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1. Collection of combustible or explosive materials and collection on flame or spark generating operations may require specific system configurations contact AER Control Systems LLC Applications Engineering Department for questions and or design assistance The combined collection of combustible or explosive materials and contaminants from spark or flame generating operations with a common collector or duct system is not recommended unless spe cial design provisions have been made to the system sparks or flames resulting from such opera tions may ignite the combustible or explosive material Under no circumstances should anyone be allowed to discard a lighted cigarette other burning materials or refuse into an inlet hood or the duct of the collection system It is the responsibility of the end user to comply with all applica ble national state and local fire and safety codes AER Control Systems LLC Incorporated liabil ity for consequential and incidental damage resulting from a fire or explosion is expressly dis claimed Installation of suitable overload protection such as a motor starter according to NEC guidelines is required Failure to provide proper overload protection will void warranty coverage on electrical components in the system Combination motor starters with fusible disconnect packages are available through your local AER Control Systems LLC representative To ensure optimum collector performance alway2. AER Control Systems Installation amp Service Manual for Horizontal Cartridge Filtration Systems MODELS HCF 3000 HCF 3030 HCF 3050 February 10 2003 TABLE OF CONTENTS Page Subject 2 HRS R eGR Table of Contents e TEN EEEE A ANT Disclaimer A a A E Uncrating e EAA AA EA AE sees Description amp Operation Aie E en aaeiGsenes Optional Equipment Drede a ee leit bccn Applications General 0 9 A ia ene ome ene Installation 1 rude cerecaua E ocecorazesucere Figure 1 Motor amp Trans Connection Diagram O Bee eeerereR eee ereeeueus Figure 2 Control Timer DO shoot net ie deep eoe Parts List Wl seeenioeete estes Maintenance PAE E EE EE AE ATT Troubleshooting Chart TOt eaea a R Specifications TA o e blouse douse Warranty DISCLAIMER Although instructions and recommendations are included for installation of your Horizontal Car tridge Filtration System the manufacturer does not assume responsibility for the installation of this equipment nor shall he be held liable for direct or consequential damages resulting from im proper installation application maintenance or use The immense variety of contaminants make it impossible to list all of the potential hazards that may be encountered with air pollution control systems It is therefore important that the applica tion of the equipment be discussed with an AER Control Systems representative or application engineer prior to use Additionally users should consult and comply wi
3. mounting hardware is in cluded Installation consists either of ceiling wall or column mounting Weld nuts for permanent mounting bolt to frame or hang with threaded rod are welded in the corners of each module on the top of the cabinet Eye bolts for lifting assembly and mounting are provided Mounting kits available The hopper has an 7 7 8 in O D outlet collar which should be connected to a 55 gallon drum or similar storage container by a flexible hose or clamp duct steel drum kits with flex hose are available from AER Control Systems LLC It is critical that the cover of the drum or container is fastened in place and has an airtight fit to avoid leakage and re entrainment of collected dust A liner can be placed in the drum to allow for easy dis posal of the collected dust flame retardant liner or no liner suggested for applications that generate sparks Assembly amp Installation All Models The integral junction box is factory wired for 460 volts 3 phase unless otherwise specified on the purchase order requiring only a qualified electrician to connect input power to the unit Suitable over load protection such as a motor starter is required Refer to the electrical section Combination motor starters with fusible disconnect packages are available through most local AER Control Systems LLC distributors A connection for clean dry compressed air is located outside the pulse tank module and con nected to the air
4. 8 5 to 180 sec 0 05 to 0 50 sec Input Power Blower Motor Type Plug Fan 110 VAC 60 Hz 1 Phase Plug Fan Plug Fan Inlet Single Ambient 2 Std up to 4 avail 2 Std up to 4 avail Wheel Diameter 12 inches 12 inches 15 inches Outlet Area N A N A N A Speed 3450 RPM 3450 RPM 3450 RPM Drive Direct Direct Direct HP 3 0 3 0 5 0 Speed RPM 3450 3450 3450 Voltage 190 380 230 460 190 380 230 460 190 380 230 460 Frequency Hz 50 60 50 60 50 60 Phase 3 3 3 Frame NEMA 56C 56C 184TC Power Factor 89 89 92 Efficiency 82 5 82 5 87 5 Start Current Amps 60 Hz 65 8 33 9 65 8 33 9 112 56 Full Load Amps 60 Hz 8 1 7 6 3 8 8 1 7 6 3 8 13 12 6 Insulation Class Min F F B Enclosure TEFC TEFC TEFC Service Factor 1 15 1 15 1 15 Duty Cycle Cont Cont Cont Exxon POLYREX EM Exxon POLYREX EM Exxon POLYREX EM UL amp CSA Approved UL amp CSA Approved UL amp CSA Approved Bearing Grease Specification AER Control Systems HMITIED WARRANTY AER Control Systems LLC warrants all products sold only to purchasers for use in busi ness or for resale against defects in workmanship or materials under normal use for one 1 year
