Donaldson Torit Downflo Evolution DFEP4 User manual

®Evolution
DFEP4 and DFEP6
Installation, Operation and
Maintenance Manual
IOM AK0303601 (ENG)
Revision 0
English
Master Language
. The hazard alert image denotes
safety related instructions and warnings in this manual. DO NOT operate or perform maintenance on this
collector until you have read and understood the instruction and warnings contained within this manual.

Donaldson Company, Inc.
This manual has been supplied to assist with the installation, operation and maintenance for
the collector purchased. Please read the manual before installing, operating, or performing
. It is the
owner’s responsibility to ensure that this manual is available for use by installers, operators and
maintenance personnel that will be working with this collector. This manual is the property of the
owner and should be left with the collector when installation has been completed. DO NOT operate
this collector until you have read and understood the instructions and warnings located in this
manual.
For additional copies of this manual, contact Donaldson Torit.
The Safety Alert Symbol indicates a hazardous situation which, if not avoided could
result in death or serious injury. Obey all safety messages following this symbol to
avoid possible injury or death. The possible hazards are explained in the associated
text messages.
The Notice symbol indicates a potential situation or practice which is not expected to
result in personal injury, but which if not avoided may result in damage to equipment.
i
IMPORTANT NOTES

ii
Contents
IMPORTANT NOTES........................................................................................................................................................................i
1 Safety Communication..............................................................................................................................................................1
2 Product Description...................................................................................................................................................................2
Standard Equipment...........................................................................................................................................................3
Inlet..............................................................................................................................................................................3
Filters ..........................................................................................................................................................................3
Delta P-C01control......................................................................................................................................................3
Top Mounted Junction Box..........................................................................................................................................5
Dust Bin.......................................................................................................................................................................4
Fan and Motor.............................................................................................................................................................4
..............................................................................................................................................4
CompressedAir Connection........................................................................................................................................4
Sprinkler Tap ...............................................................................................................................................................4
Collector Options................................................................................................................................................................5
Delta P Plus Control....................................................................................................................................................5
Extended Capacity Dust Bin........................................................................................................................................5
Accessories........................................................................................................................................................................5
....................................................................................................................................................................5
Explosion Relief Panels...............................................................................................................................................5
Remote Mounted Controls ..........................................................................................................................................5
3 Operation...................................................................................................................................................................................6
DFEP Operation Checklist..................................................................................................................................................7
4 Product Service.........................................................................................................................................................................8
Dust Bin Service.................................................................................................................................................................8
Filter Replacement.............................................................................................................................................................9
.....................................................................................................................................................10
Diaphragm Valve Repair...................................................................................................................................................11
Solenoid Valve Repair......................................................................................................................................................11
FilterAccess CoverAssembly Replacement....................................................................................................................12
Venturi Replacement........................................................................................................................................................12
Yoke Replacement (Special tool required) .......................................................................................................................13
Fan and Motor Replacement............................................................................................................................................14
Troubleshooting................................................................................................................................................................16
AppendixA- Collector Installation.................................................................................................................................................A1
...............................................................................................................................A2
Collector Installation........................................................................................................................................................A3
Collector Location and Site Selection.......................................................................................................................A3
Delivery and Inspection............................................................................................................................................A3
ProvisionalAnchor Bolt Recommendations .............................................................................................................A4
Installation.......................................................................................................................................................................A4
Collector Connections..............................................................................................................................................A4
Initial Start-up / Commissioning................................................................................................................................A6
Decommissioning Collector.............................................................................................................................................A7
Collector Information.......................................................................................................................................................A8
Service Notes..................................................................................................................................................................A8
Donaldson IndustrialAir Filtration Warranty................................................................................................................................A10

