Installation and Operation Manual

Transcription

1 Installation and Operation Manual Installation, Operation, and Service Information Downflo Oval DFO 1-1, DFO 2-2, and DFO 3-3 Patent Numbers: 6,387,162 6,090,173 6,488,746 5,562,746 6,364,921 6,368,388 Or Patents Pending DFO 1-1 DFO 2-2 DFO 3-3 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. This manual is property of owner. Leave with unit when set-up and start-up are complete. Donaldson Company reserves right to change design and specifications without prior notice. IOM AD Revision 6

2 Donaldson Company, Inc. 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 or appropriate codes when determining location and operation of dust or fume collection equipment. When combustible materials are present, consult with an installer of fire extinguishing systems familiar with se types of fire hazards and local fire codes for recommendations and installation of fire extinguishing and explosion protection systems. Donaldson dust collection equipment is not equipped with fire extinguishing or explosion protection systems. DO NOT allow sparks, cigarettes or or burning objects to enter hood or duct of any dust or fume control equipment as se may initiate a fire or explosion. For optimum collector performance, use only Donaldson replacement parts. Warning Improper operation of a dust control system may contribute to conditions in work area or facility that could result in severe personal injury and product or property damage. that all collection equipment is properly selected and sized for intended use. 2

3 Downflo Oval, Model DFO 1-1, 2-2, and 3-3 Contents Description... 4 Purpose and Intended Use... 4 Rating and Specification Information... 5 Operation... 6 Inspection on Arrival... 7 Installation Codes and Procedures... 7 Installation... 7 Site Selection, Grade-Mounted Units... 7 Unit Location... 7 Electrical Wiring... 8 Rigging Instructions... 8 Hoisting Information... 8 Typical Installation... 9 Standard Equipment Cleaning Controls Manual Motor Starter Option Downtime Cleaning Option Delta P Cleaning Option Remote-Mount Cleaning Option Control Panel and Motor Wiring Manual Motor Starter Downtime Cleaning This manual contains specific precautionary statements relative to worker safety. Read thoroughly and comply as directed. Discuss use and application of this equipment with a Donaldson representative. Instruct all personnel on safe use and maintenance procedures. Delta P Cleaning Remote-Mount Cleaning Motor Wiring Instructions Control Panels and Solenoid Specifications Compressed-Air Supply Gallon Pail Pack Gallon Dust Bin Exhaust Damper Preliminary Start-Up Service Information Operational list Filter Installation and Replacement Filter Removal Filter Replacement Dust Disposal Compressed Air Components Split Taper Bushing Mounting Instructions Optional Equipment Gallon Dust Container Sealer Gear Installation Delta P Control Delta P Control Calibration Caster Assembly HEPA Afterfilter Installation Extraction Arm and Adapter Installation Mounting Adapter Extraction Arm Installation Explosion Vents Sprinkler Installation Troubleshooting Service Notes Warranty Data Sheet Model Number Serial Number Ship Date Installation Date Customer Name Address Filter Type Accessories Or 3

4 Donaldson Company, Inc. Description The Downflo Oval, Models DFO 1-1, DFO 2-2, and DFO 3-3 are intermittent-duty dust collectors with oval, cartridge-style filters. The downward airflow design delivers high filtration efficiency while using less energy. The filters for DFO 1-1 are pulse-cleaned off-line while filters for DFO 2-2 and DFO 3-3 can be pulse-cleaned on- or off-line, depending on type of cleaning control options selected. All models are one-filter deep units; model DFO 1-1 is a single filter unit, model DFO 2-2 is a two filter high unit, and model DFO 3-3 is a three filter high unit. Options include various cleaning controls with and without motor starter controls, HEPA afterfilter packs, and various dust container options. Purpose and Intended Use Downflo Oval collectors are widely used on nuisance dust where load to collector is less than two grains per cubic foot. Some typical pointof-use applications include abrasive blasting, rmal cutting, grinding, pharmaceutical blending and packaging, powder paint applications, sand handling, and welding. Each application is different and selecting correct filter cartridge for application and type of dust collected is important. For extremely fine 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 openpleat 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 modifications. Appropriate cartridge options are available from Donaldson. Hygroscopic dust such as fertilizer, salt, and sugar should be handled under a controlled, low-humidity environment. Contact Donaldson for filter cartridge selection. Flammable or explosive dust require custom collector modifications, special cartridges, and special installation instructions. Contact Donaldson for design assistance and review related local codes for guidance on equipment location. 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. 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 or appropriate codes when determining location and operation of dust collection equipment. Donaldson equipment is not equipped with fire extinguishing or explosion protection systems. 4

5 Downflo Oval, Model DFO 1-1, 2-2, and 3-3 Ratingand Specification Information Front DFO 1-1 Front DFO 2-2 Front DFO 3-3 Side View All Models All Units (as per IBC 2003 Specifications): Seismic Spectral Acceleration, S s g Seismic Spectral Acceleration, S g Importance Factor, Compressed air, maximum psig Housing rating, inches water gauge Power, valves and controls Volt 50/60 Hz 5

