DUST COLLECTOR / FILTER RECEIVER

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TABLE OF CONTENTS Product overview Page 3 Safety precautions Page 4 Equipment storage Page 4 External components Page 5 Internal components Page 6 Installation instructions Page 7 Electrical installation and controls Page 8 Operation and start-up Page 8-9 Maintenance instructions Page 9-10 Filter bag replacement – bottom removal Page 11 Filter bag replacement – top removal Page 12 Troubleshooting Page 13 Spare parts list Page 14 Equipment warranty Page 15 Manufacturer's cut -sheets, manuals, and drawings Remaining pages

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PRODUCT OVERVIEW The filter bags are usually 16 oz. felt (polyester, acrylic, polypropylene, nomex, teflon r, huyck-glas r, or goretex r) and are supported by wire cages. The bags and cages are clamped to collars riveted to the tube sheet or a part of the venturi which extends through the tube sheet. "Blow pipes" with drilled orifices are located above each row of filter bags such that the orifices are directly above the throat of venturi. Dust laden air enters the collector under pressure or suction from a fan or another air moving device. Pulse jet cleaning takes place when the timer actuates a normally closed solenoid pilot valve causing it to open. The diaphragm valve opens as a result of the decrease in pressure from the opening of the solenoid. A momentary inrush of high pressure air (80-100 PSIG) flows from the header to the blow pipe, down through each venturi and into each bag. Thus, all the bags in a single row are cleaned simultaneously. DCL dust collectors are usually shipped completely assembled. The compressed air header with solenoids and timer are all installed and prewired. Bags and cages are shipped separately to help prevent unnecessary damage during shipping. The bags and cages will need to be installed in the field. Utilities should be connected to the dust collector in accordance with existing codes, along with the solenoids and timer which are all installed and prewired. Compressed air piping should be sized for the SCFM specified on the job drawing. Compressed air pressure should be 80 to 100 PSI, unless a lower pressure has been specified. In this event, the diaphragm valves, blow pipes, and orifices will be larger than usual to accommodate the lower air pressure. The 115 volt, single phase, 60 hertz timer is either installed in the enclosure with the solenoid valves or in a separate NEMA 4, 4X, 7, 9, or 12 enclosure as required. It can also be installed in a master control panel if desired. The compressed air supply should be free of contamination. A water tap, filter and/or regulator may be furnished with the compressed air header to accommodate a manual drain valve, a quick coupler for air tools to assist in bag changing and either end connection of the main compressed air supply. All openings not used are plugged at the factory unless otherwise specified.

SAFETY FIRST – READ THESE PRECAUTIONS DCL equipment is generally designed to be operated from a remote operator's station or control room. Extra caution should be taken when using pendant-type controls or any other time that personnel are in the area of loading operations. The operator should always be able to see the equipment when it is in operation. Standard safety lockout procedures must be followed when performing maintenance or repairs on the equipment, especially if the equipment is equipped with automatic sensors or control mechanisms. Use care to prevent uncontrolled movement of the equipment, or uncontrolled release of product. Appropriate personal safety equipment, including required fall protection, should be used while working on or around DCL equipment. Use the proper tools in good condition to maintain and service the equipment. Safety is the responsibility of the equipment owners and operators.

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EQUIPMENT STORAGE Store the equipment in a dry, cool location, preferably indoors. If outdoor storage is necessary, cover the equipment with a tarpaulin or other suitable waterproof covering, and raise the equipment off the ground, on dunnage or pallets. Protect the equipment, including electrical equipment and panels, from dust, dirt, mud, moisture, snow or ice, and sun. Note that a number of the components of DCL equipment are pilferable in unattended storage. These include motors and electrical components. Take appropriate measures to secure the equipment. Before placing the equipment into operation, inspect for damage that may have occurred during storage. Purge the factory installed lubricant by pumping fresh lubricant into each grease fitting until any contaminated grease has been expelled from each bearing. Remove the purged lubricant from the exterior surfaces of the equipment. Clean off any dirt, rust, or corrosion, and spot paint as necessary. Dry any moisture or condensation that has entered electrical equipment or panels. Inspect for damage to panels, boxes, switches, or conduits.

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DUST COLLECTOR – EXTERNAL COMPONENTS (DC style dust collector shown on left; FR style filter receiver shown on right.)

