RT DUST FILTER INSTALLATION, OPERATION & MAINTENANCE MANUAL. Mac Process LLC Corporate Office 7901 NW 107 th Terrace Kansas City, MO 64153

Transcription

1 RT DUST FILTER INSTALLATION, OPERATION & MAINTENANCE MANUAL Mac Process LLC Corporate Office 7901 NW 107 th Terrace Kansas City, MO Manufacturing Plant Addresses: 810 S. Old 75 Hwy; P.O. Box 205 Sabetha, KS FM 529 Houston, TX Sales, Parts & Service: Publication: MAN3012K Revision Date: 03/08/13

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3 TABLE OF CONTENTS DESCRIPTION PAGE General Introduction... 1 Safety Material... 1 Principle of Operation... 4 Installation... 4 System Start Up and Operation Maintenance Troubleshooting Spare Parts LIST OF FIGURES Page Figure 1-1 Typical RT Dust Filter (radial inlet type)... 1 Figure 1-2 Typical RT Dust Filter (pneumatic receiver type)... 1 Figure 2-1 Lockout and Tagout of Electrical Service and Compressed Air... 2 Figure 2-2 Typical Location of Safety Decals... 2 Figure 2-3 Typical Locations of Safety Decals For Explosion Vents... 3 Figure 3-1 Principle of Operation... 4 Figure 4-1 Typical Support Structure... 4 Figure 4-2 Filter and Support Structure... 5 Figure 4-3 Typical Rupture Style Explosion Vent... 5 Figure 4-4 Location of Ductwork and Accessories... 5 Figure 4-5 Timer Control and Wiring... 6 Figure 4-6 Installation of Differential Pressure Gauge... 7 Figure 4-7 Jumpers and Wiring of the Photohelic Switch/Gauge... 7 Figure 4-8 Ladder and Cage Assembly... 8 Figure 4-9 Removal of the Purge Pipes... 8 Figure 4-10 Drip Leg (supplied by customer) It is the owner's responsibility to maintain the safety features included with this equipment. The safety features may include, but not necessarily be limited to: guards, access doors and covers, explosion vents, warning decals, caution decals, and advisory decals. Replacement safety features are available from Mac Process LLC. DO NOT attempt to operate this equipment until you have read and understood the contents of this manual. If you do not understand the contents of the manual bring it to the attention of your supervisor. This manual contains important safety instructions concerning the maintenance, use, and operation of this product. Failure to follow these instructions may result in serious injury or death. NO haga funcionar este equipo hasta haber leido y comprehendido el contenido de este manual. Si aiguna partre del contenido del manual queda sin comprehender, notifiqueselo a su supervisor. Este manual contiene instrucciones importantes en cuanto al anterimiento, uso, y funcionamiento sequros de este producto. El no seguir las instrucciones contenidas en este manual podria ocasionar lesiones graves.

4 GENERAL INTRODUCTION Congratulations on your selection of a RT Dust Filter. As the owner/operator of this unit you have an important responsibility to see that it is operated and maintained in a safe manner. The unit will require very little attention to keep it in good operating condition. This manual has been prepared to aid you in that effort. Throughout this manual, reference may be made to various components which may or may not be part of your particular system. They are included in the interest of fully describing typical RT filter systems. Lading. The purchaser must take immediate steps to file reports and damage claims with the carrier. All damages incurred to the unit in transit are the responsibility of the common carrier since it is the policy of Mac Process LLC. to make shipment F.O.B. from its factory. Ownership passes to purchaser when the unit is loaded and accepted by carrier. Any claims for in transit damage or shortage must be brought against the carrier by the purchaser. If the unit is not going to be assembled and installed soon after arrival, it should be stored in a warm, dry location to protect against corrosion. Filter bags and cages or cartridges must be stored in a dry, rodent proof location. SAFETY INFORMATION 2 LIFTING LUGS AIR OUTLET 1/8" FNPT PORTS OPPOSITE SIDE HINGED SERVICE DOORS DIAPHRAGM VALVES AIR HEADER TIMER CONTROL PANEL WARNING! Do not attempt to operate or maintain this piece of equipment until you have read and thoroughly understood all of the safety information contained in this manual. All such information must be taken seriously. This piece of equipment contains moving parts and potential pinch points which can cause serious injury or death. If you do not understand anything in this manual seek assistance from your supervisor before operating this equipment. AIR INLET 2 LIFTING LUGS AIR OUTLET OPTIONAL AIRLOCK OPTIONAL SUPPORT STRUCTURE Figure 1-1 Typical RT Dust Filter (radial inlet type) 1/8" FNPT PORTS OPPOSITE SIDE OPTIONAL AIRLOCK HINGED SERVICE DOORS DIAPHRAGM VALVES AIR HEADER INLET TIMER CONTROL PANEL OPTIONAL SUPPORT STRUCTURE Figure 1-2 Typical RT Dust Filter (pneumatic receiver type) Receiving Your Equipment As soon as the equipment is received, it should be carefully inspected to make certain the unit is in good condition and all items listed on the packing list are received. Even though the equipment is mounted on heavy shipping skids at our plant it is possible for it to be damaged in shipment. All damages or shortages should be noted on the Bill of Recognize Safety Information The symbol at left is used to alert you to important safety messages located throughout this manual. It also appears on the equipment to alert you to potential hazards. When you see this symbol you must read, understand, and heed the information that accompanies it. Understand Signal Words DANGER! Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING! Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION! Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury and/or property damage. Warning Decals and Guards This piece of equipment contains several warning decals located in many different locations. It is the owner/operator s responsibility to maintain the integrity of these decals and to ensure that all operators of the equipment are aware of them and understand their meaning. Replacement decals are available free of charge from your Mac Process Service Representative, or by calling Mac Process LLC at This piece of equipment may contain one or more safety guards to protect the operator(s) from injury. It is the owner/operator s responsibility to maintain the integrity of these guards and ensure that they are in place when the equipment is in operation. Before inspecting or servicing this equipment perform an approved lockout-tagout procedure on the electrical service, the compressed air (or other gas) supply, or any other energy source. Lockout-Tagout Requirements DO NOT attempt to operate this equipment with any guard removed. Replace damaged guards. Publication: MAN3012K Mac Process LLC 1

