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Summary of Contents for Donaldson Downflo Evolution DFE 2-8
- Page 1 INSTALLATION, OPERATION AND MAINTENANCE MANUAL Downflo Evolution Dust Collectors ® DOC-AM04643-01 rev 02 1118 ENGLISH - MASTER VERSION...
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Page 2: Table Of Contents
Installation, Operation and Maintenance manual Downflo Evolution ® TABLE OF CONTENTS GENERAL SAFETY REQUIREMENTS................... 4 INTRODUCTION ..........................10 Product information ......................10 Function ..........................10 Protection of the dust collector against dust explosion ............11 PRIOR TO INSTALLATION ......................13 Location ..........................13 Required tools and equipment ...................13 Delivery and inspection ......................13 INSTALLATION ..........................14 Unloading and transport to location ..................14... - Page 3 Installation, Operation and Maintenance manual Downflo Evolution ® LIST OF FIGURES Figure 1: Operational schematic ......................11 Figure 2: Typical installation ......................15 Figure 3: Inside installation ......................16 Figure 4: Leg and cross brace assembly ..................17 Figure 5: Yoke, venturi and filter installation ..................18 Figure 6: Typical foundation anchor ....................19 Figure 7: Leg positioning .........................19 Figure 8: Field joining Detail A ......................21...
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Page 4: General Safety Requirements
Regular maintenance is important for a good performance of your dust collector. A prudent user of Donaldson Torit equipment should consult and comply with all relevant Fire Codes and/or other appropriate codes when determining the location and operation of dust collection equipment. - Page 5 Shutoff and bleed-off compressed air supply before doing any service work. In each individual case vent design, vent ducts and pressure resistant design are worked out by Donaldson Torit for the specific products, circumstances and environment, and should never be altered unless Donaldson Torit has given explicit admission.
- Page 6 Maintenance and explosion safety a. Introduction The collection systems are designed and installed by Donaldson Torit engineers applying the most appropriate safety measures based upon state of the art knowledge and technology. It’s safety is based upon two main objectives: •...
- Page 7 Installation, Operation and Maintenance manual Downflo Evolution ® The use of plastic bags in the receiver bin under the hopper is not recommended because sometimes, due to very high electrostatic charges, hazardous discharges may occur. c. Hazards due to relocation of the dust collector By relocating the dust collector from outside to inside you should be aware that the explosion now is vented inside a room, which is not acceptable, due to the very hazardous flame jets and fire balls.
- Page 8 Installation, Operation and Maintenance manual Downflo Evolution ® g. Do’s and don’ts Based upon several hazards a list of do’s and don’ts is given. Perform a regular maintenance by disposing the dust in a regular fashion and inspecting the cleaning mechanism on a regular basis at least once a month. Return the installation in its original state after maintenance (fixing, closing and bonding and grounding).
- Page 9 Installation, Operation and Maintenance manual Downflo Evolution ® 4. Applications having a risk of sparks and fires Where sparks are generated by the process, this must be considered as a potential ignition source which increases the risk of a fire or explosion. The filter can be supplied with an optional spark trap to help reduce the frequency of spark ignition and should be regarded as part of a risk reducing strategy.
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Page 10: Introduction
Be sure that the explosive (Kst value) of your dust is always below the maximum Kst value defined for your dust collector type. Technical and field support are available from your local Donaldson Torit representative or distributors to answer your questions. -
Page 11: Protection Of The Dust Collector Against Dust Explosion
Installation, Operation and Maintenance manual Downflo Evolution ® dirty air diaphragm inlet valve cartridge filter clean air compressed outlet air supply hopper NORMAL OPERATION FILTER CLEANING OPERATION Figure 1: Operational schematic Protection of the dust collector against dust explosion The reinforced dust collectors are protected against dust explosions both by preventive and by constructional measures. - Page 12 Vent ducts, however, will increase the expected reduced explosion pressure considerably. To prevent that the expected reduced explosion pressure exceeds the design strength of your Donaldson Torit dust collector, the maximum Kst value of your dust to be collected has to be considerably lower in case of using vent ducts .