1. Main housing 7. Clean air fan assembly 2. Access door 8. Clean air fan outlet 3. Dust laden airstream inlet 9. Clean air outlet 4. Product dust outlet 10. Clean air plenum 5. Dust collector hopper 11. Pulse jet header assembly 6. Clean air fan motor

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DUST COLLECTOR – INTERNAL COMPONENTS 1. Timer (not shown; mounted in enclosure) 8. Venturi 2. Filter bag 9. Blow pipe 3. Filter bag support cage 10. Compressed air header 4. Filter bag clamp 11. Filter housing 5. Diaphragm valve 12. Clean air plenum 6. Solenoid pilot valve 13. Clean air outlet 7. Magnehelic differential pressure gauge

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INSTALLATION INSTRUCTIONS The dust collector housing is usually shipped completely assembled, in a wooden shipping cradle on a pallet. Filter bags and cages are usually shipped separately to help prevent unnecessary damage during shipping. Always use good safety practices and due care while working on DCL equipment. Adhere to all applicable OSHA, MSHA, state, and local safety regulations. Note: The purchaser must use good engineering and operating practice in the design and fabrication of support structure, interfaces, and power supplies for DCL equipment. 1. Remove the shipping bracing and packing from the pallet. Inspect the dust collector, filter bags, and

hardware for damage or missing parts. Report any damage or breakage to the shipping company. 2. For free-standing models: Make sure that the surface on which the dust collector will be located is clean, is

straight, flat, and level in all directions, and is firm, preferably made of concrete. Using a crane, forklift, hoist, or other suitable lifting device, set the dust collector into position. Check the orientation and level of the dust collector. Take care to avoid interferences with other equipment and structures, particularly for moving equipment. Securely bolt the dust collector into position.

3. For bin-vent style models: Make sure that the flange on which the dust collector will be located is clean, is

straight, flat, and level in all directions, and is the correct size and bolt pattern. Apply an even bead of caulk or sealant on the mounting flange. The type of caulk used will depend on the expected operating conditions, but DCL recommends a high quality silicone caulk. Using a crane, forklift, hoist, or other suitable lifting device, set the dust collector into position. Check the orientation and level of the dust collector. Take care to avoid interferences with other equipment and structures, particularly for moving equipment. Securely bolt the dust collector into position.

4. If the exhaust fan is not already installed: Apply an even bead of caulk or sealant on the exhaust fan

mounting flange of the dust collector. The type of caulk used will depend on the expected operating conditions, but DCL recommends a high quality silicone caulk. Securely install the exhaust fan to the filter module in the correct orientation. Connect the dust outlet flange to the existing dust withdrawal ducting. A manual blast gate and/or gravity type bleed damper is recommended to control the air flow and static pressure in the ductwork system, especially in systems where multiple inlets exist.

Note: Adhere to good industrial ventilation practice when designing dust withdrawal ducting. Improper design can lead to unacceptably low flow velocities, or high transition losses in the piping. This results in clogging of dust ducting, and poor dust collection at the spout.

5. Apply an even bead of caulk or sealant on the flanges at the dirty air inlet, product inlet, product outlet, and

clean air outlet as applicable. The type of caulk used will depend on the expected operating conditions, but DCL recommends a high quality silicone caulk. Install the appropriate system ducting to the flanges as applicable.

6. Install the filter bags and cages into the dust collector. See the filter bag replacement instructions.

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ELECTRICAL INSTALLATION AND CONTROLS Always use good electrical and safety practices and due care while working on DCL equipment. Adhere to all applicable OSHA, MSHA, state, and local safety regulations and code requirements. Note: DCL does all electrical work and prewiring according to the NEC effective at the time of manufacture. Because of differences in local code requirements, the purchaser is responsible for the compliance of DCL equipment after installation. Good electrical practice is assumed in the design and installation of power supplies and connections not supplied by DCL. Electrical installation consists of making all electrical connections to the fan motor and control panel, pneumatic connection to the compressed air header, and any optional accessory as specified in the electrical schematic or pneumatic diagram supplied with the equipment. 1. Install wiring/cable from the junction box to the control panel and fan motor. The 3-phase power leads for

the fan motor should be placed in a separate conduit to provide electrical isolation between the high voltage and the control circuits.

2. Connect the fan motor to the correct voltage. Test for rotation by "bumping" (momentarily energizing) the

motor to determine the direction of rotation. If rotation is incorrect, reverse any two legs of the 3-phase motor power leads to change direction of rotation.

