Includes Installation, Operation, Service Instructions
and Replacement Parts List
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.
Statements indicate precautions necessary
to avoid potential equipment failure.
CAUTION
APPLICATION OF DUST CONTROL EQUIPMENT:
•Special care must be exercised in the use
of dust collection equipment when
combustible material, such as buffing lint,
paper, wood dust, aluminum, and
magnesium dust are present. These
materials may present a fire or explosion
hazard. A prudent user of Amada
equipment should consult and must
comply with all National and Local Fire
Codes and/or other appropriate codes
when determining the location and
operation of dust collection equipment.
•Under no conditions should anyone,
including the machine operator, allow
burning objects or lit cigarettes to enter
the hood or ducting of any dust control
system.
•Avoid mixing combustible materials with
dust generated from grinding of ferrous
metals due to the potential fire hazard
caused by sparks being pulled into the
dust collection equipment.
•When collection equipment is used to
collect flammable or explosive dusts, the
dust collection equipment should be
Statements indicate potential safety hazards.
located outside the building. Also, an
installer of fire extinguishing equipment,
familiar with the type of fire hazard and
local fire codes, should be consulted for
recommendations and installation of the
proper fire extinguishing equipment.
Amada equipment does NOT contain
fire extinguishing equipment.
•Explosion relief vents are required on
some applications. Consult with an
insurance underwriter or a NFPA
Manual to determine proper vent sizing
requirements. Vents installed on dust
collection equipment must relieve to the
outside of the building to minimize
chances of a secondary explosion.
Consult the proper authority to
determine proper method of venting the
dust collection equipment. Amada
equipment does NOT contain explosion
relief vents, except on special order.
•To insure optimum collector
performance, always use Torit® UltraWeb® II FR replacement filters.
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.
1.1Operational Explanation
(See Figure 2)
1.1.1Normal Operation
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.
Technical and field support are always available
from your local Amada representative and
distributors.
Clean-Air Outlet
1.1.2Filter Cartridge Cleaning
Filter cartridges are cleaned automatically and
sequentially. The result is that only one filter
cartridge will be off-line at any given time.
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.
2.0Quick Start
(See Figure 1)
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.
3.0Installation
(See Figure 1)
3.1Inspection
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.
3.3Preinstallation
(See Figure 1)
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.
CAUTION
Location must be free of obstructions, such
as utility lines or roof overhang. See
Specification Control Drawing. A crane
must be used to position the collector.
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.
3.2Equipment/Tools Required
Typical tools and equipment required to install
and assemble the unit:
A crane or forklift is recommended for
unloading, assembly, and installation of
the dust collector.
CAUTION
•Connect the lifting sling to the four (4)
cabinet lifting lugs.
•Use clevice pins, not hooks, on the
lifting sling.
•Do not lean unit on legs.
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.
•All electrical work must be performed
by a qualified electrician according to
all applicable national and local codes.
•Turn electrical power OFF during
installation.
•Do not apply in classified hazardous
atmospheres without an appropriatelyrated enclosure.
NOTE
•Do not mount controls in high-vibration
areas without shock mounts.
•Do not mount controls in corrosive
atmospheres without an appropriate
enclosure.
•Do not operate with enclosure open.
NOTE
Each item to be attached to the collector is
accompanied by a drawing that shows the
attachment process. Refer to both the
drawing and this manual to install the unit.
procedures to prevent permanent
damage to this device.
•Handle printed circuit board by the
edges only.
•Avoid touching the socketed E2PROM
pins.
NOTE
In grounded systems, connect neutral to
control box to terminal L2 of the solid-state
control timer.
7
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).
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
2. Check the tubing to the high and low
pressure ports on the control enclosure. The
high-pressure connection goes to the dirtyair, or filter side of the collector. The lowpressure connection goes to the clean-air
side of the collector.
Do not attempt to adjust the ON or OFF
time. These values are factory set for
maximum performance of pulsing system
and minimum compressed-air use.
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
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.
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.
3.5Electrical Operation
Each dust collector comes equipped with 115VAC 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.
3.6Compressed Air Supply Installation
(See Figure 1)
4.0Prestart-Up Check
(See Figure 1)
NOTE
•The compressed-air supply must be
both oil and moisture free.
Contamination in the compressed-air
used to clean filter cartridges will result
in poor cleaning or cleaning valve
failure and poor collector performance.
•Purge compressed-air lines to remove
debris before connecting to the
compressed-air manifold on the unit.
CAUTION
Turn compressed-air supply OFF and bleed
supply lines before performing service work.
CAUTION
Check that the blower-fan exhaust is free
of debris before starting.
On hoppers with drum arrangements, make sure
that all the connections are airtight.
NOTE
Check that the hopper discharge is sealed
and not open to the atmosphere. Too
much airflow to the blower fan will cause
electrical failure.
1. Remove the plastic pipe plug from the end of
the unit's compressed-air manifold and
connect the compressed-air supply line.
