modular mediafilter horizontal ambient iom · title: modular mediafilter horizontal ambient iom...
TRANSCRIPT
Installation
and Operation Manual
IOM AD3029501Revision 2
Modular MediaFilter™ – Horizontal Series –
Ambient Collectors
Models HA-1A, HA-1B, HA-2A, and HA-2B
Throughout this manualstatements indicatingprecautions necessary
to avoid equipment failure arereferenced in a Note. Statementsindicating potential hazards thatcould result in personal injury orproperty damage are referencedin a CAUTION! box.
Illustrations in this manual are forreference only, as actual productmay vary.
Installation,
Operation and
Service Information
This manual is property of the owner. Leave with the unit when set-up andstart-up are complete. Donaldson Company reserves the right to change designand specifications without prior notice.
Donaldson Company, Inc.
2
CAUTION!
Application of Mist Control Equipment
• Combustible materials such as buffing lint, rouge, aluminum and steel dust, weld fume,or flammable solvents represent fire or explosion hazards. Use special care whenselecting and operating all mist collection equipment when combustible materials arepresent 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, andall other appropriate codes when determining the location and operation of mistcollection equipment.
• When combustible materials are present, consult with an installer of fire extinguishingsystems familiar with these types of fire hazards and local fire codes forrecommendations and installation of fire extinguishing and explosion protectionsystems. Donaldson dust collection equipment is not equipped with fire extinguishingor explosion protection systems.
• DO NOT allow sparks, cigarettes, or other burning objects to enter the hood or ductof any mist control equipment.
• For optimum collector performance, use only Donaldson replacement parts.
Warning – Improper operation of a mist control system may result in conditions in the workarea or facility that could result in severe personal injury and product or property damage.Check that all collection equipment is properly selected and sized for the intended use.
Modular MediaFilter – Horizontal Series – Ambient Collectors
3
This manual contains specific precautionary statements relative to worker safety. Readthoroughly and comply as directed. Discuss the use and application of this equipment with aDonaldson Torit representative. Instruct all personnel on safe use and maintenanceprocedures.
Data Sheet
Model Number _______________________________ Serial Number ________________________________
Ship Date ____________________________________ Installation Date ______________________________
Customer Name ____________________________________________________________________________
Address ____________________________________________________________________________
____________________________________________________________________________
Filter Type ____________________________________________________________________________
Accessories ____________________________________________________________________________
Other ____________________________________________________________________________
Contents
Description ........................................................... 4Purpose and Intended Use .................................... 4Rating and Specification Information .................. 5Operation ............................................................. 6Inspection on Arrival ........................................... 7Installation Codes and Procedures ....................... 7Site Selection ........................................................ 7Unit Location ....................................................... 7Electrical Wiring .................................................. 8Rigging Instructions ............................................. 8
Hoisting Information ..................................... 8Standard Equipment ............................................ 9
Ceiling Mount ................................................ 9Magnehelic® Gauge ..................................... 10
Electrical Connection ......................................... 12Preliminary Start-Up Check ............................... 13
Optional Equipment ........................................... 13Drain Collection Container ......................... 13P-Trap or Y-Strainer Installation .................. 14
Service Information ........................................... 14Operational Checklist .................................. 14
Troubleshooting ................................................. 19Service Notes ..................................................... 21Warranty ............................................................ 24
Magnehelic® is a registered trademark of Dwyer Instruments, Inc.
Donaldson Company, Inc.
4
CAUTION!
• Misuse or modification of thisequipment may result in personal injury.
• Do not misuse or modify.
Description
The Modular MediaFilter –Horizontal Seriesambient collectors are designed to collect airbornemist such as oil- or water-soluble and syntheticcoolant from machining operations. Two stages offiltration plus an optional HEPA filter provide acleaner, healthier work environment as well as amore cost efficient means of mist collection. Withairflow capacities from 1,500 to 6,000 cfm, theModular MediaFilter –Horizontal Series is astrategic component to meeting industrial andgovernment air-quality standards. The highefficiency filter system allows filtered air to bereturned to the plant environment.
Designed to increase the versatility of the unit,standard options include motor starter controls,drain collection containers, and control boxes withremote START/STOP or machine interlockcapabilities.
