Installation and Operation Manual Installation, Downflo Oval Operation, and DFO 2-4 and DFO 3-6 ® Service Information Patent Numbers: 6,387,162 6,090,173 6,488,746 5,562,746 6,364,921 6,368,388 Other Patents Pending Throughout this manual statements indicating precautions necessary to avoid equipment failure are referenced in a Note. Statements indicating potential hazards that could result in personal injury or property damage are referenced in a Caution! box.
Donaldson Company, Inc. CAUTION! Application of Dust Control Equipment • Combustible materials such as buffing lint, paper, wood, aluminum or steel dust, weld fume, or flammable solvents represent fire or explosion hazards. Use special care when selecting and operating all dust or fume collection equipment when combustible materials are present to protect workers and property from damage due to fire and/or explosion.
Downflo Oval, Model DFO 2-4 and DFO 3-6 Contents Description ........................................................... 4 Purpose and Intended Use..................................... 4 Rating and Specification Information ................... 5 Operation ............................................................. 6 Inspection on Arrival ............................................ 7 Installation Codes and Procedures ........................ 7 Installation ................................................
Donaldson Company, Inc. Description Purpose and Intended Use The Downflo Oval, Models DFO 2-4 and DFO 3-6 are continuous-duty dust collectors with oval, cartridge-style filters. The downward airflow design delivers high filtration efficiency while using less energy. Continuous-duty means no downtime. The filters are pulse-cleaned in sequence, one set at a time, without turning the unit off.
Downflo Oval, Model DFO 2-4 and DFO 3-6 Rating and Specification Information DFO 2-4 DFO 3-6 Side View DFO 2-4 and DFO 3-6 All Units (per IBC 2003 Specifications): Wind ........................................ 90 MPH Exposure C Seismic Spectral Acceleration, Ss .................................... 1.5 g Seismic Spectral Acceleration, S1 ....................................... 0.6 g Importance Factor, 1............................................ 1.0 Ground Snow Load ...............................
Donaldson Company, Inc. Operation During normal operation, dust-laden air enters the unit through the dirty-air inlet. Airflow is directed downward through the collector and heavier particulate falls directly into the hopper. The cartridges remove fine particulate and clean, filtered air passes through the cartridge to the clean-air plenum and discharges through the clean-air outlet. optional clean-air outlet Filter cleaning is completed using pulse-jet technology.
Downflo Oval, Model DFO 2-4 and DFO 3-6 Inspection on Arrival Installation 1. Inspect unit on delivery. Site Selection, Grade-Mounted Units 2. Report any damage to the delivery carrier. 3. Request a written inspection report from the Claims Inspector to substantiate claim. 4. File claims with the delivery carrier. 5. Compare unit received with description of product ordered. 6. Report incomplete shipments to the delivery carrier and your Donaldson Torit representative. 1.
Donaldson Company, Inc. Electrical Wiring CAUTION! • Electrical installation must be performed by a qualified electrician and comply with all applicable national and local codes. • Lock out electrical power sources before performing service or maintenance work. • Do not install in classified hazardous atmospheres without an enclosure rated for the application. 1. All electrical wiring and connections, including electrical grounding, should be made in accordance with the National Electric Code, NFPA No.
Downflo Oval, Model DFO 2-4 and DFO 3-6 Typical Installation 1. Lift cabinet. 2. Apply sealant to hopper flange. 3. Fasten hopper to cabinet. 4. Assemble legs and cross braces. 5. Lift unit and hopper into position over legs and lower slowly. 6. Fasten legs to unit securely. 7. Lift assembled unit to location. 8. Support and level unit. 9. Tighten all fasteners. 10. Remove crane.
Donaldson Company, Inc. Standard Equipment Standard equipment consists of a collector cabinet, hopper, and legs. Basic assembly starts by attaching the hopper to the cabinet, then attaching the legs. A detailed instruction drawing, shipped with each collector, provides specific assembly and lifting instructions. CAUTION! • Failure to lift the collector correctly can result in severe personal injury or property damage.
