Donaldson DFPRE 1 Installation, Operation And Maintenance Manual

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Installation, Operation and Maintenance manual

This manual contains specific precautions related to worker safety. The hazard alert image denote

related instructions and warnings in this manual. DO NOT install, operate, or perform

safety

maintenance on this collector until you have read and understood the instructions,

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Installation , Operation And Maintenance

Manual

DFPRE Dust Collector

DFPRE 1 / 2 / 3

DFPRE1/2/3 Dust Collectors

0306801

IOM

Revision 1

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Summary of Contents for Donaldson DFPRE 1

Page 1 Installation , Operation And Maintenance Manual DFPRE Dust Collector DFPRE 1 / 2 / 3 This manual contains specific precautions related to worker safety. The hazard alert image denote related instructions and warnings in this manual. DO NOT install, operate, or perform...
Page 2: Table Of Contents
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors TABLE OF CONTENTS IMPORTANT ..................................3 Applications having a risk of sparks and fires ...................... 3 GENERAL SAFETY REQUIREMENTS ........................... 4 PRIOR TO INSTALLATION ............................... 7 Location ..................................7 INSTALLATION .................................. 8 Required tools and equipment ..........................
Page 3 Figure 12-1a: Control Panel For DFPRE1 ........................23 Figure 12-1b: Control Panel For DFPRE2/3 ....................... 23 Figure 12-2a: Wiring Diagram For DFPRE 1 ......................24 Figure 12-2b: Wiring Diagram For DFPRE2 ......................25 Figure 12-2c: Wiring Diagram For DFPRE3 ......................26 Figure 13: Collector Operation ............................
Page 4: Important
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors IMPORTANT Please read this manual carefully before installation. This manual should be read in conjunction with the respective controller manual supplied with the dust collector. Product reliability, warranty and safe operation may be compromised by not following the guidance given in these documents.
Page 5: General Safety Requirements
The Scope of Delivery is an integral part of the manual. Other items of equipment, not supplied under the Scope of Delivery from Donaldson, should be installed, operated and maintained according to the documentation supplied with the respective equipment.
Page 6 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 7: Figure 1:Schematic
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors 1.Lift lug 11.Damper valve 2.Filter access cover 12.Compressed air inlet 3.HOPPER 13.Power supply cable inlet 4.LEG 14.Sprinkler coupling 5.Dustbin 15.ICUE（option） 6.Inlet 7.Outlet 8.Control panel 9.Inspevtion cover 10.Exhaust plenum assembly Figure 1 Schematic...
Page 8: Prior To Installation
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors PRIOR TO INSTALLATION Location The dust collector should be located with consideration for: • emptying the dust disposal • shortest runs of inlet and outlet ductwork • radius bends on elbows as big as possible •...
Page 9: Installation
All external equipment connected to the dust collector (e.g. ducting) should be correctly sealed. For non-Donaldson equipment please also check supplier’s IOM manual for any specific requirements. Strength of ducting should match with capability of the fans ducting. The collector is not designed to support site-installed ducts, interconnecting piping, or electrical services.
Page 10: General Guidance To Lifting
(Refer to lifting label located adjacent to lifting points for weight of equipment supplied by Donaldson). Chains must be long enough to ensure that the included angle between diagonal chains is not greater than 90° (refer to figure 2)).
Page 11: Positioning The Collector
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors Positioning the collector 1. Lift the collector into position following the general guidance to lifting. Take care not to damage dust container and cables when using forklift method. 2. Using spirit levels, line up both horizontally and vertically, using shims where required. 3.
Page 12: Compressed Air Installation
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors Compressed air installation Turn compressed air supply OFF, bleed and lock out lines before performing service or maintenance work. A safety exhaust valve should be used to isolate the compressed air supply. The safety exhaust valve should completely exhaust pressure in the collector manifolds when closed, should be capable of being interlocked with ﬁre or explosion mitigation equipment and should include provisions to allow closed-position locking.
Page 13: Exhaust Damper
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors Exhaust Damper When starting DFPRE collector, set the exhaust damper valve at 35° deg. Turn the collector on and measure airflow. Adjust the exhaust damper valve (higher for less flow, lower for more flow) until the designed airflow is reached. Lock the damper in place.
Page 14: Optional Icue Gateway Installation
Donaldson iCue application. The cellular data plan and preinstalled SIM card are provided by Donaldson. The SIM card will only work with Donaldson’s service and should not be removed.