6 Donaldson Company, Inc. Operation During normal operation, dust-laden air enters unit through top dirty-air inlet. Airflow is directed downward through collector and heavier particulate falls directly into hopper. The cartridges remove fine particulate and clean, filtered air passes through cartridge to clean-air plenum and discharges through clean-air outlet. Filter cleaning is completed using pulse-jet technology. An air diaphragm valve aligned to each filter provides pulse cleaning. Eir a manual push-button valve or electronic solenoid valve actuates pulse cleaning. The cleaning sequence starts at top filter and continues down through each filter. Remove, inspect, or change filter cartridges from outside unit by removing filter access cover and sliding filter out. clean-air outlet dirty-air inlet compressed-air manifold filter cartridge filter access hopper Normal Operation (Yoke not shown for clarity) fan motor Filter Cleaning Operation dust disposal Unit Operation 6

7 Downflo Oval, Model DFO 1-1, 2-2, and 3-3 Inspection on Arrival 1. Inspect unit on delivery. 2. Report any damage to delivery carrier. 3. Request a written inspection report from Claims Inspector to substantiate claim. 4. File claims with delivery carrier. 5. Compare unit received with description of product ordered. 6. Report incomplete shipments to delivery carrier and your Donaldson 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 unit depends on proper installation. 2. Authorities with jurisdiction should be consulted before installing to verify local codes and installation procedures. In absence of such codes, install unit according to National Electric Code, NFPA No. 70-latest edition. 3. A qualified installation and service agent must complete installation and service of this equipment. WARNING! 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 application. Installation Site Selection, Grade-Mounted Units 1. The unit is to be located indoors on a reinforced concrete foundation. 2. Portable units require no special installation accommodations. Unit Location 1. When hazardous conditions or materials are present, consult with local authorities for proper location of collector. 2. Foundation must be capable of supporting entire weight of unit, plus weight of collected material, piping, and ductwork. 3. Prepare foundation in selected location. Install anchor bolts to extend a minimum of 1 3/4-inches above foundation. 4. Locate collector to ensure shortest and straightest inlet- and outlet-duct length, easy access to electrical and compressed-air connections, and routine maintenance. CAUTION! OSHA may have requirements regarding recirculating filtered air in your facility. Consult with appropriate local authorities to ensure compliance with all codes regarding recirculating filtered air. 7

8 Donaldson Company, Inc. Electrical Wiring 1. All electrical wiring and connections, including electrical grounding, should be made in accordance with National Electric Code, NFPA No. 70-latest edition. 2. 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 unit is not furnished with a factorymounted disconnect, an electric disconnect switch having adequate amp capacity shall be installed in accordance with Part IX, Article 430 of National Electrical Code, NFPA No. 70-latest edition. unit s rating plate for voltage and amperage ratings. 5. Refer to wiring diagram for number of wires required for main power wiring and remote 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 CAUTION! Failure to lift 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 equipment. A crane or forklift is recommended for unloading, assembly, and installation of collector. Location must be clear of all obstructions, such as utility lines or roof overhang. 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. Specification Control drawing for weight and dimensions of unit and components to ensure adequate crane capacity. 5. Allow only qualified crane operators to lift equipment. 6. Refer to applicable OSHA regulations and local codes when using cranes, forklifts, and or lifting equipment. 7. Lift unit and accessories separately, and assemble after unit is in place. 8

9 Downflo Oval, Model DFO 1-1, 2-2, and 3-3 Typical Installation Typical Installation 9

10 Donaldson Company, Inc. Standard Equipment Standard collectors include a fan, motor, control panel, 10-gallon dust container, and an exhaust silencer and damper. Depending on type of control selected, motor may or may not be prewired. Orwise, unit is fully assembled and ready to connect to electrical supply, compressed air, and ductwork. A detailed drawing, shipped with each collector, provides weight, specifications, and unit dimensions including anchor bolt locations for collector s base plate. Cleaning Controls All units include standard cleaning controls that are manually- or timer-controlled depending on model and options selected. Controls are available in a variety of voltages and are available in one of four basic types: 1. Manual push-button with or without motor starter. 2. Downtime cleaning with or without motor starter. 3. Delta P cleaning with or without motor starter. 4. Manual push-button, Delta P, or downtime cleaning without motor starter in a remotemount option. Model DFO 1-1 standard controls include a manual motor starter that is prewired to motor and a push-button valve for pulse cleaning control. Options include downtime cleaning with or without motor starter and remote-mount, downtime cleaning without motor starter. Models DFO 2-2 and DFO 3-3 standard controls include downtime cleaning without a motor starter. Available options include downtime cleaning with a motor starter, remote-mount downtime cleaning without motor starter, Delta P cleaning with or without motor starter, and remote-mount Delta P cleaning without motor starter. All control panels, except remote-mount, are located inside unit. Manual Motor Starter Option The manual motor starter is standard option for Model DFO 1-1 and is not available for or models. It is prewired to motor and filter cleaning is completed using a separate, manual push-button valve located next to motor starter. Downtime Cleaning Option Primarily used for intermittent duty, light dust-load applications, downtime cleaning option provides automatic, downtime filter cleaning when collector is turned OFF. Downtime cleaning WILL occur every time unit is shut down. The valves start to pulse one minute after unit is shut down and continue pulsing every 10-seconds for 3 minutes to reduce differential pressure. Downtime cleaning without motor starter is standard for Models DFO 2-2 and DFO 3-3. The option is specified at time of order and available with and without a motor starter. Delta P Cleaning Option Primarily used for continuous duty or heavy dustload applications, Delta P option provides automatic, on-line filter cleaning. The high- and low-pressure setpoints initiate pulse cleaning cycle. The pulse-cleaning cycle begins when filter pressure reaches high-pressure setpoint. The valves continue to pulse every 10 seconds until low-pressure setpoint is reached. The Delta P option is available for models DFO 2-2 and DFO 3-3 only, with or without a motor starter. 10