Downflo Oval, Model DFO 2-4 and DFO 3-6 Leg Assembly Leg sets are designed for standard height collectors and are rated as shown in the Rating and Specification Information. Reference the drawing shown below and the leg assembly drawing shipped with the leg set for proper location and assembly. 4. Recheck the position of the leg sets and cross braces. 1. Position and assemble legs and cross braces as shown in Leg and Cross Brace Assembly. 5. Using a crane, lift the assembled unit onto the anchor bolts.
Donaldson Company, Inc. Compressed Air Installation CAUTION! Units Built Before November 2006 • 60-psig maximum operating pressure. • Air regulator required. 1. Remove the 1-in pipe cap from one of the unit’s two air manifolds and connect the compressedair supply line. Use thread-sealing tape or pipe sealant on all compressed-air connections. 2. Install a customer-supplied shut-off valve, bleedtype regulator with gauge, filter, and automatic condensate valve in the compressed-air supply line.
Downflo Oval, Model DFO 2-4 and DFO 3-6 blower fan diaphragm valve solenoid enclosure manifold power supply disconnect switch* 120-Volt blower motor starter* solid-state timer solenoid electrical connection* Magnehelic gauge* hopper air supply to manifold* compressed-air supply line* regulator* automatic shut-off condensate valve* valve* bleed-type air filter* Notes: 1. * Not included with standard unit. 2. Sprinkler taps not shown.
Donaldson Company, Inc. Solid-State Timer Installation The solid-state timer is an electronic timer used to control the filter cleaning system. 2. Plug the program lug into the pin that corresponds with the number of solenoid valves controlled. CAUTION! 3. With power supply ON, check the operation of the solenoid valves. The valves should open and close sequentially at factory set 10-second intervals. The solid-state timer requires a 105 to 135-Volt, customer-supplied power supply.
Downflo Oval, Model DFO 2-4 and DFO 3-6 Solenoid Connection The unit is equipped with 115-Volt solenoid valves that control the pulse-cleaning valves, which clean the filters. One of three types of solenoid enclosures, the weatherproof NEMA 4 with 1/8-in solenoid valves; the gas-explosion proof NEMA 7 with 1/8-in solenoid valves; or the dust-explosion proof NEMA 9 with 1/8-in solenoid valves, is mounted near or on the unit’s compressed-air manifold.
Donaldson Company, Inc. Preliminary Start-Up Check Service Information 1. Check all electrical connections for tightness and contact. Operational Checklist 2. Check for and remove all loose items in or near the inlet and outlet of the unit. 3. Check that all remote controls are wired into the control system and all service switches are in the OFF position. 4. Check that all optional accessories are installed properly and secured. 5.
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Donaldson Company, Inc. Filter Installation and Replacement CAUTION! • Use proper safety and protective equipment when removing contaminants and filters. • Dirty filters may be heavier than they appear. • Use care when removing filters to avoid personal injury. • Do not drop filters. Filter Removal 1. Turn power to unit OFF. 2. Start at the top access port. 3. Remove access cover. For units without Bag-In/ Bag-Out: remove access cover by lifting latch handle and lifting cover to remove from yoke.
Downflo Oval, Model DFO 2-4 and DFO 3-6 Filter Access Cover Removal (Side View) yoke access cover filter cartridge yoke latched access cover cover handle unlatched removal Optional and Bag-In/Bag-Out Filter Access Cover Removal (Top View) access cover yoke access cover hook Front of DFO latched unlatched removal Filter Replacement 19
Donaldson Company, Inc. Optional Equipment Power Pack Radial Blade The 3 through 10 horsepower power packs are designed to fit on top or side of the unit. 1. The power packs are shipped assembled and partial disassembly is required before installing. 2. Remove the blower housing fasteners and split the blower halves. The motor side contains the motor, half of the blower housing, and the blower wheel. The inlet side consists of the inlet half of the blower housing. 3.
Downflo Oval, Model DFO 2-4 and DFO 3-6 Radial Blade Power Pak, Top or Side Mount motor side bolt inlet side blower outlet apply sealant between blower housing sections flat washer lock washer hex nut 1/4-in diameter rope-type sealant TBI with Spacer Ring and TBI with Spacer Spool for Explosion Vented Units motor mount blower wheel motor mount blower wheel sealant sealant blower housing blower housing sealant sealant spacer spool spacer ring sealant collector mounting surface .
