Attachment 6 - DCU Install and Ops Manual.pdf

Installation and Operation Manual

IOM AD3310701

Revision 7

Downflo® II

DFT 2-8, 2-12, 2-16, 2-24, 2-36

DFT 3-12, 3-24, 3-26, 3-48, 3-60, 3-72,

DFT 4-16, 4-32, 4-48, 4-64, 4-80, 4-96, 4-112, 4-128

Units Built After July 2003

Throughout this manual statements indicating precautions necessary to avoid equipment failure are referenced in a Note. Statements indicating potential hazards that could result in personal injury or property damage are referenced in a CAUTION! box.

Installation, Operation, and

Service Information

This manual is property of the owner. Leave with the unit when set-up and start-up are complete. Donaldson Company reserves the right to change design and specifications without prior notice.

Donaldson Company, Inc.

Data Sheet

Model Number _______________________________ Serial Number ________________________________

Ship Date ____________________________________ Installation Date ______________________________

Customer Name ____________________________________________________________________________

Address ____________________________________________________________________________

Filter Type ____________________________________________________________________________

Accessories ____________________________________________________________________________

Other ____________________________________________________________________________

CAUTION!

Application of Dust Control Equipment

• Combustible materials such as buffing lint, paper, wood, aluminum or steel dust, weld fume, or flammable solvents represent fire or explosion hazards. Use special care when selecting and operating all dust or fume collection equipment when combustible materials are present to protect workers and property from damage due to fire and/or explosion. Consult and comply with National and Local Codes relating to fire or explosion and all other appropriate codes when determining the location and operation of dust or fume collection equipment.

• When combustible materials are present, consult with an installer of fire extinguishing systems familiar with these types of fire hazards and local fire codes for recommendations and installation of fire extinguishing and explosion protection systems. Donaldson Torit dust collection equipment is not equipped with fire extinguishing or explosion protection systems.

• DO NOT allow sparks, cigarettes or other burning objects to enter the hood or duct of any dust or fume control equipment as these may initiate a fire or explosion.

• For optimum collector performance, use only Donaldson Torit replacement parts.

Warning – Improper operation of a dust control system may contribute to conditions in the work area or facility that could result in severe personal injury and product or property damage. Check that all collection equipment is properly selected and sized for the intended use.

Downflo II, Model DFT 2-8 through 4-128

This manual contains specific precautionary statements relative to worker safety. Read thoroughly and comply as directed. Discuss the use and application of this equipment with a Donaldson Torit representative. Instruct all personnel on safe use and maintenance procedures.

Magnehelic® and Photohelic® are registered trademarks of Dwyer Instruments, Inc.

Contents

Description Purpose and Intended Use Rating and Specification Information Operation Inspection on Arrival Installation Codes and Procedures Installation

Site Selection, Grade-Mounted Units Unit Location

Electrical Wiring Rigging Instructions

Hoisting Information Typical Installation Standard Equipment

Field Assembly Module Assembly Yoke, Venturi, and Filter Installation Hopper Installation Leg Installation Compressed Air Installation

Solid-State Timer Installation Solenoid Connection Timer and Solenoid Specifications

Preliminary Start-Up Service Information

Operational Checklist Filter Installation and Replacement

Filter Removal Filter Replacement Dust Disposal Compressed Air Components

Optional Equipment Power Pack Side Mount Power Pack 55-Gallon Drum Pack Magnehelic® Gauge Photohelic® Gauge Delta P Control Delta P Plus Control Transition and Rotary Valve Damper and Silencer, TBI Plenum Silencer, TRB Abrasion-Resistant Inlet Collar Platforms and Ladders Cold Climate Kit Explosion Vents Sprinkler Installation

Troubleshooting Service Notes Warranty

Description

The Downflo II dust collector is a continuous-duty, modular collector with cartridge-style filters. The downward airflow design delivers high filtration efficiency while using less energy. Continuous-duty means no downtime. The filters are pulse-cleaned in sequence, one set at a time, without turning the unit off. The modular design allows flexibility in system design and adapts easily to limited space areas. Each standard module is two or three filter rows wide by two, three, or four rows high by two filters deep.

Designed to increase the versatility of the unit, standard options include top or front inlets, filter access covers, Bag Out, cold climate kits, steep-slope ledge-free hoppers, trough hoppers, and stationary service platforms.

Purpose and Intended Use

Downflo II collectors are widely used on nuisance dust where the load to the collector is less than two grains per cubic foot. Some typical applications include abrasive blasting, grinding, mixing, blending, processing, pan coating, powder paint applications, sand handling, welding, and machining. Each application is different and selecting the correct filter cartridge for the application and type of dust collected is important.

• For all ambient, extremely fine, and non-fibrous dust, use Ultra Web® filter cartridges which offer high efficiency and performance on fine particulate.

• For fibrous dust, use a cartridge with an open-pleat design, such as Fibra-Web®.

• Operations involving high temperature and high humidity may require special attention.

Temperature, moisture content, and chemistry issues may require custom collector design.

Appropriate cartridge options are available from Donaldson Torit.

• Hygroscopic dust such as fertilizer, salt, and sugar should be handled under a controlled, low humidity environment. Contact Donaldson Torit for filter cartridge selection.

• Flammable or explosive dust may require custom collector design options and special cartridges. Contact Donaldson Torit for design assistance.

• Applications with high hydrocarbon or high oil content may require special treatment or filter media.

CAUTION!

• Misuse or modification of this equipment may result in personal injury.

• Do not misuse or modify.

