Installation and Operation Manual Installation, Downflo® II Operation, and DFT 2-8, 2-12, 2-16, 2-24, 2-36 DFT 3-12, 3-24, 3-26, 3-48, 3-60, 3-72, DFT 4-16, 4-32, 4-48, 4-64, 4-80, 4-96, 4-112, 4-128 Service Information Units Built After July 2003 Patent Number: 4,395,269 5,562,746 5,954,849 6,090,173 5,803,941 Throughout this manual statements indicating precautions necessary to avoid equipment failure are referenced in a Note.
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 II Dust Collector Contents Description ........................................................... 4 Purpose and Intended Use .................................... 4 Operation ............................................................. 5 Inspection on Arrival ........................................... 6 Installation Codes and Procedures ....................... 6 Installation ........................................................... 6 Site Selection, Grade-Mounted Units ............
Donaldson Company, Inc. Description Purpose and Intended Use The Downflo II dust collector is a continuous-duty, modular collector with 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. The modular design allows flexibility in system design and adapts easily to limited space areas.
Downflo II Dust Collector 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 cartridges to the clean-air plenum and discharges through the cleanair outlet. Filter cleaning is completed using pulse-jet technology.
Donaldson Company, Inc. 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 representative. 7. Remove crates and shipping straps.
Downflo II Dust Collector Electrical Wiring Unit Location Caution! 1. When hazardous conditions or materials are present, consult with local authorities for the proper location of the collector. • Electrical installation must be performed by a qualified electrician and comply with all applicable national and local codes. 2. Foundation or roof support must be sized to accommodate the entire weight of the unit, plus the weight of the collected material, piping, and ductwork.
Donaldson Company, Inc. Rigging Instructions Suggested Tools & Equipment Clevis Pins and Clamps Crane or Forklift Drift Pins Drill and Drill Bits End Wrenches Large Crescent Wrench Lifting Slings Pipe Sealant Pipe Wrenches Screwdrivers Socket Wrenches Spreader Bars Hoisting Information 1. Use all lifting points provided. 2. Use clevis connectors, not hooks, on lifting slings. 3. Use spreader bars to prevent damage to unit’s casing. 4.
Downflo II Dust Collector Typical Installation 1. Stand hopper on the discharge end. 2. Apply sealant around the top flange of the hopper toward the inside edge of the bolt pattern. 3. Lift collector into position over the hopper and lower slowly 4. Use drift pins to align holes and secure with hardware provided. 5. Assemble legs and cross braces. 6. Lift unit and hopper assembly into position over legs and lower slowly 7. Fasten legs to unit and to foundation. 8. 9. 9. 10.
Donaldson Company, Inc. bolting, see Detail C inlet deflector sealant, see Detail B yoke installation, see Detail E yoke alignment, see Detail D clean-air plenum filter access cover see Detail A clean-air outlet cover see Detail F Module Assembly Standard Equipment Standard equipment consists of modules, inlet deflectors, yokes, filters, hoppers, and legs. Singlemodule through six-module units are delivered with the inlet deflectors, yokes, and filters factory installed.
Downflo II Dust Collector Module Assembly Note: Two cranes are required to lift and assemble modules. sealant 1. Remove the protective cover from the end of each module. 2. Remove one column of access covers, filters, venturis, yokes, and deflector panels from the joint-side of each module. See Detail A. 3. Remove outlet cover from the bottom of the clean-air plenum and set aside. 4.
Donaldson Company, Inc. Yoke, Venturi, and Filter Installation venturi Notes: 1. Installing yokes requires two people. 2. Place blocks under assembled modules during yoke and filter installation. 1. Thread a thin jam-nut on each of the three yoke rod ends to the shoulder. See Detail Dand E. 3/8-in hex nut 3/8-in flat washer 3/8-in lock washer filter cartridge panel 2. Start at the bottom access port and work upward. Position the yoke as shown in Detail D.
Downflo II Dust Collector Hopper Installation There are four ledge-free hopper styles offered for the Downflo II. A single-module wide that spans two portholes; a single-module wide that spans three portholes; a taller, steeper, single-module wide module which spans two portholes, and a doublemodule wide spanning four portholes. All styles transition to a single, 10-inch square discharge. 1. Stand the hopper on the discharge end. Note: Remove hopper access covers on double module hoppers if necessary.
Donaldson Company, Inc. Leg Installation Leg sets are designed for standard height collectors and are rated Seismic Zone 4 and 100 mph wind load. Reference the drawing shown below and the leg assembly drawing shipped with the leg set for proper location and assembly. 1. Position and assemble legs and cross braces as shown in Leg and Cross Brace Assembly. 2. Lift the cabinet and hopper assembly into position over the legs and lower slowly.
Downflo II Dust Collector 5. Recheck the position of the leg sets and cross braces. 7. Level unit. Tighten all hardware on legs, cross braces, and foundation anchors. 6. Using a crane, lift the assembled unit onto the anchor bolts. Fasten each leg pad to the anchor bolts using flat washers, lock washers, and hex nuts provided by others. Do not tighten hardware at this time. 8. Remove crane. Caution Tighten all leg and cross brace hardware before removing crane.
