Operation Manual Operation Manual RYOUSEI Dust Collector

Operation Manual Operation Manual RYOUSEI Dust Collector
(3) Locations for use
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Operation Manual
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RYOUSEI Dust Collector
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Warning
In flammability or explosive atmospheres, do not use the machine if kept
intact in a normal version. This can cause an injury or fire. For various
dangerous areas specified in Articles 280 to 282 of the Labor Safety and
Health Rules, use an explosion-proof model suitable for such dangerous
areas.
Cautions
Except for the models intended for outdoor purposes, do not use the
machine outdoors. This can possibly cause a short circuit.
Avoid modification of the product at the customer’s own discretion. In
this case, the manufacturer assumes no responsibility for the product set
out in the warranty.
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Use the machine in an ambient temperature range from -15 °C to +40 °C
and at a humidity of 80 percent or less.
(4) Instructions in connecting the power supply
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(2) Operation
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Warnings
Allow only the qualified personnel to route and connect the wiring. This
is to avoid a possible electric shock, injury, or fire. When connecting the
power supply, refer to the wiring diagram, or an electric shock or fire can
possibly arise.
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Thank you for buying the RYOUSEI dust collector this time.
To learn the proper use of the machine, ensure to read this operation
manual. It will certainly help you to solve a problem or doubt, if any,
encountered in use.
Make sure that the production serial number marked on the product
main body is consistent with the number printed on the letter of
guarantee because the production serial number is important for
quality control.
In this operation manual, the safety instructions are divided into “warnings”
and “cautions.”
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Warning
Improper handling can cause a dangerous situation,
resulting in a possibility of a heavy injury or death.
Cautions
Improper handling can cause a dangerous situation,
resulting in a possibility of a slight or middle level
injury and/or a damaged material.
Before Use
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Ensure that this machine is used with the power supply of the voltage and
frequency instructed on the nameplate.
Make sure that the capacity of the breaker connected with the power
supply cable is approximately three times of the reading on the
nameplate.
(5) Check on the motor running direction
● Connect the main body definitely with the power supply, switch on the
main body, run the motor for a moment, and check the running direction.
To make a check, open the main body maintenance door (or top plate for
some models) and then connect wires according to the running direction
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Warning
Allow only the qualified personnel to transfer and install the machine.
When relocating the unit, take care not to drop or overturn it. This can
possibly cause an injury. If the unit is equipped with lift bolts, ensure to
use them.
Cautions
Ensure to place the machine on a flat plane. If required, resurface the
foundations. A skewed surface can cause a tumble.
In the case of a wooden frame package, pay attention to the nails when
unpacking because they can possibly cause an injury.
Keep the warning label sticker visible at all times, but do not peel it off or
conceal it behind an obstruction.
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indicated by the arrowhead showing the reading direction.
(1) Check items
On receiving this machine, check the following points while the unit has
been delivered after strict inspection:
● Check whether or not the nameplate reads the type, output, voltage, and
frequency as you have ordered.
● Check for damage resulting from an accident in transportation. If any
part is found unacceptable, keep the current condition as it is as far as
possible, and check the type and production serial number and then
contact the dealer.
(2) Transfer and installation
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Also, to prevent a short circuit from causing an electric shock accident, be
sure to connect the main body with the earth at a ground resistance of 100
Ω or less before use.
Make sure the grounding wire is in green. (Articles 18 to 28, Electric
Equipment Engineering Standards).
Cautions
Just all the cables and wires according to the Electric Equipment
Engineering Standards and the electric power company’s instructions.
Particularly, in the case of an extended wire, which will entail a voltage
drop, select the wiring capacity so that the voltage drop would not exceed
two percent.
While all of our products (besides those specially designed) are equipped
with an overload preventive device, a leak current breaker or an
equivalent should be installed to avoid a fire or electric shock accident.
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Warning
Be sure to make a visual check on the motor running direction. Never
touch the motor shaft with a finger or tool because this can cause an
injury.
Caution
In the case of a reverse rotation, exchange the red and black wires with
each other among the three wires, except for the grounding wire.
Even if the shaft turns in the reverse direction, the machine tends to be
operated in some cases as it is due to its suction force. In such a case,
however, the dust collector will not only fail in demonstrating its
performance but also cause the motor to be overloaded or burn out and,
therefore, close attention should be paid.
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(6) With respect to equipment such as the ducts and hood, negotiate in
advance so as to configure them efficiently.
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Instructions
Instructions for use
(1) Power supply
● Make sure that the power supply cable and the power supply plug are
securely connected before use. Incomplete contact may cause a
single-phase operation, resulting in a motor burned out.