Purpose and Intended Use
Airborne mist is small droplets of liquid that aresuspended in the air. Modular MediaFilter –Horizontal Series collectors are commonly used inmachine tool operations where metalworking fluidsare used. Metalworking fluids include straight oil,water-soluble coolants, soluble oil, and semi-synthetic coolants. Other contaminants, such asdust from the part or the tool or smoke from thecombustion of the oil or coolant are also generatedwhen using metalworking fluids and should beconsidered when selecting equipment.
Modular MediaFilter – Horizontal Series – Ambient Collectors
5
Modular MediaFilter –Horizontal Series
Rating and Specification Information
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Donaldson Company, Inc.
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Unit Operation
Operation
During normal operation, contaminated air entersthe unit through the open inlet located on the backof the unit. The air passes through the first-stagefilter assembly designed to collect and coalescelarge droplets and particles. Smaller mist dropletspass to a second-stage fiberglass vee-bag filter. Thevee-bag’s open pleat design and precise bag spacing
allows contaminant loading throughout the life ofthe filter. As mist particles coalesce and form largedroplets, the droplets run down into the bottom ofthe filter and drain into the hopper. The collectedliquid drains from the hopper into a P-trap orcollection bottle. Clean, mist-free air exits the filterand discharges through the end of the collector.
prefilter vee-bag filter
dirty-airinlet
clean-airoutlet
large mist droplets
Modular MediaFilter – Horizontal Series – Ambient Collectors
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CAUTION!
OSHA may have requirements regardingrecirculating filtered air in your facility.Consult with the appropriate localauthorities to ensure compliance with allcodes regarding recirculating filtered air.
Inspection on Arrival
1. Inspect unit on delivery.
2. Report any damage to the delivery carrier.
3. Request a written inspection report from theClaims Inspector to substantiate claim.
4. File claims with the delivery carrier.
5. Compare unit received with description ofproduct ordered.
6. Report incomplete shipments to the deliverycarrier and your Donaldson Toritrepresentative.
7. Remove crates and shipping straps. Removeloose components and accessory packagesbefore lifting unit from truck.
Installation Codes and Procedures
1. Safe and efficient operation of the unit dependson proper installation.
2. Authorities with jurisdiction should beconsulted before installing to verify local codesand installation procedures. In the absence ofsuch codes, install unit according to theNational Electric Code and NFPA No. 70-latestedition.
3. A qualified installation and service agent mustcomplete installation and service of thisequipment.
4. All shipping materials, including shippingcovers, must be removed from the unit prior to,or during unit installation.
Note: Failure to remove shipping materialsfrom the unit will compromise unitperformance.
Site Selection
1. The unit can be suspended or hung fromoverhead supports. The supports must beadequate to carry the live load of the unit andinstallation performed to reduce sway orvibration to the unit.
2. Provide clearance from heat sources andinterference with utilities when selecting thelocation for suspended units. Reference theSpecification Control drawing.
Unit Location
1. When hazardous conditions or materials arepresent, consult with local authorities for theproper location of the collector.
2. Load-bearing supports must be sized toaccommodate the entire weight of the unit plusthe weight of the collected material, and piping.Reference the Specification Control drawingshipped with the unit.
3. Locate the collector to ensure easy access toelectrical connections and routine maintenance.
CAUTION!
Donaldson Torit equipment is notdesigned to support site-installed ducts,interconnecting piping, or electricalservices. All ducts, piping, or electricalservices supplied by others must beadequately supported to prevent severepersonal injury and/or property damage.
Donaldson Company, Inc.
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CAUTION!
• Electrical installation must beperformed by a qualified electricianand comply with all applicablenational and local codes.
• Lock out electrical power sourcesbefore performing service ormaintenance work.
• Do not install in classified hazardousatmospheres without an enclosurerated for the application.
CAUTION!
• Failure to lift the collector correctlycan result in severe personal injury orproperty damage.
• Use appropriate lifting equipment andadopt all safety precautions neededfor moving and handling theequipment.
• A crane or forklift is recommendedfor unloading, assembly, andinstallation of the collector.
• Location must be clear of allobstructions, such as utility lines orroof overhang.