Donaldson Company, Inc. Power Pack The two types of power packs, Torit Backward Incline, TBI, and Torit Radial Blade, TRB, are installed following the same procedure. Both power packs are designed to fit on the top or side of the Downflo II. Notes: For a top-mounted TBI, or a TRB with a blast-gate style damper, install a spacer ring between the fan housing and the collector to provide the necessary clearance for the damper installation.
Downflo II Dust Collector motor mount blower wheel sealant blower housing sealant spacer spool sealant Top-Mount Power Pack with Spacer Spool, Explosion Vented Units Only blower housing side mount bracket* sealant motor mount spacer hex nut lock washer bolt bolt flat washer flat washer bolt bolt flat washer flat washer *usually factory installed Side-Mount Power Pack with Spacer Ring Installation 17
Donaldson Company, Inc. Solid-State Timer Installation The solid-state timer is an electronic timer used to control the filter cleaning system. Available options include 3, 6, 10, 20, and 32-pin solenoid valve control. Note: The solid-state timer requires a 105 to 135Volt customer-supplied power supply. Do not mount the solid-state timer on the unit. Mechanical vibration can damage the control. 1.
Downflo II Dust Collector 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 3D2 solenoids, the explosion proof NEMA 7 with 5D2 solenoids, or the explosion proof NEMA 9 with 5D2 solenoids, is mounted near or on the unit’s compressed-air manifold. Wire the solenoids to the solid-state timer following the wiring diagram supplied with the unit.
Donaldson Company, Inc. Delta P Control When combined with a pulse timer, the Delta P control monitors the differential pressure between the clean- and dirty-air chambers, providing a visual display of the filter condition. Set the highpressure ON and low-pressure OFF setpoints to control the filter cleaning system. 1. Choose a location near the unit that permits access to the keypad for adjustments and observation of the pressure drop. If possible, mount the control indoors. 2.
Downflo II Dust Collector tap on the clean-air plenum. Additional tubing can be ordered from your representative. panel if the pressure drop reaches the alarm setpoint. The auxiliary relay can also be used to activate visual or audible alarms provided by others. 7. Place the program wire on the solid-state timer board pin to match the number of solenoidvalve connections used. 6. Thirty-five feet of plastic tubing is supplied with the control and must be cut in two sections.
Donaldson Company, Inc. Optional Settings Delta P Control Calibration 2PMJVolt Power Supply To operate at 230-Volt, remove two jumpers labeled W1 and W3. Reinsert one of the jumpers in position W2. The only user calibration is the zero adjustment of the display. Due to slight changes in electronic components over time, or pressure differentials within the plant environment, the display may read something other than 0.0 while at rest. Use the following procedure to recalibrate the operating system.
Downflo II Dust Collector 2. Install a customer-supplied shut-off valve, bleed-type regulator with gauge, filter, and automatic condensate valve in the compressedair supply line. Note: All compressed-air components must be sized to meet the maximum system requirements of 10 to 20 scfm (depending on size of unit) at 90-psi supply pressure. See Specification Control Drawing shipped with unit. Do not increase supply pressure above 100-psi. Component damage can result.
Donaldson Company, Inc. Preliminary Start-Up 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. 1. Monitor overall performance of the collector. 2. Monitor exhaust. 3. Check that all remote controls are wired into the control system and all service switches are in the OFF position. 3. Monitor pressure drop across filters. 4.
Downflo II Dust Collector filter cartridge insert gasket end first access cover yoke Filter Cartridge Replacement 25
Donaldson Company, Inc. Filter Replacement Note: Place filter part-number label (supplied with each replacement filter) over the filter part number listed on the unit’s rating plate. 1. Slide the new filter cartridge onto each suspension yoke. Note: Insert the filter with the gasket end facing the clean-air plenum. 2. Wipe cover gaskets clean and replace covers by turning the knob clockwise. Tighten securely by hand. Note: Tighten access covers securely by hand. Gaskets must be compressed to seal properly.
Downflo II Dust Collector Optional Equipment 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 and slide gate, or drum cover and adapter. Placing a pallet under the drum allows heavier product 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. With Slide Gate 1.
Donaldson Company, Inc. Without Slide Gate 1. Place the 1/4-in diameter rope-type sealant between the hopper flange and the adapter as shown. 2. Attach the adapter to the hopper flange using 3/8-16 bolts, washers, and hex nuts. 3. Attach the drum cover to the 55-gallon drum. 4. Use latches to secure the cover to the drum, if equipped. 5. Connect the flexible hose between the drum cover and the adapter. Secure with hose clamps.
Downflo II Dust Collector 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 high-pressure 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.
Donaldson Company, Inc. 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 dirtyair 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.
Downflo II Dust Collector 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 dirtyair 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. jumper wires supplied by customer HI NO NC NC NO C C NO NC NC NO C neutral 110-V L1 L2 5.