3. Connect the dust collector to a source of clean, dry compressed air. For best function, the air should be 80 to

110 PSI (check the General Arrangement drawing for air volume requirements).

(If the dust collector has been stored for an extended period or has been exposed to moisture/weather, add a few drops of good pneumatic lubricating oil to the solenoid valve inlets before connecting the air supply.)

OPERATION AND START-UP Always use good safety practices while using DCL equipment. 1. Before start-up with material, check for flange and draw band leakage at the inlet, outlet, dust discharge,

duct discharge, duct work and fan connections in the systems. 2. Listen for air noise. Leaks into a collector can cause condensation and moisture problems. Leaks out

can cause dusting. Check the electrical, wiring connections, proper fan rotation, and fuse selection. 3. The pulse timer should usually be connected to 115 volt, 60 hertz, and single phase current only. Refer

to the schematic for special control voltages. 4. During initial start-up with new bags, there will be very little resistance across the collector. If the

operating bag pressure drop is a large percentage of the total system, then fan motor overloading can take place with clean bags. (The fan will pull more air due to low resistance.) Install a fan discharge or inlet damper to control BHP within motor limits. The use of this throttling device will also let dust build up

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slowly and prolong the life of the bags. It will also keep the exhaust volume within design limits and save energy.

5. A differential pressure gauge is supplied with each collector. Occasional checks of the differential

pressure are desirable. Most installations are designed for a pressure differential of three to four inches of water column. Readings from one to six inches are normal.

6. Controlling the operation pressure differential: A. Increase or decrease the compressed air pressure (recommended 80 to 100 PSIG). The result is more

or less vigorous cleaning of the bags. This will then produce a lower or higher static pressure differential across the bags.

B. An increase or decrease in the time between cleaning pulses will also increase or decrease the static

pressure differential. (If the differential pressure is low, the length of time between pulses may be increased to conserve compressed air and extend the life of the filter cartridges.) A one-second pulse is the recommended minimum pulse duration for this installation. The pulse length should only be increased enough to produce a good, sharp "pulse" for all valves. Longer pulses only waste air with no noticeable increase in cleaning.

7. A visual operating check should be made of the discharge gases. No dust should be visible at the

exhaust. Should dust be visible, check Troubleshooting.

MAINTENANCE INSTRUCTIONS Always use good safety practices and due care while working on DCL equipment. Note: These are general guidelines for maintaining a typical dust collector. Some options may include equipment with a different maintenance schedule. Instructions direct from the manufacturer for each purchased maintenance item are located at the rear of this manual, and they may vary from the procedures listed here. Always use the instructions direct from the manufacturer first. These instructions are obtained as close as possible to the time of printing. The manufacturer reserves the right to change these instructions without notice. DAILY:

1. Visually inspect the equipment for damage or wear. 2. Inspect all warning and caution stickers, placards, etc. for legibility or damage. Replace any that are

missing or cannot be read immediately. 3. During operation, observe the equipment for abnormal behavior, malfunction, or damage.

4. Make sure that the equipment is stored properly at the conclusion of loading operations.

MONTHLY:

1. Inspect all electrical connections and conduits for damage or improper installation.

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2. Inspect for fluid leakage around shaft seals, and on reducers and motors.

3. Check the pressure differential reading. At 5 inches of water column, check the filters for buildup

and wear, and look into filter replacement. At 7 inches of water column, the filters must be replaced. This interval may be adjusted depending on operating conditions.

4. Inspect the door seals and latches for wear, damage, or improper operation. Make any adjustments

or needed repairs. Lubricate the door latches with a good spray lubricant, such as WD40, and exercise the latches to maintain free function. A rubber seal lubricant will extend the life of the door seals.

5. Clean any product or dust build-up from the entire dust collector assembly by sweeping or washing

as needed. Use a warm mild detergent solution for cleaning. Do not use extreme heat or pressure. Do not use any harsh chemicals or abrasives.

3 MONTH SERVICE INTERVAL:

1. Inspect the inner surfaces for wear or product buildup. Buildup of hygroscopic or sticky product should be removed.

2. Inspect the solenoid and diaphragm valve assemblies for damage. Remove the exhaust mufflers and

clean out any debris or dirt that may have accumulated inside. Inspect electrical conduits and connections for security or damage.

6 MONTH SERVICE INTERVAL:

1. Inspect all electrical equipment for moisture, corrosion, or arcing contacts. Clean any dust or debris out of all electrical enclosures.