All Units ( per IBC 2003 Specifications):

Wind ........................................ 90 MPH Exposure C Seismic Spectral Acceleration, Ss ............................................ 1.5 Seismic Spectral Acceleration, S1 ........................................... 0.6 Importance Factor, 1 ............................................ 1.0

Ground Snow Load ............................... Pg = 40 PSF Compressed air, psi ........................................90-100 Housing rating, "wg ..........................................+-20 Power, valves and controls .... 120-Volt AC, 50/60 Hz

Rating and Specification Information

Front DFT 2-Model

Front DFT 3-Model

Front DFT 4-Model

DFT 2-12 Front 3-wide models

DFT 3-18 Front 3-wide models

Side View All Models

Operation

During normal operation, dust-laden air enters the unit through the dirty-air inlet. Airflow is directed downward through the collector and heavier particulate falls directly into the hopper. The cartridges remove fine particulate and clean filtered air passes through the cartridges to the clean-air plenum and discharges through the clean-air outlet.

Filter cleaning is completed using pulse-jet technology. A solenoid and diaphragm valve aligned to each row of filters provides the pulse cleaning.

The cleaning sequence starts at the top filter row and continues down through each row. Remove, inspect, or change the cartridges from outside the unit by removing the filter access cover and sliding the filters out.

Unit Operation

CAUTION!

• Combustible materials such as buffing lint, paper, wood, aluminum or steel dust, weld fume, and flammable solvents represent fire or explosion hazards.

• Use special care when selecting and operating all collection equipment when combustible materials are present to protect workers and property from damage due to fire and/or explosion.

• Consult and comply with all National and Local Codes relating to fire or explosion, and all other appropriate codes when determining the location and operation of dust collection equipment.

• Donaldson Torit equipment is not equipped with fire extinguishing or explosion protection systems.

filter cartridges ExtraLife™ filter cleaning system dirty-air inlet clean-air outlet diaphragm valve compressed-air supply

Normal Operation hopper

Filter Cleaning Operation

Inspection on Arrival

1. Inspect unit on delivery.

2. Report any damage to the delivery carrier.

3. Request a written inspection report from the Claims Inspector to substantiate claim.

4. File claims with the delivery carrier.

5. Compare unit received with description of product ordered.

6. Report incomplete shipments to the delivery carrier and your Donaldson Torit representative.

7. Remove crates and shipping straps. Remove loose components and accessory packages before lifting unit from truck.

Installation Codes and Procedures

1. Safe and efficient operation of the unit depends on proper installation.

2. Authorities with jurisdiction should be consulted before installing to verify local codes and installation procedures. In the absence of such codes, install unit according to the National Electric Code, NFPA No. 70-latest edition.

3. A qualified installation and service agent must complete installation and service of this equipment.

CAUTION!

OSHA may have requirements regarding recirculating filtered air in your facility.

Consult with the appropriate local authorities to ensure compliance with all codes regarding recirculating filtered air.

Installation

Site Selection, Grade-Mounted Units

1. The unit can be located on a reinforced concrete foundation or rooftop.

2. Wind, seismic zone, and other live-load conditions must be considered when selecting the location for rooftop-mounted units.

Reference the Specification and Rating Information.

3. Provide clearance from heat sources and interference with utilities when selecting the location for grade-mounted units. Reference the Specification and Rating Information.

4. Portable units require no special installation accommodations.

Note: Units with explosion vents are not available in portable configurations.

Unit Location

1. When hazardous conditions or materials are present, consult with local authorities for the proper location of the collector.

2. Foundation or roof support must be sized to accommodate the entire weight of the unit, plus the weight of the collected material, piping, and ductwork. Reference the Specification and Rating Information.

3. Prepare the foundation in the selected location.

Install anchor bolts to extend a minimum of 1 3/4-inches above foundation unless otherwise indicated on the Specification Control drawing.

4. Locate the collector to ensure the shortest and straightest inlet- and outlet-duct length, easy access to electrical and compressed-air connections, and routine maintenance.

CAUTION!

Donaldson Torit equipment is not designed to support site-installed ducts, interconnecting piping, or electrical services. All ducts, piping, or electrical services supplied by others must be adequately supported to prevent severe personal injury and/or property damage.

CAUTION!

• Failure to lift the collector correctly can result in severe personal injury or property damage.

• Use appropriate lifting equipment and adopt all safety precautions needed for moving and handling the equipment.

• A crane or forklift is recommended for unloading, assembly, and installation of the collector.

• Location must be clear of all obstructions, such as utility lines or roof overhang.

Electrical Wiring Rigging Instructions

Suggested Tools & Equipment

Clevis Pins and Clamps Lifting Slings Crane or Forklift Pipe Sealant Drift Pins Pipe Wrenches Drill and Drill Bits Screwdrivers End Wrenches Socket Wrenches Large Crescent Wrench Spreader Bars

Hoisting Information

1. Use all lifting points provided.

2. Use clevis connectors, not hooks, on lifting slings.

3. Use spreader bars to prevent damage to unit’s casing.

4. Check the Specification Control drawing for weight and dimensions of the unit, subassemblies, and components to ensure adequate crane capacity.

5. Allow only qualified crane operators to lift the equipment.

6. Refer to applicable OSHA regulations and local codes when using cranes, forklifts, and other lifting equipment.

7. Lift unit and accessories separately, and assemble after unit is in place.

8. Use drift pins to align holes in section flanges during assembly.

CAUTION!

• Electrical installation must be performed by a qualified electrician and comply with all applicable national and local codes.

• Lock out electrical power sources before performing service or maintenance work.

• Do not install in classified hazardous atmospheres without an enclosure rated for the application.

1. All electrical wiring and connections, including electrical grounding, should be made in accordance with the National Electric Code, NFPA No. 70-latest edition.

2. Check local ordinances for additional requirements that apply.

3. The appropriate wiring schematic and electrical rating must be used. See unit’s rating plate for required voltage.

4. If the unit is not furnished with a factory-mounted disconnect, an electric disconnect switch having adequate amp capacity shall be installed in accordance with Part IX, Article 430 of the National Electric Code, NFPA No. 70-latest edition. Check unit’s rating plate for voltage and amperage ratings.