5. reservoir tank A 120 PSI relief valve to prevent tank over pressurization and a condensate drain check periodically are provided and are pre connected to the reservoir tank The supply airline should be purged to remove any debris before connecting it to the unit to pre vent damage to the pulse valves on the system The supply compressed air line should be equipped with a manual shut off valve a filter separator air regulator and a pressure gauge and located close to the HCF system If the unit is to be installed in an area where freezing tem peratures or high humidity are to be expected an air dryer capable of drying the compressed air to below the dew point must also be provided If excessive moisture is present check conden sate drain frequently or install an automatic drain SECTION 3 INSTALLATION continued Electrical All three phase units are wired for the input voltage specified on the purchase order Unless specified otherwise standard units are wired for 460 volt 3 phase 60 Hz opera tion Motors used on the HCF collectors are UL recognized and internal wiring is UL rated at 600 volts Input power line protection is required for the motor and electrical components Line load and current requirements are identified on the motor nameplate Unless ordered with the machine the power switch for operating the machine any fusible disconnect mo tor starter or controller are to be provided by the customer user and located externa
6. after the date of purchase from AER Control Systems LLC Misapplication of the product decom position by reaction or chemical action and wear caused by abrasion will not constitute or be con sidered as a defect Warranty is void if the product has been subject to damage unreasonable use neglect improper service improper installation or other causes not arising from defects in original material or workmanship Any part that is determined to be defective in material or work manship and returned to an AER Control Systems LLC distributor or authorized service facility as AER Control Systems LLC designates shipping cost prepaid will be as the exclusive remedy repaired or replaced at AER Control Systems LLC s option AER Control Systems LLC shall not be liable for any incidental or consequential cost expenses or damages resulting from any fail ure defect or malfunction of this product liability is expressly disclaimed AER Control Systems LLC s liability in all events is limited to and will not exceed the purchase price of the product Ti tle and risk of loss pass to the buyer on delivery to the common carrier If a product is damaged in transit the recipient MUST make note of the damage on upon receipt of the product and file a claim with the carrier AER Control Systems LLC will make a good faith effort for prompt correc tion or other adjustment with respect to any product that proves to be defective within the war ranty period
7. cement 5 Reinstall cartridges noting that the cartridge filter that is open at both ends is inserted sealing gasket first HCF 3000 HCF 3030 and HCF 3050 into the cabinet The cartridge with one end capped is assembled so that the closed end is at the door end of the cabinet and compressed by the filter compression spring 6 Make certain that the edge of the cap does not hang up on the cabinet opening 7 Close the cartridge access doors and retighten the ball handle knob until doors are fully sealed against cabinet Troubleshooting Motor fails to start No power to unit indicator light is not Check overload heaters in starter and fuses lit and replace or reset if necessary Check for proper wire connections to and from the starter and collector Power to unit indicator light is lit Check wires from input electrical box on collector to motor Check motor wiring Check to see if motor is faulty Low airflow and or suction Blower is running backwards Check rotation of blower If running back wards interchange 2 of the 3 input power leads 3 phase motors only Cartridges are not being cleaned Check air pulse system to determine if it is working properly Check air pressure Obstruction in ducting Check ducting for blockage Check for dampers in the duct system they may be closed Improper duct design Contaminant blowing out of collector exhaust Unit is not pulsing but motor is running Unit is n
8. ck flushes collected contaminants off of the exterior surface of the filter bank By alternating the compressed air cleaning of the filter banks the system can continue to collect contaminants while cleaning takes place The motor blower module is located on the clean air side of the system after the pulse tank module and provides air flow for the collection system Optional Equipment Special Filters Drum Kit Mounting Brackets amp Stands Motor Starters Mechanical Arms Photohelic On Demand Pulse Delay Pulse Timer Attenuators SECTION 2 APPLICATIONS GENERAL 1 Dust amp Fume The Horizontal Cartridge Filtration System HCF is designed for the capture and removal of DRY dust and or fumes generated from sanding grinding welding and other industrial processes The HCF cartridge collector is a modular system consisting of a filter media cartridge filter module collection hopper and a final module containing the air reservoir tank and pulse jet cleaning system blower and motor The unit can be arranged in a variety of configurations and can be equipped with specialized filters for application specific filtration requirements The ceiling or wall mounted collectors can be used for direct ducted source capture applications or as free hanging un ducted ambient collectors for removal of general airborne contaminants Size Itis important that the proper size unit has been selected for the application Too little airflow will not d