Donaldson Company, Inc. Side-Mount Power Pack for Units Built After July 2003 CAUTION! • Side mounting a power pack requires side power adapter to support the weight of the power pack. • Poorly installed power packs may not stay properly attached to the collector resulting in personal injury and damage to equipment or property. 4. Install the motor and blower assembly to the fan housing using the original hardware and caulk sealant. 5. Connect power supply to the motor.
Downflo Oval, Model DFO 2-4 and DFO 3-6 55-Gallon Drum Pack The drum pack is designed to fit a customersupplied, standard 55-gallon drum and provides easy access for dust removal and disposal. A flexible hose connects the drum cover hopper. Placing a pallet under the drum allows heavier materials to be moved quickly using a forklift or pallet jack. If a pallet is used, the length of flexible hose may need to be shortened. Drum Cover Pack with Gate Valve 1.
Donaldson Company, Inc. 5-Gallon Pail Pack The pail pack includes a 5-gallon pail and provides easy access for dust removal and storage. 3. Place pail beneath sealer mechanism. 4. Tighten clamps on either side by pulling down. 1. Apply sealant to the hopper flange or the pail cover mounting plate flange toward the inside edge of the bolt pattern. 2. Fasten the pail pack to the hopper using the bolts, washers, and nuts supplied.
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Donaldson Company, Inc. Magnehelic Gauge The Magnehelic is a differential pressure gauge used to measure the pressure difference between the clean- and dirty-air chambers and provides a visual display of filter change requirements. The highpressure tap is located in the dirty-air plenum and the low-pressure tap is located in the clean-air plenum. 1. Choose a convenient, accessible location on or near the unit for mounting that provides the best visual advantage.
Downflo Oval, Model DFO 2-4 and DFO 3-6 6. Mount the gauge and bracket assembly to the supporting structure using two self-drilling screws. 7. Thirty-five feet of plastic tubing is supplied and must be cut in two sections. Connect one section of tubing from the gauge’s high-pressure port to the pressure fitting located in the dirty-air plenum. Connect remaining tubing from the gauge’s low-pressure port to the fitting in the clean-air plenum. Additional tubing can be ordered from your representative. 8.
Donaldson Company, Inc. Photohelic Gauge The Photohelic combines the functions of a differential pressure gauge and a pressure-based switch. The gauge function measures the pressure difference between the clean- and dirty-air plenum and provides a visual display of filter condition. The high-pressure tap is located in the dirty-air plenum and a low-pressure tap is located in the clean-air plenum.
Downflo Oval, Model DFO 2-4 and DFO 3-6 4. Thirty-five feet of plastic tubing is supplied and must be cut in two sections. Connect one section of tubing from the gauge’s high-pressure port to the pressure fitting located in the dirty-air plenum. Connect remaining tubing from the gauge’s low-pressure port to the fitting in the clean-air plenum. Additional tubing can be ordered from your representative. 5.
Donaldson Company, Inc. Delta P Control Description The Delta P Control monitors the differential pressure between the clean and dirty air plenums, providing a visual display of the filter condition. When combined with a pulse timer, it controls the pressure drop by turning the cleaning mechanism On and Off at the chosen limits. There are three (3) set points: High Pressure On, Low Pressure Off, and Alarm. The first two, High Pressure On and Low Pressure Off, control the filter cleaning system.
Downflo Oval, Model DFO 2-4 and DFO 3-6 Delta P Plus Control The Delta P Plus Control monitors the differential pressure between the clean and dirty air plenums, providing a visual display of the filter condition. When combined with a pulse timer, it controls the pressure drop by turning the cleaning mechanism On and Off at the chosen limits. There are three (3) set points: High Pressure Drop On, Low Pressure Drop Off, and Alarm.
Donaldson Company, Inc. Damper Installation A damper can be added to the power pack outlet to limit and regulate airflow when unit is in operation. Radial Blade 1. Apply 1/4-in diameter bead of sealant toward the inside edge of the bolt pattern on both sides of the spacer ring. Backward Inclined 1. Apply sealant around the inside edge of the bolt pattern on the power pack outlet. 2. Fasten damper to the blower outlet using the hardware provided. 2.