Electrical Wiring
1. All electrical wiring and connections, includingelectrical grounding, should be made inaccordance with the National Electric Codeand NFPA No. 70-latest edition.
2. Check local ordinances for additionalrequirements that apply.
3. The appropriate wiring schematic and electricalrating must be used. See unit’s rating plate forrequired voltage.
4. If the unit is not furnished with a factory-mounted disconnect, an electric disconnectswitch having adequate amp capacity shall beinstalled in accordance with Part IX, Article430 of the National Electric Code and NFPANo. 70-latest edition. Check unit’s rating platefor voltage and amperage ratings.
5. Refer to the wiring diagram for the number ofwires required for main power wiring andremote wiring.
Rigging Instructions
Suggested Tools & Equipment
Crane or Forklift Socket Wrenches, metricSlings, Spreader Bars, End Wrenches, metric and Clevis Pins LevelDrift Pins Drill and Drill BitsClamps Reciprocating SawScrewdrivers
Hoisting Information
1. Use all lifting points provided.
2. Use clevis connectors, not hooks, on liftingslings.
3. Use spreader bars to prevent damage to unitscasing.
4. Check the Specification Control drawing forweight and dimensions of the unit,subassemblies, and components to ensureadequate crane capacity.
5. Allow only qualified crane operators to lift theequipment.
6. Refer to applicable OSHA regulations and localcodes when using cranes, forklifts, and otherlifting equipment.
7. Lift unit and accessories separately, andassemble after unit is in place.
8. Use drift pins to align holes in section flangesduring assembly.
Modular MediaFilter – Horizontal Series – Ambient Collectors
9
Ceiling Mount
Standard Equipment
Ceiling Mount
1. Position the unit as close to the mist source aspossible allowing optimum extraction airmovement.
2. Remove the transportation support from thepower pack.
3. Install the discharge cover.
4. Use six pieces of 1-13 threaded rod to suspendunit.
5. Place a 1-in flat washer on the threaded rodand thread a 1-13 lock nut a minimum of1 1/2-in.
6. Insert rod with washer and hex nut through theceiling mount bracket from the bottom up.
7. Place another 1-in flat washer from the topdown and secure with a hex nut as shown.
8. Lift the unit into position and secure to ceilingjoists.
9. Level unit and tighten all hardware.
1-13 threaded
1-13 hex
1-in flat washer
1-in flat washer1-13 lock
ceiling mount bracket
Note: unit shown is for reference only
Donaldson Company, Inc.
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Magnehelic Gauge
The Magnehelic is a differential pressure gaugeused to measure the pressure difference betweenthe clean- and dirty-air chambers and provides avisual display of filter change requirements. Thehigh-pressure tap is located in the dirty-airchamber and the low-pressure tap is connected theclean-air chamber.
1. Choose a convenient, accessible location on ornear the unit for mounting that provides thebest visual advantage.
If unit is equipped with factory-installed pressuretaps, skip to Step 5.
2. Before drilling, place a piece of non-combustiblecloth over the filter opening in the clean-airchamber to protect them from drilling chips.
3. Place a piece of wood behind the drill locationin the dirty-air chamber to protect the filtersfrom damage by the drill bit. Use a .406-inchdiameter bit to drill the holes.
4. Mount the pressure tap hardware in the clean-and dirty-air chamber.
5. Plug the pressure ports on the back of the gaugeusing two, 1/8-in NPT pipe plugs supplied.Install two, 1/8-in NPT male adapters suppliedwith the gauge into the high- and low-pressureports on the side of the gauge. Attach themounting bracket using three, #6-32 x 1/4-inscrews supplied.
6. Mount the gauge and bracket assembly to thesupporting structure using two self-drillingscrews.
7. Thirty-five feet of plastic tubing is supplied andmust be cut in two sections. Connect onesection of tubing from the gauge’s high-pressureport to the pressure fitting located in the dirty-air chamber. Connect remaining tubing fromthe gauge’s low-pressure port to the fitting inthe clean-air chamber. Additional tubing can beordered from your representative.
