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Donaldson Torit DWS 4-1, Installation And Operation Manual

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Donaldson Torit DWS 4-1 Installation And Operation Manual Download Page 3

DANGER indicates a hazardous situation which, if not avoided, will result 
in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, could 
result in death or serious injury.

CAUTION, used with the safety alert symbol, indicates a hazardous 
situation which, if not avoided, could result in minor or moderate injury.

NOTICE is used to address practices not related to personal injury that 
may result in damage to equipment.

Downflo Workstation, DWS 4-1 to 6-4

 i

Magnehelic

® 

and Photohelic

®

 are registered trademarks of Dwyer Instruments, Inc.

Contents

Description ................................................................................1

Purpose and Intended Use  ....................................................1

Rating and Specification Information ...................................3

Operation ...................................................................................4

Inspection on Arrival ...............................................................5

Installation Codes and Procedures ......................................5

Installation.................................................................................5

Site Selection, Grade-Mounted Units ...............................5

Unit Location .........................................................................5

Rigging Instructions.................................................................6

Hoisting Information ................................................................6

Electrical Wiring.......................................................................6

Standard Equipment ................................................................7

Single Power Module Installation .....................................7

Multiple Power Module Installation ..................................7

DWS 4-1 to 4-4 and 6-1 to 6-4 Installation ........................7

Acoustic Hard Sided Booth Assembly ..............................9

Galvanized Hard Sided Booth Assembly ........................11

Light Fixture for Hard Sided Booths ................................11

Soft Sided Weld Curtain Booth Assembly ......................13

Soft Sided Acoustical Booth Assembly ..........................14

Compressed Air Installation .............................................15

Solid-State Timer Installation in NEMA 4 Enclosure .......16

Preliminary Start-Up Check .................................................21

Maintenance Information .....................................................22

Operational Checklist ........................................................22

Filter Removal and Installation .........................................23

Filter Removal .....................................................................23

Filter Installation .................................................................23

Fluorescent Bulb Replacement ........................................23

Optional Afterfilter Replacement .....................................23

Optional Equipment................................................................24

Magnehelic

®

 Gauge ...........................................................24

Photohelic

®

 Gauge .............................................................25

Acoustic Curtain for Power Module ...............................27

Light Fixture  ........................................................................27

Afterfilters ............................................................................28

Chamber Silencer  ..............................................................29

IEC Control Panel with Programmable Logic Control ..29

Optional IEC Control Panel Installation...........................31

Sprinkler Installation ..........................................................32

Troubleshooting ......................................................................33

Service Notes .........................................................................39

Summary of Contents for DWS 4-1

Page 1: ...of the owner Leave with the unit when set up and start up are complete Donaldson Company reserves the right to change design and specifications without prior notice Illustrations are for reference only as actual product may vary Downflo Workstation DWS 4 1 4 2 4 3 4 4 and DWS 6 1 6 2 6 3 and 6 4 Installation and Operation Manual Installation Operation and Service Information IOM AD3430701 Revision...

Page 2: ... permit program is required Recirculating filtered air in your facility can be a hazard Consult with OSHA to ensure compliance with all codes regarding recirculating filtered air Improper operation of a dust fume or mist control system may contribute to conditions in the work area or facility that could result in severe personal injury and product or property damage Check that all dust fume or mis...

Page 3: ...ns 6 Hoisting Information 6 Electrical Wiring 6 Standard Equipment 7 Single Power Module Installation 7 Multiple Power Module Installation 7 DWS 4 1 to 4 4 and 6 1 to 6 4 Installation 7 Acoustic Hard Sided Booth Assembly 9 Galvanized Hard Sided Booth Assembly 11 Light Fixture for Hard Sided Booths 11 Soft Sided Weld Curtain Booth Assembly 13 Soft Sided Acoustical Booth Assembly 14 Compressed Air I...

Page 4: ...module on hard sided and roof booths in dust tight or flush mounting lighting Soft side weld and acoustical curtain booths are also available with a clear plastic ceiling to allow plant light to illuminate the booth Also a moveable side shield with canopy booth is available for one module and two module configurations Purpose and Intended Use The DWS is commonly installed in applications where dus...

Page 5: ...mmended air to media ratio for weld fume and provides optimum filter life Recommended options include acoustic panels for a quiet work environment with flush lights for increased headroom on hard sided booths or soft sided weld curtain booths control panel for reduced installation expense and ASHRAE or HEPA afterfilters for added safety on hazardous dust such as chromium cadmium and zinc Powder Pa...