5 Failure to follow these instructions may result in death, personal injury, and/or property damage! Read and Understand Safety Decals Several safety labels are located on this piece of equipment to warn the operator(s) of potentially hazardous situations. ELECTRICAL POWER COMPRESSED AIR OR GAS Figure 2-1 Lockout and Tagout of Electrical Service and Compressed Air (or other gas) Decal Locations The following figure shows typical locations for safety decals on the RT filter. The locations of decals for your particular filter may vary from those indicated. Inspect your filter for locations of all decals. Control of this equipment must be in accordance with OSHA Standard "The control of hazardous energy (lockout-tagout)". This standard "requires employers to establish a program and utilize procedures for affixing appropriate lockout devices or tagout devices to energy isolating devices and to otherwise disable machines or equipment to prevent unexpected energizing, start-up or release of stored energy in order to prevent injury to employees". For further information on Lockout-Tagout requirements, see your company's Safety Director or refer to OSHA Standard Safety Precautions Do not operate, inspect, or service this equipment unless all the following safety precautions are in effect: Guards, access doors, and covers are in place and secure. The equipment has been wired and grounded in accordance with all applicable codes. If air being filtered contains toxic materials all necessary precautions to protect personnel have been taken. An approved lockout-tagout procedure has been followed before the equipment is inspected, disassembled, and/or serviced. The equipment is automatically controlled and may start without warning unless energy supplies are properly disconnected and locked outtagged out. The control panel enclosure is closed and secured except as is necessary for service or adjustment. The service door is closed and secured. Do not enter filter while the system exhaust fan is operating; air flow can pull service door closed, trapping personnel inside. A confined space permit, if required by authorities having jurisdiction, has been obtained prior to personnel entering the unit. Check with your company s safety director for special instructions, testing prior to entry, etc. that may be required by the specific application. Explosion vents have been properly installed and ducted, as described below in the Installation section. Do not cut, weld or grind on the filter while it is in operation; dust laden air may be highly explosive. Refer to the proper National Fire Protection Association Manual for information on cutting, welding or grinding in hazardous areas. The work area is clean and orderly, free of debris, materials, tools, etc. Operating personnel are wearing proper ear and eye protection and have secured loose hair, clothing, jewelry, etc. Figure 2-2 Typical Locations of Safety Decals Safety Decals Safety decals (and other information labels) may include, but are not necessarily limited to, the examples shown below. Locate all of the safety decals on your equipment and know their meaning prior to operating this dust filter. Free replacement decals are available; ask for decal kit P/N A. End User must determine hazard level for entry permit requirements. Publication: MAN3012K Mac Process LLC 2

6 B. Equipment has moving blades, shaft, rotor or arm which may cause injury. It may also have valves discharging compressed gases. C. Equipment can start without warning. Exhaust fan can create enough force to close and hold service door closed. D. Typical Mac Process LLC nameplate. Figure 2-3 Typical Locations of Safety Decals for Explosion Vents J. Stay clear of explosion vent. During an explosion, flame, explosive gases or flying material will be released. F. Equipment piping and/or valves are under pressure. Servicing while pressurized can cause injury. G. Typical Mac Process logo The following ISO decals may appear on your RT Filter: Disconnect, lockout and tagout electrical and all other energy sources before inspecting, cleaning or performing maintenance on this filter. H. Moving blades will cause serious injury. Equipment has rotating screw conveyor which may cause injury. Operate only when covers are in place. This warning sign reminds operators and other users that they must read and understand the Operator Manual before storing, installing, inspecting, cleaning or servicing the filter. This filter may be remotely controlled. It can start without warning unless it is properly locked out at the motor starter or local disconnect. Do not rely on the control system for safe lockout. Either of the two above decals may be used at location "H," depending upon which equipment is connected to the discharge on your particular filter. Equipment can start without warning. This access port should be equipped with safety lock. In addition, if your filter is equipped with an explosion vent the following figure shows typical locations for other safety decals. Publication: MAN3012K Mac Process LLC 3