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Warnings
Do not skew, trample, or pinch the power supply cable. This can give you
an electric shock. In addition, take care not to apply oil or petroleum to
the cable, which may be dissolved.
With the control panel or terminal box door (lid) open, do not operate the
unit because this can result in an electric shock.
In the case of a power failure, be sure to turn off the power switch or
primary power supply. Note that some models will automatically start
running on a recovery from the power outage, possibly resulting in an
injury.
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Warnings
Irrespective of whether or not the machine is in operation, prevent a
burning substance or an equivalent from being sucked through or thrown
into the suction port. This can cause a fire.
In operation, do not open the maintenance door to place a hand or object.
This can possibly result in an injury.
Before attracting inflammable or explosive powder or gas or installing the
machine in a hazardous atmosphere, make sure that the unit is designed
to have an explosion-proof structure with electric and structural measures
adopted as required.
Except for specially designed units, our dust collectors are intended for dry
powder. Prevent soggy powder with oil or water from being attracted.
When a large amount of particulate powder such as cement, lime,
chemical, or toner is sucked, it may pass through the filter mesh to be
released externally along with the exhaust. If this poses a problem in
such a place as a clean room, hospital, or chemical company, employ a
model incorporating an HEPA exhaust filter oriented to clean rooms.
Some models are not suitable for some types of powder. If a different
type of powder is to be applied because the unit is relocated for example,
please contact the manufacturer.
(3) Dust dump (cleaning)
○RV, RSV, RC, RSC, and RF Series
● When the dust collector is used for an extended period of time, the
filtering material is loaded with powder to result in a lowered suction flow
rate. In this case, stop running once and remove the powder from the
filter.
● In the case of a manual shaking type, shake the shaking handle several
times to unload from the filter dust.
● For those models of an electric power shaking type, turn off the fan
operation switch and wait for 60 seconds until the shaking motor is
automatically activated to shed the dust. While the shaking duration
will vary depending on the amount and type of the attracted powder, 60
seconds is sufficient in general. To reconfigure the shaking standby and
operating time parameters, turn the adjuster knob located on the
sequencer in the main body control panel.
VR1:Shaking standby time of 60 to 310 seconds (60 seconds preset at factory)
VR2:Shaking operation time of 0 to 250 seconds (60 seconds preset at factory)
● If this machine is to be operated intermittently and shut down frequently,
the shaking operation time will be extended, possibly resulting in a
considerably short service life of the filter. To use the machine in such a
way, adjust the periods of time mentioned above (extend the standby time
or reduce the operation time so that operation time of the shaker becomes
at most five minutes in total per day).
○RSP Series
● For the RSP series, a pulse jet cleaning method is adopted for the powder
shedder, which will automatically start shedding the dust at the specified
intervals with the sequencer when the power supply is turned on for the
machine to start running. Connect a compressor line (at 0.4 or 0.5 MPa)
to the compressed air receiving port (air filter) on the side of the main
body when using the machine.
● In a standard condition preset at the manufacturer’s factory before
delivery, the solenoid valve is set to be activated at intervals of 60 seconds.
And then, after the fan motor stops running, the solenoid valve is further
activated for 60 seconds during which the valve operates at intervals of 5
seconds to conduct cleaning. In addition, the activation intervals and the
post-shutdown activation period are designed to be variable with the
external knobs of the controller for you to make an adjustment as
required depending on the using conditions.
(4) Powder disposal
● Release the collected powder as soon as possible. If kept remaining for
an extended period of time, the powder will become compact in the
dust-collecting bucket (hopper), possibly resulting in a clogged filter or fire.
● After shedding (cleaning) the dust, take out the powder collected in the
bucket and hopper each time.
To remove the dust-collecting bucket, turn down the installation handle
(or to the right for some models) to lower the bucket and pull it out.
● In the case of a hopper type, when opening or closing the valve attached to
the discharge port, use a bit by bit opening motion to operate the valve
taking care not to allow powder to scatter subsequently.
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Maintenance and Inspection for Long Service Life
(1) Maintenance and inspection
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Caution
Before starting inspection, service, or disassembly, make sure that the
power supply switch or primary power is turned off in order to avoid a
possible electric shock, injury, or fire.
※Precautions for maintenance and inspection
● When starting maintenance or inspection work, make a safety check
definitely based on the safety control standards of your company and the
Labor Safety and Health Rules.
● To conduct maintenance and inspection work, put on working clothes and
wear protective equipment (e.g., dustproof mask and safety glasses).
● If any flammable substance is handled, make sure there is no fire.
● In the case of maintenance or inspection work without running this
machine, turn off the primary power supply and indicate that no
activation is allowed.
※Maintenance and inspection items
○Before running the machine
● Inspect the appearances to check for any deformation or breakage
degrading the functions.
