INDEX

INTRODUCTION ....................................................................................................................... 3 RECEIVING YOUR EQUIPMENT............................................................................................... 3 SAFETY PRECAUTIONS .......................................................................................................... 4 DEFINITIONS ........................................................................................................................... 5 THE FILTRATION PROCESS .................................................................................................... 6
Pulse jet Theory............................................................................................................................................................. 8 E-86 Theory ................................................................................................................................................................... 9

FILTER MEDIA PROPERTIES..................................................................................................10

Surface Treatment of Filtration Media......................................................................................................................12 Pre-coating Filter Media .............................................................................................................................................12

INSTALLATION .......................................................................................................................13
Bags and Cages - bottom access ...........................................................................................................................13 Bags and Cages - top access ..................................................................................................................................14 E86 cartridge installation ...........................................................................................................................................15 Explosion vents (optional) .........................................................................................................................................16

MAINTENANCE ......................................................................................................................17 TROUBLESHOOTING FILTERS ................................................................................................19 CONNECTIONS AND WIRING..................................................................................................21

Magnehelic Gauge......................................................................................................................................................21 Timer Circuit Schematic.............................................................................................................................................22 Timer Board..................................................................................................................................................................23 Bag Dump Station with Limit Switch........................................................................................................................24 Bag Dump Station with Door Limit Switch & Bypass ...........................................................................................25

INTRODUCTION
Airlanco along with all of our employees thank you for selecting us to fulfill your needs for environmental control equipment. Pulse jet filters provide a mechanically simple, efficient and economical means to separate particulate from a gas stream. The absolute minimum of moving parts enhances the efficiency and durability of the system. This manual will provide the information needed for an operator or maintenance technician to understand the process of fabric filtration and the mechanical operation of your Airlanco pulse jet filter. Understanding these basic principles will assure that this filter will provide years of dependable service with minimum maintenance. Thank You.

RECEIVING YOUR EQUIPMENT

A visual inspection of your equipment should be performed before it is removed from the truck. Dents, scratches and other damage should be noted and photographed. The structural integrity of the filter housing will be adversely affected by dents. Airlanco should be notified of any structural damage to your equipment immediately. Packing lists should be checked thoroughly and shortages should also be reported to Airlanco. It is the purchasers responsibility to file shortage reports and damage claims with the carrier and the supplier. The carrier is responsible for any damage to the equipment while it is in transit.

SAFETY PRECAUTIONS
Warnings Do not operate this equipment without guards, access doors and covers secured. Lock out power before servicing this equipment. This equipment is automatically controlled and will start at any time without warning. Do not enter access plenum while system fan is operating: airflow can pull service door closed causing severe injury or entrapment. OSHA considers some filter housings a confined space. Follow procedures set forth by your safety administrator.

FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE! !READ AND UNDERSTAND SAFETY DECALS! Decals

DEFINITIONS
ACR Air to Cloth Ratio. The velocity that a gas moves through filter media. Divide the gas volumetric flow rate (cfm) by the total area of filtration media in (sq. ft.) To gather into a mass. Filter element, sock. Usually supported by a wire cage. Agglomeration of dust particles on the surface of a filter element. Upward speed of air moving through a filter housing (fpm). Divide the gas volumetric flow (cfm) by the cross sectional area of the baghouse (sq. ft.) Filter element consisting of a pleated filter media supported on a steel or plastic skeletal frame. Cubic Feet per Minute gas flow rate. Section of a baghouse directly above the tubesheet and filter bags or cartridges. The temperature at which water vapor in a gas will condense into a liquid state. The accumulation of dust on a filter element before cleaning. assists in the filtration of dust. Refers to a filter bag or cartridge. The pressurized pipe that contains the compressed air supply for pulsing. A unit of pressure equal to the pressure exerted by a column of water oneinch in height at a standard temperature. 27.7 in. wg. = 1psi. The apparent velocity of a gas as it passes through the filter element matrix. It is found by dividing the gas flow rate (cfm) by the cross sectional area of the filter housing less the area occupied by the filter elements. The resistance of flow of a fluid between two points. The length of time a cleaning pulse lasts. The time between pulses in a baghouse cleaning system. Generic name given to all pulsing dust collectors. Pipe with holes in it that extends into a filter clean air plenum and delivers cleaning air from the header to the filter elements. The phenomenon whereby dust is collected from the air stream and then is returned to the air stream. Occurs when dust is pulsed from a filter element and then caught by an upward moving air stream. The application of a relatively coarse, dry dust to a filter element before startup to provide an initial filter cake for immediate high efficiency and to protect filter elements from blinding. The steel plate that filter elements are suspended from. Separates the clean air and dirty sections of the baghouse. Device used to increase the efficiency of a compressed air pulse. This cake Agglomeration Bag Cake Can Velocity