7 PRINCIPLE OF OPERATION The RT filter is a top bag removal, automatically controlled, reverse air pulse cleaning dust filter. RT models are rated for 17" Hg. or 40 H20 in sizes ranging from the 18RT7 with 15 sq. ft. of cloth to the 96RT80 with 1,004 sq. ft. of cloth. CLEAN AIR OUT CLEANING PULSE COMPRESSED AIR HEADER TUBESHEET FILTER BAGS COMPRESSED AIR SUPPLY INSTALLATION The RT filter housing and internal components are shipped factory assembled. The hopper, unassembled support structure (if provided), magnehelic or photohelic pressure gauges, bags and cages are shipped loose and require field assembly. Location Locate the RT filter in a clear area away from normal personnel traffic on a flat and solid concrete or steel surface. Locate the filter so as to minimize supply and exhaust ductwork and so that explosion venting, if required, can be directed so that injury to personnel and damage to property cannot occur. Provide sufficient space for emptying the hopper and maintaining the unit. Foundation DUST LADEN AIR IN HOPPER PRODUCT DISCHARGE Figure 3-1 Principle of Operation Air Flow through the Unit Dust laden air enters the RT near the bottom of the unit. Rows of filter bags are mounted on a horizontal tubesheet and suspended in the filter housing. A remote fan on the exhaust side draws air through the filter. Filtered dust collects on the outside of the filter media, and falls into the hopper where it can be collected. Filtered air passes through the center of the filter bags and out through the clean air discharge at the top of the unit. During an explosion, a vent will release flame, explosive gases or flying material. The explosion venting must be directed away from personnel to prevent injury. The filter requires an adequate foundation, designed by a qualified structural engineer. Refer to the General Dimension drawings of your system for foot pad layout and weights. When calculating the loading for the foundation, the weight of the filter, material collected, and all auxiliary equipment must be considered together with snow, wind and seismic loads. Support Structure A support structure may be supplied by Mac Process LLC as part of your RT filter system. The figure below shows a typical structure, which will vary from system to system depending on the size of the RT filter. Pulse Cleaning An air pulse cleaning system cleans the filter bags and dislodges filtered product so that it drops into the hopper. A system of compressed air manifolds is mounted above the bank of filter bags. A pulse of compressed air is periodically directed downwards through the bag. The pulse flexes the filter bag, causing accumulated dust to be dislodged and fall to the hopper below. The cleaning pulse is controlled by a solid state electronic timer which automatically sequences through the bank of filter bags, one row at a time. The timer can be set to operate at a predetermined interval. The pulse can also be controlled by a photohelic differential pressure switch/gauge which responds to pressure differences across the filter. When controlled by the switch/gauge, cleaning occurs only when needed, decreasing air consumption and increasing filter bag life by avoiding unnecessary pulsing. Air Exhaust Returning filtered exhaust air into a facility can present hazards. The type of dust, its characteristics and the effect of a recirculation system malfunction must be considered. If system design dictates that filtered air be returned into the facility, the buyer is cautioned to take appropriate steps to monitor the air quality and provide appropriate safeguards as prescribed by OSHA, NFPA, Federal, State and Local codes and regulations. Never return filtered air to a habitable space or building without proper monitoring and precautions. Figure 4-1 Typical Support Structure To install the support structure: 1. Review the components of the support structure. 2. Loosely assemble the structure. Do not tighten any bolts until all assembly is complete. 3. Set anchor bolts in the foundation according to the plan drawing. Position the legs on anchor bolts. Attach the cross bracing with A325 3/4" or 5/8"UNC (as provided) bolts, lock washers and nuts. 4. Tighten all bolts. Bolts must be tightened before allowing the structure to support the weight of the filter. 5. Touch-up paint on the support structure as needed. Assembly should be complete and all bolts tightened prior to painting. Setting in Place It is recommended that a properly sized crane be used for unloading the filter and setting it in place. Publication: MAN3012K Mac Process LLC 4

8 Spreader bars are recommended to distribute the load evenly while lifting the filter. Installing Domed Rupture Panel Style Vents The installation of the rupture panel style vent should be performed by two people. Refer to Figure 4-3. CLEAN AIR PLENUM TUBE SHEET FILTER HOUSING HOPPER Figure 4-3 Typical Rupture Style Explosion Vent Figure 4-2 Filter and Support Structure SUPPORT STRUCTURE To set up the RT filter: 1. Position the hopper on the support structure and fasten the hopper to the support structure with 1/2" UNC x 1 1/2" long bolts, lock washers and nuts. Note: Occasionally, due to shipping limitations, the clean air plenum, tubesheet, and filter housing are shipped unassembled. If so, apply silicone caulk to flanges, match alignment notches on tubesheet and flanges, and bolt together with 3/8" UNC x 3/4" long bolts. 2. Apply silicone caulk to the hopper flange in a figure eight pattern around the bolt holes. 3. Lift the filter housing and set in place on the hopper. Bolt the housing and hopper together with 3/8" UNC x 1-1/2" long bolts, lock washers and nuts. Tighten all bolts before removing the crane. Explosion Venting Venting Guidelines This section is intended as a general guide only: For further information refer to NFPA Standard 68, "Explosion Venting" and consult with your insurance carrier. Explosion venting is required whenever the filter will process explosive dusts as defined by NFPA. Dust filters handling explosive dusts should be located outside of buildings wherever possible. Explosion vents must not be obstructed in any way and must be protected from snow/ice buildup. Explosion vents must be oriented so that flame, explosive gases, or flying material cannot injure personnel or damage property. Dust filters inside of buildings should be located next to an exterior wall; the explosion vent(s) must be ducted to the outside of the building. Vent ducts must be kept as short and straight as possible, avoiding bends. Such ducts must be capable of withstanding a pressure at least as high as that expected to develop inside the filter itself in the event of an explosion. Ducts increase internal pressures inside the filter, and special reinforcement of the filter may be required. Consult Mac Process LLC Engineering Department regarding your specific application. Any duct will decrease the effectiveness of the vent. Explosion Vents-General Explosion vents are available from Mac Process LLC, are domed rupture panel styles as part of the filter system. The rupture panel style functions by bursting the panel itself. Explosion vents are installed after the filter unit is assembled on its support structure. 1. Remove the hold-down frame from the vent mount on the side of the filter. 2. Carefully remove the rupture style vent panel from the crate (CAUTION! Edges of the vent panel are sharp!) Avoid excessive flexure of the vent. 3. Place the vent panel over the protruding bolts in the housing wall. The vent panel must be oriented correctly. The panel ruptures on three sides and hinges on the fourth. The hinge side is indicated by a v-notch in the edge. Place the panel with the v-notch to the left and the I.D. tag at the bottom as shown in the figure above. The dome must protrude outward as shown or the panel will not function. 4. Place the hold down frame over the bolts, making sure that an even pressure is brought to bear on the panel. 5. Tighten nuts evenly and use an alternating pattern to prevent damage to the vent panel. Tighten nuts to ft. lbs. of torque. It is not necessary to use an excessive amount of pressure to clamp the panel securely. Excessive tightening may damage fasteners or the explosion vent panel. Ductwork and Accessories CLEAN AIR DUCT AIRLOCK OR OTHER OUTPUT ACCESSORY Figure 4-4 Location of Ductwork and Accessories Publication: MAN3012K Mac Process LLC 5 RADIAL INLET TIMER CONTROL TANGENTIAL INLET 1. Connect the inlet duct to the inlet on the filter. 2. Connect the clean air duct to the exhaust located at the top of the filter housing. Ductwork must be constructed to withstand the system design pressure. The ductwork must be independently supported; the RT filter is not designed to support ductwork. 3. Attach any auxiliary equipment (such as an airlock or screw conveyor) to the discharge flange of the hopper. Electrical Controls and Wiring The filter is supplied with NEMA 4 electrical solenoids and timer control. A NEMA 7 or 9 option is available. The timer is protected by a board