Donaldson Company, Inc.
1
Improper operation of dust collectors and/or dust control systems may contribute to conditions in a work area or facility
which could result in severe personal injury, and product or property damage.All dust collection equipment should be
used only for its intended purpose and should be properly selected and sized for its intended use.
Process owners have important responsibilities relating to identifying and addressing potential hazards in their
processes. When the potential for handling combustible dust exists within a process the process owner should include
combustion hazards in their risk management activities and should comply with applicable codes and standards
related to combustible dust.
This equipment is not designed to support site ducts, piping, or electrical services.All ducts, piping, or electrical
services must be adequately supported to prevent injury and/or property damage.
Site selection must account for wind, seismic zone, and other load conditions.
Equipment may reach peak sound pressure levels above 80 dB (A). Noise levels should be considered when selecting
collector location.
Combustible Dust Hazards
Among other considerations, the current NFPAstandards require owners whose processes involve potentially combustible
materials to have a current Dust HazardAnalysis, which can serve as the foundation for their process hazard mitigation strategy.
Mitigation may include but is not limited to:
• Prevention of all ignition sources from entering any dust collection equipment.
•risks in their process.
• Development and use of work practices to maintain safe operating conditions, and to ensure combustible dust does not
accumulate within their plant or process equipment.
Donaldson recommends process owners consult experts in combustion risks to ensure these responsibilities are met. Some
The process owner retains
responsibility to comply with applicable codes and standards and to manage the risks associated with the process or materials.
does not provide engineering consulting services related to process or dust hazard analyses, or code and standard compliance.
Donaldson may provide referrals to consultants and/or suppliers of equipment or services related to the detection and/or mitigation
The process owner’s
Analysis performed by the process owner.Although early engagement of a dust collector supplier can provide helpful insights on
the availability and features of various products, process owners should consult with combustible dust experts and/or process
safety experts before making actual product and mitigation strategy selections.
for the integrity of the system design and compliance with applicable codes and standards. It is the process owner’s responsibility
to understand risks in their process and mitigate those risks in accordance with all applicable laws, regulations and standards,
including those published by the NFPA. Donaldson also recommends proper maintenance and housekeeping procedures and work
Many factors beyond the control of Donaldson can affect the use and performance of Donaldson products in a particular
application, including the conditions under which the product is used. Since these factors are uniquely within the user’s knowledge
purpose and suitable for the user’s application.
1 Safety Communication

2
®
air stream. The standard collector comes equipped with an inlet near the top of the collector which allows an integrated fan to draw
.
The
standard pulse cleaning controls can be upgraded to allow for ‘down-time’
collector is positioned and anchored in place. Plant power is wired to the top mounted junction box. Compressed air is supplied to
collector is ready for operation.
The standard DFEP collector comes with a dust bin located at the base of the collector. This dust bin is on rollers and can be
serviced without tools, which makes dust removal a simple task.An optional extended capacity bin can be selected as an alternate
for situations where larger volumes of dust are expected.
integrated fan to accommodate a range of performance conditions.
Intended Use
nuisance dust or fume. Typical applications
during laser cutting, plasma cutting, thermal
spraying, welding, or abrasive blasting processes.
are very well served by Ultra-Web®
standard in DFEP collectors.
2 Product Description

3
Donaldson Company, Inc.
Inlet
.
Filters
are installed in the correct orientation and direction during servicing.
Delta P-C01 Control
The DFEP ships with a Delta Pcontroller to monitor differential pressure between the clean-air and dirty-air plenums and provides
The Delta P control and a pulse control timer manage pulse cleaning from user established High and Low Pressure Set Points.An
The Delta P controller includes start/stop buttons to control fan motor operation and an E-stop for emergency shut-down of the
DFEP fan and pulse cleaning controls.
For complete information see the current Delta P Installation, Operation, and Maintenance manual.
Standard Equipment
air inlet box
with collar clean air collector
exhaust compressed air
connection
control box
with Delta P
C-01 and
motor starter
collector exhaust
electrical service
connection (junction
box)
cover
sprinkler tap
dust bin access
door (open)
dust bin

4
Dust Bin
The standard dust bin is located below the hopper to collect dust removed from the air stream. The dust bin is sealed to the hopper
discharge with a convenient clamping arrangement which lifts the dust bin against a sealing gasket on the base of the hopper to
ensure a dust tight seal during operation.
Fan and Motor The fan and motor assembly is
located near the base of the collector to increase stability by lowering the collector's center of gravity. The fan/motor chamber is
lined with acoustical foam and is designed in combination with the exhaust plenum to reduce average operational sound pressure
levels below 80 dBa (at distances up to 1 meter from the DFEP).
operation.
Compressed Air Connection
compressed air line upstream of the collector.
pulse cleaning cycle is active.
Sprinkler Tap