Page 15: Optional Hepa Afterfilter Installation
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors Optional HEPA Afterfilter installation On the DFPRE 1/2/3 collector the HEPA filter assembly, if supplied, is a separate item and should be installed as follows: 1. Turn supply power off. 2. Select the CAP cover assembly for mounting HEPA, and install the cover.
Page 16: Optional Spark Trap Inlet Installation
Optional spark trap inlet installation On the DFPRE 1/2/3 collector the spark trap inlet, if supplied, is a separate item and should be installed as follows: 1. Attach the support channel to the spark trap inlet using the bolts and washers supplied.
Page 17: Optional Bag-Out Installation
ﬁlter change. This is not for contamination prevention or full containment purposes and is not a substitute for BIBO. Contact Donaldson Torit for selection assistance. 1. Turn all power to the collector OFF. 2. Begin ﬁlter replacement at one of the top ﬁlter access ports. Continue by replacing the remaining ﬁlters in the top row.Proceed to replace the ﬁlters in the next row.
Page 18: Optional Bag-In Bag-Out Installation
This procedure must be followed in order to ensure safe changeover of filters. Since this is not a simple procedure, and errors may have very serious health consequences. Donaldson Company recommends purchase of a practice cabinet with BAG-IN, BAG-OUT so that maintenance personnel can practice this procedure.
Page 19: Figure 11-2: Initial Filter Installation Of Bibo
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors Original equipment filter To ensure performance levels, use only Donaldson replacement filters. Initial filter installation of BIBO If filters, Bag-In/Bag-Out (BIBO) bags and BIBO Collar Breathers are not preinstalled,please follow these steps per opening, before the collector is turned on.
Page 20: Figure 11-3A: Filter Removal
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors Turn power off and lock out electrical power sources before performing service or maintenance work. Turn compressed air supply off, bleed and lock out lines before performing service or maintenance work. Do not operate with missing or damaged filters. Ensure all pre-installed items are present, undamaged and in the correct place before proceeding with filter removal and replacement.
Page 21: Figure 11-3B: Tape Wrap(Steps 10-13)
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors Figure 11-3c: Tape Wrap (Steps 14-17) Figure 11-3b: Tape Wrap (Steps 10-13) 14. Properly dispose of the BIBO bag containing the filter. 15. If collector contains two filters per opening,gently push the stub into the collar. 16.
Page 22: Figure 11-4A: Filter Installation
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors Clean change filter installation 1. Place a clean filter cartridge in a new BIBO bag with the filter gasket side facing the bag opening toward the collar on the collector. 2. Slide the new BIBO bag over the collar and past the bag stub and bag stub O-ring gasket. Position the bag extension on the opposite side of the access cover hinge 3.
Page 23: Figure 11-4B: Bag Setup (Side View)
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors 10. Close the filter access cover and tighten onto the yoke. 11. Slowly roll bag back into the collar to allow air to escape through the BIBO collar breather (see Bag Setup). 12.
Page 24: Controller
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors Controller Electrical installation, service, or maintenance work must be performed by a qualified electrician and comply with all applicable national and local codes. Turn all power off and lock out all power before performing service or maintenance work. It is not unusual for the equipment to be operated from a remote location so equipment may start or stop unexpectedly.
Page 25: Overload Protection
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors Delta P-C01 Control For complete information, see the most current version of the Delta P-C01 Installation, Operation, and Maintenance manual. All collectors include standars cleaning controls that are manually-or timer-controlled depending on the model and options selected.Models DFPRE2 and DFPRE3 standard controls include Delta P cleaning with motor starter.
Page 26: Figure 12-2B: Wiring Diagram For Dfpre2
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors Figure 12-2b: Wiring Diagram For DFPRE2...
Page 27: Figure 12-2C: Wiring Diagram For Dfpre3
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors Figure 12-2c: Wiring Diagram For DFPRE3...
Page 28: Explosion Relief Panel
Unless otherwise noted, the explosion venting calculations are subject to the relevant criteria and are for outdoor applications only, with no duct or obstructions on the explosion vent panel. Contact Donaldson Torit for assistance in calculating speciﬁc venting requirements for equipment. Flameless Explosion Relief Device A ﬂameless venting device may be placed on top of the vent panel to extinguish explosion ﬂames but...
Page 29: Commissioning
COMMISSIONING It is a requirement of the Supply to provide adequate isolation and emergency stop facilities. Due to the varied nature of site installations, this cannot be provided by Donaldson but instead is the responsibility of the customer. Before putting the dust collector into service, the following items should be checked. Similar checks, as appropriate, should be made after any major overhaul.