Page 6: ...ypical Side View DWS 4 Compressed air maximum psig 50 Housing rating inches water gauge 20 Power valves and controls 120 Volt 50 60 Hz or 200 VAC 50 60 Hz If unit was supplied with a Record Drawing the specifications on the drawing will supersede the standard specifications above ...

Page 7: ...eaning is completed using pulse jet technology A solenoid valve controlled by a solid state timer and a diaphragm valve aligned to each filter provides the pulse cleaning The diaphragm valve sends a pulse of compressed air through the filter cartridge from the inside out and collected contaminants fall into the dust drawers At the end of each pulse the diaphragm valve closes and the filter cartrid...

Page 8: ...ipment All shipping materials including shipping covers must be removed from the unit prior to or during unit installation Failure to remove shipping materials from the unit will compromise unit performance Inspect unit to ensure all hardware is properly installed and tight prior to operating collector Installation Site selection must account for wind seismic zone and other live load conditions wh...

Page 9: ...regulations and local codes when using cranes forklifts and other lifting equipment Lift unit and accessories separately and assemble after unit is in place Use drift pins to align holes in flanges during assembly Electrical Wiring Electrical work must be performed by a qualified electrician and comply with all applicable national and local codes Turn power off and lock out electrical power source...

Page 10: ... or chains to the four lifting eyes located on the roof of the power module 2 Position the modules side by side Position the first power module remove the lifting eyes before positioning the next power module as the lifting slings and chains can interfere 3 Secure the power modules together using the joining strips bolt hole plug pack M8 x 20 mm bolts and flat washers 4 Lifting eyes can be removed...

Page 11: ...Downflo Workstation DWS 4 1 to 6 4 8 This Page Intentionally Left Blank ...

Page 12: ...the support legs to the edge of the corresponding walls 7 Bolt the top support channel to the gussets Note The DWS 2 requires one top support channel DWS 3 and DWS 4 require two top support channels When assembling the DWS 3 or DWS 4 bolt the two top support channels and the top support tie in together and then bolt to the gussets Roof panels are not intended as platforms Personnel should use ladd...

Page 13: ...1 to 6 4 10 Acoustic Hard Sided Booth Assembly support leg side rail channel module side angle side panel angle gusset top support tie in top support channel booth panel top panel angle splicer plate mounting angle light fixture ...

Page 14: ...the two top support channels and the top support tie in together and then bolt to the gussets Roof panels are not intended as platforms Personnel should use ladders or other appropriate equipment to avoid risk of personal injury and or property damage 8 Install and bolt the booth roof panels in place Note Temporary roof support during assembly is not required The top panel angles and the top suppo...

Page 15: ...usset side rail channel top support channel top panel angle splicer plate Galvanized Hard Sided Booth Assembly mounting angle light fixture M8 x 20mm bolt M8 flat washer M8 hex nut 0 34 in diameter Detail A industrial or dust tight light fixture mounting angle see Detail A Light Fixture Installation ...

Page 16: ...roller hooks Attach the side curtain to the hook and loop strips Repeat this for the opposite side of the booth assembly Soft Sided Weld Curtain Booth Assembly DWS Models 4 2 3 4 1 Position the power modules in line so fronts are even and two sides are touching face to face Position the first power module and remove lifting eyes repeat this for each additional power module 2 Remove and reuse the e...

Page 17: ... the joining strips in between the power modules DWS Models 6 1 2 3 1 For DWS Models 6 2 and 3 check assembly drawings for power module spacing positions Also a spacer panel will need to be installed in between the power modules on these models See drawings for details 2 Install the side panels on each end of the power module assembly Remove and reuse the existing bolts and washers on the front of...

Page 18: ... power modules 0 86 CF at 50 psig or 1 0 CF at 60 psig 2 Connect the compressed air supply line to the 1 in NPT connection located at the rear of each power module Use thread sealing tape or pipe sealant on all compressed air connections 3 Install a customer supplied shut off valve bleed type regulator with gauge filter and automatic condensate valve in the compressed air supply line 4 With power ...

Page 19: ...rs at the rear of the power module After wiring is complete replace the covers Route wiring through the conduit holes located at the rear of the power module All conduit holes are sized for 3 4 in fittings Secure all conduit in the blower and solenoid plenums Seal conduit to prevent airflow from passing through to the control panels 4 Diaphragm valves have an external solenoid enclosure mounted in...