5
Donaldson Company, Inc.
Accessories
performance monitoring is desired.
Explosion Relief Panels
The DFEP can be equipped with factory installed explosion relief panels to support a process owner's combustible dust mitigation
strategy. Explosion vent sizing follows NFPA-68 formulas assuming outdoor location of the collector, with no duct or obstruction on
the explosion vent panel(s). Contact Donaldson Torit for explosion venting requirements for other conditions.
Remote Mounted Controls
The DFEP controls can be provided external rather than internal to the collector if desired. Situations such as combustible dusts
may require controls to be mounted at a remote location some distance from the dust collector. This option cannot be pre-wired at
the factory, so additional wiring is required during installation.
Delta P Plus Control
The Delta P Plus offers the same features as the Delta P control with additional pulse cleaning options. The Delta PPlus control
allows an operator to include a pulse cleaning cycle after the collector is shut down (after-shift cleaning), either in addition to, or
instead of, pulse cleaning while the collector is operating.
For complete information, see the current Delta P Plus Installation, Operation, and Maintenance manual.
Aback draft damper may reduce the potential for dust to migrate from the collector inlet when after-shift cleaning is
active.
Extended Capacity Dust Bin
An extended capacity dust bin may be available to provide additional temporary dust storage for situations with heavier dust
loading and does not alter the overall collector height.
Collector Options
Top Mounted Junction Box
The DFEP ships with internal wiring pre-wired at the factory. The top mounted junction box provides the terminal block interface
between the internal wiring and the site-specific incoming wiring. Please refer to the wiring diagram print shipped within the
internal electrical controller enclosure for wiring details.

6
During normal operation, dust-laden air is drawn into the collector through a duct connected to the inlet box, near the top of the
collector. The dust-laden air is then directed downward through the collector body where heavier dust falls directly into the hopper.
air passes into the clean-air plenum where it is drawn through the fan and is discharged through the clean-air outlet.
Dust and fume reaching the base of the collector is directed into a dust bin where it can be removed easily without the need for
tools.
Collector Operation
3 Operation
dirty-air inlet
cartridge
Normal Operation Filter Pulse Cleaning Operation
dust bin
diaphragm
valve
dirty-air inlet
clean-air outlet clean-air outlet

7
Donaldson Company, Inc.
more frequently if more than 2/3 full.
• The DFEP collector can be interlocked to start and stop operation with associated fume producing equipment. Observe
is shut down.
• If the DFEP is operated independently from associated fume producing equipment the DFEPshould be turned on before
turning on any associated equipment, and shut off after the associated equipment is shut down.
• Observe DFEP filter pressure drop on the controller.Asudden change in pressure drop may
indicate the need for service
or maintenance.
•pressure set-points. Excessive differential pressure reduces air volume through the collector.An inability to reduce
•
DFEP Operation Checklist

8
During any service activities there is some potential for exposure to the dust in the collector. Most dusts present safety
and health hazards that require precautions. Wear eye, respiratory, head, and other protection equipment suitable for
the type of dust when performing any service activities..
LOCK-OUT all energy sources prior to performing any service or maintenance on the equipment.The E-Stop feature
of the DFEP Control is NOTa Lock-Out device.
Dust Bin Service
The dust bin should be emptied daily or more frequently as required.
1. Turn off collector.
2. If equippped with a Delta P Plus/Delta P-C01controller, ensure the downtime cleaning cycle has ended.
3. Open the dust bin access door by rotating the two handles counter clockwise.
4. Reach in and lift the dust bin locking bar up until the bar clears the top of the bin. This should lower the dust bin to the ground.
5. Roll the dust bin from under the collector hopper.
6. Transfer dust from the dust bin to a suitable disposal site.Aliner may be used in the dust bin and dust can then be transferred
from the dust bin for suitable disposal using the liner. (Avacuum is not required or recommended for servicing the bin.)
a. For the extended capacity dust bin, remove the bag liner retention bar.
b. Close and seal the bag liner.
c. Lift the bag liner from the dust bin and properly dispose of sealed bag liner and dust.
d. Install a fresh bag liner in dust bin.
e. For the extended capacity dust bin, replace bag liner retention bar.
7. Inspect the area around the dust bin and remove any spilled dust.
If a vacuum is used to remove dust from below the hopper, make certain it is suitable for the type of dust and the
operator is trained in its operation.
8. Inspect and clean the hopper discharge gasket surface. Replace gasket if worn or damaged.
9. With the locking bar up, align and insert the dust bin under the collection hopper until it contacts the mechanical stops on the
hopper assembly.
10. Lower dust bin locking bar to its down and locked position.
11. Close and latch dust bin access door by rotating the two handles clockwise.
4 Product Service

9
Donaldson Company, Inc.
Most dusts present safety and health hazards that require precautions. Wear eye, respiratory, head and other
protection equipment suitable for the type of dust.
damage.
1. Turn off collector and Lock-Out all energy sources.
2.
3.
4.
5.
U
endcap (non-gasketed end) must match with the alignment mark (U
6.
7. Inspect and clean the access cover gaskets. Replace gaskets if they become worn or damaged.
8.
9. may be used.
to ensure a dust tight seal.
10.
. This condition will result in shorter
alignment marker
yoke filter cartridge
access cover
cover knob
Filter Replacement
Filter Replacement

10
which can be monitored.
1. Turn off collector and Lock-Out all energy sources.
2.
3.
4.
5.
6.
7.
8.