11 Downflo Oval, Model DFO 1-1, 2-2, and 3-3 Control Panel and Motor Wiring Remote-Mount Cleaning Option Primarily used in applications that require cleaning controls to be located away from a hazardous environment, remote-mount controls are available with downtime cleaning and Delta P cleaning options. Remote downtime cleaning is available for all three models while remote Delta P is available for models DFO 2-2 and DFO 3-3 only. This option is specified at time of order and collector is equipped with a 115-Volt AC NEMA 12 solenoid valve enclosure. Explosion-protected units include a NEMA 9 dust explosion-proof solenoid enclosure. Contact Donaldson for information about a NEMA 7 gas explosion-proof solenoid enclosure. Motor starters for remote-mount cleaning options are customer-supplied. 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. Manual Motor Starter Control panels with a manual motor starter require three-phase power with requirements as listed on motor s nameplate and are wired directly to terminals on motor disconnect switch located inside control panel. See wiring diagram inside control panel. L1 L2 L3 GRD black red white 16-ft power cable green MMP1 3-ft blower motor cable adjust overload to motor nameplate FLA blower motor 1 1/2 Hp Manual Motor Starter 11

12 Donaldson Company, Inc. Downtime Cleaning With Motor Starter The downtime cleaning control panel with motor starter requires three-phase power with requirements as listed on motor s nameplate and is wired directly to terminals on motor disconnect switch located inside control panel. See wiring diagram inside control panel. Delta P Cleaning With Motor Starter The Delta P control panel with motor starter requires three-phase power with requirements as listed on motor s nameplate and is wired directly to terminals on motor disconnect switch located inside control panel. See wiring diagram inside control panel. L1 L2 L3 fused disconnect 30A PE PE 1L1 1L2 1L3 M1 OL ground lug blower motor M1 L1 L2 L3 fused disconnect 30A PE PE 1L1 1L2 1L3 M1 OL ground lug blower motor M1 1L1 1L2 3-ft blower motor cable 1L1 1L2 3-ft blower motor cable 3-Phase 3-Phase Downtime Cleaning with Motor Starter Without Motor Starter The downtime cleaning panel without motor starter requires 120-Volt AC, single-phase power to be wired directly to control panel terminal block at Terminals L, N, and G. Separate power must be supplied directly to motor. See wiring diagram on motor's nameplate and Motor Wiring Instructions on Page 12. Delta P Cleaning with Motor Starter Without Motor Starter The Delta P control panel without motor starter requires 120-Volt AC, single-phase power to be wired directly to control panel two-point terminal block located on 3-pin timer subpanel. Separate power must be supplied directly to motor. See wiring diagram on motor's nameplate and Motor Wiring Instructions on Page 12. NNNL FU1 120-Volt 120-Volt AC N L TR1 SV1 SV2 PS1 SV3 SEQ1 G G ground lug ground lug FU1 Downtime Cleaning without Motor Starter Delta P Cleaning without Motor Starter 12

13 Downflo Oval, Model DFO 1-1, 2-2, and 3-3 Remote-Mount Cleaning Remote-mount control panels are not equipped with a motor starter and require 120-Volt AC, singlephase power to be wired directly to control panel. Separate power must be supplied directly to motor. See wiring diagram on motor's nameplate and Motor Wiring Instructions. Downtime Cleaning Wire 120-Volt AC directly to control panel PLC terminal block at Terminals L, N, and G. Solenoid Connection Connect solenoid valves to PLC relay outputs located inside control panel. Delta P Cleaning Wire 120-Volt AC power directly to control panel two-point terminal block located on 3-pin timer subpanel. Solenoid Connection Wire each solenoid valve to 3-pin timer board. Motor Wiring Instructions For Customer-Supplied Motor Starters 1. Power is always routed through one or both of top electrical openings and through an internal bulkhead knockout provided on blower motor plate inside collector. 2. Remove electrical-access panels and set aside. 3. Using wiring diagram on motor, wire directly to motor. Do not wire through control panel. Use appropriate wire gauge for rated amp load as specified by local codes. 4. With power supply ON, check operation of motor and fan rotation. The fan can be viewed through control panel access door. Proper rotation is counterclockwise from top of unit N N L FU1 ground lug 120-Volt AC to solenoid enclosure 120-Volt AC TR1 to solenoid enclosure PS1 SEQ1 ground lug 120-Volt AC FU1 Downtime Cleaning Delta P Control Remote-Mount Cleaning Controls 13