2. The compressed-air supply line should be
installed with a safety exhaust shutoff valve,
a bleed-type regulator with a gauge adjusted
to 90-psi, and a coalescing filter with an
automatic drain, all supplied by others. Use
pipe sealant on all compressed-air
connections and locate components for
convenient service.
3. Be sure that all compressed-air components
are adequately sized to meet the maximum
system requirements of 1.1 scfm per pulse at
90- psi supply pressure.
1. Turn the compressed-air to the dust
collector's compressed-air manifold ON. Use
the compressed-air regulator to adjust to
90- psig. Pressure of 90 to 100-psig is the
most typical setting for satisfactory cleaning
performance. See Section 6.0, Operating
Adjustments. The lower the compressed-air
setting, the less pulse-valve air consumption
will be.
2. Turn the blower fan motor ON and check the
rotation by referencing the rotation arrow
decal on the blower fan housing. Rotation
should be clockwise looking down from the
top of the blower fan motor.
CAUTION
Stand clear of blower fan exhaust area, as
debris can be exhausted and cause injury.
3. Adjust the blower fan for proper system
airflow by adjusting the volume control
damper on the chamber silencer discharge.
6.1Delta P Control Calibration
The only user calibration is the zero adjustment
of the display. Due to slight changes in either
electronic components over time, or pressure
differentials within the plant environment,
occasionally the display may show something
other than 0.0 while at rest. Use the following
procedure to recalibrate the operating system.
1. Power the control for a minimum of thirty
(30) minutes to stabilize the operating
pressure.
2. Remove power from the control so that the
display shuts down.
3. Press and hold the LOW SET, HIGH SET,
and ALARM SET keys while reapplying
power to the control. Continue to hold these
keys while the control goes through a
power-up routine. This is indicated by
sequentially displaying "8" in each digit, and
then displaying "0.0" (see Figure 3, Delta P
Control Display).
4. Release the three keys. The new calibration
automatically stores in the memory.
NOTE
Too much airflow can cause electrical
system failure and result in eventual blower
motor failure.
Compressed air is recommended to be set at 90
psig. The control timer is factory set to clean
one filter cartridge every 10 seconds.
If the filter cartridges are operating at a higher
than design pressure drop, it may be lowered by
increasing the frequency of cleaning. See Section
5.4, Operating Checks. The minimum off time
between pulses is three (3) seconds. Additional
cleaning energy may be obtained by adjusting
the pressure upward to a maximum of 100 psig.
If the filter cartridges are operating at a low
operating pressure drop, you may want to raise
to a higher pressure drop level by increasing the
OFF time between pulses on the solid-state
control board. See Section 6.4, Operating
Checks. This will greatly reduce your
compressed air consumption.
6.3Airflow Adjustment
Airflow adjustments can be made by testing the
duct system flow rate and adjusting the volume
control damper to the desired system flow rate.
Adjust the flow rate to a level that evacuates the
funes from the cutting area.
NOTE
•Do not increase compressed air pressure
beyond 100 psig as component damage
may result.
•Do not increase or decrease pulse ON
time on the solid-state control timer.
Longer or shorter pulse ON times do
not aid in cleaning the filter cartridges,
they just waste compressed air and
cause shortened filter cartridge life.
Pulse ON time can be checked or adjusted by
consulting your local Amada representative.
NOTE
Excess airflow can cause shortened
filter life.
NOTE
Check the blower fan motor amp draw to
the motor manufacturer's nameplate amp
rating. Over amperage will cause damage.
NOTE
At initial start-up with any new filter
cartridges, the fan motor may overload
because of airflow higher than design level.
If this happens, partially close a volume
control damper and check blower fan
motor amp draw.
1. Monitor exhaust. Exhaust should remain
visually clean. If a dust leak develops, it will
be noticed as a visual puff of dust
immediately after a cleaning pulse.
2. Monitor filter cartridge pressure drop.
Stable pressure drop is generally 3 to 4inches water gauge on a Magnehelic or
Photohelic for seasoned filter cartridges, but
1 to 6-inches water gauge is considered
normal.
7.1Filter Cartridges
(See Figure 5)
CAUTION
•Turn off and lock out power so that the
fan cannot be started and pulsing can
not start.
•Dust-laden filter cartridges may be
heavy and difficult to handle.
NOTE
At initial start-up with any new filter
cartridges, the fan motor may overload
because of airflow higher than design level.
If this happens, partially close a volume
control damper and check blower fan
motor amp draw.
7.0Service
CAUTION
•Disconnect electrical power before
servicing any electrical components.
•Shut off and bleed compressed air
supply before servicing any compressed
air components.
7.1.1Filter Cartridge Removal
When changing the filter cartridges, start at the
top access ports of the unit first, so that the dust
which falls down into the hopper does not have
open access ports below or does not fall on
newly installed filter cartridges.