5. Refer to the wiring diagram for the number of wires required for main power wiring and remote wiring.

Typical Installation

1. Stand hopper on the discharge end.

2. Apply sealant around the top flange of the hopper toward the inside edge of the bolt pattern.

3. Lift collector into position over the hopper and lower slowly

4. Use drift pins to align holes and secure with hardware provided.

5. Assemble legs and cross braces.

6. Lift unit and hopper assembly into position over legs and lower slowly

7. Fasten legs to unit and to foundation.

8. Lift assembled unit to location.

9. Support and level unit.

9. Tighten all hardware.

10. Remove crane.

Module Assembly

CAUTION!

• Failure to lift the collector correctly can result in severe personal injury or property damage.

• Use appropriate lifting equipment and adopt all safety precautions needed for moving and handling the equipment.

Standard Equipment

Standard equipment consists of modules, inlet deflectors, yokes, filters, hoppers, and legs. Single-module through six-module units are delivered with the inlet deflectors, yokes, and filters factory installed.

Field Assembly

Field assembly of modules may be required due to truck capacity, crane capacity, or specific customer requirements. A detailed instruction drawing, shipped with each module, provides specific assembly and lifting instructions.

If unit has been shipped with fully-assembled modules, skip to Hopper Installation.

filter acces cover see Detail A clean-air outlet cover see Detail F clean-air plenum bolting, see Detail C inlet deflector sealant, see Detail B yoke installation, see Detail E yoke alignment, see Detail D filter cartridge access cover

Detail A

Detail B

Detail C

Module Assembly

Note: Two cranes are required to lift and assemble modules.

1. Remove the protective cover from the end of each module.

2. Remove one column of access covers, filters, venturis, yokes, and deflector panels from the joint-side of each module. See Detail A.

3. Remove outlet cover from the bottom of the clean-air plenum and set aside.

4. Apply a generous amount of sealant to one module to create an airtight seal between the clean and dirty-air chambers as shown in Detail B.

5. Lift both modules into position using two cranes.

6. Use drift pins to align the bolt holes in the mating flanges.

7. Bolt the modules together using 5/16-18 x 1 1/4-in bolts, washers, and nuts as shown Details B, and C. Do not tighten hardware at this time.

8. Check that all joints and flanges are flush and tighten hardware starting with the joint between the clean- and dirty-air plenums.

5/16-18 x 1 1/4-in bolt

5/16-in flat washer sealant module flange

5/16-in lock washer module flange

5/16-16 hex nut

5/16-in flat washer dirty-air plenum clean-air plenum sealant

Detail E

Detail F

Detail D

Yoke, Venturi, and Filter Installation

Notes: Installing yokes requires two people.

Place blocks under assembled modules during yoke and filter installation.

1. Thread a thin jam-nut on each of the yoke rod ends to the shoulder. See Detail D and E.

2. Start at the bottom access port and work upward. Position the yoke as shown in Detail D.

From the filter section, have one person hold the yoke in position while another person installs the venturi and hardware from the clean-air plenum. See Detail E. Do not tighten hardware at this time.

3. Center the yoke from side-to-side horizontally and 1/4-in above center vertically. See Detail D.

Adjust jam nut against the filter cartridge panel.

Have one person hold the yoke in position while another person tightens the three hex nuts from the clean-air plenum. Repeat to install all yokes.

4. Slide the filter cartridge on the yoke gasket-end first. Replace access cover and tighten securely by hand. Repeat for all filter cartridges.

5. Replace the outlet cover on the bottom of the clean-air plenum. See Detail F.

clean-air plenum outlet cover

5/16-in seal washer

5/16 x 3/4-in thread-forming screw

3/8-in hex nut venturi

3/8-in flat washer 3/8-in lock washer

3/8-in hex jam nut yoke shoulder filter cartridge panel yoke

1/4-in filter access

52.63-in

3/8-16 x 1-in bolt 3/8-in flat washer

3/8-in flat washer 3/8-in lock washer

3/8-16 hex nut

3/8-16 x 1-in bolt 3/8-in flat washer

3/8-16 x 1-in bolt

3/8-in flat washer 3/8-in lock washer

3/8-in flat washer 3/8-in lock washer 3/8-16 hex nut

3/8-16 x 1-in bolt 3/8-in flat washer hopper access cover (four port hole only)

Hopper Installation

Hopper Styles

Hopper Installation

There are four ledge-free hopper styles offered for the Downflo II. A single-module wide that spans two portholes; a single-module wide that spans three portholes; a taller, steeper, single-module wide module which spans two portholes, and a double-module wide spanning four portholes. All styles transition to a single, 10-inch square discharge.

1. Stand the hopper on the discharge end.

Note: Remove hopper access covers on double module hoppers if necessary.

2. Apply sealant around the hoppers top flange toward the inside of the bolt pattern.

3. Lift the collector and position over the hopper and lower slowly.

4. Use drift pins to align holes.

5. Secure collector to hopper using 3/8-16 x 1 1/4-in bolts, flat washers, and nuts. Tighten all hardware securely.

6. Replace all access covers and tighten securely.

single module spanning two portholes single module spanning three portholes dual module spanning four portholes steep-sided, single module spanning two portholes

Leg Positioning

3. Use drift pins to align the holes in the collector with the holes in the legs. Attach each leg with the hardware supplied. Do not tighten hardware at this time.

4. Use drift pins to align the holes in the cross braces to the back of the leg set. Attach using the hardware supplied. Do not tighten hardware at this time.

Leg Installation

Leg sets are designed for standard height collectors and are rated as shown in the Rating and Specification Information. Reference the drawing shown below and the leg assembly drawing shipped with the leg set for proper location and assembly.