9 mounted fuse. Refer to the label on the timer control for power requirements. Only trained and authorized persons should be permitted to service or maintain electrical components. It is the buyer s/installer s responsibility to ensure that all applicable electrical codes are met. Timer Control Logic Input power is applied to the timer control at all times that the RT filter is in operation. Continuous cleaning occurs if the Pressure Switch HI and CM contacts on the timer board are jumpered; if so, cleaning will occur whenever the system is energized, and is controlled by an electronic timer. When energized, the timer begins the OFF TIME part of its cycle. At the end of the off period, the control energizes solenoid Number 1 to provide a timed (ON TIME) cleaning pulse to the first row of bags. At the end of the pulse the OFF TIME period begins again; when it ends the control energizes solenoid Number 2. The control cycles through each of the solenoids in turn, providing a cleaning pulse to each row of filter bags. The process continues as long as the system is energized. The durations of the cleaning pulse ( ON TIME ) and OFF TIME are both programmable. The number of solenoids is programmable. For on demand cleaning, the pressure switch contacts are wired to a remote photohelic switch/gauge or other pressure sensing device. Cleaning occurs as above as long as the remote contacts on the switch/gauge are closed. When they open the cleaning operation stops. When the contacts close again the control remembers the last solenoid activated and resumes the cleaning cycle with the next one in line. Timer Control Wiring and Adjustment Refer to Figure 4-5 below and to the timer manufacturer s documentation. for the majority of applications and should not be changed unless directed by Mac Process LLC. Set the "OFF TIME" to 15 seconds (see Timer Board Programming); this is the length of time between successive cleaning pulses. For example, if the filter has six rows of bags, each row would be cleaned every 90 seconds, 6 x 15 seconds. After operating experience has been gained, the "OFF TIME" setting may be adjusted to the maximum time possible that will maintain effective bag cleaning, which will conserve compressed air. When a photohelic differential pressure switch/gauge is used, only the pressure settings should be adjusted instead of the "OFF TIME" setting. Effective bag cleaning is directly related to the differential pressure. Refer to the System Startup and Operation Chapter for more information about differential pressure and adjustment of the switch/gauge. 3. Program the board for the correct number of outputs (see Timer Board Programming) to correspond with the number of solenoid valves mounted on or in the timer enclosure. 4. Ensure each of the solenoids is energized as the timer cycles. If a photohelic switch/gauge is in use, the high pressure setting on the switch/gauge must be set to zero to start pulsing. After pulsing is confirmed, restore the setting to its previous value. 5. De-energize electrical service to the timer. Timer Board Programming During normal operation only the LED next to Cleaning will be illuminated and the LCD READOUT will show the current output in the cycle. 1. To adjust the ON TIME, press the SELECT button on the timer board. The LED next to On Time (Sec) should light up indicating the ON TIME will be adjusted. Use the and buttons to adjust to the desired time (shown on the LCD READOUT.) 2. To adjust the OFF TIME, press the SELECT button again. The LED next to Off Time (Sec) should light up indicating the OFF TIME will be adjusted. Use the and buttons to adjust to the desired time (shown on the LCD READOUT.) 3. To adjust the number of outputs to be used, press the SELECT button once more. The LED next to Last Output should light up, indicating the last output used will be adjusted. Use the and buttons to adjust the value (shown on the LCD READOUT.) 4. Press the SELECT button a final time to return to normal operating mode. Other Electrical Connections Make electrical connections to the motor(s) on any auxiliary equipment such as an airlock, screw conveyor or fan. Verify that all motors are rotating in the proper direction. Figure 4-5 Timer Control and Wiring 1. Open the timer enclosure and connect the electrical service to the terminals labeled L1 and L2. If a photohelic switch/gauge (or other pressure switch) is not used, connect a jumper wire across the terminals labeled Pressure Switch. Do not connect power to the Pressure Switch terminals; the timer board will be damaged. Energize the electrical service to the timer. 2. Check both the "ON TIME" and the "OFF TIME" settings. "ON TIME" determines the duration of the cleaning air blast and should be set at 0.10 seconds (see Timer Board Programming). The 0.10 second "ON TIME" has been determined as the optimum duration NOTE: The motors should be interlocked such that they start in the following sequence: (1) airlock, (2) RT timer, and (3) main exhaust fan. The motors should be shut down in the reverse order. Shut down the exhaust fan first; using an adjustable time delay (0-15 minutes) shut down the timer 15 minutes after the exhaust fan. Finally, shut down the airlock. If the filter is being used to vent a gas fired dryer, to prevent fires and explosions, the main exhaust fan must be interlocked with the gas burner in such a way as to allow the fan to operate an adequate period of time to purge the dust collector of combustible gases before turning on the burner. The installation of a gas detection device in the system should be investigated and evaluated for each application. Magnehelic Gauge or Photohelic Switch/Gauge A magnehelic differential pressure gauge is available as an option. The gauge indicates the difference in pressure between the input and discharge sides of the filter. An excessively high reading indicates that filter media are becoming clogged and that more frequent cleaning pulses are required. A photohelic switch/gauge is a second option. The photohelic switch/gauge indicates differential pressure and controls the cleaning operation. When an electronic circuit in the switch/gauge detects differential pressure in excess of a predetermined set point, it provides a dry contact closure which initiates the cleaning cycle. When differential pressure drops to a predetermined set point, the switch/gauge opens the Publication: MAN3012K Mac Process LLC 6

