Installation, Operation and Maintenance Manual PowerCore Dust Collectors ® Series CPV Publication 3012C (GB) • 1108 Donaldson reserve the right to alter design without notice. 'MASTER' LANGUAGE 1A 6519 8000 (03) Freedom from patent restrictions must not be assumed.
Installation, Operation and Maintenance Manual PowerCore Dust Collectors – Series CPV ® IMPORTANT PLEASE READ THIS MANUAL CAREFULLY BEFORE INSTALLATION. THIS MANUAL SHOULD BE READ IN CONJUNCTION WITH THE CONTROLLER MANUAL, PUBLICATION 2699, SUPPLIED WITH THE DUST COLLECTOR. PRODUCT RELIABILITY, WARRANTY AND SAFE OPERATION MAY BE COMPROMISED BY NOT FOLLOWING THE GUIDANCE GIVEN IN THESE DOCUMENTS. EXPLANATION OF SYMBOLS USED Indicates information on the efficient operation of the collector.
Installation, Operation and Maintenance Manual PowerCore Dust Collectors – Series CPV ® IMPORTANT Improper operation of a dust control system may contribute to conditions in the work area or facility that could result in severe personal injury and product or property damage. Check that all collection equipment is properly selected, sized and operated for the intended use.
Installation, Operation and Maintenance Manual PowerCore Dust Collectors – Series CPV ® CONTENTS General safety requirements .................................................................................. 5 Installation ............................................................................................................... 8 General guidance to lifting ............................................................................. 8 Mounting over aperture ...........................................
Installation, Operation and Maintenance Manual PowerCore Dust Collectors – Series CPV ® GENERAL SAFETY REQUIREMENTS The dust collector should be used only when it is in a technically acceptable condition. Regular maintenance, as set out in this manual, is required to minimise technical failure. Third party supplied components (for example motors) should be maintained according to the manufacturer's instructions.
Installation, Operation and Maintenance Manual PowerCore Dust Collectors – Series CPV ® GENERAL SAFETY REQUIREMENTS 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.
Installation, Operation and Maintenance Manual PowerCore Dust Collectors – Series CPV ® Compressed air distribution manifold Compressed air inlet Hinged access door Diaphragm valves Filter packs Lifting eyebolts Cleaned air outlet Mounting flange Figure 1 PowerCore dust collector Model CPV-3 illustrated 7
Installation, Operation and Maintenance Manual PowerCore Dust Collectors – Series CPV ® INSTALLATION Where equipment is installed in a Potentially Explosive Atmosphere, care should be taken not to locate or use the collector where external ignition sources can be introduced, for example stray electric currents, lightening, electromagnetic waves, ionising radiation, ultrasonic waves. General guidance to lifting Refer also to Figure 2 The collector should be lifted using the lifting eyebolts provided.
Installation, Operation and Maintenance Manual PowerCore Dust Collectors – Series CPV ® INSTALLATION Mounting over aperture 1 Check that the aperture and fixing holes are correct in size and position to suit the mounting-flanges of the PowerCore dust collector (details of aperture and mounting flange fixing positions are provided in Publication 3010). 2 Open the access door and remove the pack of sealing strip from the clean air chamber.
Installation, Operation and Maintenance Manual PowerCore Dust Collectors – Series CPV ® INSTALLATION Pressure relief The manifold has a maximum operating pressure of 6.2 bar (see Table 2 in ‘Specifications’ section). It is a requirement that adequate precaution is taken to avoid exceeding this pressure. Where a relief valve is supplied by Donaldson this device has a relief rating of 25 dm3/s at 7.1 bar. Extra system relief will be required if the connected supply can exceed this.
Installation, Operation and Maintenance Manual PowerCore Dust Collectors – Series CPV ® COMMISSIONING It is a requirement of the Supply of Machinery (Safety) Regulations 1992 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. Commissioning check list Ensure the dust collector is securely bolted over the aperture.
Installation, Operation and Maintenance Manual PowerCore Dust Collectors – Series CPV ® COMMISSIONING Shut-down sequence At the end of any period of operation it is most important that all residual deposits are cleared from the PowerCore filter packs. To achieve this, equipment should be shut down in the following order: 1 Stop the main fan, any blower or pneumatic conveying system, leaving the controller and compressed air supply switched on to allow the collector to be cleaned ‘off-line’.
Installation, Operation and Maintenance Manual PowerCore Dust Collectors – Series CPV ® OPERATION Principle of operation Filtering operation (Fig. 3a) With the collector mounted on the silo or storage container, dust-laden air enters the collector through the aperture at the bottom of the collector. Airflow is directed upwards through the PowerCore filter packs, removing the fine particulate (heavier particulate falls back into the process).