11
Donaldson Company, Inc.
Solenoid Valve Repair
Adamaged solenoid valve can be serviced by repairing or replacing the individual solenoids located within the solenoid enclosure.
To repair or replace an individual solenoid:
1. many indicate a damaged cleaning valve).
2. Turn off collector and Lock-Out all energy sources.
3. Close the compressed air shut off valve (owner supplied) and bleed the pressure from the DFEPmanifold.
4.
5. Locate and mark each tube between the diaphragm valves and the solenoid enclosure to ensure they can be
reconnected in their original locations.
6. Disconnect all tubes from the solenoid enclosure.
7. Remove the bolts attaching the solenoid enclosure to the manifold.
8. On the underside of the solenoid enclosure, unscrew the two screws securing the solenoid cover until the cover
comes loose.
9. Remove the solenoid cover.
10. Replace or repair the damaged solenoid(s).
11. Re-attach the solenoid cover.
12. Reconnect the solenoid enclosure to the manifold.
13. Reconnect all tubing to original positions on the solenoid enclosure.
14.
15. Open the compressed air shut-off valve and re-pressurize the manifold.
16. Return power to the collector and resume DFEP operation.
Adamaged diaphragm valve can be serviced, repaired or replaced. To repair or replace a damaged valve:
1. may indicate a damaged cleaning valve).
2. Turn off the collector and Lock-Out all energy sources being certain
to close the compressed air shut off valve (owner supplied) and bleed
pressure from the DFEP manifold.
3. Remove the rear access panel of the DFEP. For collectors with
4. Locate and repair or replace the damaged valve.
5.
6. Open the compressed air shut-off valve and re-pressurize the
manifold.
7. Resume DFEP operation.
Diaphragm Valve Repair

12
Venturi Replacement
To replace a damaged venturi:
1. Turn off the collector and Lock-Out all energy sources.
2.
3.
4.
5. Open the control panel access door.
6. panel, from the control panel access door.
7.
8.
9.
10.
11. Tighten the six thread forming screws to attach the venturi.
12.
13.
14. Close and secure the control panel access door.
15. Return power to the collector and resume DFEP operation.
1. Turn off collector and Lock-Out all energy sources
2.
3.
4. Remove theAccess Cover Pin, Clevis and E-Clip from the collector end of the access cover hinge assembly.
5. the upper and lower Hinge Pin Shoulder Spacers.
6. After the knob has been hand tightened
(3-turns) a tool assist may be used.
to ensure a dust tight seal.
Step 6
Step 9
Filter Access Cover Assembly Replacement

13
Donaldson Company, Inc.
1. Turn off the collector and Lock-Out all energy sources.
2.
3.
4.
5. Open the control panel access door.
6. Locate and remove the nuts, fender washers and star washers from the damaged yoke through
the control panel access door. Note the sequence of the hardware placement on the yoke threads.
7. the damaged yoke.
8. , and
star washer).
9.
10. Position the yoke alignment tool (part numberAG8265294) over the front threaded end of the
yoke and securing the alignment tool to the front face of the collector. This tool ensures optimum
positioning for the new yoke.
11. onto the yoke.
12.
hardware is hand tight, continue to tighten hardware until the yoke is secure.
When properly tightened, the hardware should secure the yoke
in the position established by the alignment tool (i.e. when the
alignment tool is removed, the yoke should not spring to a new position).
13. Remove the YokeAlignment Tool from front of yoke.
14.
15.
to ensure a dust tight seal.
16. Return power to the collector and resume DFEP operation.
Yoke Alignment Tool
Yoke Replacement (Special tool required)