1. Position and assemble legs and cross braces as shown in Leg and Cross Brace Assembly.

2. Lift the cabinet and hopper assembly into position over the legs and lower slowly.

single module dual module 3-module

5-module DFT 3-60 and 4-80

7-module

DFT 4-112

6-module DFT 3-72 and 4-96

8-module

DFT 4-128

4-module DFT 3-48 and 4-64

DFT 2-8, 3-12

and 4-16

DFT 2-12

and 3-18

DFT 3-24

and 4-32

DFT 2-16

and 2-24

DFT 3-36

and 4-48 DFT 2-36

Leg and Cross Brace Assembly

Tighten all leg and cross brace hardware before removing crane.

CAUTION

5. Recheck the position of the leg sets and cross braces.

6. Using a crane, lift the assembled unit onto the anchor bolts. Fasten each leg pad to the anchor bolts using flat washers, lock washers, and hex nuts provided by others. Do not tighten hardware at this time.

7. Level unit. Tighten all hardware on legs, cross braces, and foundation anchors.

8. Remove crane.

hex nut lock washer flat washer cross brace leg flat washer

Gr 5 hex bolt cross brace leg lock washer flat washer

Gr 5 hex bolt flat washer hex nut hex nut lock washer flat washer flat washer

Gr 5 hex bolt

Compressed Air Installation

1. Remove the plastic pipe plug from the unit’s air manifold and connect the compressed-air supply line. Use thread-sealing tape or pipe sealant on all compressed-air connections.

2. Install a customer-supplied shut-off valve, bleed-type regulator with gauge, filter, and automatic condensate valve in the compressed-air supply line.

Note: All compressed-air components must be sized to meet the maximum system requirements of 10 to 20 scfm (depending on size of unit) at 90-psi supply pressure. See Specification Control Drawing shipped with unit.

Do not increase supply pressure above 100-psi.

Component damage can result.

CAUTION!

• The compressed-air supply must be oil and moisture free. Contamination in the compressed air used to clean filters will result in poor cleaning, cleaning valve failure or poor collector performance.

• Purge compressed-air lines to remove debris before connecting to the unit’s compressed-air manifold.

• Turn compressed-air supply OFF and bleed lines before performing service or maintenance work.

Compressed Air and Component Installation clean-air outlet* clean-air plenum diaphragm valve solenoid enclosure manifold air regulator* bleed-type air filter* automatic condensate valve* compressed-air supply line* solid-state timer blower motor starter* power supply disconnect switch* blower assembly*

Magnehelic gauge

Notes: 1. *Not included with standard unit.

2. Sprindler taps not shown.

CAUTION!

• Electrical installation must be performed by a qualified electrician and comply with all applicable national and local codes.

• Turn power OFF during installation or maintenance.

• Do not install in classified hazardous atmospheres without an enclosure rated for the application.

Solid-State Timer Installation

The solid-state timer is an electronic timer used to control the filter cleaning system. Available options include 3, 6, 10, 20, and 32-pin solenoid valve control.

Note: The solid-state timer requires a 105 to 135- Volt customer-supplied power supply.

Do not mount the solid-state timer on the unit. Mechanical vibration can damage the control.

1. Using the wiring diagram supplied, wire the fan motor, fan-motor starter, solid-state timer, and solenoid valves. Use appropriate wire gauge for rated amp load as specified by local codes.

2. Plug the program lug into the pin that corresponds with the number of solenoid valves controlled.

3. With power supply ON, check the operation of the solenoid valves. The valves should open and close sequentially at factory set 10-second intervals.

4. If a Photohelic gauge or similar device is used to control the solid-state timer and the jumper on the pressure switch portion of the timer is removed, the solenoid valves pulse only when the differential pressure reaches the high-pressure setpoint. The valves continue to pulse until the low-pressure setpoint is reached.

Solenoid Connection

The unit is equipped with 115-Volt solenoid valves that control the pulse-cleaning valves, which clean the filters.

One of three types of solenoid enclosures, the weatherproof NEMA 4 with 3D2 solenoids, the explosion proof NEMA 7 with 5D2 solenoids, or the explosion proof NEMA 9 with 5D2 solenoids, is mounted near or on the unit’s compressed-air manifold.

Wire the solenoids to the solid-state timer following the wiring diagram supplied with the unit. Filter life and cleaning operation will be affected if not wired correctly.

Timer and Solenoid Specifications

Power to the solid-state timer is supplied to Terminals L1 and L2, which operate in parallel with the fan starter’s low-voltage coil. On fan start-up, power is supplied to the timer and the preset OFF time is initiated. At the end of the OFF time, the timer energizes the corresponding solenoid valve to provide the ON time cleaning pulse for one diaphragm valve and then steps to the next until all filters have been cleaned.

To pulse when the fan is OFF, install a toggle switch as shown on the Solid-State Timer Wiring Diagram.

When the toggle switch is ON, the timer receives power and energizes the solenoid valves’ pulse-cleaning operation even though the fan is turned

OFF.

Input 105-135V/50-60Hz/1Ph

Output Solenoids The load is carried and turned ON and OFF by the 200 watt maximum-load-per-output solid-state switch.

Pulse ON Time Factory set at 100-milliseconds, or 1/10-second.

Note: Do not adjust pulse ON time unless the proper test equipment is available. Too much or too little ON time can cause shortened filter life.

Solid-State Timer Wiring Diagram

Fan Starter Control BoxDisconnect

1FU

2FU

3FU

208-230V 60 Hz/3Ph

IL1

IL2

IL3

1M 1OL 1T1

1T2

1T3

230V

115V

H1 H2H3 H4

X1 X2 stop star

1M

1M

1TGS

fan motor

OFF time ON time program pins program lug pressure switch timing logic power supply control logic

4FU, 3A

105 to 135 V 50-60 Hz solenoid valves

L1 L2

COM

1 2

L1

L2

L3

Disconnect, fuses, low voltage blower starter, and 1TGS switch are customer-supplied.