Installation, Operation and Maintenance Manual PowerCore Dust Collectors – Series CPV ® MAINTENANCE A platform should be used when carrying out maintenance where the position of the technician’s feet is greater or equal to 2 metres above ground level. Before any work is carried out, ensure the equipment is adequately isolated and safe. Ensure the pneumatic system is fully isolated and depressurised before any work is carried out.
Installation, Operation and Maintenance Manual PowerCore Dust Collectors – Series CPV ® MAINTENANCE After the fault has been rectified, resumption of compressed air cleaning will usually return the filter packs to normal efficiency. However, it is advisable to operate the controller in still-air conditions for a short period to dislodge any accumulated dust before putting the collector into operation.
Installation, Operation and Maintenance Manual PowerCore Dust Collectors – Series CPV ® MAINTENANCE 7 Refit and tighten the hexagonal head set screws and shakeproof washers. 8 Push-fit 6 mm diameter nylon tube back into valve. Annually 1 Moisture separator – Isolate the compressed air supply; remove and clean the filter element.
Installation, Operation and Maintenance Manual PowerCore Dust Collectors – Series CPV ® MAINTENANCE Filter pack replacement Use safety and protective equipment when removing contaminants and filter packs. Dirty filter packs may be heavier than they appear. Use care when removing filter packs to avoid personal injury. Do not drop filter packs. Refer also to Figure 5. 1 Turn off and isolate any air movement equipment associated with the process (e.g.
Installation, Operation and Maintenance Manual PowerCore Dust Collectors – Series CPV ® MAINTENANCE TABLE 1 – FAULT LOCATION Symptom 1 Possible cause Excessive pressure differential. Action 1.1 Compressed air malfunction. a If compressor stopped, rectify compressor fault; check interlocks; check motor and supply; check drive. b If compressor OK, check pulses at manifold pressure gauge. c Clean filters, dismantle and clean moisture separator.
Installation, Operation and Maintenance Manual PowerCore Dust Collectors – Series CPV ® SPECIFICATION For other specifications on this product refer to Publication 3010. For controller specifications refer to Publication 2699.
Installation, Operation and Maintenance Manual PowerCore Dust Collectors – Series CPV ® SPECIFICATION TABLE 3 – COMPRESSED AIR REQUIREMENTS Collector type CPV-2 CPV-3 CPV-4 CPV-6 CPV-8 CPV-12 6.2 bar 6.2 bar 6.2 bar 6.2 bar 6.2 bar 6.2 bar a c Atmospheric air volume – F.A.D. at 12 sec. intervals b Working compressed air pressure a Normal operating pressure. 90 psig 90 psig 90 psig 90 psig 90 psig 90 psig b 10 m³/h* 16 m³/h 20 m³/h* 16 m³/h 25 m³/h* 25 m³/h 5.9 cfm* 9.4 cfm 11.8 cfm* 9.4 cfm 14.
Installation, Operation and Maintenance Manual PowerCore Dust Collectors – Series CPV ® SPARE PARTS 2 1 4 5 3 6 7 CPV-4 illustrated Figure 6 Spare parts identification 21 9
Installation, Operation and Maintenance Manual PowerCore Dust Collectors – Series CPV ® Item Description Part number / P032422 Filter pack assembly 1 Filter pack, Ultra-Web 2 Filter pack retainer AD 382 6701 Access door assembly 3 Access door CPV-2 CPV-3 CPV-4 CPV-6 CPV-8 CPV-12 AD 383 6206 AD 383 2103 AD 381 3903 AD 383 6801 AD 383 5204 AD 382 6805 4 Door seal 5 Door fastener 6 Eyebolt, door fastener 282 4500 7 Door hinge 759 6101 334 1209 AD 382 9701 Controller 8 For cont
Installation, Operation and Maintenance Manual PowerCore Dust Collectors – Series CPV ® DECLARATION OF CONFORMITY GB EC DECLARATION OF CONFORMITY (Machinery directives 98/37/EEC) Head Office: Donaldson Europe B.V.B.A. Interleuvenlaan 1, B-3001 Leuven (Heverlee), Belgium Manufacturing Centres: Donaldson Filtration (GB) Ltd. Humberstone Lane, Thurmaston, Leicester LE4 8HP, England Donaldson Industrial CR – koncern s.r.o.
Installation, Operation and Maintenance Manual PowerCore Dust Collectors – Series CPV ® CONTACT DETAILS BE GB FR Research Park Zone 1 Interleuvenlaan 1 B-3001 Leuven (Heverlee) Belgium Tel +32 (0)16 383 970 Fax +32 (0)16 383 938 Email: IFS-europe@emea.donaldson.com IT Via Cesare Pavese, 5/7 I-20090 Opera (Milano) Italia Tel +39 025 300 521 Fax +39 025 760 5862 Email: IFS-it@emea.donaldson.