14 Donaldson Company, Inc. Control Panels and Solenoid Specifications Control Panel Input Without Motor Starter Volts AC/50-60Hz/1 Phase With Motor Starter See motor voltage/50-60hz/3 Phase Pulse ON Time Factory set at 200-milliseconds. Pulse OFF Time Factory set at 10-seconds. The pulse OFF time can only be adjusted by modifying parameters contained in microprocessor software. Contact your representative for assistance. Pulse Cleaning Cycle Downtime Cleaning 3 minutes Delta P Cleaning Until low-pressure setpoint is reached. Solenoid Valves 115-Volt AC at 19.7 watts each Operating Temperature Range Ambient 0 to 140 F. 14

15 Downflo Oval, Model DFO 1-1, 2-2, and 3-3 Compressed-Air Supply Note: CAUTION! Turn compressed-air supply OFF and bleed lines before performing service or maintenance work. The compressed-air supply must be oil and moisture free. Contamination in 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 unit s compressed-air manifold. Use thread-sealing tape or pipe sealant on all compressed-air connections and fittings. 1. Connect compressed-air supply line to 3/4-in MNPT compressed-air coupling located on top roof panel of unit. 2. Install a customer-supplied shut-off valve, bleedtype regulator with gauge, filter, and automatic condensate valve in compressed-air supply line. 3. Set compressed-air supply at 60-psig. The pulsecleaning controls are factory set to clean one filter every 10-seconds during a cleaning cycle. Note: All compressed-air components must be sized to meet maximum system requirements of 0.86 cu ft/pulse at 60-psi supply pressure. Do not increase supply pressure above 60-psi. Component damage can result. 3/4-in MNPT coupling regulator* bleed-type air filter* shut-off valve* automatic condensate valve* compressed-air supply motor starter power supply disconnect switch * customer-supplied Compressed-Air Connection 15

16 Donaldson Company, Inc. 10-Gallon Pail Pack A 10-gallon pail pack is standard with all models. A sturdy band clamp secures cover to 10-gallon pail. For dust removal: 1. Loosen and remove cover clamp and cover. 2. Dispose of dust. 3. Reinstall dust bin, cover and clamp. 7. Install band clamp over hopper outlet and bin cover and tighten band clamp. band clamp cover 25-gallon hopper hex bolt sealant flat washer hex nut adapter collar flexible hose hose clamp pail cover cover clamp 10-gallon pail dust bin 25-gal Exhaust Damper 25-Gallon Dust Bin draw latch An exhaust damper control regulates or limits airflow when unit is in operation. Before start-up, set damper control to fully-closed position as shown below. Adjust airflow by loosening wing nut and sliding handle to open damper. When replacing filters, reset damper to fullyclosed position and n adjust airflow. 25-Gallon Dust Bin 10-Gallon Pail Pack A 25-gallon dust bin is optional with all models. A sturdy band clamp secures cover and dust bin to collector hopper flange. For dust removal: 1. Loosen and remove band clamp. 2. Remove dust bin with cover. 3. Remove cover by releasing draw latches. 4. Empty dust bin. 5. Install cover on dust bin and clamp down with draw latches. 6. Install dust bin with cover under collector hopper flange. fully closed damper open Exhaust Damper Adjustment 16

17 Downflo Oval, Model DFO 1-1, 2-2, and 3-3 This Page Intentionally Left Blank 17

18 Donaldson Company, Inc. Preliminary Start-Up 1. all electrical connections for tightness and contact. 2. Motor and fan should be wired for counter clockwise rotation when viewed through control access panel. To reverse rotation, single-phase power supply: Follow manufacturer s instructions on motor s nameplate. To reverse rotation, three-phase power supply: Turn electrical power OFF at source and switch any two leads on motor junction box. 3. All access panels should be sealed and secure. 4. that dust container is properly sealed and clamped. 5. that exhaust damper is set to fullyclosed position. 6. and remove all loose items in or near inlet and outlet of unit. 7. that all remote controls and solenoid enclosures (if applicable) are properly wired and all service switches are in OFF position. 8. that all optional accessories are installed properly and secured. 9. Turn power ON at source. 10. Turn compressed-air supply ON. Adjust pressure regulator for 60-psi. 11. Turn blower fan motor ON. 12. Adjust airflow with exhaust damper. Note: Excess airflow can shorten filter life, cause electrical system failure, and blower motor failure. Service Information Operational list 1. Monitor overall performance of collector. 2. Monitor exhaust. 3. Monitor pressure drop across filters. 4. Monitor dust disposal. Filter Installation and Replacement Filter Removal CAUTION! Use proper safety and protective equipment when removing contaminants and filters. Dirty filters may be heavier than y appear. Use care when removing filters to avoid personal injury. Do not drop filters. 1. Turn power to unit OFF. 2. Start at top access port. 3. Remove access cover. For units built after November 2006: lift up access cover handle and while pushing in on cover, slide access cover to side 1-inch to remove access cover. For units built before November 2006: remove access cover by lifting latch handle and lifting cover to remove from yoke. If access cover clamp fails to operate smoothly, apply WD-40 to riveted pivot points and to clamp rod where it passes through outside of cover. Wipe off over spray. 4. Break seal between filter cartridge and sealing surface. 5. Slide filter out access port along suspension yoke and dispose of properly. WD-40 is a registered trademark of WD-40 Company. 18