10 contact, thus stopping the cleaning cycle. This method of control reduces compressed air needed and increases bag life. To install either type of gauge refer to Figure 4-6 and to the manufacturers documentation. LOW PRESSURE PORT (OPPOSITE SIDE OF FILTER) Two sections with half the ladder step-through, for the ladder side of the plenum, and One section for the other sides of the plenum. Loosely assemble the sections to the mounting brackets on the sides of the clean air plenum with 1/2"-13UNC x 1 1/2" long bolts, lockwashers, and nuts. Assemble the safety rail sections together with two rail clips (2 1/2 x 2 1/2 angle, 2 long) and 3/8"-16UNC x 1" long bolts, lockwashers, and nuts at each corner. Tighten all the bolts. HIGH PRESSURE PORT (OPPOSITE SIDE OF FILTER) GAUGE Ladder and Cage Assembly The cage assembly package will contain: 1. Bundles of "cage bars" in 2 ft., 3 ft., and 4 ft. lengths. The lengths included in the package will depend on the height of your particular filter. 2. A number of "hoops" 31" in diameter, and one "entry hoop" 35" in diameter. 3. Bags of 5/16" diameter bolts, used to fasten hoops to the ladder. The ladder assembly package will contain: 1. A number of 72" ladder sections and one short section. 2. Miscellaneous hardware items necessary for assembly of the ladder. These are packaged in the same container as hardware for the filter itself. Figure 4-6 Installation of Differential Pressure Gauge Installing the Magnehelic Differential Pressure Gauge 1. Mount the gauge in a convenient place for easy viewing. 2. Install the tubing fittings in the pressure ports of the magnehelic pressure gauge and in the ports on the filter. The filter ports are normally located on the right side of the filter from the service door. 3. Run the plastic tubing supplied from the filter ports to the gauge ports. The low pressure line runs from the filter port above the tube sheet to the low pressure port (usually the lower port) on the gauge. The high pressure line runs from the filter port below the tube sheet to the high pressure port (usually the upper port) on the gauge. 4. Verify that the filter is installed inside the housing on the high pressure port. Installing the Photohelic Differential Pressure Switch/Gauge Install the photohelic switch/gauge and run air piping as for the magnehelic gauge as described above. In addition: 1. Connect electric power to contacts labeled L1 and L2 on the switch/gauge. Refer to the label on the switch/gauge for power requirements. 2. Wire the switch/gauge according to the Figure 4-7 below. Ladder, Safety Cage, and Ladder Stand-off Ladder and safety cages will come in pre-assembled 6 ft., 4 ft., or 3 ft. lengths and (1) 8 ft. section without a safety cage attached. To assemble ladder and safety cages: (see figure 4-8) 1. Position ladder and safety cage assemblies on ground end to end with the entry section at either end. (Note: If ladder rungs are not 12 apart flip section end for end). 2. Join ladder side rails together with splice plate (as provided), 3/8 UNC bolts, and locknuts 3. Join lower safety cage bars to upper safety cage hoop using 3/8 UNC bolts and locknuts. (Note: safety bars should be on the inside of safety hoop.) 4. After all sections are joined together lift ladder into position and attach to ladder step-thru. 5. Attach ladder stand-off to baghouse flange with ½ UNC (as provided) bolts, nuts, and flatwashers. Level stand-off and clamp to ladder rail. Pilot drill through hole in stand-off into ladder rail on both sides. Secure stand-off to ladder rail with ½ UNC (as provided) bolts, nuts, and flatwashers. (Note: Stand-off to ladder connection can be welded or bolted.) 6. Measure distance from bottom of ladder rung to ground. Cut 8 ft. section to this length. (Note: Check to make sure what end will maintain the 12 distance from rung to rung and cut the opposite end). Join ladder side rails together as described in step #2. Position ladder foundation clip by clamping to the bottom of the ladder rail and pilot drill through (2) holes in foundation clip into ladder rail on both sides. Secure stand-off to rail with 3/8 UNC (as provided) bolts and locknuts. Secure foundation clip to ground. (Note: Foundation clips to ladder connection can be welded or bolted). Figure 4-7 Jumpers and Wiring of the Photohelic Switch/Gauge Safety Rail Assembly The safety rail assembly consists of three sections: Publication: MAN3012K Mac Process LLC 7

11 4. Check the fit of the snap band. It should be a secure fit all around with no wrinkles in the snap band. The top of the bag should be approximately 3/8" above the tube sheet. 5. Lower the cage into the bag. When in position, the flange will rest on the tube sheet. Figure 4-8 Ladder and Cage Assembly Bag and Cage Installation Filter bags and cages are shipped loose and are installed after the RT filter has been assembled and set in place. Installation of bags and cages is made from the top of the unit, after the purge pipes are temporarily removed. Purge Pipes To remove the purge pipes: 1. Open the service doors on top of the filter. 2. Loosen the bolts holding the coupling at the header end of the purge pipe. Slide the coupling sideways to expose the end of the pipe. 3. Slide the purge pipe toward the header until the tail end is free of its support. 4. Remove the purge pipe and set it aside. Repeat for each purge pipe. 6. Repeat this procedure for all bags and cages. Do not use bent or rusted cages. 7. Replace the purge pipes. When replacing the pipes, the air holes must be facing towards the tube sheet. Slide the tail end of the pipe into place. Position the pipe with 1/8" gap towards the header pipe. Center coupling over gap and tighten bolts holding the coupling. Repeat for all pipes. Close and secure the service doors. HEADER SUPPORT RAIL PURGE PIPE COUPLING Figure 4-9 Removal of the Purge Pipes Bags and Cages The tube sheet separates the intake and discharge sections of the filter. Install bags and cages as follows: 1. Lower the bottom of the bag through the hole in the tube sheet. 2. Fold the snap band (bag top) to insert it into the hole. 3. Fit the groove of the snap band to the edge of the tube sheet and allow the band to snap in place. Publication: MAN3012K Mac Process LLC 8