2. Lubricate the exhaust fan motor bearings with a good quality lithium-based grease. Refer to the

motor instructions for the proper lubrication procedure. 3. Inspect the exhaust fan damper for wear or damage. Lubricate the friction points with a good quality

lithium-based grease. Exercise the damper to maintain free function. ANNUALLY:

1. Check all hoses, conduits, and cables for dry rot, cuts, wear or abrasion.

2. Inspect all hose clamps, fittings, restraints, and terminations for rust, corrosion, and wear or damage.

These service intervals are based on normal use and conditions. In severe conditions, intervals should be shortened. Product sizes under 35 mesh will also shorten intervals, especially for lubrication.

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FILTER BAG REPLACEMENT - BOTTOM REMOVAL 1. Remove the filter bag clamp from the top of the filter bag assembly. Discard the clamp. 2. Slide the filter bag and cage assembly off the mounting cup. 3. Remove the worn filter bag from the support cage. Check the cage for damage. 4. Install the new filter bag over the support cage and fold the top of the filter bag into the top of the

support cage. If the new filter bag is equipped with an anti-static line, make sure that it is folded over to make contact with the filter bag mounting cup.

5. Slide the new filter bag clamp over the bag assembly and slide the assembly over the mounting cup.

Tighten the clamp. 6. Operate the system as usual, observing the fan discharge for dust emissions. If any dust emissions are

observed, one or more of the filter bags have been improperly installed.

BOTTOM REMOVAL 1. Mounting cup 2. Venturi 3. Filter bag clamp 4. Filter bag support cage 5. Filter bag

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FILTER BAG REPLACEMENT - TOP REMOVAL 1. Remove the bolt securing the blow pipe to the support angle. Loosen the locking collar on the bulkhead

fitting, and remove the blow pipe. 2. Remove the blow pipe support angles from the rear of the clean air plenum. 3. Remove the bulkhead fitting by removing the outside locking collar and locknut from the fitting. The

bulkhead fitting may now be pulled inside the clean air plenum without dismantling the compressed air header and diaphragm valve assembly.

4. To install the filter bag, place the bag through the hole in the tube sheet. Squeeze the top band of the

bag, and the lower unit edge of the tube sheet hole will nest in the groove in the top of the bag. This ensures a tight seal and complete support of the filter bag.

5. Lower the cage and venturi assembly into the filter bag. The cage is completely installed when the cage

and venturi are supported on the tube sheet by the top ring of the cage assembly. 6. Assemble the pulse jet cleaning system in the reverse order of steps 1, 2, and 3.

TOP REMOVAL 1. Venturi, cage, and mounting

ring assembly 2. Filter bag media 3. Filter bag sealing ring

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TROUBLESHOOTING Always use good safety practices while working on DCL equipment. Common system faults 1. Bag(s) installed improperly or missing. Check bags and reinstall if necessary. 2. Loose bag clamps. Do not use clamps more than once. Check clamps and tighten or replace if

necessary. 3. Bag(s) damaged during installation. Check bags and replace if necessary 4. Operating temperature too high for filter material. Lower the operating temperature, or switch to bags

that are designed for the operating temperature. Consult DCL if necessary. 5. Operating humidity, free moisture, etc. Consult DCL if necessary 6. Hopper bridging - use sponge rubber seal with drum, larger slide gate, airlock or vibration. 7. Collector overload with too much air - check system design, fan speed, damper adjustment. 8. Compressed air supply pressure too low – 80-100 PSIG required. Check air supply and adjust or service

if necessary. Check all connections for leakage. 9. Solenoid valve(s) stuck, damaged, or inoperative. Check valves and repair or replace if necessary. 10. Diaphragm valve(s) ruptured or stuck. Check valves and repair or replace if necessary. 11. Blinding of filter bags - high static pressure. Consult DCL if necessary. 12. Static electricity. Switch to grounded filter bags. Consult DCL if necessary. 13. Wrong direction of rotation for fan. Check fan and reverse the rotation if necessary. See the section on

electrical installation and controls. 14. Leaking duct work or access doors, airlock or discharge valve on hopper - air is short circuited. Repair

or replace door seals, check ductwork and repair if necessary. 15. Slipping fan belt. Check belt and tighten or replace if necessary. 16. Clogged ductwork or closed damper. Check ductwork and damper adjustment. 17. Improper duct size. Check system design. 18. Bad electrical connections. Make sure all connections are clean, tight, and there are no arcing contacts. If the above steps do not resolve the problem, consult DCL for assistance.