Cartridge Filter

CFM Clean Air Plenum

Dew Point

Filter Cake

Filter Element Header Inch of water

Interstitial Velocity

Pressure drop Pulse duration Pulse frequency Pulse Jet Purgepipe

Re-entrainment

Seeding

Tubesheet

Venturi

THE FILTRATION PROCESS

Filtration is a dry method of particulate collection in which an array of many individual targets is assembled into a porous structure through which the aerosol-laden gas is passed. In a pulse jet filter the collection target is the filter media. Inertial, diffusional, electrostatic, and direct interception are the primary forces that influence the collection of dry particulate on the filter media. As collection proceeds, particles impinge upon previously collected particles and a deposit is built up which in turn becomes a principal collection medium. This agglomeration of particles is referred to as a filter cake. Filtration efficiency is not maximized until this filter cake has formed. It is normal for a new filter element, which has not been broken in, to allow some fine dust to pass through it. This slightly visible emission should subside after 72 hrs of operation or sooner. As the dust cake builds on the filter element surface it becomes increasingly difficult for the gas to pass through the element. A differential pressure gauge mounted on the filter measures the force required to pass the gas through the filter media. Normal pressure drop for a pulse jet filter will fall in the range of 3 to 5 inches of water after the elements are broken in. As the elements get dirty the differential pressure reading will increase. Eventually the dust cake must be removed from the filter element surface or airflow will fall to unacceptable levels. Pulse jet filters are continuous self-cleaning units. A high-pressure blast of clean dry compressed air is injected into each filter element at periodic intervals. This air is stored in a reservoir called a header. Several purgepipes are attached to the header and extend into the clean air plenum above rows of filter elements or cartridges. Holes are drilled in the purgepipes directly above each of the filter elements. Several elements are cleaned by one purge pipe. A solid state timer controls a solenoid that opens a diaphragm valve allowing air to flow from the reservoir into the purge pipe and filter element. The element experiences a shock wave while air is forced through it in a direction opposite to the dirty air flow. A percentage of the dust cake will fall away from the bag into the filters hopper. It is normal for some of the dust to re-entrain itself onto the filter element. High Temperature Precautions Moisture is one of the most predominate causes for fabric filter failures. Care must be taken in applications involving high humidity gas streams. Dryers and other combustion processes pose the greatest danger for condensation in the filter. The filters and gas stream temperatures must be maintained at 50oF above the dewpoint of the gas stream. Excursions near or below the dewpoint of the gas stream will result in condensation of the gas on the baghouse and filter media. This moisture will change the desired dust cake into an undesirable mud cake, which is difficult to remove, and may permanently damage the filter media. Corrosion is also intensified under these conditions. Filters operating under high humidity conditions at any temperature should be protected from gas condensation. This will require heating the filter to 50oF above the gas stream temperature and insulation of the filter and ducting. Failure to take these precautions will result in unsatisfactory performance of the equipment and possible catastrophic failure of the filter media. Mechanical Operation Airlanco Pulse jet filters are available with continuous or "on demand" cleaning control. Cleaning duration and frequency are adjustable on the timer board. Photohelic pressure switches can be used to control the cleaning cycle, which will conserve energy, element wear, and emissions by maintaining a set pressure drop across the filter elements. Filter bags are made from felted fibers and are supported on a rigid wire cage. Filter cartridges are made from pleated filter media and supported on skeletal frames. The composition of the fiber will vary depending on the dust and gas chemistry, temperature and gas stream humidity. Consult Airlanco engineering for further information on the characteristics and types of available filter medias.

THE FILTRATION PROCESS - Continued

Filter elements are suspended in the filter from the tubesheet. Wire cages slip into bags and provide support. Cartridges are self-supporting. On bottom removal filters the filter element attaches to the factory installed venturi collar with a clamp band. For bag and cage assemblies, the cage is inserted into the bag and this assembly is slipped over the venturi collar. Cartridges install directly onto the venturi collar. On top removal filters the bag or cartridge snaps into the tubesheet hole. Bags require a cage to be slipped into the bag and its top collar rests on top of the tubesheet. Dust is collected on the surface of the filter media and eventually forms a thick cake. When a pulse of compressed air is injected into the filter element a shock wave is induced that causes the dust cake to break away. Some of this air will pass through the filter media in a reverse direction and further separate the dust cake from it. The name "Reverse Pulse Jet" is derived from this cleaning method. Separated dust falls into the hopper where it is removed through an airlock or other airtight device. The airlock has a very important function of preventing air from entering the hopper through its discharge. Leakage at the hopper's discharge will cause re-entrainment of dust onto the filter elements, which could contribute to high differential pressures. The solid state programmable timer is available with 3 to 32 output connections. A potentiometer is provided for the adjustment of the pulse duration and frequency. Duration of the pulse is factory set at 50 milliseconds. Frequency of the pulse is factory set at 10 to 15 seconds. Solenoid & Diaphragm Valve Cleaning air passes from the header through a large diaphragm valve into the purge pipe and into the filter element. This diaphragm valve is controlled by the timer board with a normally closed solenoid valve (Figure 1).

SOLENOID & DIAPHRAGM VALVE OPERATION

SOLENOID ENCLOSURE SOLENOID VALVE SOLENOID VALVE DIAPHRAGM VALVE VENT TO ATMOSHERE DIAPHRAGM VALVE DIAPHRAGM (OPEN) AIR TO BLOWPIPE DIAPHRAGM (CLOSED)

1/4" TUBING

BLEED POINT COMPRESSED AIR FROM HEADER

SOLENOID DE - ENERGIZED

SOLENOID ENERGIZED

Figure 1 Solenoid valve operation 7

Pulse jet Theory

THEORY OF OPERATION (BAG & CAGE PULSE JET FILTER)

# DUST LADEN AIR OR GAS ENTERS THE DUST COLLECTOR THROUGH THE MATERIAL INLET # AIR PASSES THROUGH THE FILTER MEDIA WHILE SOLIDS ARE RETAINED ON THE FILTER SURFACE. # A SIGNAL FROM THE TIMER ACTUATES THE OPENING OF THE NORMALLY CLOSED SOLENOID VALVE. # THIS PERMITS A MOMENTARY PULSE OF COMPRESSED AIR TO FLOW FROM THE AIR HEADER DOWN THE BLOWPIPE AND OUT INTO EACH FILTER BAG. # THIS MOMENTARY PULSE TAKES ALL BAGS IN ONE ROW OFF LINE THROUGH PRESSURE REVERSAL. # SOLIDS ARE RELEASED TO FALL INTO FILTER HOPPER OR EXISTING BIN.