9. lly to the machine After electrical hook up it is important to verify that the fan rotation is correct Incorrect ro tation results in much lower airflow and increased noise For standard three phase installa tions changing connections of any two of the three input power lines will usually reverse fan rotation Rotation direction can be found on the side and or back of the motor If it becomes necessary to change the input voltage the wiring diagram on the motor and transformer nameplates show the appropriate wire connections these diagrams are also shown below 110 volt LOW VOLTAGE HIGH VOLTAGE a fd E ie Peel eae LINE LINE Interchange any two line wires to reverse rotation HIGH VOLTAGE Figure 1 Motor amp Transformer Connection Diagram Optional Switch Input For on demand photohelic cleaning or optional on off switch jumper provided on standard unit Of time adjustment 6 5 to 160 sec On time adjustment 05 to 5 sec Program wire Murmber of valves that need to be controlled set at 2 3 Amp fuse 1 2 Amp fuse Transformer output 110 volt 1 phase Solenoid valves 1 Amp fuses Control Main Diaphragm alves qty 2 Transformer 50 Watt Motor Blower Standard Input Power 230 460 Volt 60 Hz 3 Phase FIGURE 2 Control Timer 8 SECTION 3 INSTALLATION continued Control Systems AUTOMATIC CONTROLS include an integrated electrically operated pi
10. lot solenoid valve for each diaphragm valve The solenoid valves are controlled by a solid state sequential control timer that determines the order in which the solenoid valves are operated the length of time that the valves remain open and the time interval between each valve open ing The compressed air tank and valves are fully enclosed and located between the car tridges and the blower The sequential control timer input power connection transformer and indicator light are contained in the electrical box mounted on top of the unit WARNINGS Take special care when the electrical box is opened When power is ON the full line voltage can appear from any electri cal point on the circuit board to the metal enclosure or to ground Compressed Air Requirements Air reservoir pressure should be set between 90 psig the minimum pressure which will as sure truly effective cleaning of the cartridges and 105 psig the maximum recommended working pressure of the valves and air reservoir Note The air reservoir system has a 120 psig relief valve The total consumption of compressed air is variable and is dependent upon the set points of the ON and OFF time of the timer and the air pressure in the reservoir at the time of the air pulse When the ON timer is set at its recommended time of 0 1 second and the air reser voir pressure is at 100 psig approximately 0 9 cubic feet of free air will be used per pulse While the cart
11. n this manual have been thoroughly checked however we cannot as sume responsibility for possible errors or omissions We reserve the right to change designs and or specifications without notice SECTION 1 UNCRATING 1 Remove banding and cardboard shipping carton and packing 2 Hoppers plenum boxes and attenuators are typically labeled and packed with the unit but not installed Mounting hardware is included for mounting these items be sure to check all boxes for any miscellaneous parts or hardware items before dis carding 3 Inspect the exterior of the unit and accessories for shipping damage or shortages that may not have been noticed or recorded when the shipment was initially re ceived contact the shipping company if any damage or shortages have occurred Description amp Operation The HCF series collector consists of a horizontally mounted filter module which house the cartridge filters Each cartridge has a filter media pack of 2 inch pleated media with a filter surface area of 240 sq ft and is formed in the shape of a hollow cylinder The interior of the cartridge cylinder is open to the pulse tank module which periodically cleans the car tridges by compressed air pulse jet flushing Diaphragm valves are mounted to a com pressed air reservoir tank and activated by a solenoid valve During operation a short blast of compressed air to the interior of one bank of filters results in media vibration and airflow reversal that ba
12. ot pulsing but motor is running units with delay timer or Photohelic pulse option Unit pulses all the time Hole in cartridge Replace Cartridge Cartridge not properly installed Check for correct cartridge orientation Check cartridge gasket gasket must seal around hole in tube sheet of cartridge cabi net Check cartridge access door knob should be tight for proper door and filter sealing No power to timer board Check for blown fuses Replace if neces sary Check transformer Power is getting to timer board Check to see if compressed air is on Check wiring from board to valve assembly Check to see if valves are opening Not set properly Check timer set points Off time may set for a longer period than you expect Check high and low pressure set points on Photohelic High pressure set point may be set too high Off time set to short Check timer board settings Timer board is designed for pulse intervals every 8 5 sec onds to 3 minutes Set times on Photohelic option are not High pressure and or low pressure set properly set points may be set too low 12 Specifications Nominal Airflow CFM Available External Pressure In H2O Filters Quantity Total Filter Area Sq Ft Motor HP Motor Temp Max C Compressed Air 90 to 105 PSIG Tank Qty 1 Tank Volume 0 32 Cu Ft Diaphragm Valve 2 1 in Program Timer off time on time Solid state