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Page 13: Prior To Installation
Compare the parts received against the packing list. If there is damage or parts missing, notify the delivery company and your local Donaldson Torit representative. Parts shipped loose with the delivery (depending on your order): •... -
Page 14: Installation
(e.g. ducting, rotary valve) should be correctly sealed. This can be achieved by applying a continuous 5 mm bead of sealing compound to the mounting surface, along each side of the hole pattern. For non-Donaldson Torit equipment please also check supplier’s IOM manual for any specific requirements. -
Page 15: Figure 2: Typical Installation
Installation, Operation and Maintenance manual Downflo Evolution ® Place hopper discharge-side up on ground or other level surface and attach legs to hopper. Assemble leg cross braces. Turn hopper and leg assembly over and lift into position over anchor bolts. Level hopper. -
Page 16: Installation And Assembly
Installation, Operation and Maintenance manual Downflo Evolution ® OUTSIDE back-flap valve INSIDE inlet roof blow-off channel dust collector outlet Figure 3: Inside installation Installation and assembly Anchor the dust collector to the foundations. If any of the following equipment is ordered and mounted please follow the respective instructions. -
Page 17: Hopper & Leg Installation
Installation, Operation and Maintenance manual Downflo Evolution ® Hopper & leg installation (see figure ‘Hopper & Leg Installation’) There are three types of hoppers for your dust collector: a single module wide which spans two portholes 2. a single module wide which spans three portholes 3. -
Page 18: Figure 5: Yoke, Venturi And Filter Installation
Installation, Operation and Maintenance manual Downflo Evolution ® access cover yoke, see detail A filter cartridge yoke detail A detail B filter cartridge panel clean air plenum flat washer hex nut hex jam nut thread- forming flat screw washer outlet cover thread- gasket forming screw... -
Page 19: Figure 6: Typical Foundation Anchor
Installation, Operation and Maintenance manual Downflo Evolution ® Provisional anchor bolt recommendations Consider Hilti HIT-HY 200 Anchor System or equivalent. Quantity of anchor bolts should match the number of holes provided in the base plates 10. Anchor diameter is typically 3 mm less than basebplate hole diameter. -
Page 20: Field Joining Installation
Installation, Operation and Maintenance manual Downflo Evolution ® Field joining installation (See figure ‘Field Joining Installation’) The dust collector is a modular unit that may require field joining. The field joint may be a result of truck capacity, crane capacity or specific customer requirement. A detailed drawing of how to join your dust collector has been shipped with your dust collector. -
Page 21: Figure 8: Field Joining Detail A
Installation, Operation and Maintenance manual Downflo Evolution ® clean-air yoke, plenum see Figure 10, Yoke, venturi and filter installation filter access cover, see Figure 10, Yoke, venturi and filter installation Figure 8: Field joining Detail A Bolt the modules together using bolts, washers and nuts as shown in Details B and C. -
Page 22: Yoke, Venturi And Filter Installation
Installation, Operation and Maintenance manual Downflo Evolution ® bolt flat washer sealant flat washer lock washer hex nut Figure 10: Field joining Detail C 8. Check that all joints and flanges are flush and tighten hardware starting with the joint between the clean- and dirty-air plenums. Remove excess sealant. Yoke, venturi and filter installation Installing yokes requires two people. -
Page 23: Platforms And Ladders
Installation, Operation and Maintenance manual Downflo Evolution ® Platforms and ladders Stationary platforms are available for each size collector. For two filter wide models the platform is available for standard or steep-sided hoppers with the ladder located left, right, or front of the platform. On three filter wide models the platform is available for standard hoppers only with ladder access on the left or right side only. -
Page 24: Control Box
Installation, Operation and Maintenance manual Downflo Evolution ® Control box The controlbox is factory mounted on the hopper according to our standards (except when specified by order). If not pre-mounted please make sure that the in-line filter is positioned correctly on the dirtyside tapping point connection to the control box (refer to figure 12 for mounting details). -
Page 25: Electrical Connection
Installation, Operation and Maintenance manual Downflo Evolution ® Turn power off and lock out electrical power sources. Turn compressed-air supply OFF , bleed and lock out lines before performing service or maintenance work. shut-off valve/safety exhaust valve* compressed-air supply* air regulator* automatic condesate valve* bleed-type air filter* *customer supplied... -
Page 26: Inlet Plenum
Installation, Operation and Maintenance manual Downflo Evolution ® Inlet plenum The inlet plenum is standard on Downflo Evolution collectors unless another inlet ® plenum option has been selected. The inlet plenum directs the dirty air stream to the back of the dirty-air plenum over the venturi section. -
Page 27: Extended Dirty-Air Plenum
Installation, Operation and Maintenance manual Downflo Evolution ® Figure 15: High flow inlet plenum Extended Dirty-Air Plenum The extended dirty-air plenum is used in applications requiring an air management module or when a single inlet serves multiple modules. The extended dirty-air plenum is supplied with standard service access panels on the sides and top of the plenum. -
Page 28: Air Management Module
Fire control sprinklers are available for models operating under negative pressure. Donaldson Torit supplied sprinklers require a minimum of 1 bar water pressure which will produce a discharge per sprinkler head of 77 liters per minute. -
Page 29: Bursting Panel And Indicator