# OPENING OF THE SOLENOID VALVE # FILTERED AIR EXITS THROUGH THE CLEAN DECREASES THE AIR PRESSURE IN THE AIR PLENUM EXHAUST. TUBE CONNECTING THE SOLENOID TO THE DIAPHRAGM VALVE CAUSING THE THE VALVE TO OPEN. MODEL NUMBER DEFINITION (EXAMPLE) 64 AVS 8 STYLE III

TIMER & SOLENOID ENCLOSURES DIAPHRAGM VALVE COMPRESSED AIR HEADER

NUMBER OF BAGS PURGE AIR PIPE

STYLE OF FILTER CLEAN AIR PLENUM

NOMINAL LENGTH OF BAGS IN FEET

CLEAN AIR EXHAUST TUBESHEET

MAGNEHELIC GAUGE

NO-TOOL ACCESS DOOR

FILTER BAG & CAGE ASSEMBLY

DIRTY AIR HOUSING

SECONDARY AIR

PRIMARY PULSE

MATERIAL INLET

TUBESHEET BAG CUP BAG CLAMP VENTURI

HOPPER

AIRLOCK

Figure 2 Pulse jet filter operation

E-86 Theory

THEORY OF OPERATION E - 86 (CARTRIDGE PULSE JET FILTER)

# DUST LADEN AIR OR GAS ENTERS THE DUST COLLECTOR THROUGH THE MATERIAL INLET # AIR PASSES THROUGH THE FILTER MEDIA WHILE SOLIDS ARE RETAINED ON THE FILTER SURFACE. # A SIGNAL FROM THE TIMER ACTUATES THE OPENING OF THE NORMALLY CLOSED SOLENOID VALVE. # OPENING OF THE SOLENOID VALVE DECREASES THE AIR PRESSURE IN THE TUBE CONNECTION THE SOLENOID TO THE DIAPHRAGM VALVE CAUSING THE THE VALVE TO OPEN. # THIS PERMITS A MOMENTARY PULSE OF COMPRESSED AIR TO FLOW FROM THE AIR HEADER DOWN THE BLOWPIPE AND OUT INTO EACH FILTER BAG. # THIS MOMENTARY TAKES ALL BAGS IN ONE ROW OFF LINE THROUGH PRESSURE REVERSAL. # SOLIDS ARE RELEASED TO FALL INTO FILTER HOPPER OR EXISTING BIN. # FILTERED AIR EXITS THROUGH CLEAN AIR PLENUM EXHAUST.

MODEL NUMBER DEFINITION (EXAMPLE) 202 55 E86

NUMBER OF ROWS

NUMBER OF COLUMNS

NOMINAL LENGTH OF ELEMENT CARTRIDGE IN INCHES DIA. 8.6"

CLEAN AIR EXHAUST MATERIAL INLET

MAGNEHELIC GAUGE CARTRIDGE FILTER PURGE AIR PIPE CLEAN AIR PLENUM TIMER & SOLENOID ENCLOSURES DIRTY AIR HOUSING DIAPHRAGM VALVE COMPRESSED HEADER

SECONDARY AIR (TYP) PRIMARY PULSE (TYP) PURGE AIR PIPE

CARTRIDGE FILTERS HOPPER CARTRIDGE FILTER SEAL

AIRLOCK

Figure 3 E86 filter operation 9

FILTER MEDIA PROPERTIES

Filter media is manufactured from various materials, which provide different beneficial characteristics: Table 1 is a Fabric Selection chart, which summarizes some of the properties of common fabric materials.

FILTRATION PROPERTIES

STRENGTH & ABRASION

SOLVENT RESISTNACE

MATERIAL POLYESTER POLYPROPYLENE WOOL ACRYLIC COPOLYMER FIBERGLASS NOMEX P-84 RYTON TEFLON LEGEND POOR FAIR GOOD VERY GOOD EXCELLENT

G E G G E F V E E

G E F F F G F E E

G E G G E V V E E

E E P G P G G G G

G P P P E E E E E

E G G G F E E V F

1 1 1 2 3 4 5 6 8

P F G V E Table 1

Cotton While cotton is an excellent, low cost natural filtration fiber available in a wide variety of fabric styles, the primary limitation of cotton fabrics is their temperature limit for continuous operation of 180F (83C) and for maximum surges of 225F (105C). Cotton is also subject to shrinkage and damage by bacteria and acidic environments. Cotton is being displaced by synthetic fibers such as polyesters and acrylics, which offer extended life and resistance to acids and to higher temperatures. Application is still seen in ambient-temperature industries such as quarry operations. Polypropylene This synthetic is available in both continuous filament and staple fiber form and is produced as either a felt or woven material but its major limitation is its low maximum continuous operating temperature of 180F (88C). Polypropylene is damaged by oxidizing agents, copper, and related salts. Its primary benefit is that it is non-hygroscopic (i.e., does not chemically react with water). It exhibits great resistance to static build-up and abrasion, and provides a slick surface for good dust cake release during cleaning pulses. Polypropylene is widely used in the food, detergent, chemical processing, pharmaceutical and tobacco industries.