8. Carefully remove the cloth protecting thefilters. Close access doors and tighten securelyby hand.
9. Zero and maintain the gauge as directed in themanufacturer’s Operating and MaintenanceInstructions provided.
10. Repeat the above steps to install theMagnehelic Gauge for the HEPA module.
Modular MediaFilter – Horizontal Series – Ambient Collectors
11
Magnehelic Gauge Installation
1/8-in NPT x 90°male elbow
clean-air plenumdrill location
mounting bracket
#6-32 x 1/4-in mounting screws
support structuremounting surface
Magnehelic gauge
high-pressure portlow-pressure port
two, 1/8-in NPTadapters
plastic tubing
two, 1/8-in NPT pipe plugstwo, self-drilling screws
1/8-in NPT x 90° male elbow
dirty-air plenumdrill location
Donaldson Company, Inc.
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Electrical Connection
All the Modular MediaFilter —Horizontal SeriesAmbient collectors must be equipped with acustomer-supplied safety disconnect with shortcircuit protection, contactors, and overloadprotection.
CAUTION!
• Electrical installation must beperformed by a qualified electricianand comply with all applicablenational and local codes.
• Lock out electrical power sourcesbefore performing service ormaintenance work.
• Do not install in classified hazardousatmospheres without an enclosurerated for the application.
Motor Starter Wiring Diagram
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1. Mount the control box in a convenient,accessible location.
2. Make the wiring connections to the fan motoraccording to the wiring diagram located insidethe control box and the instructions on themotor decal.
Note: All electrical components must be sizedfor the supply voltage and motorhorsepower.
3. Turn the fan-motor ON then OFF and check forproper rotation by removing the inspectioncover located on the side of the unit. Properrotation is counterclockwise.
To reverse rotation, single-phase power supply:
Follow manufacturer’s instructions on themotor’s nameplate.
To reverse rotation, three-phase power supply:
Turn electrical power OFF at source and switchany two leads on the output-side of the fan-motor starter.
Modular MediaFilter – Horizontal Series – Ambient Collectors
13
Preliminary Start-Up Check
1. Check all electrical connections for tightnessand contact.
2. Check for and remove all loose items in or nearthe inlet and outlet of the unit.
3. Check that all remote controls are wired intothe control system and all service switches arein the OFF position.
4. Check that all optional accessories are installedproperly and secured.
5. Check that hopper discharge is open and thestorage container or drains are installed andsealed properly.
6. Turn power ON at source.
7. Turn the fan motor ON then OFF to check forproper rotation by referencing the rotationarrow located on the motor’s mounting plate.
To reverse rotation, single-phase power supply:
Follow manufacturer’s instructions on themotor’s nameplate.
To reverse rotation, three-phase power supply:
Turn electrical power OFF at source and switchany two leads on the output-side of the fan-motor starter.
Optional Equipment
Drain Collection Container
1. Install the drain collection container duringinstallation or after unit is in its final operatingposition.
2. Turn unit OFF.
3. Remove the container by unscrewing thecontainer from the cap. Clean the container,faucet, and re-install.
Note: Close the faucet before turning thecollector back ON.
Drain Collection Container
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Donaldson Company, Inc.
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P-Trap or Y-Strainer Installation
1. Install the 1 1/2-in NPT pipe as shown below.
2. Plumb the P-trap to a receptacle or install areturn line back to the machine center.
3. Fill P-trap before starting unit.
First-Stage Filters
An optional 4-in impinger with a 1-in aluminummesh filter, or a 4-in high efficiency filter areavailable for heavy liquid-load applications. Theseare re-usable filters and may need periodiccleaning.
HEPA Filter
Recommended for applications generating smokeor other fine particulate, the optional HEPA filterfeatures 99.97% efficiency on 0.3-micron particles.The HEPA filter is used in machining processesgenerating large amounts of heat or in applicationsusing straight oil as a lubricant or coolant.
Service Information
Operational Checklist
1. Monitor overall performance of the collector.
2. Monitor exhaust. Exhaust should remainvisually clean throughout filter life. If leaks arevisible, check the filters and optional HEPAfilter for positive gasket seals.
3. Monitor hopper drainage. If slow or stopped,check hopper and drain lines for obstructionsand clean as necessary.
4. Check P-trap and refill if necessary.
5. Monitor pressure drop across filters. If thepressure is high, clean or replace the first-stagefilters. If the reading remains high, the second-stage vee-bag filter may need replacement.