Donaldson Company, Inc.
Downflo II Dust Collector Transition and Rotary Valve The 7-inch tall transition is designed to connect a standard hopper and a rotary valve. Rotary valves are used as an airlock and a metering device in dust control applications. When used as an airlock, an airtight seal between the valve’s inlet and outlet is maintained while allowing dust or material to pass through.
Donaldson Company, Inc. Damper and Silencer, TBI Side and Top Mount b. Drill pilot holes with a 0.339-inch bit. 1. Install the power pack as described in Power Pack on Page 16. c. Secure brackets using 3/8-in thread-forming bolts. 2. Attach the damper to the fan exhaust outlet using the bolts, washers, and hex nuts supplied. Silencer Support Brackets, Side Mount 3. Attach the flange to the damper using the bolts, washers, and hex nuts supplied. a.
Downflo II Dust Collector Plenum Silencer, TRB Abrasion-Resistant Inlet Collar Top Mount 1. Remove the unit’s front cover plate. Remove excess sealant from opening. 1. Apply sealant and attach the bottom panel to the collector as described on the assembly drawing shipped with the silencer. Use a combination of hardware removed from the unit and hardware supplied. 2. Apply 1/4-in diameter rope-type sealant around the opening toward the inside edge of the bolt pattern. 2.
Donaldson Company, Inc. Extended Dirty-Air Plenum, Custom Explosion Vents The extended dirty-air plenum is a custom design module used in applications requiring an air management module, an end inlet, or when a single inlet serves multiple modules. Caution! • Personal injury, death, or property damage can result from material discharge during venting. When positioned as an end module, it is supplied with a standard 24 x 47-in covered opening that may be used as an access, inlet, or explosion vent area.
Downflo II Dust Collector Air Management Module, Custom Platforms and Ladders The air management module is a custom design module used in applications involving heavy grain loading, large or abrasive particles in the airstream, or in applications when a collector with a single inlet serves multiple modules. It is equipped with a louvered panel near the bottom, which prevents re-entrainment of the dust that falls through to the hopper.
Donaldson Company, Inc.
Downflo II Dust Collector Sprinkler Installation Caution! 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. Optional fire control sprinklers are available for all models operating under negative pressure. Toritsupplied sprinklers require a minimum of 15-psig water pressure to each module. The volume of water discharged per sprinkler head is 17 gallons per minute. 1.
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 amount 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.
Downflo II Dust Collector Drum Sentry, Drum-Full Indicator The drum sentry provides a visual readout of the 55-gallon drum contents. When the dust level in the drum covers the opening on the bottom of the drum sentry, the gauge indicator changes from E, empty to Full. Note: Do not use the drum sentry on dust with low-bulk densities such as wood-dust shavings and cotton fibers. 1. Drill a 1 3/8-in diameter hole in the drum cover. Remove excess gasket material from the underside of the cover. 2.
Donaldson Company, Inc. 8. Apply sealant to the treads of the nylon barbed nipple and thread onto the coupling hand tight. 9. Trim the 1-in diameter hose to extend into the drum at the desired drum-full level. Note: Dust with low-bulk density such as weld fume require the hose to be immersed a minimum of 6-in. dirty-air plenum pneumatic tubing nylon barbed tee 10. Place the cover on the drum and position under hopper. 11.
Downflo II Dust Collector Troubleshooting Problem Probable Cause R em edy Blower fan and motor do not start Improper motor wire size Rewire using the correct wire gauge as specified by national and local codes. Not wired correctly Check and correct motor wiring for supply voltage. See motor manufacturer's wiring diagram. Follow wiring diagram and the National Electric Code. Unit not wired for available voltage Correct wiring for proper supply voltage.
Donaldson Company, Inc. Troubleshooting, continued Problem Probable Cause R em edy Insufficient airflow continued Access doors open or not closed tight Check that all access doors are in place and secured. Check that the hopper discharge opening is sealed and that optional attachments are installed correctly. See Hopper Installation on Page 13. Fan exhaust area restricted Check fan exhaust area for obstructions. Remove material or debris. Adjust damper flow control.
Downflo II Dust Collector Problem Probable Cause R em edy Display on Delta P control does not read zero when at rest Out of calibration Disconnect pressure tubing. See Delta P Control on Page 20. With collector discharging outside, differential pressure is present from indoor to outdoor Recalibrate with the pressure tubing attached as described in the Delta P Control section on Page 20.
Donaldson Company, Inc. Troubleshooting, continued Problem Probable Cause R em edy Cleaning light is ON, but cleaning system not functioning Improper wiring Check wiring between the Delta P Control and the timer board, and between the timer board and solenoid valve coils. Defective solenoids Check all solenoid coils for proper operation. Timer board not powered Check power ON light on timer board's LED display. If not illuminated, check the supply voltage to the timer board.
Downflo II Dust Collector Service Notes Date Service Performed Notes 47
Donaldson Company, Inc.
Downflo II Dust Collector Date Service Performed Notes 49
Limited 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.