OPERATING TEMP F 275 180 200 260 500 425 500 375 450

ALKALI RESISTANCE

FLAMERESISTANCE

ACID RESISTANCE

RELATIVE COST

10

FILTER MEDIA PROPERTIES - Continued

Acrylics These synthetic fibers offer good hydrolytic resistance over a limited temperature range, 260F (127C) continuous, 275F (135C) surge. The homopolymer versions, such as Draylon T produced by Farbenfabriken Bayer AG, are normally recommended. Acrylic fibers are used in the manufacture of ferrous and of ferrous metals, carbon black, cement, lime, fertilizers and following spray-dryers in coal-fired burners. They are also used extensively in wet-filtration applications. Polyesters Today, polyesters are among the most widely used fabrics for general applications below 275F (135C), their maximum continuous-use temperature. Their maximum surge temperature is about 300F (149C). Polyester fibers are produced in both filament and staple form and are available in both woven and felted fabrics. The primary damaging agents are water (hydrolysis) and concentrated sulfuric, nitric and carbolic acids. They have good resistance to weak alkalies and fair resistance to strong alkalies at low temperatures. They have good resistance to most oxidizing agents and excellent resistance to most organic solvents. Ryton This is a relatively new synthetic fiber with a moderate temperature range, 375F (190C) continuous, 450F, (232C) surge. It will hydrolyze, but only at temperatures above 375F. It has excellent resistance to both acids and alkalies, which makes it very useful in combustion-control applications. Its early applications have been on industrial coal-fired boilers, waste-to-energy incineration -- with and without spray dryers --, titanium dioxide, and installations where Nomex does not perform well due to chemical or hydrolytic attack. Nomex This is a commonly used fiber for applications in the 275-400F (135-204C) range. It is produced in both filament and staple fiber form and is available as both woven and felted fabrics. It has excellent thermal stability, shrinking less than 1% at 350F (177C). The fiber is flame resistant, but when impregnated with combustible dusts will support combustion that will melt and destroy the fabric. Nomex will begin to hydrolyze at 375oF (190C) when the relative humidity is 10% or greater. Hydrolysis changes the normal white or grey fabric to a red-brown color. The presence of acids will catalyze the hydrolysis process. Unacceptably short element life will result where SOx and moisture are present and frequent dew point excursions occur -- such as coal-fired boilers. Some acidretardant finishes have been developed for Nomex, but have been found to improve element life by no more than 50%, leaving most element life cycles unacceptably short. Teflon (PTFE) Teflon is unique among synthetics in its ability to resist chemical attack across the entire pH range throughout its operating temperature range of 450F (232C) continuous, to 500F (260C) surge. This fluorocarbon fiber is non-adhesive, has zero moisture absorption and is unaffected by mildew or ultraviolet light. The primary shortcomings of Teflon are its poorer abrasion resistance and relatively high cost. However, the higher cost can often be justified through longer element life in extreme corrosive atmospheres. Felted Teflon is also produced in combination with staple glass fibers and marketed by DuPont as Tefaire. This combination produces some improved filtration and flow characteristics. Applications of Teflon include coal-fired boilers, waste-to-energy incinerators, carbon black, titanium dioxide, primary and secondary smelting operations, and chemical processing.

11

FILTER MEDIA PROPERTIES - Continued

Fiberglass Most fiberglass fabrics are woven from minute, 0.00015 inch (.0038 mm) filaments. Many variations of yarn construction, fabric weaves, and fabric finishes are available. It is also produced in a felted form. Fiberglass has the highest operating temperature range available in conventional fabrics: 500F (260C) continuous, 550F (288C) surge. Above 500F (260 C), the fiberglass itself is not directly damaged, but the finish which provides yarn-to-yarn lubrication begins to vaporize, resulting in accelerated mechanical wear of the glass fibers. Fiberglass is noncombustible, has zero moisture absorption (cannot hydrolyze), has excellent dimensional stability, and has reasonably good strength characteristics. Woven glass fabrics have high tensile strength characteristics but relatively low flex strength, especially in the fill (circumference) direction of the element, and low abrasion resistance. Care must be taken to minimize flexing and rubbing. Fiberglass fabrics have relatively good resistance to acids but impurities in the glass fibers are attacked by hydrofluoric, concentrated sulfuric, and hot phosphoric acids. They also have poor resistance to hot solutions of week alkalies, acid anhydrides, and metallic oxides. For these reasons, glass fabrics should not be operated below the acid dew point. Fiberglass fabrics are used extensively with coal-fired boilers and high temperature metals applications. P-84 P-84 is an aromatic polymer fiber produced in felt form only. The unique shape of the fiber produces improved capture efficiency characteristics. This fabric is specified at 500F. Composites are available that take advantage of the superior filtration characteristics of P-84 while reducing its cost. Any of the previous felted materials can be combined with P-84 to produce a fabric composite that exhibits the characteristics of both materials. Surface Treatment of Filtration Media Various types of surface treatment are available to enhance the filter medias performance. Discussion of these treatments and their benefits are beyond the scope of this manual. Please consult Airlanco engineering for further information on this subject. Pre-coating Filter Media Fine, moist, or adhesive dusts will contribute to premature blinding of filter media. Pre-coating of the filter media with a layer of an inert dust of known particle size distribution, such as calcium carbonate (CaCO3), can minimize problems associated with these types of dusts. Consult Airlanco engineering for information and recommendations regarding the pre-coating of your filter media.