19 Downflo Oval, Model DFO 1-1, 2-2, and Clean sealing surface with damp cloth. Note: Clean dust from gasket sealing area to ensure a positive filter gasket seal. 7. for an accumulation of dust in storage area and empty as necessary. Filter Replacement Note: Place filter part number label (supplied with each replacement filter) over filter part number listed on unit's rating plate. 1. Slide new filter cartridge onto each suspension yoke. Note: Insert filter gasket-end first. 2. Wipe cover gaskets clean and replace covers by attaching cover to yoke hook and firmly latching cover handle. Note: that access covers are seated and seal properly. Gaskets must be compressed to ensure an airtight seal. 3. Reset exhaust damper control to fully closed position. 4. Turn electrical power and compressed air supply ON before starting unit. filter suspension yoke filter cartridge filter access cover quick-release handle Filter Removal and Replacement 19

20 Donaldson Company, Inc. Dust Disposal 1. Turn unit OFF and empty dust container as necessary to minimize dust in hopper. 2. Reinstall dust container. Compressed Air Components 1. Periodically check compressed air components and replace compressed-air filter. CAUTION! Turn compressed-air supply OFF and bleed lines before performing service work. 2. Drain moisture following manufacturer s instructions. 3. With compressed-air supply ON, check cleaning valves, solenoid valves, and tubing for leaks. Replace as necessary. Note: Do not set compressed-air pressure above 60-psig. Component damage can occur. 20

21 Downflo Oval, Model DFO 1-1, 2-2, and 3-3 Split Taper Bushing Mounting Instructions Many fans are furnished with split taper bushings for mounting impeller to shaft. When properly assembled, bushings grip hub with a positive clamping action. 1. Bushel barrel and bore of impeller are tapered to ensure concentric mounting and a true running propeller. 2. Capscrews, when tightened, lock bushing in propeller. Use special plated capscrews and nylock nuts. Torque Bushing No. Bolt Size Ft-Lbs QT/QH/L/H 1/ / 2 3. Bushing is split so that when locking capscrews force bushing into tapered bore, bushing grips shaft with a positive clamping fit. This will withstand vibration and heavy loads without being loosened. 4. Impeller and bushing assembly is keyed to shaft and held in place by compression, which adds driving strength. Note: Before assembly, ensure shaft and keyway are clean and smooth. key size with both shaft and bushing keyway. 5. To assemble, insert capscrews through clearance holes in bushing and install bushing loosely into impeller. Do not press or drive. Start capscrews by hand, turning m just enough to engage threads in nylock nut. Do not use a wrench at this time. The bushing should be loose enough in propeller to move freely. Slide impeller and bushing assembly onto shaft, allowing adequate clearance for shaft end play to prevent friction. Fit key into keyway. Do not force impeller and bushing onto shaft. If it does not go on easily, check shaft, bushing, and key sizes once again. Tighten capscrews gradually and evenly with wrench similar to mounting an automobile wheel. Rotate a quarter turn on each capscrew successively until all capscrews are tight. These capscrews force taper bushing into hub, which in turn compresses bushing onto Split Taper Bushing C E D B A Split Taper Bushing Installation shaft. This makes a positive clamping fit. The torque must not exceed value specified in table. CAUTION! BROWNING Split Taper Bushed Product (Gripbelt Sheave Shown) A. External key, except G, H and Idler Bushings B. Bushing barrel and Product bore are tapered C. Bushing cap screws D. Bushing barrel is split (except idler bushings) E. Removal holes are threaded, installation holes are not Do not attempt to pull bushing flange flush with hub end. There should be a clearance which varies approximately 3/16-in to 1/4-in with bushing size when tightened. This is not a locating dimension. Impeller Assembly Removal 1. Remove all capscrews from impeller and hub assembly. 2. Insert capscrews into threaded holes in bushing flange. 3. Tighten each bolt in quarter of a turn increments to push impeller off bushing. This forces bushing loose from propeller hub and releases compression so that entire assembly will slide from shaft. 4. Pull bushing off shaft. Note: If assembly has been in place sometime it may be necessary to use a wheel puller to remove bushing. Never use a wheel puller on impeller. Browning is a registered trademark and Split Taper is a tradename of Emerson Power Transmission Manufacturing, L.P. 21