16
Fan and Motor Access
Front Access Cover Fan and Motor Access
Rear Acccess Cover
To replace a damaged fan or motor assembly:
1. Turn off the collector and Lock-Out all energy sources.
2. Open the dust bin access door.
3. Remove the dust bin. (If collector has an extended capacity dust bin, skip to Step 5.)
4. Remove the lower hopper assembly
a. Block up the sides of the dust bin assembly
b. Loosen the lower hopper hardware (nuts and bolts) and remove the lower hopper assembly.
c.
d. .
5. Remove the bolts securing the front and rear motor access panels.
6. Disconnect the motor from electrical wiring.
7. Loosen and remove the bolts securing the motor to the motor mount.
8. Carefully lower the motor and fan for removal from the collector housing.
9. From the front motor access opening, remove the
motor and fan wheel assembly from the housing.
(Removal through the rear motor access opening
is an option .)
For KV11 fan, only can remove the fan from the
rear access opening.
10. Insert the new or repaired motor and fan
assembly into the collector through the motor
access opening.
11. Lift the motor and fan assembly to the motor
mount and install and tighten the motor mounting
bolts.
12. Adjust the motor fan position such that the cone
position is 0.188-inches inside the fan wheel
entrance.
13. Adjust the fan inlet cone to ensure no contact
bewteen the fan wheel and fan inlet cone.
14. Connect fan to electrical wiring. (Note: fan
been disconnected and reconnected.)
15. Reinstall the front and rear motor access panels.
Fan and Motor Replacement

17
Donaldson Company, Inc.
16. Reinstall the lower hopper assembly for the dust bin. (If you have an extended capacity drum skip to step 17.)
a.
b. Position lower hopper assembly under hopper.
c.
d. Lift lower hopper assembly into position and tighten hardware.
e.
17. Position and seal dust bin to hopper.
18. Close the dust bin access door.
19. Return power to the collector and resume DFEP operation.

18
Problem Probable Cause Remedy
Fan/blower does not
start Not wired correctly Check supply voltage and wiring connections. Review
motor manufacturer’s wiring diagram, collector wiring
schematics, and the National Electric Code and correct
any wiring errors.
Electrical circuit down Check power supply and correct any faults to restore
power.
Input control circuit down Check wiring to ensure motor starter engages when
appropriate.
Damaged motor Replace or repair damaged motor.
Fan/blower starts but
does not continue to run static pressure resistance Check access covers, dust bin and ducts. All access
panels and doors must be secured before operation. Dust
bin must be in place and sealed prior to operation.All
Damper control not adjusted
properly
Electrical circuit overload protection
trips equipment on circuit and matches motor voltage
requirements.
Motor starter not properly selected
for motor size and voltage Check starter and replace if necessary for actual motor size and voltage.
Dust emissions at air
outlet Access cover(s) loose Tighten all access covers securely. See Filter Installation.
Filter(s) damaged Inspect gaskets, end caps, liners and media for damage
Filters not properly installed See Filter Installation.
Correct any faults in the cleaning system (compressed air
Restriction exists despite pulse
cleaning system operation (end of
Open door, bin connection, or
missing duct Check access covers, dust bin, and ducts. All access panels, and doors must be secured before operation.
Dust bin must be in place and sealed prior to operation.
All ducts must be connected to the system prior to
operation.
Incorrect collector/fan selection
Restriction in hoods, ducts, or other
system components. Inspect system components and remove any restrictions such as material deposits in hoods or ducts.
Troubleshooting

19
Donaldson Company, Inc.
Problem Probable Cause Remedy
continued Fan exhaust restricted Check fan exhaust area and remove any obstructions.
Fan rotation backwards Check fan rotation when observed through control panel
access opening. Reverse rotation if necessary.
No display on the Delta P
Controller No power to the controller Use a voltmeter to check for supply voltage.
Fuse blown Check the fuse in the control panel. See wiring diagram
inside the control panel. Replace if necessary.
Display on Delta P
Controller does not read
zero when at rest
Out of calibration Recalibrate as described in Delta P Maintenance Manual.
Ensure the fan is not running during the calibration.
With collector discharging outside,
differential pressure is present from
indoor to outdoor
Recalibrate with the pressure tubing attached as
described in the Delta P Maintenance Manual.
Delta P Controller ON,
but cleaning system
does not start
Pressure tubing disconnected,
ruptured, or plugged Check tubing for kinks, breaks, contamination, or loose connections.
Not wired to the timing board
correctly Connect the pressure switch on the timer board to Terminals 7 and 8 on TB3.
Faulty relay Using a multimeter, test relay for proper closure. Replace
if necessary.
Troubleshooting