Downflo Oval, Model DFO 2-4 and DFO 3-6 Plenum Silencer Radial Blade and Backward Inclined 1. Apply 1/4-in diameter rope-type sealant towards the outside edge of the bolt pattern on the cleanair outlet. 2. Position the silencer mounting base aligning the bolt patterns of the collector and the mounting base. chamber silencer damper with slide gate 3. Apply 1/4-in diameter rope-type sealant towards the outside edge of the bolt pattern on the silencer mounting base. 4.
Donaldson Company, Inc. HEPA or ASHRAE Afterfilter Installation The afterfilter plenum is mounted on top of the unit and the blower is positioned inside the plenum. 1. Apply sealant around the clean-air outlet toward the outside edge of the bolt hole pattern located on the top of the collector. 2. Position the afterfilter plenum mounting base aligning the bolt patterns. 3. Apply sealant to the plenum mounting base toward the outside edge of the bolt pattern. 4.
Downflo Oval, Model DFO 2-4 and DFO 3-6 Abrasion-Resistant Inlet Collar 1. Remove the unit’s front cover plate. Remove excess sealant from opening. 2. Apply 1/4-in sealant around the opening toward the inside edge of the bolt pattern. 3. Align the holes on the inlet collar with the holes in the unit and secure using 3/8-16 x 1-in bolts and flat washers supplied.
Donaldson Company, Inc. Cold Climate Kit A cold climate kit provides heat to the pulse valves to prevent cold weather freeze up. The basic kit, for use in applications that have a moderate of moisture in the compressed-air supply, consists of a small heating element and thermostat installed in the solenoid enclosure. The basic kit is factory-installed and supplied with the appropriate solenoid wiring instructions. 2. Start with the upper right-hand valve, wrap heat cable around the valve.
Downflo Oval, Model DFO 2-4 and DFO 3-6 Explosion Vents CAUTION! CAUTION! • Personal injury or property damage can result from material discharge during venting. Sprinkler systems place a large quantity of water in the dust collector when activated. Provide adequate drainage to remove water. Excess water weight can cause the leg structure to collapse. • The material discharged from an enclosure during the venting of an explosion should be directed safely to an outside location.
Donaldson Company, Inc. Troubleshooting Problem Probable Cause Rem edy Blower fan and motor do not start Improper motor wire size R ewire using the correct wire gauge as specified by national and local codes. Not wired correctly C heck and correct motor wiring for supply voltage. See motor manufacturer's wiring diagram. Follow wiring diagram and the National Electric C ode. U nit not wired for available voltage C orrect wiring for proper supply voltage.
Downflo Oval, Model DFO 2-4 and DFO 3-6 Problem Probable Cause Rem edy Insufficient airflow continued A ccess doors open or not closed tight C heck that all access doors are in place and secured. C heck that the hopper discharge opening is sealed and that optional attachments are installed correctly. See Hopper A ssembly. Fan exhaust area restricted C heck fan exhaust area for obstructions. R emove material or debris. A djust damper flow control.
Donaldson Company, Inc. Troubleshooting Problem Probable Cause Rem edy Display on Delta P control does not read zero when at rest Out of calibration Disconnect pressure tubing. See Delta P Maintenance Manual, IOM 7546301. With collector discharging outside, differential pressure is present from indoor to outdoor R ecalibrate with the pressure tubing attached as described in the Delta P Maintenance Manual, IOM 7546301.
Downflo Oval, Model DFO 2-4 and DFO 3-6 Problem Probable Cause Rem edy C leaning light is ON, but cleaning system not functioning Improper wiring C heck wiring between the Delta P C ontrol and the timer board, and between the timer board and solenoid valve coils. Defective solenoids C heck all solenoid coils for proper operation. Timer board not powered C heck power ON light on timer board's LED display. If not illuminated, check the supply voltage to the timer board.
Donaldson Company, Inc.
The Donaldson Torit Warranty Donaldson warrants to the original purchaser that the major structural components of the goods will be free from defects in materials and workmanship for ten (10) years from the date of shipment, if properly installed, maintained and operated under normal conditions.