22 Donaldson Company, Inc. Optional Equipment 25-Gallon Dust Container An optional 25-gallon dust container with casters is also available. The 25-gallon dust container is secured to adapter collar with a band clamp similar to standard 10-gallon dust container. 1. Apply sealant to adapter collar mounting flange toward inside edge of bolt pattern. 2. Attach adapter collar to hopper flange using bolts, washers, and hex nuts supplied. 3. Place cover on container and secure latches. 4. Position container under hopper outlet. 5. Secure adapter collar and container cover wide band clamp. hex bolt sealant sealed washer hex nut adapter collar band clamp cover 25-Gallon Dust Container 25-gallon dust container 22

23 Downflo Oval, Model DFO 1-1, 2-2, and 3-3 Sealer Gear Installation The sealer gear provides an airtight seal between hopper flange and 10-gallon dust disposal container. Simply lift sealer gear handle to remove dust container or lower handle to seal dust container. To install on an existing unit: 1. Remove cover and clamp from dust container. 2. Remove dust container and set aside. 3. Remove flexible duct and adapter collar from unit s hopper flange. 4. Place 1/4-in diameter rope-type sealant on sealer gear flange toward inside edge of bolt pattern. See Sealer Gear Installation. 5. Lift sealer gear to hopper flange, align bolt patterns, and secure using 5/16-18 x 5/8-in bolts, flat washers, and lock nuts supplied. Note: For ease of maintenance, position sealer gear with handle toward front or side of unit. 6. Replace dust container and push sealer gear handle down. 5/16-18 x 5/8-in hex bolt 5/16-in sealed washer 1/4-in diameter rope-type sealant sealer gear assembly 5/16-in flat washer 5/16-18 lock nut handle lift up to remove container push down to seal 10-gallon dust container Sealer Gear Installation 23

24 Donaldson Company, Inc. Delta P Control Delta P control monitors differential pressure between clean- and dirty-air chambers, providing a visual display of filter condition. Set high-pressure ON and low-pressure OFF setpoints to control filter cleaning system. The ALARM setpoint activates alarm display indicating filter replacement. The ALARM setpoint must be set higher than high-pressure setpoint. Delta P Control Calibration The only user calibration is zero adjustment of display. Due to slight changes in electronic components over time or pressure differentials within plant environment, display may read something or than 0.0 while at rest. To recalibrate operating system: 1. Turn power to Delta P Control ON for a minimum of 30-minutes to stabilize operating temperature. 2. Turn power to control OFF. 3. Press and hold LOW SET, HIGH SET, and ALARM SET keys while turning power to control back ON. Continue holding keys as control goes through its power-up sequence. The number 8 is displayed in each digit, and n display reads Release three keys. The new calibration is automatically stored in memory. Torit P " Control 3-digit display indicates closed alarm relay low setpoint Alarm 06.5 Cleaning "wg dapa indicates closed cleaning relay high setpoint alarm setpoint increase setpoint Low Set High Set Alarm Set decrease setpoint Delta P Control Display Panel 24

25 Downflo Oval, Model DFO 1-1, 2-2, and 3-3 Caster Assembly The caster assembly includes one rigid and one swivel caster set. 1. Lift unit approximately 24-in with a crane or forklift. 2. Position swivel caster assembly under front filter-access end of unit. Align bolt holes and secure using 3/8-16 x 5-in bolts, flat washers, lock washers, and hex nuts supplied. See Caster Installation. 3. Remove lower side motor panel from unit. 4. Position rigid caster assembly under back edge of unit and fasten as described in Step Replace motor panel and lower unit. 3/8-16 x 5-in Gr2 hex bolt 3/8-in flat washer 3/8-in flat washer remove motor panel 3/8-in lock washer 3/8-16 hex nut rigid caster assembly swivel caster assembly Caster Installation 25

26 Donaldson Company, Inc. HEPA Afterfilter Installation The optional HEPA afterfilter is designed to capture small particulate and is attached to units cleanair outlet. 1. Turn supply power OFF. 2. Remove bolts from top back roof panel. 3. Position HEPA mounting frame on top of clean-air outlet aligning existing hole pattern. 4. Mark and match-drill front flange holes in roof panel using a in diameter drill bit. 5. Apply 1/4-in diameter rope-type sealant toward inside of bolt pattern. 6. Position HEPA mounting frame on top panel aligning bolt patterns. 7. Bolt in place using hardware supplied and hardware removed in Step Position HEPA filter on mounting frame and secure with latches. 9. Reset exhaust damper to fully closed position. 10. Turn unit ON. 11. Adjust airflow using airflow control damper. HEPA filter bolt match-drill holes HEPA mounting frame latch 1/4-in diameter rope-type sealant HEPA Afterfilter Installation 26