● Make sure that the maintenance door is closed and the dust-collecting
bucket is definitely set in position.
● Ensure that dust powder in the dust-collecting bucket (hopper) is
disposed.
○In operation
● Check for any air leak from the packing of the maintenance door or
dust-collecting bucket.
● Make sure that the indicator lamps (e. g., power supply and operation) on
the control panel are turned on.
● Check whether or not the motor squeals or makes an unacceptable noise.
Particulate powder leak can cause the ball bearings as the motor of this
machine to be excessively worn or damaged.
● Open all the suction ports of the pipe ducts to make an electric current
check with the ammeter. If the reading is far smaller than the rated
value, the filter may be clogged.
○In periodic inspection or disassembly
● Open the maintenance door to inspect the filter and, if heavily
contaminated, then clean or replace it. Note that the filter must be
replaced if torn off or there’s a hole, even partially.
● Inspect the packing of the maintenance door and dust collecting bucket
unit. If there is unacceptable deformation or deterioration, replace the
packing with a new one.
○Other parts
● Check whether or not the hood, hoses, and pipes are installed properly
with no deformation or damage. When the machine is operated, check
for any air leak from the connections. In addition, if powder is found
accumulating internally, take it out.
● Inspect the control panel for inside powder accumulation. In the case of
conductive powder, this can cause a leak current or a short circuit to the
ground and, therefore, periodic cleaning is required.
● Check the filter housing for internal powder deposition. If a lot of powder
remains, the filter may be attached incorrectly, torn off, or broken.
(2) Replacing the filter
● In the long run, the filter will be clogged and worn and, therefore, must be
washed with water or replaced in approximately one year as an aim. In
addition, if the filter is washed, check it carefully for breakage.
● Depending on the type of powder to be collected, the collected powder can
not fully be removed in some cases when shedding the dust (cleaning).
In such a case, remove the filter from the main body and clean it with an
electric cleaner or wash it with water (with commercially available
detergent added for efficiency).
Moreover, make sure that the filter is completely dried before installation.
Depending on the type of filter, the filter may not be washable with water.
For further information, contact us.
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Cautions
Before inspecting or replacing the filter, be sure to turn off the primary
power supply for all the machine units to stop running.
When placing or removing the filter port rubber, the perforated plate (port
rubber mount disk) can possibly injure your fingers. To avoid such a
problem, you are recommended put on gloves, etc.
If the filter is incompletely fitted, attracted powder may be discharged
from the exhaust port. Ensure tight seating.
○RV, RSV, RC, RSC, and RF Series
① Apply a centripetal force to the filter port rubber and pull upward to
remove it.
② Detach the lock rubber located at the edge of the filter hanger.
In the case of an RF series, remove the split pin and flat washer.
③ Detach the filter from the filter hanger.
④ In the same manner, demount all the filters. To install the filters, reverse
the procedure shown above.
At this time, take care not to twist the filter when inserting the filter into
the hanger. Additionally, make sure that the port rubber is firmly
seated.
○RSP-520 Series
① Loosen the fastener bolts (at four locations) on the upper inside of the
filter housing.
② Wait for the filter mount frame to descend.
③ Pull out the filters.
④ To install them, reverse this procedure.
Make sure that the packing on top of the filter is in intimate contact with
the top plate.
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After installing the filters, touch them to check for looseness, and, if any,
then it is unlikely that the filters are mounted properly. If the upper
packing is considerably deformed, it must be replaced with a new one.
○RSP Series
For this series, the cassette holder and the mount position are marked
with A and B respectively. In replacing a filter, ensure to match these
symbols with each other.
① Loosen and remove the eye bolts retaining the cassette holder A.
② Slightly pull the cassette holder outward to remove the filter in the front.
③ Further slightly pull the cassette holder outward to remove the second
and then the third filter.
④ Take out the cassette holder from the rails.
⑤ Then, remove the filters from the cassette holder B in the same manner.
⑥ To install them, reverse this procedure to place B at first, followed by A.
Additionally, take care in mounting the filter not to break it.
● Finally, touch the filters to make sure that the filters have tightly been
installed. If any filter is found loose, it seems to have been miss-fitted.
○RV-05B Type
① Remove the maintenance door fastener bolts to open the maintenance
door.
② Detach the set screws retaining the filter mount frame.
③ Draw out the filter mount frame.
④ At last, pull out the filter.
○RSV-211B Type
① Remove the catch clips to open the maintenance door.
② Pull out the dust-collecting bucket.
③ Loosen the butterfly screws at two locations on the lower portion of the
filter.
④ Draw out the filter.
○RC-560 Series
① Remove the maintenance door fastener nuts to open the maintenance
door.