Wiring by others Wiring by factory

Pulse OFF Time Factory set at 10-seconds, adjustable from 1.5-sec minimum to maximum 30-seconds.

Operating Temperature Range -20° F to 130° F

Transient Voltage Protection 50 kW transient volts for 20-millisecond duration once every 20 seconds, 1% duty cycle.

Solenoid Valves 115-Volt at 19.7 watts each

Compressed-Air Set compressed-air supply at 90-psig. The timer is factory set to clean one filter or set of filters every 10-seconds.

Note: Do not set compressed-air pressure above 100-psig. Component damage will occur.

Preliminary Start-Up

1. Check all electrical connections for tightness and contact.

2. Check for and remove all loose items in or near the inlet and outlet of the unit.

3. Check that all remote controls are wired into the control system and all service switches are in the OFF position.

4. Check that all optional accessories are installed properly and secured.

5. Check that hopper discharge is open and the storage container is sealed, if equipped. Excess airflow to the fan will cause electrical failure.

6. Turn power ON at source.

7. Turn the compressed-air supply ON. Adjust pressure regulator for 90 to 100-psig.

8. Turn the fan motor ON then OFF to check for proper rotation by referencing the rotation arrow located on the motor’s mounting plate.

To reverse rotation, single-phase power supply:

Follow manufacturer’s instructions on the motor’s nameplate.

To reverse rotation, three-phase power supply:

Turn electrical power OFF at source and switch any two leads on the output-side of the fan-motor starter.

9. Adjust the fan for proper airflow by adjusting the volume control damper on the fan discharge and silencer, if equipped.

Note: Excess airflow can shorten filter life, cause electrical system failure, and fan motor failure.

Service Information

Operational Checklist

1. Monitor overall performance of the collector.

2. Monitor exhaust.

3. Monitor pressure drop across filters.

4. Monitor dust disposal.

Filter Installation and Replacement

CAUTION!

• Use proper safety and protective equipment when removing contaminants and filters.

• Dirty filters may be heavier than they appear.

• Use care when removing filters to avoid personal injury.

• Do not drop filters.

Filter Removal

1. Turn power to unit OFF.

2. Start at the top access port.

3. Remove access cover by turning knob counterclockwise.

4. Break the seal between the filter cartridge and the sealing surface.

5. Slowly rotate the cartridge 1/2-turn to remove dust that may have accumulated on the top of the filter.

6. Slide the filter out the access port along the suspension yoke and dispose of properly.

7. Clean the sealing surface with damp cloth.

Note: Clean dust from gasket sealing area to ensure a positive filter gasket seal.

8. Check for an accumulation of dust in the storage area and empty as necessary.

Filter Replacement yokeaccess cover filter cartridge insert gasket end first

CAUTION!

• The compressed-air supply must be oil and moisture free. Contamination in the compressed air used to clean filters will result in poor cleaning, cleaning valve failure or poor collector performance.

• Purge compressed-air lines to remove debris before connecting to the unit’s compressed-air manifold.

• Turn compressed-air supply OFF and bleed lines before performing service or maintenance work.

Filter Replacement

Note: Place filter part number label (supplied with each replacement filter) over the filter part number listed on the unit’s rating plate.

1. Slide the new filter cartridge onto each suspension yoke.

Note: Insert the filter, gasket end first.

2. Wipe cover gaskets clean and replace covers by turning the knob clockwise. Tighten securely by hand.

Note: Tighten access covers securely by hand.

Gaskets must be compressed to seal properly.

3. Turn electrical power and compressed air supply ON before starting unit.

Dust Disposal

1. Turn unit OFF and empty dust container as necessary to minimize dust in the hopper.

2. If the optional 55-gallon drum attachment is used, empty when drum is 2/3 full.

3. If optional slide gate is used, close gate before servicing drum.

4. Reinstall drum and open gate.

Compressed Air Components

1. Periodically check the compressed air components and replace compressed-air filters.

2. Drain moisture following the manufacturer’s instructions.

3. With the compressed-air supply ON, check the cleaning valves, solenoid valves, and tubing for leaks. Replace as necessary.

This Page Intentionally Left Blank

CAUTION!

BEFORE INITIAL OPERATION:

• Tighten all set screws in fan wheel.*

• Tighten all set screws in bearings.*

• Repeat after 8 hours of operation.

• Repeat again after two weeks of operation.

Reference Wheel Setscrew Torque Table below.

eziSwercsteS retemaiD leetSnobraC

*euqroTwercsteS

.nI .nI-.bL .tF-.bL

4/1 57 2.6

61/5 441 21

8/3 252 12

61/7 693 33

2/1 006 05

8/5 4611 79

4/3 6102 861

8/7 4023 762

1 0084 004 dluohsdnadenedrahtoneraswercstesleetssselniatS* seulavehtfoflahnahteromotdenethgitebton

.nwohs

Wheel Setscrew Torque

Optional Equipment

Power Pack

The two types of power packs, Torit Backward Incline, TBI, and Torit Radial Blade, TRB, are installed following the same procedure. Both power packs are designed to fit on the top or side of the Downflo II.

Note: The use of a damper is required to control airflow through unit. Lack of a control damper will shorten filter life.

1. The power packs are shipped assembled and partial disassembly is required before installing.

2. Mark the motor mount location on the housing before removing motor assembly on 30 Hp, 60 Hz and 20 and 30 Hp, 50 Hz units. It is not necessary to mark location on other motors.

Remove eight motor-mount bracket fasteners and remove the motor, motor-mount bracket, and fan wheel as an assembly as shown.

3. Turn housing over and apply sealant to the outside edge of the bolt pattern on the fan housing. Mount the fan housing to the collector using the fasteners supplied.