Installation, Operation and Maintenance manual Downflo Evolution ® sprinkler Figure 18: Sprinkler Bursting panel and indicator bursting panel bursting panel TOP VENTING SIDE VENTING Figure 19: Bursting panel location Remove protective shipping cover from top of collector (underneath is the explosion panel positioned upside-down). -
Page 30: Figure 20: Bursting Panel Serial Plate And Label
Installation, Operation and Maintenance manual Downflo Evolution ® Figure 20: Bursting panel serial plate and label 3. Apply sealant to top flange of collector, making a continuous 5 mm bead along each side of the holes. 4. Place panel on flange (bulged side facing upwards) and align bolt holes in flanges with drift pin. -
Page 31: Figure 21: Bursting Panel And Indicator Installation
Installation, Operation and Maintenance manual Downflo Evolution ® cable loop thread signal cable vent panel angular frame signal cable thread angular frame signal cable cable loop Figure 21: Bursting panel and indicator installation... -
Page 32: Bursting Panel Indicator Switch
Bursting panel indicator switch According VDI, each bursting panel may be combined with signalling devices which will trigger a shut down or a controlling mode. Therefore Donaldson Torit will supply a bursting disc indicator switch with each bursting disc (see scope of delivery). -
Page 33: Dust Outlet Connection
Installation, Operation and Maintenance manual Downflo Evolution ® HAZARDOUS AREA (IF APPLICABLE) Explosion panel Explosion panel Explosion panel detection device detection device detection device disconnect: fan set dust relase system (rotary INTRINSICALLY SAFE airlock, screw conveyor, etc) BARRIER (IF REQUIRED) power supply to printed circuit board (pulse cleaning) engage:... -
Page 34: Figure 24: Dust Outlet Connection
Installation, Operation and Maintenance manual Downflo Evolution ® hopper bolt/washer/nut M10 gasket transition piece bolt/washer/nut M10 gasket rotary airlock Figure 24: Dust outlet connection... -
Page 35: Start-Up Checklist
Installation, Operation and Maintenance manual Downflo Evolution ® START-UP CHECKLIST Electrical connection Follow all steps before first start-up and when the dust collector is not been used for a long period. For daily use follow steps 1, 2, 3, 5, 6 and 8. Check that the outlet of the fan is free of debris before starting. -
Page 36: Operation Schedule
Installation, Operation and Maintenance manual Downflo Evolution ® OPERATION SCHEDULE To ensure a good performance of your dust collector follow the checkpoints mentioned below according the timetable. Weeks Checkpoint Type of control Measures Control box Visual check ∆P See trouble shooting guide in Control manual •... -
Page 37: Service
Do not use the access cover features as climbing equipment. Use safe practices for maintenance and installation. The genuine Donaldson Torit filter cartridge is the only replacement filter that will provide the high level of performance that you expect from your investment... - Page 38 Installation, Operation and Maintenance manual Downflo Evolution ® Do not drop or rap the new filter cartridge on the floor or any other hard surface. Damage to the filter cartridge will occur, resulting in leakage. It is necessary to clean the dust off of the tube sheet all around the opening to ensure a positive seal of the filter gasket.
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Page 39: Figure 25: Exchanging Filter Cartridge
Installation, Operation and Maintenance manual Downflo Evolution ® access cover cover knob yoke filter cartridge alignment marker alignment marker Figure 25: Exchanging filter cartridge... -
Page 40: Diaphragm Valve
Installation, Operation and Maintenance manual Downflo Evolution ® Diaphragm valve Valve disassembly Disassemble in an orderly fashion. Pay careful attention to exploded views provided for identification of parts. Remove the clipring from the valve body to remove the bonnet. Use a screwdriver on 3 places at the bonnet, start removing the clipring on the inlet side. -
Page 41: Troubleshooting Guide
See Filter Installation. discharging dust correctly Filter damage, dents Replace filters as necessary. Use only genuine in the end caps, Donaldson Torit replacement parts. See Filter gasket damage, or Installation. holes in media Access cover(s) Tighten access doors securely. See Filter Installation. - Page 42 Fan exhaust area Check fan exhaust area for obstructions. Remove restricted material or debris. Adjust damper flow control. Filters need Remove and replace using genuine Donaldson replacement Torit replacement filters. See Filter Removal and Installation. Lack of compressed See Rating and Specification Information for compressed air supply requirements.
- Page 43 Installation, Operation and Maintenance manual Downflo Evolution ® Problem Probable cause Remedy Pulse cleaning Pressure switch not Connect the pressure switch on the timer board to never stops wired to the timer Terminals 7 and 8 on TB3. board correctly Pressure switch Remove jumper wire on Solid-State Timer board terminals on...
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Page 44: Supplementary Information
5. Other items of equipment, not supplied under the Scope of Delivery from Donaldson Torit, should be installed, operated and maintained according to the documentation supplied with the respective equipment. 6. Before any work is carried out, ensure the equipment is adequately isolated. - Page 45 Installation, Operation and Maintenance manual Downflo Evolution ® 12. If it is unavoidable to work on the equipment while an explosive atmosphere is present, care should be taken to avoid introducing ignition sources not present during the expected operation. Non-sparking tools should be used. 13.
- Page 46 Installation, Operation and Maintenance manual Downflo Evolution ® 24. Compressed air is recommended for collectors that operate using reverse jet cleaning. Alternative gases should be assessed before use to ensure that explosive atmospheres are not introduced during media cleaning. 25. It may be necessary to provide a facility to shut down the equipment in the event of an explosion (where collectors are fitted with explosion relief panels).
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