12 Installation Instructions: Bags with Grounding Straps for Grounding Metal Cages Proper installation of bags and cages is required to ensure that the metal cages are not isolated from ground with the tubesheet (cell plate) in applications that have potential for an explosion hazard. Section B: Verification of Proper Grounding Proper installation must be confirmed by testing to verify 1x10 6 (1 megohm) maximum resistance at 500 volts between cage and tubesheet (cell plate). The effectiveness of a grounding mechanism depends upon proper installation and connection of the grounding mechanism to an adequately collector component. Failure to properly install and connect grounding mechanism or maintain grounding of the collector component may result in static electricity discharge and possible explosion of dust stream within the collector and serious property damage and/or bodily injury. Proper installation must be verified per Section B of these instructions prior to operating collector. Section A: Bag Installation The two grounding straps at the top of the bag are intended to ground the cage to the tubesheet. Ensure that the hole is cleaned to remove dust and corrosion buildup. Install bag in hole and insert cage. Grounding strap Grounding Strap Top load collector: testing resistance between cage and tubesheet. In addition to the proper installation and grounding of bags and cages, the end user should select an appropriate filter media for use in bags. Refer to the National Fire Protection Association (NFPA) Recommended Practice on Static Electricity, NFPA edition for more information ( Compressed Air Requirements Compressed Air For most applications, compressed air at PSIG at the filter header is adequate for proper cleaning of the filter bags. Pressures between PSIG may be appropriate for some critical applications. Operations at pressures above 100 PSIG should be reviewed with Mac Process LLC for approval and recommendations. Compressed air pressures below 80 PSIG require special considerations in the design and sizing of the filter and also should be reviewed with Mac Process. Compressed Air Quality Trouble free, maintenance free operation is largely dependent on providing clean, dry, oil free compressed air. The importance of clean, dry, oil free compressed air cannot be over emphasized. Dirt, rust and scale can prevent diaphragm valves from operating properly. Moisture can cause valves to freeze in cold weather. Moisture and oil can cause deterioration of the valve diaphragms, and if the interior of the filter bags become coated with moisture and/ or oil, eventual plugging of the filter media can occur. The degree to which a compressed air system must be provided with safeguards to eliminate dirt, scale, moisture, and oil, will depend on the type of compressor, aftercoolers, receivers, and accessory equipment chosen or available, the piping material used, the piping layout between the compressor and the dust collector compressed air header, the lowest temperature to which the piping will be exposed, and the type of process and process conditions encountered. Clean Compressed Air 1. A simple drip leg installed at the point where the air line connects to the compressed air header is usually sufficient to trap small amounts of dirt, rust, and scale, and to serve as a low point to drain moisture when a shutoff valve is installed. Publication: MAN3012K Mac Process LLC 9

13 AIR HEADER Recommended Piping Sizes Total Free Air Consumption Pipe Length Up to 50 SCFM SCFM AIR SUPPLY up to 100 ft. 1" dia. 1-1/4" dia. 100 to 500 ft. 1-1/4" dia. 1-1/2" dia. 500 to 1000 ft. 1-1/2" dia. 2" dia. TO DRAIN Figure 4-10 Drip Leg (supplied by customer) 2. An in line filter or a centrifugal separator is required where large amounts of dirt, rust and scale are present, and especially where a possible shut down of the system is critical. Dry Compressed Air Liquid Moisture Traps: 1. An automatic moisture drain should be installed on the compressed air receiver. Automatic drains are available in a variety of float operated types, piston types and pilot types. 2. Small amounts of liquid moisture can be handled with in-line air filters with automatic drains. 3. Large amounts of liquid moisture require a centrifugal separator followed by a chemical dryer (consumable desiccant requiring replacement) to filter out the water droplet carry over. The dew point is dependent on the temperature of the cooling water used at the after cooler. Compressed Air Dryers: 1. In applications where the compressed air piping is indoors or where the installation is in a warm or moderate climate and a compressed air dew point of 35 to 50 F is sufficient to prevent moisture condensation in the pipe lines, the following types of equipment are available: the deliquescent desiccant non-regenerative type for small to medium volumes of air, and the mechanical refrigeration type with or without an after warmer for large volumes of air. 2. In applications where the compressed air piping is outdoors or where the installation is in a cold climate and a compressed air dew point of-10 F to -40 F is required to prevent moisture condensation in the pipe lines, the following types of equipment are available: the in-line desiccant type with manual regeneration for small volumes of air; the desiccant type with heatless automatic regeneration for medium volumes of air; and the dual tower desiccant type with automatic regeneration by heat for large volumes of air. Air Volume Requirements The RT filter typically requires the following SCFM at 80 to 100 PSIG: Model Number RT7 3.3 RT RT RT RT RT RT RT SCFM Required Oil Free Compressed Air 1. Much of the above mentioned equipment used to remove liquid moisture can also be used to remove condensed oil and oil mist. 2. For installation where condensed oil and oil mist are the major problems, special in-line filters are available that use desiccant absorptive elements or packed beds of an oil absorbing granular organic polymer. Compressed Air Piping The compressed air header on the RT filter should be connected with at least 1" diameter pipe. The air piping for multiple units should be sized in relation to air consumption. A drain should be installed at the lowest point in this piping. The following table is a guideline for selecting the proper pipe size and is based on PSIG air. Publication: MAN3012K Mac Process LLC 10