Notes: For a top-mounted TBI, or a TRB with a blast-gate style damper, install a spacer ring between the fan housing and the collector to provide the necessary clearance for the damper installation.

For top-mount TBI with explosion vent, install the spacer spool between the blower housing and the collector to provide the necessary clearance for explosion vent and weather dome. Position of the blower fan housing should not restrict explosion vent opening.

4. Apply sealant to the outside edge of the bolt pattern on the fan housing. Reinstall the motor, bracket, and fan wheel assembly. Align motor mount bracket to the mark on the housing on 30 Hp, 60 Hz and 20 and 30 Hp, 50 Hz units.

Other motor sizes do not require alignment, but consider the electrical connection location.

5. Rotate fan wheel after installation to ensure proper clearance between the inlet cone and the fan wheel.

Power Pack, TBI with Spacer Ring and TBI with Spacer Spool for Explosion Vented Units blower housing sealant collector mounting surface sealant motor mount blower wheel sealant spacer ring

Spacer Ring Top-Mount Only

3.62

.50

Top Mount Power Pack with Spacer Ring sealant spacer spool sealant blower housing motor mount blower wheel sealant

Top Mount Power Pack with Spacer Spool

Side-Mount Power Pack for Units Built After July

4. Install the motor and blower assembly to the fan housing using the original hardware and caulk sealant.

5. Connect power supply to the motor. Turn the fan motor ON then OFF to check motor rotation by referencing the rotation arrow on the blower.

Note: To change rotation on three phase units, turn power supply OFF and switch any two leads on the output side of the fan motor starter.

CAUTION!

• Side mounting a power pack requires side power adapter to support the weight of the power pack.

• Poorly installed power packs may not stay properly attached to the collector resulting in personal injury and damage to equipment or property.

1. Disconnect power supply.

2. Apply 1/4-in diameter rope-type sealant to the outside surface of the power adapter between the fan mount bolt holes and the round fan inlet hole.

3. Install the fan housing to the power adapter using 3/8 x 1 1/4-in bolts, flat washers, and hex nuts.

Note: Install bolts with the bolt head in the fan housing and the threaded end in the power adapter.

Side-Mount Power Pack blower housing sealant motor mount side mount bracket*

*usually factory installed sealant

This Page Intentionally Left Blank

55-Gallon Drum Pack

The drum pack is designed to fit a customer-supplied, standard 55-gallon drum and provides easy access for dust removal and disposal. A flexible hose connects the drum cover and slide gate, or drum cover and adapter. Placing a pallet under the drum allows heavier product to be moved quickly using a forklift or pallet jack. If a pallet is used, the length of flexible hose may need to be shortened.

With Slide Gate

1. Place the 1/8-in gasket spacer between the hopper flange and slide gate as shown.

2. Attach the drum pack and slide gate to the hopper flange using 3/8-16 bolts, washers, and hex nuts.

3. Attach the drum cover to the 55-gallon drum.

4. Use latches to secure the cover to the drum, if equipped.

5. Connect the flexible hose between the drum cover and slide gate. Secure with hose clamps.

Without Slide Gate

1. Place the 1/4-in diameter rope-type sealant between the hopper flange and the adapter as shown.

2. Attach the adapter to the hopper flange using 3/8-16 bolts, washers, and hex nuts.

3. Attach the drum cover to the 55-gallon drum.

4. Use latches to secure the cover to the drum, if equipped.

5. Connect the flexible hose between the drum cover and the adapter. Secure with hose clamps.

hopper flange drum cover optional latch customer-supplied 55-gallon drum hose clamp flexible hose

1/4-in diameter rope-type sealant

3/8-16 bolt

3/8-in flat washer

3/8-in lock washer

3/8-16 hex nut adapter

55-Gallon Drum Pack without Slide Gate hopper flange drum cover slide gate optional latch customer-supplied 55-gallon drumhose clamp flexible hose

1/8-in gasket spacer

3/8-16 bolt

3/8-in flat washer

3/8-in lock washer

3/8-16 hex nut

55-Gallon Drum Pack with Slide Gate

Magnehelic Gauge Installation

Magnehelic Gauge

The Magnehelic is a differential pressure gauge used to measure the pressure difference between the clean- and dirty-air chambers and provides a visual display of filter change requirements. The high-pressure tap is located in the dirty-air plenum and the low-pressure tap is located in the clean-air plenum.

1. Choose a convenient, accessible location on or near the unit for mounting that provides the best visual advantage.

If unit is equipped with factory-installed pressure taps, skip to Step 5.

2. Before drilling, place a piece of non-combustible cloth over the filter opening in the clean-air plenum to protect them from drilling chips.

3. Place a piece of wood behind the drill location in the dirty-air plenum to protect the filters from damage by the drill bit. Use a .406-inch diameter bit to drill the holes as shown in Magnehelic Gauge, Detail A.

4. Mount the pressure tap hardware on the clean-air plenum panel. Mount the pressure tap with the tee inside the dirty-air plenum.

1/8-in NPT x 90° male elbow clean-air plenum

3/8-in flat washer 1/8-in NPT coupling mounting bracket

#6-32 x 1/4-in mounting screws support structure mounting surface

Magnehelic gauge high-pressure port low-pressure port two, 1/8-in NPT adapters plastic tubing two, 1/8-in NPT pipe plugs two, self-drilling screws

1/8-in NPT x 90° male elbow dirty-air plenum drill location

3/8-in flat washer

1/8-in NPT adapter

1/8-in NPT x 90° elbow static pressure tee

Magnehelic Gauge, Detail A

5. Plug the pressure ports on the back of the gauge using two, 1/8-in NPT pipe plugs supplied.

Install two, 1/8-in NPT male adapters supplied with the gauge into the high- and low-pressure ports on the side of the gauge. Attach the mounting bracket using three, #6-32 x 1/4-in screws supplied.