27 Downflo Oval, Model DFO 1-1, 2-2, and 3-3 Extraction Arm and Adapter Installation Extraction Arms (Ex-Arms) are designed to carry dust, fume, and mist away from worker s breathing zone. The operator positions hood 8- to 12-inches above work area. Contaminated air is drawn into hood, through Ex-Arm and into dirty-air plenum of unit where it is filtered and exhausted. Mounting Adapter 1. Remove four self-threading bolts from roof panel. See Mounting Adapter Installation. 2. Place mounting adapter on roof panel aligning bolt holes from bolts removed in Step 1 with bolt pattern on mounting adapter. Note: The bolt pattern of mounting adapter is not symmetrical. If bolt patterns do not line up, turn mounting adapter Match-drill eight 3/8-in holes in roof panel using mounting adapter as a guide. 4. Remove mounting adapter and set aside. 5. Place 1/4-in diameter, rope-type sealant on roof panel toward inside of bolt pattern. 6. Place mounting adapter on roof panel and align bolt patterns. 7. Remove filter-access cover and filters to access inside of unit when attaching mounting adapter. 8. Secure mounting adapter to roof panel using four self-threading bolts removed in Step 1 and 5/16-18 x 1-in bolts, sealed washers, lock washers, and hex nuts provided. See Mounting Adapter Installation. 9. Tighten all hardware securely. 10. Replace filter and filter-access cover. four self-threading bolts 5/16-18 x 1-in hex bolt 5/16-in sealed washer match-drill eight 3/8-in diameter holes 1 2 1/4-in diameter rope-type sealant remove four self-threading bolts 5/16-in sealed washer 5/16-in lock washer 5/16-18 hex nut 3 4 Mounting Adapter Installation 27

28 Donaldson Company, Inc. Extraction Arm Installation Lift Ex-Arm into position over mounting adapter inlet flange, align bolt patterns, and secure with hardware provided. See Extraction Arm Installation. 1/4-20 x 1 1/4-in hex bolt 1/4-in flat washer 6-in Extraction Arm mounting adapter inlet flange 1/4-in flat washer 1/4-in lock washer 1/4-20 hex nut Extraction Arm (Ex-Arm) Installation 28

29 Downflo Oval, Model DFO 1-1, 2-2, and 3-3 Explosion Vents CAUTION! Personal injury, death, or property damage can result from material discharge during venting. The material discharged from an enclosure during venting of an explosion should be directed safely to an outside location. The risk of damage or injury can be minimized or avoided by locating vented equipment outside buildings and away from normally occupied areas. Standard explosion vents are intended for outdoor installations only. Note: Remove all shipping materials, including covers, from explosion relief vents prior to installation. Failure to remove shipping covers will seriously compromise explosion vent operation. Explosion relief vents must be safely directed outdoors away from personnel, buildings, property, offices, walkways, and catwalks to reduce risk of damage to property and personal injury. Explosion venting calculations are based on formulas from NFPA-68 for outdoor applications only, with no duct or obstructions on explosion vent panel. Explosion vents are suitable for negative pressure installations only. Contact Donaldson for assistance in calculating safe and specific venting requirements for Torit equipment. Sprinkler Installation CAUTION! Sprinkler systems place a large quantity of water in dust collector when activated. Provide adequate drainage to remove water. Excess water weight can cause leg structure to collapse. Optional fire control sprinklers are available for all models operating under negative pressure. Toritsupplied sprinklers require a minimum of 15-psig water pressure. The volume of water discharged per sprinkler head is 17 gallons per minute. Note: Consult with local authorities when installing fire control systems on dust collection equipment. 1. Remove or open filter access covers to access sprinkler tap located in dirty-air plenum. 2. Apply pipe sealant to threads of pipe reducer located on sprinkler assembly. 3. Thread sprinkler assembly onto 1-in diameter sprinkler tap. 4. Tighten securely. access from inside dirty-air plenum Sprinkler Installation 29

30 Donaldson Company, Inc. 30 roblem P e Caus robable P y Remed motor and fan Blower start not do size wire motor mproper I d specifie as gauge wire correct using Rewire codes. local and national by correctly wired ot N y suppl for wiring motor correct and wiring manufacturer's motor See voltage. diagram and Follow wiring diagram. Code. Electric National available for wired not Unit voltage voltage. supply proper for wiring Correct down circuit nput I l al on circuit motor to supply power leads. down circuit supply lectrical E. voltage proper for circuit supply power Replace fault. breaker circuit or fuse for necessary. as motor and fan Blower stay not do but start, running installed motor-starter ncorrect I f i replace and starter motor proper for necessary. not or open are doors Access tight closed Filter See doors. access tighten and Close Replacement. open discharge opper H d an installed is container dust that sealed. properly control Damper properly adjusted not control damper Adjust duct. airflow in blower and achieved airflow is proper until manufacturer's within draw is amp motor's amps. rated overload circuit lectrical E s ha circuit supply power that equipment. all run to power sufficient outlet Clean-air dust discharging installed not cartridges Filter correctly Replacement. Filter See in dents damage, cartridge Filter or damage gasket caps, end media pleated in holes genuine only Use necessary. as filters Replace Filter See parts. replacement Donaldson Replacement. loose cover(s) ccess A r Filte See securely. doors access Tighten Replacement. airflow nsufficient I s backward rotation an F m fro counterclockwise is rotation fan Proper viewed be can fan The unit. of top See door. access panel control through. Start-Up Preliminary Troubleshooting