12

INSTALLATION
Filter Airlanco pulse jet filters, depending on size, will be shipped either as complete units or in sections. All units require the installation of the filter elements along with connections to 110 VAC and compressed air. Larger filters are shipped in major sub assemblies that are bolted together at the jobsite and set on the foundation. Refer to the general arrangement drawing for details on the number of sub-assemblies and the extent of assembly required for your unit. Compressed Air Airlanco pulse jet filters having bags and cages require 90-100 psi CLEAN, DRY, compressed air. Cartridge filters require 60 psi max. This supply is connected to the filter header. The general arrangement drawing will note the location and pipe size for the compressed air feed. Lubrication There are not any lubrication requirements on a pulse jet filter. However, discharge devices such as a rotary airlock will require lubrication. Refer to the specific manuals for lubrication of this equipment.

Bags and Cages

BOTTOM ACCESS BAG AND CAGE INSTALLATION

STEP 4
ENTER FILTER HOUSING WITH BAG, CAGE AND CLAMP BAND ASSEMBLY AND SLIDE THE CAGE COLLAR OVER THE BAG CUP UNTILL LOCKING RIDGES ARE ENGAGED. TIGHTEN CLAMP BAND.

STEP 3
SLIDE CLAMP BAND OVER BAG AND CAGE ALIGNING IT ABOVE THE CAGE COLLAR RIDGE. BAG CUP CLAMP BAND SPLIT TOP CAGE COLLAR SUPPORT CAGE

STEP 2
FOLD TOP OF BAG AND GROUND STRIP (IF SUPPLIED) INTO CAGE.

STEP 1
SLIDE CAGE INTO BAG BEFORE ENTERING FILTER HOUSING. ALIGN SEAM IN BAG WITH SPLIT IN CAGE COLLAR.

FILTER BAG

Figure 4 Bottom access bag and cage installation

13

INSTALLATION - Continued
TOP ACCESS BAG AND CAGE INSTALLATION

1. 2. 3. 4. 5.

6.

Lower bottom of bag through hole in tubesheet. Fold snap band (bag top) to insert it into tubesheet hole. Fit the groove of snap band to the edge of the tubesheet and allow band to snap in place. Slide cage into bag until it rests on the tubesheet. If the bags are equipped with a grounding strip, fold the wire over the top of the bag and down its side prior to fitting in the tubesheet. Wire should be between bag cuff and tubesheet as shown in the illustration. Check the fit of the snap band. It should be a secure fit all around with no wrinkles in the snap band. The top of the bag should be above tubesheet approximately 3/8".

CAGE TOP TUBESHEET

SPRING STEEL SNAP BAND

WIRE CAGE GROUND WIRE BAG CUFF

FILTER BAG

Figure 5 Top access bag and cage installation

14

INSTALLATION - Continued
E86 cartridge installation

OUTSIDE CARTRIDGE PLATE WING NUTS OPEN END COLLAR

CLOSED END

GUIDE RODS

WELDED STUDS

Check the sealing gasket on the filter element. It should be secure on both ends. If the gasket has been damaged it can be repaired with silicone caulk if the damage is minor. Major damage will require replacement of the gasket, contact Airlanco. If the gasket is loose it can be re-attached with silicone caulk. Insert filter element into the cartridge plate hole. Avoid pleated element contact with the cartridge plate hole edges. This could damage the filter media. Align the flange holes with the studs in the cartridge plate. Tighten the wing nuts by hand until the flange touches the cartridge plate. The gasket will be fully compressed.

Figure 6 E86 cartridge installation

15

INSTALLATION - Continued
Explosion vents (optional) Explosion vent panels should be oriented away from inhabited work zones or traffic ways. Filters located in a building should be situated on an outside wall and ducted through the wall to the outside. These ducts should not exceed 10 ft. Consult Airlanco for further information on explosion vent ducts. Airlanco explosion vents use polymer shear fasteners. Airlanco filters are shipped with the explosion vents fully installed. Four steel shipping bolts located in the corners of the vents must be replaced with the polymer bolts supplied. These bolts should be torqued snug not to exceed 20 in. lb. FAILURE TO REPLACE THESE STEEL BOLTS COULD RESULT IN INJURY AND DAMAGE TO PROPERTY! Periodic inspection of the explosion panels should be performed. Check bolt torque and replace when they will no longer torque to 20 in. lb. Check safety chain bolts and tighten or replace if necessary.

BAGHOUSE

EXPLOSION VENT PANEL

REPLACE STEEL SHIPPING BOLTS WITH POLYMER BOLTS SUPPLIED TORQUE TO 20 IN LBS.