13. raw the contaminant into the filter and the unit will not be completely effective Too much airflow may result in loss of efficiency or the unit will pick up large or heavy solid particles increasing the frequency of maintenance or filter replacement Questions regarding proper unit sizing should be directed to your local AER Control Systems representative or the main office toll free 866 265 2372 Models Model codes are utilized to identify the various unit configurations available The model HCF Horizontal Cartridge Filtration system uses a direct drive blower Sometimes called a plug fan along with the number 3000 3030 or 3050 The 3000 unit is designed to be a un ducted horizontal ambient collection system for control of airborne contaminants in the general room The remaining units are designed for direct ducted source capture applications The 3000 and 3030 units have a 3 HP direct drive motor and fan and the 3050 unit has a 5 HP direct drive motor and fan Drum Kits Drum kits are available for connection to the hopper on the Horizontal Cartridge Filter unit for storage of removed contaminant Collars amp Inlet Plenums Ducted source capture units are provided with inlet collars and or inlet plenum boxes for attaching ductwork or for direct mounting of mechanical arms SECTION 3 INSTALLATION Assembly amp Installation HCF 3000 HCF 3030 and HCF 3050 Standard collectors are shipped without hoppers installed
14. ridges are being cleaned the average usage rate in CFM of free air depends upon the setting of the OFF timer If set at 30 second intervals 2 pulses per minute the av erage usage rate during a cleaning cycle would be 0 9 cu ft pulse x 2 pulses minute 1 8 CFM of free air SECTION 4 Ordering Replacement Parts Information required for prompt delivery of replacement parts will be 1 Model and Serial Number 2 Part Number and Description Contact your local AER Control Systems LLC distributor for replacement parts Use our toll free telephone number to obtain the nearest AER Control Systems LLC distributor s name and telephone number 1 866 265 2372 Part Number Description 1015 02 Blower Inlet Cone 12 inch 1015 04 Blower Inlet Cone 15 inch 1012 01 Blower Impeller Wheel 12 100 1013 02 Blower Impeller Wheel 15 53 1003 15 Motor 3 H P 1003 17 Motor 5 H P 1041 05 Cartridge One End Open 1041 07 Cartridge Both Ends Open 1218 03 Diaphragm Solenoid Valve 1 1220 01 Control Timer Board 1089 01 Pressure Relief Valve 1233 11 Transformer 50 Watt 1224 22 1 Amp Fuse 1224 18 1 2 Amp Fuse 1221 01 Delay Relay Timer optional 1084 01 Louvre Exhaust 14 x 8 SECTION 5 MAINTENANCE Operation amp Maintenance Lubrication or other routine periodic preventative maintenance is not required All that is needed is an occasional check of fas
15. s use AER Control Systems replacement filters
16. teners hoses and clamps and a general visual check of the unit to make sure that nothing has gone wrong Periodic replacement of the cartridges is required when necessary and check draining of condensation from air reservoir Draining can be done automatically if the drain is opened slowly while the tank is under pressure Always empty the dust storage drum before it fills completely Do NOT allow the dust to col lect to the point where it begins to fill the flexible hose and enter the bottom of the hopper since this would result in the dust being re entrained in the air stream re depositing on the cartridges and shortening their life Do NOT use the hopper as a dust storage device Cartridge Replacement HCF 3000 HCF 3030 and HCF 3050 The pressure drop across the cartridges will eventually reach a point at which the airflow and suction are too low At this time the cartridges should be replaced as follows 1 Shut off electrical power to the blower and control box 2 Open the cartridge access doors on the end of the filter cartridge module 3 Turn the ball handle knob counterclockwise to release the tension on the doors each door has a filter compression spring which pushes against the cartridge to seal the car tridge against the tube sheet Once the knob is loosened the door retainer bar can be ro tated and the doors can be swung open and the filter cartridges can be accessed 4 Cartridges may be easily removed for inspection or repla
17. th all National and Local Fire Electrical and or other appropriate codes when determining the application location and op eration of any air pollution control equipment Collection of combustible or explosive materials and collection on flame or spark generating op erations may require specific system configurations contact AER Control Systems LLC Applica tions Engineering Department for questions and or design assistance The combined collection of combustible or explosive materials and contaminants from spark or flame generating opera tions with a common collector or duct system is not recommended unless special design provi sions have been made to the system sparks or flames resulting from such operations may ignite the combustible or explosive material Under no circumstances should anyone be allowed to dis card a lighted cigarette other burning materials or refuse into an inlet hood or the duct of the col lection system It is the responsibility of the end user to comply with all applicable national state and local fire and safety codes This manual should be read completely before attempting Operation or Maintenance of this equipment All work should be performed by qualified personnel according to local requirements WARNING Failure to comply fully with the following instructions and local code requirements may increase your risk of physical injury due to fire explosion or electrical shock All data and dimensions i
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