPC (DR) Controllers
When replacing a new DR PCB the switch on the upper PCB (when fitted) should be set as
indicated on the circuit board.
i.e. Software versions 1.45 and below – Switch S1 Position ON, Switch S2 Position 1.
Software versions 1.57 and above – Switch S1 Position 1, Switch S2 Position ON.
(Software version is labelled on the processor of the lower PCB).
Additionally, if replacing a PCB from a serial-linked slave module, ensure that the input
connections (and, where applicable, the outlet connections) are made to the same
terminals as the PCB being replaced. Also, ensure that the valve switch (see fig. 15) is set
in accordance with Table 4.
Failure to carry out these procedures will result in poor filter performance.
IPC (DR) Controller upgrade
A standard IPC Controller can be upgraded to an IPC (DR) Controller, on-site, relatively easily.
In order to perform an upgrade, an IPC (DR) Controller upgrade kit is available.
The IPC (DR) Controller is not suitable for use with Sintamatic Insertable dust
collectors. (Collectors with sintered elements must be cleaned continuously).
The upgrade kit contains the following:
Top PCB assembly (with 4-20mA output)
Two rear pillar and hinge assemblies
Front support pillar
Two lengths of 4 mm o/d tubing
Dual tubing connector and nut
Cleanside/dirtyside label
Lid with bar graph display
External fitting kit is supplied to suit.
MAINTENANCE
TABLE 4 – SWITCH SETTING FOR SLAVE MODULE PCBS
Maximum number
Switch position
of valves per module
8 9
10 B
12 D
In a serial-linked system which has a combination of slave modules
containing different numbers of valves, the switches for all slave
modules should be set to the position corresponding to the module
with the most valves connected. i.e. in a system with a combination of
8 and 12 valve modules, set all switches to position D (12 valves).
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20
Installation, Operation and Maintenance Manual
IPC and IPC (DR) Controllers
To perform the upgrade the following procedure should be used (refer also to fig. 16):
Isolate supply to controller.
1 Fit the two rear pillar and hinge assemblies into the corner bosses at the rear of the
enclosure base.
2 Fit the front support pillar into the central boss, between the solenoid valves on the
enclosure base.
3 Fit the top PCB assembly to the two rear hinged pillars.
4 Connect the top PCB to the base PCB using the ribbon cable.
5 Set the switch on the new DR PCB as indicated on the circuit board.
i.e. Software versions 1.45 and below – Switch S1 Position ON, Switch S2 Position 1.
Software versions 1.57 and above – Switch S1 Position 1, Switch S2 Position ON.
(Software version is labelled on the processor of the lower PCB).
6 Fit the dual tubing connector through the side of the controller box, using the nut.
7 Fit cleanside and dirtyside label to outside of the box, so that P1 and P2 correspond
to the cleanside and dirtyside connectors respectively (see fig. 5).
8 Connect the pressure transducer on the underside of the top PCB to the dual tubing
connector, using the tubing. (The dirtyside connection on the pressure transducer is
the one nearest to the PCB).
9 Connect cleanside and dirtyside tappings on the dust collector to the cleanside
(coloured blue and labelled P1) and dirtyside (labelled P2) tappings on the controller,
using the tubing.
10 Close hinged top PCB and secure to front pillar.
11 Switch on power.
12 Refer to 'Installation' section for set-up instructions.
Fault location
In the event of a controller failure, refer to Table 5 to identify the fault.
MAINTENANCE
Ribbon cable
connection
Tubing (dirtyside)
Figure 16 IPC (DR) upgrade assembly
Tubing (cleanside)
Pressure transducer
Dual tubing
connector
Front support pillar
Rear pillar and
hinge assembly
Top PCB assembly
For inspection purposes only.
Consent of copyright owner required for any other use.
EPA Export 30-10-2020:11:37:38