1. Remove access cover and set aside.
2. Move the filter cartridge to break the gasket
seal between the filter element and the
element panel sealing surfaces. Rotate the
filter cartridge slowly half a turn to dump
any loose buildup of dust off the top of the
filter cartridge. Slide the filter cartridge out
of the front of the dust collector.
•No welding should be performed inside
the unit without fire protection.
•Do not drop or rap the filter cartridge
on the floor or any other hard surface.
Damage to the filter cartridge will occur
and result in leakage.
•It is necessary to clean the dust off the
filter cartridge support panel around
the opening and around the access
cover gasket to ensure a positive seal of
the new filter gasket.
•Insert new filter cartridge gasket-endfirst, facing toward the clean-air section
or leakage will occur.
•Access cover knobs must be securely
tightened. Lack of filter-cartridge gasket
compression can cause leakage.
NOTE
Do not let the dust storage container
overfill. It can cause poor collector
performance and create an extensive
cleanup due to overflow of dust when
removing the container.
Turn unit OFF and empty container as
necessary to keep the dust in the bin to a
minimum.
7.3Original Equipment Filter Cartridge
(See Replacement Parts List)
The filter cartridges provided by Amada are the
only replacement filter cartridges that will
provide the high level of performance that you
expect from your investment in the dust
collector.
1. Install the new filter cartridges gasket end
first.
2. Wipe off access cover gaskets and reinstall
the access covers. Tighten securely by hand.
3. The dust collector is now ready to start. Turn
electrical power ON at source and turn the
compressed-air supply ON before starting.
7.4 Compressed Air Components
CAUTION
Turn compressed air supply OFF and bleed
lines before performing service work.
1. Periodically check the compressed air
components and service by installing new
compressed air filters and draining any
moisture off by following manufacturer's
instructions.
2. With the compressed air supply turned ON,
check the cleaning valves, solenoid valves,
and tubing for any leakage. Replace any
components that are leaking compressed air.
See the Replacement Parts List.
1. Starter kicks out (contd).
d. Blower fan damper
control not adjusted
properly.
e. Electrical circuit
overload.
1. Filter cartridges installed
improperly.
REMEDY
1d. Check airflow in duct for
proper requirements.
Adjust the damper control
until the proper airflow is
achieved and the blower
fan motor amp draw is
within motor's ratings.
1e. Check that the supply
circuit has sufficient power
to run all equipment.
1. Check that the gaskets on
the filter cartridges are
facing into the cabinet first.
See Figure 5, Filter
Cartridge Replacement and
Section 7.1, Filter
Cartridges.
2. Filter cartridge damage,
dents in the end caps,
gasket damage or holes in
pleated media.
3. Access covers are loose.
2. Replace the filter
cartridges. Use only Torit
Ultra-Web II FR filter
cartridges.
1. Check fan rotation.
Rotation should be
clockwise when looking
down at the top of the
blower fan motor. See
Section 5.0, Start-Up.
2. Check the access covers to
make sure that they are in
place and tightened
securely. Also check hopper
discharge area to make
sure that the openings are
closed off and that the
optional hopper
attachments are installed.
3. Check fan exhaust area for
blockage. Remove material
or debris blocking the fan
exhaust area or adjust
damper flow control on fan
exhaust area.
4. Filter cartridges plugged
with particulate.
a. Filter cartridges need to
be replaced.
b. Lack of compressed air.
4a. Remove and replace filter
cartridges. See Figure 5,
Filter Cartridge
Replacement and Section
7.1, Filter Cartridges.
Reference the Replacement
Parts List.
4b. Check compressed air
supply for 90 psig
minimum. See Figure 1,
Typical Installation.
Increase pressure as
described in Section 6.0,
Operating Adjustments.
4. Filter cartridges plugged
with particulate (contd).
c. Pulse cleaning not
energized.
d. Dust storage area is too
full or plugged.
5. Pulse valves are not
functioning.
a. Pulse valves are leaking
compressed air.
REMEDY
4c. Check supply voltage to the
timer board with a volt
ohm meter. Check the fuse
on the timer board. If the
fuse is blown, replace it
with one of equal value.
See Section 3.5, Electrical
Operation.
4d. Clean out dust storage area
as described in the Section
7.2, Dust Removal.
5a. Lock out all electrical
power and bleed off the
compressed air supply.
Check for debris, valve
wear or diaphragm failure
by removing the diaphragm
cover on the pulse valves.
Also check for solenoid
leakage and/or damage. If
pulse valves or solenoid
valves and solenoid tubing
are damaged replace parts.
See the Replacement Parts
List.
timer board with a volt
ohm meter. Check the fuse
on the timer board. If the
fuse is blown, replace it
with one of equal value. If
the fuse and input power to
the control board is okay,
but there is not any output
voltage to the solenoid
pulse control valves,
replace the pulse control
timer board. See Section
3.5, Electrical Operation
and reference Replacement
Parts List.