Page 30: Shut-Down Sequence
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors Shut-down sequence At the end of any period of operation it is most important that all residual deposits are cleared from the filter cartridges, casing, and discharge hopper. To achieve this, equipment should be shut down in the following order: 1.
Page 31: Operation
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors OPERATION On installations where the inlet duct is relatively short, this procedure may result in a dust emission occurring at the inlet and therefore may not be an appropriate procedure if the dust being handled is dangerous.
Page 32: Dust Disposal
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors Dust disposal For safe handling of the dust container an assessment must be made to satisfy the requirements of the Directive. Dust containers may require regular emptying. Dust containers should be securely replaced and resealed prior to collector restart. This is a good time to check the dust container for damage, which may lead to a dust leak or flame emission in the rare instance of an internal explosion.
Page 33: Maintenance
Ensure the pneumatic system is fully isolated and depressurized before any work is carried out. For ancillary equipment not manufactured by Donaldson, refer to manufacturer’s instructions. If it is unavoidable to work on the equipment while a potentially explosive atmosphere is present, care should be taken to avoid introducing ignition sources not present during expected operation.
Page 34: Routine Inspection
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors Routine inspection To maintain the optimum performance of the dust collector, a routine inspection should be made to minimize down-time in the event of equipment malfunction, particularly on continuous performance applications and to ensure the equipment is maintained to its original supply condition.
Page 35: Servicing Schedule
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors Servicing schedule A record of all pressure checks should be kept in a log book to aid the speedy diagnosis of faulty operation. Daily Check level of contents in dust container and cyclopeel if applicable, and empty if ¾ full. Weekly 1.
Page 36: Valve Disassembly / Reassembly
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors 3. If applicable, check all flameproof enclosures, motors and cable glands for corrosion and tightness. In particularly aggressive environments, this period should be more frequent. 4. If applicable, check collector earthing continuity. 5.
Page 37: Filter Cartridge Replacement
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors Filter cartridge replacement Most dusts present safety and health hazards that require precautions. Wear eye, respiratory, head and other protection equipment suitable for the type of dust. Use proper safety and protective equipment when removing contaminants and filters. Dirty filters may be heavier than they appear.
Page 38: Fan Assembly Removal
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors Figure 14: Filter Removal and Installation Fan assembly removal Isolate electrical power supply. 1. Remove fan chamber access panel. 2. Open control equipment access panel. 3. Disconnect electrical cables from fan motor terminal box. 4.
Page 39: Dismantle/Decommission Dust Collector
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors Dismantle/decommission dust collector Make sure to empty dust container and cover all the open areas to prevent possible dust spillage/exposure during transportation. Use appropriate personal protection equipment (PPE) during service process, e.g., dust mask, safety hat, gloves, etc.
Page 40 Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors TABLE 1 – FAULT LOCATION Symptom Possible cause Action Part loss of Compressed air If compressor stopped, rectify compressor fault; check interlocks; suction (excessive malfunction. check motor and supply; check drive. pressure If compressor OK, check pulses at manifold pressure gauge.
Page 41 Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors TABLE 1 – FAULT LOCATION (CONTINUED) Symptom Possible cause Action Check motor supply overloads, fuses and interlocks (if fitted). Total loss of Fan motor stopped. suction. Check motor connections and windings. Check that dust container is not overfull. Check starter overloads, Unit blocked.
Page 42: Specification
6-7 bar 100 ms 13.5 m Normal operating pressure. Recommended initial settings; these may be varied with experience. Sizes suitable for runs of pipe up to 30 m (100ft) in length; for longer runs consult with Donaldson. 1 bar = 10...
Page 43: Spare Parts List
Installation, Operation and Maintenance manual DFPRE1/2/3 Dust Collectors SPARE PARTS LIST Item Description Part number Filter Assembly-ULTRA WEB STD P034301 Filter Assembly-ULTRA WEB CD FR P034584 Filter Assembly-ULTRA WEB FR P034303 Filter Assembly-ULTRA WEB SB CD P281902 Diaphragm valve 1 in 2SG-75492-03 Solenoid Valve Enclosure (DFPRE2) 8PP-48948-10...
Page 44: Parts And Service
Parts and Service For genuine Donaldson replacement ﬁlters and parts, call the Parts Express Line. For faster service, have unit’s model and serial number, quantity, part number, and description available. Donaldson Company, Inc. China Korea Email: info.cn@donaldson.com Email: iaf-kr@donaldson.com Minneapolis, MN...

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