6. Mount the gauge and bracket assembly to the supporting structure using two, self-drilling screws.

7. Thirty-five feet of plastic tubing is supplied and must be cut in two sections. Connect one section of tubing from the gauge’s high-pressure port to the pressure fitting located in the dirty-air plenum. Connect remaining tubing from the gauge’s low-pressure port to the fitting in the clean-air plenum. Additional tubing can be ordered from your representative.

8. Carefully remove the cloth protecting the filters.

Close access doors and tighten securely by hand.

9. Zero and maintain the gauge as directed in the manufacturer’s Operating and Maintenance Instructions provided.

6.00 16.00

6.00

.406" dia (2x)

Note:

For use with solid-state timer only.

All parts, except the mounting bracket shown in the Photohelic Gauge Standard Installation drawing are included with the NEMA 4, Weatherproof Enclosure.

Photohelic Gauge in Optional NEMA 4 Weatherproof Enclosure

Photohelic Gauge Wiring Diagram

Photohelic Gauge

The Photohelic combines the functions of a differential pressure gauge and a pressure-based switch. The gauge function measures the pressure difference between the clean- and dirty-air chambers and provides a visual display of filter condition. The high-pressure tap is located in the dirty-air plenum and a low-pressure tap is located in the clean-air plenum. The pressure-based switch function provides high-pressure ON and low-pressure OFF control of the filter cleaning system.

1. Choose a convenient, accessible location on or near the unit for mounting that provides the best visual advantage.

2. Mount the gauge to the remote panel or door using the mounting ring, retaining ring, and four #6-32 x 1 1/4-in screws. Do not tighten screws.

Connect two, 1/8-in NPT x 1/4-in OD male adapters to the gauge’s high- and low-pressure ports. Align the adapters to the 2.375-in hole in the right-hand side of the mounting bracket.

Tighten screws.

Photohelic gauge solenoid valves

Delta P terminals neutral 110-V jumper wires supplied by customer timer board L1 L2 1 2 3 sol com

L2 L1

HI LO

C NO NC NC NO C

C NO NC NC NO C

3. On the back of the gauge, remove four #6-32 x 5/16-in screws and plastic enclosure. Set aside.

Add two jumper wires supplied by customer.

Remove the jumper from the pressure switch located on the timer board, if equipped. Using the 3/4-in conduit opening, wire the gauge as shown. Reassemble and fasten the enclosure securely.

4. Thirty-five feet of plastic tubing is supplied and must be cut in two sections. Connect one section of tubing from the gauge’s high-pressure port to the pressure fitting located in the dirty-air plenum. Connect remaining tubing from the gauge’s low-pressure port to the fitting in the clean-air plenum. Additional tubing can be ordered from your representative.

5. Zero and maintain the gauge as directed in the manufacturer’s Operating and Maintenance Instructions provided.

6. To install the Photohelic Gauge mounted in a NEMA 4, Weatherproof Enclosure, follow Steps 4 and 5.

Photohelic Gauge Installation

1/8-in NPT x 90° male elbow clean-air plenum

3/8-in flat washer 1/8-in NPT coupling mounting bracket

#6-32 x 1/4-in mounting screws support structure mounting surface

Photohelic gauge high-pressure port low-pressure port two 1/8-in NPT adapters plastic tubing

1/8-in NPT x 90° male elbow dirty-air plenum

3/8-in flat washer

1/8-in NPT adapter

1/8-in NPT x 90° elbow static pressure tee

Delta P Control

Description

The Delta P Control monitors the differential pressure between the clean and dirty air plenums, providing a visual display of the filter condition.

When combined with a pulse timer, it controls the pressure drop by turning the cleaning mechanism On and Off at the chosen limits. There are three (3) set points: High Pressure On, Low Pressure Off, and Alarm. The first two, High Pressure On and Low Pressure Off, control the filter cleaning system. The third, Alarm, provides a relay output to activate an external alarm supplied by others.

Operation

Normal

The Delta P Control monitors the pressure in the clean and dirty air plenums while the unit is running. The blower draws air through the filters, creating a pressure drop. The Delta P control measures the pressure drop and provides a visual display in inches water gauge or metric (SI) units.

Filter Cleaning

When the pressure drop across the filter bags reach the control's High setpoint, the control closes an output relay allowing a timer to trigger the cleaning valves sequentially. When the control senses that the pressure drop has decreased to the Low setpoint, the relay opens and the cleaning cycle stops. This sequence continues as long as the collector is in use, maintaining the pressure drop within a narrow range.

Alarm

The alarm setpoint is set to a higher setting than used to start the filter cleaning cycle. It indicates situations when the cleaning system cannot reduce the pressure drop due to cleaning system failure, lack of compressed air, or the end of the filter's useful life. There is a time delay prior to setting the alarm to prevent nuisance trips. The Delta P Control also provides an input connection for a remote alarm reset.

For complete information, see the most current version of the Delta P Installation, Operation, and Maintenance manual.

Delta P Control Display

Low Set

Alarm Set

Alarm Cleaning

High Set

Delta P Control

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Delta P Plus Control

Description

The Delta P Plus Control monitors the differential pressure between the clean and dirty air plenums, providing a visual display of the filter condition.

When combined with a pulse timer, it controls the pressure drop by turning the cleaning mechanism On and Off at the chosen limits. There are three (3) set points: High Pressure Drop On, Low Pressure Drop Off, and Alarm. The first two, High Pressure Drop On and Low Pressure Drop Off, control the filter cleaning system. The third, Alarm, provides a relay output to activate an external alarm supplied by others.

The user can program the Delta P Plus Control to pulse while the collector is running, to maintain a relatively constant pressure drop across the filters, pulse only after the collector is shut down (after-shift cleaning), or a combination of both, cleaning while running as well as end of the shift.