14 SYSTEM START-UP AND OPERATION The following inspection should be made before the initial start-up of the system and for normal operation thereafter. Disconnect and properly lockout-tagout the electrical and compressed air service before performing any inspection procedures. 1. Check filter bags for proper installation. 2. Check all air and electrical connections for proper routing. The compressed air supply should be connected to the 3/4" FNPT port on the air header. Turn on the compressed air supply to the header. Pressure should be PSIG. 3. Be sure to remove the plastic exhaust shipping plug in each diaphragm valve before operating. 4. Check out and start up any auxiliary equipment such as an airlock, screw conveyor, or fan and see that any control interlocks are operating properly. 5. Energize the timer panel. Listen for the sound of pulsing of the solenoids and diaphragm valves to verify that they are operating. (If the filter is equipped with a photohelic gauge, decrease the high pressure setting on the gauge to zero to activate the timer. Restore the pressure setting to its normal value after pulsing is verified.) 6. When all components are operating correctly, start the dust laden air through the filter and observe the differential pressure at the gauge. (The differential pressure is the air resistance across the filter bags). The pressure should stabilize between ½" and 4" H 2 O. Never allow pressure drop across the filter to exceed 17" H 2 O; this may damage the bag cages. 7. If the pressure continues to rise over 5" H 2 O and does not stabilize, shut off flow of dust laden air and decrease the "Off Time" setting by one-half the initial setting. This will result in a more frequent cleaning cycle. Restart the system. 8. When collector stabilizes between ½" and 4" H 2 O, you may then "fine tune" for least air consumption by gradually increasing "Off Time" setting. Do not exceed 4" to 5" H 2 O on clean bags because as the filter bags become "dirty" the differential pressure will increase. Note: If a photohelic switch/gauge is in use, do not change the "Off Time" setting. (With the photohelic gauge the cleaning cycle is initiated by pressure differential, not time.) Set the pressure set points on the photohelic switch/gauge at 1.5" H 2 O for the low pressure setting and 4" H 2 O for the high pressure setting. If the unit pulses continually, decrease both pressure set points to lower the differential pressure and initiate the cleaning cycle sooner. MAINTENANCE It is recommended that one individual be assigned to monitor the operation of the dust-collection system. The individual assigned should have maintenance manuals and manufacturer s documentation for all components readily available. He/she should be thoroughly familiar with the manuals so as to be able to pinpoint trouble should it occur. The individual responsible for the system should follow a regular schedule of inspection and maintenance. The exact schedule will depend on the particular system and the number of hours it operates per day or week. A typical maintenance schedule is shown below. Disconnect and properly lockout-tagout the electrical and compressed air service before performing any maintenance or service procedures on the filter. Sample Maintenance Schedule Weekly 1. Check and record magnehelic (or photohelic) gauge readings on all filters. Adverse operating conditions can be detected by a change in pressure drop. 2. Check for dust in clean air outlet from filter. 3. Check filter hoppers for continuous discharge of dust. 4. Open petcock to check for moisture in the compressed air header. 5. Listen to the diaphragm valves and verify that each row of bags is being cleaned. 6. Check fan and motor bearings for excessive heat or vibration. 7. If pressure pneumatic conveying equipment is used to dispose of dust, check the positive displacement pump for vibration, overheating, and proper lubrication. Also, compare reading on the pressure gauge with previous readings. Clean air-inlet filter or replace as necessary. It is important to follow the manufacturer's recommendation on equipment of this nature. 8. Check explosion vent(s) (if provided) for damage (broken bolts or damaged panel). Monthly (or at manufacturer's recommended intervals) 1. Check the filter bags for signs of excessive wear or damage. 2. Drain condensation from air reservoir. Check the compressed air dryer and filter for proper operation. Six Months 1. Check for evidence of moisture or dust buildup inside the filter housing. 2. Check operation of solenoids and diaphragm valves. 3. Check oil in all gear motors. Do not overfill. 4. Check belt tension on all V-belt drives. Bag Replacement The filter bags are the heart of the filter and need a program of inspection, cleaning, and replacement to maintain high operating efficiency. 1. Shut down the system, and lockout-tagout the electrical and compressed air service. 2. Open the service door. Remove the purge pipes as describe in section titled "Installation". 3. Remove the cages by lifting them upwards. 4. Fold the snap band on the bags away from the hole in the tube sheet and remove the bags. 5. Reinstall clean filter bags as described in the section titled "Installation". 6. Inspect the cages for rust or damage and replace if necessary. Reinstall as described in the section titled "Installation". Bag Cleaning Natural fiber fabrics (wool or cotton) are subject to shrinkage when wet with water. These fabrics must be dry cleaned. Synthetic filter fabrics (Orlon, Dacron, Nomex, polypropylene, and Teflon) should also be dry cleaned. 1. Thoroughly vacuum clean the filter bags to remove the bulk of the dust. 2. Dry clean the bags using a standard dry cleaning procedure. Use pure dry cleaning solvent. Do not use dry cleaning detergents and/or additives that require the addition of water, as these may cause fabric shrinkage. 3. Dry the bags. Drip drying is the recommended drying method. Tumble drying, if used, must be done at low temperatures. Industrial dry cleaning establishments are available in many cities. These companies specialize in filter bag cleaning and will normally provide the most satisfactory results. Header Assembly Publication: MAN3012K Mac Process LLC 11

15 The header assembly does not need maintenance other than weekly inspection and draining as described above. In the event that disassembly of the header is required, refer to the figure in the Section titled "Spare Parts" for details of the construction. Publication: MAN3012K Mac Process LLC 12