Figure 7 Explosion vent

16

MAINTENANCE
Very little maintenance is required to achieve maximum efficiency and life from your Airlanco Pulse jet filter. The following items should be periodically serviced. Lubrication Pulse jet filters have no lubrication requirements. Timer Adjustments Do not change the timer adjustments until the filter has had several weeks to stabilize. This break-in period is required for the filter media to develop a stable interstitial dust cake. After the break-in period the cleaning frequency can be increased in order to conserve energy and compressed air. Increase the pulse frequency by adjusting the potentiometer clearly marked on the timer board. Adjust in 5 second increments allowing 24 hrs of operation between adjustments. After 24 hrs observe the differential pressure of the unit. The pulse frequency can be extended until an increase in differential pressure is observed in the filter. For additional information refer to the manufacturers instructions in the appendix. The timer board does not require any maintenance but must be kept free of dust and moisture. Refer to the timer manufacture's manual (attached) for more detailed operation and maintenance information. Cleaning and Repair The external portion of this unit should be treated as any other metal surface that is subject to corrosion. Clean periodically and repaint damaged surfaces when needed to prevent corrosion. Dust may enter the clean air plenum through a leaking or broken filter element. Remove accumulated dust from clean air plenum immediately. Dust in the clean air side of a filter element will reduce the life and performance of the element. Solenoid and Diaphragm Valves The solenoid and diaphragm valves may require periodic maintenance depending on the quality of the compressed air supplied to the unit. Filter Elements Filter elements do not require any periodic maintenance. However, at some point the elements will require replacement or cleaning. This will be designated by persistent high differential pressure across the elements and are not accompanied by any other change in the operating parameters of the system. Many factors effect the life of filter elements. Refer to the section on trouble shooting if low element life or persistent wear problems are evident. NOTE: All elements that are to be cleaned should be vacuum cleaned prior to the cleaning process. Element Cleaning Process: Polyester felt fibers are not subject to shrinkage by water alone. They may be washed in water that does not exceed 140F. Use a mild soap such as standard dishwashing detergent. Tumble drying temperatures can cause the bags or cartridges to shrink. Bags will clean better if the dry cleaning process is used. Dry cleaning solvent ( Stoddard Solvent) will not harm them. Cartridges are generally not machine washable. Consult Airlanco engineering to determine if other types of filter bags or cartridges can be cleaned. Patching: Airlanco does not recommend patching filter bags because of leakage problems. Usually it is more economical to replace the bag.

17

MAINTENANCE - Continued
Rotary Valve (Airlock) The rotary valve should be serviced every six months. Remove the chain guard and end covers on the bearings; add a small amount of grease. Avoid forcing an excessive amount of grease into the bearing as the seal may become damaged. Check the wipers inside the rotary valve for wear. Replace as needed. The roller chain drive should be kept tight enough so that the chain cannot "climb the sprocket" and should be oiled lightly once a month. Remove any foreign properties and paint exterior as needed. Refer to your specific airlock manual. Screw Conveyor Periodic cleaning and painting when required. The roller chain drive should be kept tight enough so that the chain cannot "climb the sprocket" and should be oiled lightly once a month. The auger bearings have been factory pre-lubricated with high quality grease and for normal conditions of service require no further lubrication. Normal Service is considered as operation in a clean, dry atmosphere at temperatures between -20oF. and 180oF. Where service is abnormal with respect to speed, temperature, exposure to moisture, dirt or corrosive chemicals, or where extremely long life is required, periodic lubrication may be advisable. To lubricate remove pipe plug and replace with a standard grease fitting.

18

TROUBLESHOOTING FILTERS
PROBLEM
High differential pressure across tubesheet

POSSIBLE CAUSE
Bad gauge Leaking gauge lines Clogged or deteriorated gauge lines Low header pressure

SOLUTION
Check gauge by blowing into it. If needle does not move replace gauge Repair leaking gauge lines Clean or replace lines Filter requires a min of 90 psi clean dry compressed air (60 psi max for cartridge filters). Check supply lines and drain valves for leaks. Check diaphragm and solenoid operation. Refer to compressor manual. Check for moisture or ice in air lines and valves. Static electricity will interfere with the element cleaning operation. Ground filter. Water can freeze valves under cold temperatures. Water contributes to the build up of dirt in the solenoid and diaphragm valves. Remove water, clean system and take measures to provide clean dry air to filter. Inspect dust cake on filter elements. High humidity and condensation will cause dust cakes that are difficult to remove. Run filter without dust load until cake is removed. For operation above ambient temperature, preheat filter on start up to avoid condensation. If air stream is extremely humid , then review application with manufacturer. Wash or replace old bags. Replace old cartridges. Humid compressed air allows dust cake to stick to the filter media. Provide clean dry air to filter. Check air flow of system with design values. If air flow is high review application with manufacturer. High air volumes will contribute to excessive re-entrainment of dust on the filter elements. Small particles (less than 10 microns) will affect efficiency of filter media. Analyze particle size distribution with original design parameters. If excessive amounts of small particles are present then review application with manufacturer. Check bag fit on cages with the pinch test. You should be able to pinch of fabric at any position. Tight bags will not allow the bags to pop when cleaned. If bags are too tight replace them. Adjust cleaning pulse frequency in 5 second intervals allowing several hours in between adjustments for the unit to reach steady state. Note: over cleaning of filter elements will reduce life expectancy. The cleaning pulse should be set in a range of 40 to 60 milliseconds. The filter should pulse at equal regular intervals. Consult the manufacturers literature attached to this manual. Leakage past rotary valve into filter hopper will re-entrain dust onto the filter elements causing high differential pressures.