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Modular MediaFilter – Horizontal Series – Ambient Collectors
15
First-Stage Filter Cleaning
1. Remove the first-stage filter.
2. Replace 4-in multi-vee filter as necessary.
3. Tap metal first-stage filters gently over anappropriate waste container to dislodgeparticulate. If further cleaning is required, soakin an appropriate wash tank, rinse, dry, andre-install.
HEPA Filter
1. Open the HEPA module’s access door.
2. Pull the two clamping handles up to lower thefilter from its seal.
3. Remove the filter and dispose of properly.
4. Install new HEPA filter with the filter gasketand the airflow direction arrow pointingtoward the power pack. Push clamping handlesdown to raise the filter to the seal.
5. Inspect the door gaskets for condition andreplace as necessary.
6. Close and secure doors.
Dirty-Air Inlet Hopper
Clean hopper by scraping the particulate out. Donot allow particulate to fall into drain.
Vee-Bag Filter Module Hopper
1. Access the hopper through the filter accessdoors.
2. Clean hopper by scraping the particulate out.Do not allow particulate to fall into drain.
CAUTION!
• Use proper safety and protectiveequipment when removingcontaminants and filters.
• Use care when removing filters toavoid personal injury.
Second-Stage Vee-Bag Filter Replacement
1. Open the two filter access doors.
2. Remove the vee-bag filter support rod by liftingthe rod from its retaining brackets.
3. Pull rod from the bag loops.
4. Move the vee-bag filter to the filter track sideof the unit and slide it off its track while guidingthe trailing bags from the cabinet. Dispose ofproperly.
5. Install a new vee-bag filter in the track andcarefully place the individual bags in thecabinet.
6. Reach through the adjacent door and distributethe bags. Insert the support rod through allloops.
7. Place the rod in the retaining brackets at eachend.
8. Inspect the door gaskets for condition andreplace as necessary.
9. Close and secure doors.
Donaldson Company, Inc.
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P-Trap Maintenance
1. Place a suitable container under the P-trap, turnthe collector OFF, and remove the pipe plug.
2. Allow fluid and particulate to drain.
3. Use thread sealant and replace pipe plug.
4. Refill the P-trap with suitable fluid beforerestarting the collector.
P-Trap with Y Strainer, Screen Cleaning
1. Place a suitable container under the screenclean-out valve, turn the collector OFF, closethe P-trap valve, then open the screen clean-outvalve.
2. Allow fluid and particulate to drain.
3. With the clean-out valve open, slowly open theP-trap valve. This allows fluid still trapped inthe hopper to drain.
Note: A substantial amount of fluid may betrapped in the hopper and could exceedthe container capacity. Open the P-trapvalve slowly.
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Modular MediaFilter – Horizontal Series – Ambient Collectors
17
P-Trap with Y Strainer, Screen Removal
1. Close the P-trap valve.
2. Unscrew the screen cap and pull the screen out.
3. Clean the screen and the inside of the Y-strainerbody, and reassemble taking care to seat thescreen in the body and cap.
4. Close the clean-out valve.
4. Refill the P-trap with suitable fluid beforerestarting the collector.
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Drain Collection Container
Drain Collection Container
1. Turn unit OFF.
2. Remove the container by unscrewing thecontainer from the cap. Clean the container,faucet, and reinstall.
Note: Close the faucet before turning thecollector back ON.
Donaldson Company, Inc.
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Split Taper™ Bushing Mounting Instructions
Many fans are furnished with split taper bushingsfor mounting the impeller to the shaft. Whenproperly assembled, the bushings grip the hub witha positive clamping action.
1. Bushel barrel and bore of impeller are taperedto ensure concentric mounting and a truerunning propeller.
2. Capscrews, when tightened, lock bushing inpropeller. Use special plated capscrews andnylock nuts.
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3. Bushing is split so that when the lockingcapscrews force bushing into tapered bore, thebushing grips the shaft with a positive clampingfit. This will withstand vibration and heavyloads without being loosened.
4. Impeller and bushing assembly is keyed to theshaft and held in place by compression, whichadds driving strength.
Note: Before assembly, ensure shaft andkeyway are clean and smooth.Check key size with both shaft andbushing keyway.