Page 20: ...17 Donaldson Company Inc Solenoid Enclosure ...

Page 21: ...ned filter life Pulse OFF Time Factory set at 10 seconds adjustable from 1 to 1 5 second minimum to maximum 60 to 66 second Solid State Timer Typical Wiring Diagram Operating Temperature Range 20 F to 130 F Transient Voltage Protection 50 kW transient volts for 20 millisecond duration once every 20 seconds 1 duty cycle Solenoid Valves 115 V at 19 7 watts each Compressed Air Set compressed air supp...

Page 22: ...SOL 3 7 10 8 9 1 2 3 4 5 6 SOL COM L1 L2 SOL 4 SOL 5 SOL 6 DWS 4 2 SOL 7 SOL 8 CONTROL BOXWITH 10 PINTIMER SOL 1 SOL 2 SOL 3 7 10 8 9 1 2 3 4 5 6 SOL COM L1 L2 SOL 4 SOL 5 SOL 6 DWS 4 3 DWS 6 2 SOL 7 SOL 8 SOL 9 SOL 10 SOL 11 SOL 12 CONTROL BOXWITH 6 PINTIMER SOL 1 SOL 2 SOL 3 DWS 4 1 1 2 3 SOL COM L1 L2 SOL 4 4 5 6 Wiring Diagram Control Box Timer to Solenoids ...

Page 23: ... 8 SOL SOL SOL SOL SOL SOL SOL 10 11 13 12 14 15 9 SOL 16 SOL 17 SOL 18 COM DWS 6 3 SOL CONTROL BOX WITH 20 PIN TIMER L1 SOL 1 2 3 4 L2 5 6 7 8 9 10 11 20 12 13 14 15 16 17 18 19 SOL 2 SOL 1 3 SOL 5 SOL SOL 7 SOL 6 8 SOL 9 SOL COM L1 SOL 1 2 3 4 L2 5 DWS 6 4 6 7 8 9 10 11 12 13 CONTROL BOX WITH 20 PIN TIMER 4 SOL 20 15 16 17 18 19 SOL SOL SOL SOL SOL SOL 10 11 13 12 14 15 SOL 16 SOL 17 SOL 18 SOL ...

Page 24: ...e or personal injury may result 4 All access panels should be sealed and secure 5 Check that the dust container is properly sealed and clamped 6 Check that exhaust damper is set to the fully closed position 7 Check and remove all loose items in or near the inlet and outlet of the unit 8 Check that all remote controls and solenoid enclosures if applicable are properly wired and all service switches...

Page 25: ...is before connecting to the unit s compressed air manifold Operational Checklist 1 Monitor the physical condition of the collector and repair or replace any damaged components Routine inspections will minimize downtime and maintain optimum system performance This is particularly important on continuous duty applications Periodically check the compressed air components and replace compressed air fi...

Page 26: ...ture This light fixture uses latches to hold the lens to the housing To remove the lens Unsnap the latches and lower the lens from the housing To replace the bulbs Rotate and remove from the rotary lock lamp holders Replace with 40 watt 48 in long fluorescent bulbs Galvanized Booth Light Fixture 1 Lift and pull the light fixture toward the front of the booth 2 Leave the fixture on the roof turn ov...

Page 27: ...n NPT male adapter also supplied with the gauge into the low pressure port on the side of the gauge Attach the mounting bracket using three 6 32 x 1 4 in screws supplied 3 Mount the gauge and bracket assembly to the supporting structure using three self drilling screws 4 Zero and maintain the gauge as directed in the manufacturer s Operating and Maintenance Instructions provided Magnehelic Gauge I...

Page 28: ...pressure ON and low pressure OFF control of the filter cleaning system 1 Choose a convenient accessible location on or near the unit for mounting that provides the best visual advantage 2 Mount the gauge to the remote panel or door using the mounting ring retaining ring and four 6 32 x 1 1 4 in screws Do not tighten screws Connect one 1 8 in NPT x 1 4 in OD male adapter to the low pressure port of...

Page 29: ...n DWS 4 1 to 6 4 26 plastic tubing barbed nylon tee Magnehelic or Photohelic gauge low pressure port DWS 4 3 DWS 6 3 DWS 4 4 DWS 6 4 DWS 4 1 DWS 6 1 DWS 4 2 DWS 6 2 Magnehelic and Photohelic Gauge and Tubing Installation ...