② Loosen the butterfly screws attached at two locations above the filter.
③ Pull out the filter.
○RSM Series
① Remove the catch clips to open the maintenance door.
② Detach the quick installation or release hose band to take out the
dust-collecting bag.
③ Open the fastener of the dust-collecting bag to dispose of the dust.
Note that the grip of the dust-collecting bag is helpful to carry the bag.
○HEPA filter
In the case of a dust collector equipped with an HEPA filter, particulate
powder passing through the primary filter will be captured here. Since
the HEPA filter can not be regenerated, replace it with a new one in a
certain period of time (at a final pressure loss of 0.5 kPa or more when
reading the differential pressure).
(3) Replacing the motor
The fan driving motor (electric unit) includes ball bearings, and can be
worn or damaged due to particulate powder intrusion under some
condition when used for an extended period of time. In such a case, the
unit will make an abnormal noise or vibration. Therefore, pay attention
to the running noise in operation and, if an abnormal noise occurs, make
an inspection to repair or replace the part.
● Removing the top plate
● Loosen and remove the lift bolts (bolts) fitted at two or four locations and
then uninstall the top plate.
● In the case of an HEPA filter mount type, remove the HEPA filter and the
HEPA filter housing as well.
● Disconnecting the wiring routed to the motor
Open the terminal box of the electric motor to disconnect all the wires
connected.
● Detaching the motor mount plate retainer bolts
Remove the retainer bolts fitted at three or four locations.
● Removing the electric motor and turbo fan along with the motor mount
plate
Pass shackles or an equivalent through the motor retention leg holes or
lift bolts located on the electric motor so as to lift the motor with a forklift.
To place the motor mount plate on the floor, ensure that the turbo fan
faces upward.
● Uninstalling the turbo fan
Loosen and detach the retainer bolt located in the center of the shaft.
Next, grasp the turbo fan with your hands to pull and remove the fan
toward the edge of the shaft.
At this time, take care not to pull the fan forcibly because this can result
in a damaged motor shaft or turbo fan.
● Remove the electric motor from the motor mount plate by detaching the
bolts and nuts used for retention at four locations.
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If You Have Any Doubt About Failure, … First, Inspect
Symptom
Not start running
even if switched on
(Fan ON)
Motor stops running
in operation
Unacceptable
vibration or noise
Powder blown from
exhaust port
Degraded attraction
force or no suction
Possible cause
Corrective action
Power supply not turned on
Turn on power.
Overload protection device
activated
Search for cause and
then resume
running.
Magnet switch thermal
relay tripped
Search for cause and
then reset.
Switch contact fault
Repair or replace
Motor malfunction
Repair or replace
Power supply cable (wire)
broken
Repair or replace
Running in reverse
direction, resulting in over
current
Protection device activated
owing to repeated start and
stop cycles
Check running
direction.
Wait for minutes
and then restart
running.
Motor malfunction
Repair or replace
Motor bearing worn or
damaged
Repair or replace
Motor mount or another
fastener part loosened
Inspect and
retighten bolts.
Filter damaged or worn
Replace
Filter installation fault
Inspect
Clogging on filter
Wash with water or
replace.
Dust collecting bucket fully
loaded
Dispose of powder.
Dust collecting bucket
installation fault
Clogging in duct or hose
Deformation or breakage of
duct or hose
Duct or hose connection
fault
Fit firmly.
Clean
Replace
Inspect
About After-Sales Service
(1) Letter of guarantee
The warranty period lasts for one full year from the day of purchase.
(2) To ask for service in the warranty period
Search for the cause and take action according to the list in the next
section “If you have any doubt about failure, … first, inspect.” If the
problem persists, contact the manufacturer or the dealer from which you
have purchased the product.
(3) To ask for service after the warranty period
Contact the manufacturer or the dealer from which you have purchased
the product. If the performance of the product can be maintained by
repairing, the machine is serviced with fee.
(4) Minimum period to store performance maintaining parts for repair
For at least six years after discontinued production, the manufacturer
reserves service application parts for maintaining the performance of the
dust collectors in each type.
(5) If you have any question about after-sales service, such as repair in the
warranty period, contact the manufacturer or the dealer from which you
have purchased the product.
(6) This warranty, and service are valid only in Japan.
RYOUSEI Co., Ltd.
2-6-8 Obata Minami, Moriyama-ku, Nagoya 463-0048, Japan
Nagoya Headquarters Phone (052) 794-3211 (Pilot)
Tokyo Sales Office
Phone (03) 3835-4451 (Pilot)
Osaka Sales Office
Phone (06) 6302-8055 (Pilot)
Fukuoka Sales Office Phone (092) 947-2821 (Pilot)
Dust Collector Operation Manual-0710-1.2
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