Static charge on filter Water in air lines

Filter element blinding

Wet compressed air System air volume too high

Dust particle size small

Bag fit on cages too tight

Cleaning pulse frequency too long

Cleaning pulse duration needs adjustment Timer board malfunctions

Rotary valve leakage

19

High differential pressure across tubesheet (cont.)

High dust load

Low Differential pressure drop

Clogged or deteriorated gauge lines Bad gauge Holes in filter elements Low system air volume Incorrect element installation causing leakage Blank-out plugs installed incorrectly Normal for start up period and new filter elements. Holes in filter elements Blank-out plugs installed incorrectly Excessive cleaning of elements Abrasion

Filters normally can handle extremely high dust loads. The dust must be removed from the hopper quickly. The cleaning system must keep up with the dust load. Increase cleaning frequency until operation stabilizes. Note: extremely high dust loads of fines may require other solutions contact Airlanco engineering for help. Clean or replace lines. Check gauge by blowing into it. If needle does not move replace gauge. Replace worn elements Check duct system for plugs and closed gates. Look for dust in clean air plenum or discharging from fan. Look for dust in clean air plenum. Check dusty blank out plugs for tight fit. Allow filter to run for 48 to 96 hours. Replace worn elements. Check all blank out plugs for tight fit. Increase timer board pulse frequency Poor inlet design practices such as high inlet velocities and elbows on the inlet can cause accelerated abrasion of filter elements. Consult manufacturer for solutions. Replace bent cages. Replace corroded cages. High air to cloth ratios will shorten filter media life. Check original design and correct where practical. Moisture will cause some filter materials to shrink. Moisture will also cause acids to form in some applications which weaken the filter media. Check moisture level and composition of dust and air stream. Consult the manufacturer review of application.

Dust in exhaust air

Poor element life

Bent cages wearing bags Corroded cages wearing bags. High air volumes Moisture in air stream

Incorrect filter media

Hopper Plugging

High temperatures, chemical content, and dust composition will affect filter element life. Consult manufacturer for solution. Cleaning malfunction See section on high differential pressure. Removal system malfunctioning Check airlock for leaks into hopper. Airlock or auger too slow Confirm correct speed of discharge airlock or auger.

The above is intended as a quick reference for common problems that may be encountered with a dust filter. If you are experiencing any difficulties not covered above or have any questions concerning your Airlanco filter, contact your local Airlanco representative or Airlanco at (800) 500-9777.

20

MAGNEHELIC GAUGE THEORY OF OPERATION

TUBESHEET TOP PLENUM # THE MAGNEHELIC GAUGE IS USED TO MEASURE THE DIFFERENTIAL PRESSURE BETWEEN THE CLEAN GAS SIDE (TOP PLENUM) AND THE DIRTY GAS SIDE OF THE BAGHOUSE. TUBING 1/4" OD (10023989) HIGH PRESSURE DIRTY AIR HOUSING (BAG HOUSE) # A MAGNEHELIC GAUGE MEASURES THE FORCE REQUIRED TO PASS THE GAS THROUGH THE FILTER MEDIA.

# NORMAL PRESSURE DROP FOR A PULSE JET FILTER WILL FALL IN THE RANGE OF 3 TO 5 INCHES OF WATER AFTER THE ELEMENTS ESTABLISH A FILTER CAKE. # AS THE ELEMENTS GET DIRTY THE DIFFERENTIAL READING WILL INCREASE. EVENTUALLY THE DUST CAKE MUST BE REMOVED FROM THE FILTER ELEMENT SURFACE OR AIR FLOW WILL FALL TO UNACCEPTABLE LEVELS.
6 4 2 8 10 12 14 16

FAN INLET

MAGNEHELIC

BAGHOUSE

LOW PRESSURE CLEAN AIR (TOP PLENUM)

ZERO SET

MAGNEHELIC GAUGE CONNECTION DETAILS

A REV

03-19-02 DATE

RELEASED FOR SALES DESCRIPTION

FALLS CITY, NE

MDK BY
DWN. BY: SCALE: DATE: REVISION: DWG: NONE 03-19-02

UNLESS OTHERWISE NOTED: ALL DIMENSIONS ARE IN INCHES. TOLERANCES: DECIMAL FRACTION .XX +/- 0.03 +/- 1/16 .XXX +/- 0.005 OVERALL <120 +/- 3/8 >120 +/- 1

AIRLANCO

THIS DRAWING IS THE SOLE PROPERTY OF AIRLANCO (THE CO.) AND SHALL NOT BE REPRODUCED, LOANED OR USED IN ANY MANNER WITHOUT THE EXPRESS PERMISSION OF THE CO.