Operation

Normal

The Delta P Plus Control monitors the pressure on both sides of the tubesheet while the unit is running.

The blower draws air through the filters, creating a pressure drop. The Delta P Plus Control measures the pressure drop and provides a visual display in inches water gauge or metric (SI) units.

Filter Cleaning

The Delta P Plus Control offers three filter cleaning options.

1. Differential Pressure Cleaning (DFF) - When the pressure drop across the filters reaches the control's High setpoint, the control closes an output relay allowing a sequential timer to trigger the cleaning valves. When the control senses that the pressure drop has decreased to the Low setpoint, the relay opens and the cleaning cycle stops. This sequence continues as long as the collector is in use, maintaining the pressure drop within a narrow range.

2. Down Time Cleaning (DTC) - The Delta P Plus Control monitors the collection system. It watches for the blower to start, the pressure drop to exceed the Low setpoint, and then for the pressure drop to approach zero. After the blower has come to a stop, the Delta P Plus engages the cleaning mechanism for a pre-selected time.

3. Combined Differential and Down Time Cleaning (ALL) - The Delta P Plus Control combines the two functions described above; maintaining the pressure drop in a narrow band and down time cleaning the filters when the collector is shut down. The down time cleaning function can be toggled On or Off from the keyboard.

Alarm

The alarm setpoint is set to a higher setting than used to start the filter cleaning cycle. It indicates situations when the cleaning system cannot reduce the pressure drop due to cleaning system failure, lack of compressed air, or the end of the filter's useful life. There is a time delay prior to setting the alarm to prevent nuisance trips. The Delta P Plus Control also provides an input connection for a remote alarm reset.

For complete information, see the most current version of the Delta P Plus Installation, Operation, and Maintenance manual.

Delta P Plus Control Display

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Menu Downtime Clean

Alarm Cleaning

Set

Downtime Clean Delta P Plus

1. Place 1/4-in diameter rope-type sealant to the inside of the transition’s bolt pattern.

2. Use 3/8-16 bolts, washers, and hex nuts to fasten transition to hopper.

3. Determine the proper position required for the rotary airlock. Allow clearance for electrical connections and future maintenance.

4. Place a 1/4-in diameter rope-type sealant toward the inside edge of the airlock’s top flange.

5. Fasten the airlock to the transition flange using 3/8-16 bolts, washers, and hex nuts.

6. Electrical connections must be made by a qualified electrician. Refer to the motor’s nameplate for voltage, amp rating, cycle, and wiring sequence.

Transition and Rotary Valve

The 7-in tall transition is designed to connect a standard hopper and a rotary valve. Rotary valves are used as an airlock and a metering device in dust control applications. When used as an airlock, an airtight seal between the valve’s inlet and outlet is maintained while allowing dust or material to pass through. Comparatively, the airlock works along the same line as a revolving door on a building; an airtight seal is maintained while people are allowed to pass through.

When used as a metering device, the valve allows a specific amount of material to pass per revolution, depending on the size and speed of the valve. Sizing is determined at time of order and based on product load. Standard sizes include 8, 10, 12, and 16-in inlets.

3/8-16

3/8-in flat washer

1/4-in diameter rope-type sealant placed inside bolt pattern

3/8-in flat washer

3/8-16 hex hopper flange

8, 10, 12, or 16-in transition

3/8-16 hex nut

3/8-in flat washer

3/8-16 bolt

3/8-in flat washer

8, 10, 12, or 16-in rotary airlock

1/4-in diameter rope-type sealant placed inside bolt pattern

Transition and Rotary Valve Assembly

Damper and Silencer, TBI

Side and Top Mount

1. Install the power pack as described in Power Pack.

2. Attach the damper to the fan exhaust outlet using the bolts, washers, and hex nuts supplied.

3. Attach the flange to the damper using the bolts, washers, and hex nuts supplied.

4. Apply sealant to the flange and attach silencer to flange. Tighten all hardware.

5. Loosely assemble the silencer’s support brackets.

Support Brackets, Top Mount

a. Align the pivoting support brackets to extend a minimum of 30-inches from the collector and mark the drill locations.

b. Drill pilot holes with a 0.339-inch bit.

c. Secure brackets using 3/8-in thread-forming bolts.

d. If a gap exists between the silencer and the damper, install the panel filer using the screws provided.

Support Brackets, Side Mount

a. Align the support bracket to the underside of the silencer, flush with the cabinet wall, and mark the drill locations.

b. Drill pilot holes with a 0.339-inch bit.

c. Secure brackets using 3/8-in thread-forming bolts.

6. Loosen the wing nut on the damper and adjust to approximately 50% closed.

Side and Top-Mount Silencer and Damper Installation power pack damper silencer power pack silencer damper pivoting support bracket

Side Mount Top Mount

Plenum Silencer, TRB

Top Mount

1. Apply sealant and attach the bottom panel to the collector as described on the assembly drawing shipped with the silencer. Use a combination of hardware removed from the unit and hardware supplied.

2. Install the fan and motor assembly as described in the Power Pack section and the assembly drawing.

3. Route rigid or flexible conduit from the junction box on the motor to the outside wall of the silencer to house wiring.

4. Install the top of the silencer and attach the silencer to the base using the supplied hardware.

5. Loosen the wing nut on the damper and adjust to approximately 50% closed.

Abrasion-Resistant Inlet Collar

1. Remove the unit’s front cover plate. Remove excess sealant from opening.

2. Apply 1/4-in diameter rope-type sealant around the opening toward the inside edge of the bolt pattern.

3. Align the holes on the inlet collar with the holes in the unit and secure using 3/8-16 x 1-in bolts and flat washers supplied.

collector sealant 3/8-in flat washer 3/8-16 x 1-in bolt abrasion resistant inlet collar bottom cover

Abrasion-Resistant Inlet…