5. To assemble, insert the capscrews through theclearance holes in the bushing and installbushing loosely into the impeller. Do not pressor drive. Start capscrews by hand, turning themjust enough to engage threads in the nylock nut.Do not use a wrench at this time. The bushingshould be loose enough in the propeller to movefreely. Slide impeller and bushing assembly ontoshaft, allowing adequate clearance for shaftend play to prevent friction. Fit key intokeyway. Do not force impeller and bushingonto shaft. If it does not go on easily, checkshaft, bushing, and key sizes once again.
Tighten capscrews gradually and evenly withwrench similar to mounting an automobilewheel. Rotate a quarter turn on each capscrewsuccessively until all capscrews are tight.These capscrews force the taper bushing into
the hub, which in turn compresses the bushingonto the shaft. This makes a positive clampingfit. The torque must not exceed the valuespecified in the table.
CAUTION!
Do not attempt to pull bushing flangeflush with hub end. There should be aclearance which varies approximately3/16-in to 1/4-in with the bushing sizewhen tightened. This is not a locatingdimension.
Impeller Assembly Removal
1. Remove all capscrews from impeller and hubassembly.
2. Insert capscrews into the threaded holes in thebushing flange.
3. Tighten each bolt in quarter of a turnincrements to push the impeller off the bushing.This forces the bushing loose from the propellerhub and releases the compression so that theentire assembly will slide from the shaft.
4. Pull the bushing off the shaft.
Note: If the assembly has been in placesometime it may be necessary to usea wheel puller to remove thebushing. Never use a wheel puller on theimpeller.
Split Taper Bushing Installation
Split TaperBushing
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BROWNING SplitTaper BushedProduct (GripbeltSheave Shown)
®
Browning® is a registered trademark and Split Taper™ is a tradename of Emerson Power Transmission Manufacturing, L.P.
Modular MediaFilter – Horizontal Series – Ambient Collectors
19
Troubleshooting
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Modular MediaFilter – Horizontal Series – Ambient Collectors
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Service Notes
Donaldson Company, Inc.
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Service Notes, continued
Donaldson Company, Inc. is the leading designerand manufacturer of dust, mist, and fume collectionequipment used to control industrial-air pollutants.Our equipment is designed to help reduceoccupational hazards, lengthen machine life,reduce in-plant maintenance requirements,
and improve product quality.
© 2002 Donaldson Company, Inc. Printed in USA IOM AD3029501, Revision 2 November 2007
Donaldson Company, Inc.Dust Collection GroupP.O. Box 1299Minneapolis, MN [email protected]
®
Parts and Service
For genuine Donaldson Torit replacement filtersand parts, call the Parts Express Line
800-365-1331 USA
800-343-3639 Mexico
www.donaldsontorit.com
For faster service, have unit’s model and serial number,part number, description, and quantity available.
The Donaldson Torit Warranty
Donaldson warrants to the original purchaser that the major structural components of the goods willbe free from defects in materials and workmanship for ten (10) years from the date of shipment, ifproperly installed, maintained and operated under normal conditions. Donaldson warrants all otherDonaldson built components and accessories including Donaldson Airlocks, TBI Fans, TRB Fans,Fume Collector products, Donaldson built electrical control components and Donaldson built Afterfilterhousings for twelve (12) months from date of shipment. Donaldson warrants Donaldson built filterelements to be free from defects in materials and workmanship for eighteen (18) months from date ofshipment. Donaldson does not warrant against damages due to corrosion, abrasion, normal wearand tear, product modification, or product misapplication. Donaldson also makes no warrantywhatsoever as to any goods manufactured or supplied by others including electric motors, fans andcontrol components. After Donaldson has been given adequate opportunity to remedy any defects inmaterial or workmanship, Donaldson retains the sole option to accept return of the goods, with freightpaid by the purchaser, and to refund the purchase price for the goods after confirming the goods arereturned undamaged and in usable condition. Such a refund will be in the full extent of Donaldson’sliability. Donaldson shall not be liable for any other costs, expenses or damages whether direct, indirect,special, incidental, consequential or otherwise. The terms of this warranty may be modified only by aspecial 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.