31 Downflo Oval, Model DFO 1-1, 2-2, and roblem P e Caus robable P y Remed airflow Insufficient continued not or open doors Access tight closed and place in are doors access all that discharge hopper that secured. is container dust that and sealed is opening correctly. installed restricted area exhaust an F. obstructions for area exhaust fan flow damper Adjust debris. or material Remove control. need cartridges Filter replacement Donaldson genuine using replace and Remove Replacemen. Filter See filters. replacement air compressed of ack L e Se supplied. is maximum 60-psig a that ompressed C -. Supply Air energized not cleaning ulse P n i valves solenoid check to voltmeter a Use for lines pneumatic panel. control obstructions. or kinks overfilled container Dust plugged or Disposal. Dust See container. out Clean leaking valves Pulse air compressed and unit to power electrical all out Lock for supply. compressed-air bleed or fault, tubing pneumatic wear, valve debris, diaphragm removing by diaphragm failure solenoid for valves. pulse on cover solenoid or valves pulse If damage. or leaks replace. damaged, are tubing and valves Delta on display No control P control to power o N. voltage supply for check to voltmeter a Use blown use F g wirin See panel. control in fuse if Replace panel. control diagram inside necessary.

32 Donaldson Company, Inc. 32 roblem P e Caus robable P y Remed P Delta on Display read not does control rest at when zero calibration of ut O l Contro P Delta in described as Recalibrate Calibration. but ON, control P Delta system does cleaning start not disconnected, tubing Pressure plugged or ruptured, contamination, breaks, kinks, for tubing connections. loose or not low setpoint or High system conditions for adjusted conditions. current to setpoints Adjust never Pulse-cleaning stops operating not switch Pressure correctly panel. control inside switch pressure not low setpoint or High system conditions for adjusted conditions. current to setpoints Adjust disconnected, tubing Pressure kinked or plugged, ruptured, contamination, breaks, kinks, for tubing connections. loose or kinks, ON is larm light A w lo too larm setpoint A. value higher a to Adjust drop pressure xcess E r compressed-ai system and cleaning not do filters if cartridges filter Replace supply. down. clean disconnected, tubing Pressure kinked or plugged, ruptured, or contamination, breaks, for tubing connections. loose do arrow keys P Delta work not operation mproper I o t keys setpoint three of one hold and Press arrow keys. use Troubleshooting

33 Downflo Oval, Model DFO 1-1, 2-2, and 3-3 Service Notes Date Service Performed Notes 33

34 Donaldson Company, Inc. Service Notes Date Service Performed Notes 34

35

36 The Donaldson Torit Warranty Donaldson warrants to original purchaser that major structural components of goods will be free from defects in materials and workmanship for ten (10) years from date of shipment, if properly installed, maintained and operated under normal conditions. Donaldson warrants all or Donaldson built components and accessories including Donaldson Airlocks, TBI Fans, TRB Fans, Fume Collector products and Donaldson built Afterfilter housings for twelve (12) months from date of shipment. Donaldson warrants Donaldson built filter elements to be free from defects in materials and workmanship for eighteen (18) months from date of shipment. Donaldson does not warrant against damages due to corrosion, abrasion, normal wear and tear, product modification, or product misapplication. Donaldson also makes no warranty whatsoever as to any goods manufactured or supplied by ors including electric motors, fans and control components. After Donaldson has been given adequate opportunity to remedy any defects in material or workmanship, Donaldson retains sole option to accept return of goods, with freight paid by purchaser, and to refund purchase price for goods after confirming goods are returned undamaged and in usable condition. Such a refund will be in full extent of Donaldson s liability. Donaldson shall not be liable for any or costs, expenses or damages wher direct, indirect, special, incidental, consequential or orwise. The terms of this warranty may be modified only by a special warranty document signed by a Director, General Manager or Vice President of Donaldson. Failure to use genuine Donaldson replacement parts may void this warranty. THERE EXIST NO OTHER REPRESENTATIONS, WARRANTIES OR GUARANTEES EXCEPT AS STATED IN THIS PARAGRAPH AND ALL OTHER WARRANTIES INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, WHETHER EXPRESS OR IMPLIED ARE HEREBY EXPRESSLY EXCLUDED AND DISCLAIMED. Parts and Service For genuine Donaldson replacement filters and parts, call Parts Express Line USA within Mexico For faster service, have unit s model and serial number, quantity, part number, and description available. Donaldson Company, Inc. Industrial Air Filtration P.O. Box 1299 Minneapolis, MN dustmktg@mail.donaldson.com Donaldson Company, Inc. is leading designer and manufacturer of dust, mist, and fume collection equipment used to control industrial-air pollutants. Our equipment is designed to help reduce occupational hazards, lengn machine life, reduce in-plant maintenance requirements, and improve product quality Donaldson Company, Inc. Printed in USA IOM AD , Revision 6 July 2007