Page 30: ...all in classified hazardous atmospheres without an enclosure rated for the application Dust Tight 1 Bolt the mounting angles to the roof panels with M8 1 25 x 20 mm bolts flat washers and hex nuts 2 Drill two 11 32 in holes in the center of the 2 25 in diameter boss stamped in the fixture housing 3 Using the holes drilled in Step 2 attach the fixture to the mounting angles using M8 1 25 x 20 mm bo...

Page 31: ...he outside 7 Position the clamping straps and tighten the wing screws securely Flush Mount 1 Open the four snap fasteners located on top of the roof panel 2 Install customer supplied fluorescent bulbs in the fixture 3 Position the fixture between the angle stiffeners on top of the roof panel 4 Secure by lowering the snap fasteners to the light fixture flange 5 Wire the fixture as shown in Light Fi...

Page 32: ...ic starters with a low voltage control circuit 2 The blower motor ON OFF buttons are located on the control panel cover A red blower motor RUNNING light is also provided 3 Sequential start up is provided for all DWS 4 and DWS 6 2 3 and 4 modules This allows a delay between starting each blower motor and reduces undesirable overload current at start up 4 The control panel has troubleshooting capabi...

Page 33: ...can be avoided during work hours 4 In conjunction with the aftershift pulsing function a toggle switch located inside the control box turns the blower motors ON or OFF When the aftershift push button is activated with the toggle switch in the STAG position the even numbered blowers shut off and the odd numbered blowers remain on All valves starting with number one are pulsed three times The even n...

Page 34: ...ilter cartridges the timer can be adjusted from the factory setpoint to a maximum of 100 hours Optional IEC Control Panel Installation Electrical work must be performed by a qualified electrician and comply with all applicable national and local codes Turn power off and lock out electrical power sources before performing service or maintenance work Do not install in classified hazardous atmosphere...

Page 35: ...stallation 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 Donaldson Torit supplied sprinklers require a minimum of 15 psig water pressure to each module The volum...

Page 36: ...tions Remove material or debris Adjust damper flow control Filters need replacement Remove and replace using genuine Donaldson replacement filter packs See Filter Replacement Lack of compressed air See Rating and Specification Information for compressed air supply requirements Pulse cleaning not energized Use a voltmeter to check the solenoid valves in the control panel Check pneumatic lines for k...

Page 37: ...er board Check the timer board s fuse Replace with one of equal value If supply voltage and fuse are good observe the control board The outlet LED indicates if the control board is attempting to pulse LED s flash to indicate power to solenoid Check output with an analog volt meter using the 150 Volt AC scale The needle deflects if voltage is present when LED flashes If LED s do not flash or no vol...

Page 38: ...he GAUGE position Defective wiring Check wiring to solenoid valves Defective solenoid valves Check solenoid coils and replace as necessary Timer control board not energized Check supply voltage to timer board Check the timer board s fuse Replace with one of equal value If supply voltage and fuse are good observe the control board The outlet LED indicates if the control board is attempting to pulse...

Page 39: ...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 Branch circuit protection or overload tripped Disconnect power using the disconnect switch Press the black start button on the Manual Motor Protector MMP The r...

Page 40: ...ed The overload relay in the MMP resets automatically when the black start button is reset Defective motor branch circuit protection or overload relay Replace as necessary Defective control transformer or control transformer branch circuit protection Disconnect power using the disconnect switch Check the control transformer T1 the primary fuse FU1 and the secondary fuse FU2 If fuses are good check...

Page 41: ...rimary and secondary fuses FU1 and FU2 Lack of compressed air Maintain 50 60 psig Bleed compressed air supply Check for debris valve wear or diaphragm failure by removing the diaphragm cover on the pulse valves Check for solenoid leaks or damage If pulse valves or solenoid valves and tubing are damaged replace Push buttons do not work no pulse cleaning Loss of power Check disconnect fuses and tran...

Page 42: ...39 Donaldson Company Inc Service Notes Date Service Performed Notes ...

Page 43: ......

Page 44: ... free from defects in materials and workmanship for eighteen 18 months from date of shipment Donaldson does not warrant against damages due to corrosion abrasion normal wear and tear product modification or product misapplication Donaldson also makes no warranty whatsoever as to any goods manufactured or supplied by others including electric motors fans and control components After Donaldson has b...

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