MAGNEHELIC GAUGE CONNECTION DETAILS

JOB NO: P/I: P/N:

11836

CONTROL SWITCH CONTACTS

EXTERNAL PRESSURE SWITCH CONTACTS OFF & ON TIME ADJUSTMENTS

SOLID STATE TIMER BOARD

HIGH NC NO COM 120 VAC NC NO

LOW NC NO NO COM

JUMPERS

L1

L2

PROGRAM WIRE

PHOTOHELIC SWITCH 3000 SERIES STYLE HH

3A FUSE

C 1 2 3 4

SOLENOID VALVES

SWITCH LOGIC

L1 120 VAC

L2

CONTROL CONTACTS CLOSE WHEN HIGH SET POINT IS REACHED AND FILTER FULSING TIMER IS ACTIVATED. CONTACTS REMAIN CLOSED UNTIL LOW SET POINT IS CROSSED. CONTROL CONTACTS RESET TO OPEN WHEN LOW SETPOINT IS REACHED AND FILTER PULSING TIMER IS DE-ACTIVATED. UNLESS OTHERWISE NOTED: ALL DIMENSIONS ARE IN INCHES. TOLERANCES: DECIMAL FRACTION .XX +/- 0.03 +/- 1/16 .XXX +/- 0.005 OVERALL <120 +/- 3/8 >120 +/- 1

A REV

4-21-97 DATE

RELEASED TO PRODUCTION DESCRIPTION

FALLS CITY, NE

MW BY
DWN. BY: SCALE: DATE: REVISION: DWG: MW NONE 4-21-97 A

AIRLANCO

THIS DRAWING IS THE SOLE PROPERTY OF AIRLANCO (THE CO.) AND SHALL NOT BE REPRODUCED, LOANED OR USED IN ANY MANNER WITHOUT THE EXPRESS PERMISSION OF THE CO.

ELECTRICAL SCHEMATIC FOR PHOTOHELIC "ON DEMAND" CONTROL OF TIMER CIRCUIT

JOB NO: P/I: P/N:

10884

EXTERNAL CONTROL SWITCH (OPTIONAL) OFF & ON TIME ADJUSTMENTS

PROGRAM WIRE

3A FUSE L1 120 VAC L2

C 1 2 3 4

SOLENOID VALVES

A REV
UNLESS OTHERWISE NOTED: ALL DIMENSIONS ARE IN INCHES. TOLERANCES: DECIMAL FRACTION .XX +/- 0.03 +/- 1/16 .XXX +/- 0.005 OVERALL <120 +/- 3/8 >120 +/- 1

1-23-97 DATE

RELEASED FOR INFORMATION DESCRIPTION

FALLS CITY, NE

MLH BY
MLH NONE 1-23-97 A

AIRLANCO

THIS DRAWING IS THE SOLE PROPERTY OF AIRLANCO (THE CO.) AND SHALL NOT BE REPRODUCED, LOANED OR USED IN ANY MANNER WITHOUT THE EXPRESS PERMISSION OF THE CO.

DWN. BY: SCALE: DATE: REVISION: DWG:

WIRING DIAGRAM FOR TIMER BOARD

JOB NO: P/I: P/N:

10835

OFF & ON TIME ADJUSTMENTS

PROGRAM WIRE

N.C.

3A FUSE L1 N.O. LIMIT SWITCH SHOWN IN DOOR OPEN POSITION L2

C 1 2

SOLENOID VALVES

B REV
UNLESS OTHERWISE NOTED: ALL DIMENSIONS ARE IN INCHES. TOLERANCES: DECIMAL FRACTION .XX +/- 0.03 +/- 1/16 .XXX +/- 0.005 OVERALL <120 +/- 3/8 >120 +/- 1

8-30-01 DATE

REVISED AND REDRAWN DESCRIPTION

FALLS CITY, NE

MLH BY
DWN. BY: SCALE: DATE: REVISION: DWG: MLH NONE 10-25-96 B

AIRLANCO

THIS DRAWING IS THE SOLE PROPERTY OF AIRLANCO (THE CO.) AND SHALL NOT BE REPRODUCED, LOANED OR USED IN ANY MANNER WITHOUT THE EXPRESS PERMISSION OF THE CO.

WIRING DIAGRAM FOR BAG DUMP STATION W/ LIMIT SWITCH

JOB NO: P/I: P/N:

10809

LIMIT SWITCH BYPASS TIMER BOARD JUMPER L1 L2

21

13
DOOR LIMIT SWITCH

22

14

T1 T2
TO FAN

95 NC

T1 2 T2 4 T3 6 A2 A1 5
L3460VAC

1 3

L1460VAC L2460VAC

T3

L2 120VAC WITH DOOR OPEN FAN STARTS, TIMER STOPS. BYPASS SWITCH STOPS FAN FOR CARTRIDGE CHANGE.

L1 120VAC

A REV
UNLESS OTHERWISE NOTED: ALL DIMENSIONS ARE IN INCHES. TOLERANCES: DECIMAL FRACTION .XX +/- 0.03 +/- 1/16 .XXX +/- 0.005 OVERALL <120 +/- 3/8 >120 +/- 1

3-11-02 DATE

RELEASED FOR PRODUCTION DESCRIPTION

FALLS CITY, NE

MDK BY
MDK NONE 3-11-02 A

AIRLANCO

THIS DRAWING IS THE SOLE PROPERTY OF AIRLANCO (THE CO.) AND SHALL NOT BE REPRODUCED, LOANED OR USED IN ANY MANNER WITHOUT THE EXPRESS PERMISSION OF THE CO.

DWN. BY: SCALE: DATE: REVISION: DWG:

WIRING DIAGRAM FOR BAG DUMP STATION WITH DOOR LIMIT SWITCH & BYPASS

JOB NO: P/I: P/N:

11835