Donaldson Torit DCE 2000 Series Manuale utente

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

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Installation, Operation and Maintenance Manual

IPC and IPC (DR) Controllers

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

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

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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