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22 TROUBLESHOOTING The items listed below are intended as a quick reference for common problems that may be encountered with a dust filter. If you are experiencing any difficulties not covered or have any questions concerning your filter, contact your local Mac Process representative or Mac Process LLC. Disconnect and properly lockout-tagout the electrical and compressed air service before performing any maintenance or service procedures on the filter. It is imperative that the timer control panel enclosure be secured at all times unless access is required. g) Dust particle size too small. h) Bags fit on cages too tightly. Small particles (less than 10 microns) will affect efficiency of filter media. Analyze particle size distribution with original design parameters. If excessive amounts of small particles are present then review application with Mac Process LLC. Check bag fit on cages with the pinch test. You should be able to pinch ½" of fabric at any position. Tight bags will not allow the bags to 'flex' properly for cleaning. If bags are too tight replace them. Bags which have been cleaned or washed may shrink and must be checked for proper fit on cage. POSSIBLE CAUSE 1. High differential pressure across tube sheet. (5 H 2 O and rising) a) Clogged, kinked, damaged, or deteriorated gauge lines. SOLUTION Clean or replace lines. If installation is several years old replacement of lines may be necessary. Check internal filter on differential pressure port on filter housing. Replace if blocked. b) Bad gauge. Normally the gauge will fluctuate during cleaning pulse. If needle does not move replace the gauge. c) Cleaning mechanism not working. Listen to filter for the distinct cleaning pulse. If it is not present: Check timer for proper functioning. (Refer to start-up instructions.) Check air supply pressure at header (should be psig). Check solenoid and diaphragm valve operation. Check for loose wiring or dirt in the valves. Check for moisture or oil in air lines. d) Bags binding. Inspect bag dust cake. High humidity and condensation will cause dust cakes that are difficult to remove. Run filter with exhaust fan off and without dust load for 15 to 30 minutes until cake is removed. Preheat filter on start up to avoid condensation. If air stream is extremely humid then review application with Mac Process LLC. If condensation is a recurring problem, start and operate the system with no dust load until the filter reaches ambient temperature. It may also be necessary to operate the system with no dust load for a time at shut down. e) Hopper overloading. f) System air volume too high. Check discharge mechanism for proper operation. Do not use the hopper for storage of material unless the collector has been designed for this function. Check for material bridging across hopper. Coat hopper with Teflon type material or add a properly sized vibrator to keep hopper clear. Check air flow of system and compare with design values. If air flow is too high review application with Mac Process LLC. 2. Low differential pressure drop. (less than 1/2 H 2 O) a) Check items 1a and 1b. b) Holes in bags. Replace worn bags c) Incorrect bag installation causing leakage. 3. Dust in exhaust air. a) Normal for start up period with new bags. b) Check items 2b and 2c. c) Over-cleaning of bags. 4. Poor bag life. a) Incorrect filter media. Look for dust in clean air plenum. Refer to bag installation procedure. Allow filter to run with a dust load for 48 to 96 hours. Increase the "Off Time" setting on the timer board. If a photohelic gauge is in use, increase high setting on the gauge. High temperatures, chemical content, and dust composition will affect bag life. b) Abrasion Poor inlet design practices such as high inlet velocities and elbows on the inlet can cause accelerated abrasion on bags. Consult Mac Process LLC for guidance. c) Damaged cages Damaged, corroded or bent cages can wear on bags. Replace cages. Coated or stainless steel cages are available. d) Moisture in air stream. Moisture will cause acids to form in some applications which weaken the filter media. Check moisture level and composition of dust and air stream. Consult Mac Process LLC for review of application. e) Excessive air to Check air to cloth ratio and compare to cloth ratio. original specifications. f) Improper cleaning. Review cleaning procedures. Improper cleaning can shorten bag life. Publication: MAN3012K Mac Process LLC 19

23 ORDERING SPARE PARTS To order spare parts by phone, dial (U.S. & Canada) or (International). The following information is necessary when placing an order for spare parts to help ensure prompt service: 1. Model Number 2. Serial Number 3. Part Description 4. Part Number 5. Quantity Required 6. Mac Job Process Number (or Sales Order Number) Order Acknowledgement Model Designations 18 *** 7 Number of bags in unit Basic filter style Length of bags in unit. Top Removal 6.2" SNAP BAND Bags Bag Length 16 Oz. Dacron 16Oz. DYNA-MAC 14 Oz. Polypropylene 18" V B01 V B01 V B01 36" V B01 V B01 V B01 54" V B01 V B01 V B01 72" V B01 V B01 V B01 96" V B01 V B01 V B01 Top Removal Cages Galvanized Cage Length and Part Number Filter Style RT or ST 18 V B01 36 V B01 54 V B01 72 V B01 96 V B01 System Parameters Use this page to record the operating conditions of the system once startup is complete and you have made the final adjustments. You will find this information very valuable for future reference when troubleshooting the system or when monitoring its performance. DUST MATERIAL: DUST PARTICLE SIZE: FILTER MODEL: FILTER S/N: AIR/CLOTH RATIO: AIR FLOW CFM PHOTOHELIC GAUGE SET POINTS: (if provided) High: "H 2 O Low: "H 2 O DIFFERENTIAL PRESSURE: "H 2 O (after the filter has stabilized) FAN MODEL/MANUFACTURER: FAN S/N: FAN RPM: FAN DESIGN: "SP, BHP Notes: Publication: MAN3012K Mac Process LLC 20

24 Header Assembly Timer Control Assembly Number Part Number Description Header (4" schedule 40 pipe) 2 Diaphragm Valve Fittings: 90 1/4 x 1/8 brass " I.D. hose " hose clamps /4" x 3" pipe nipple T.O.E /4" NPT air inlet Timer Control Assembly (see detailed drawing next page) /16" - 18x1" hex head bolt /16" lockwasher /16" 18 hex nut Control panel mounting plate Number Part Number Description Enclosure Back Panel 3 Timer Control 4 Solenoid Valve Fitting - 1/4 x 1/8 brass Hose, 1/4 44NF Poly-Flo Publication: MAN3012K Mac Process LLC 21