mcf dust filter - A Resource for the Packaging Industry by Bid on
Contents
1. 2 Carefully remove the rupture style vent panel from the crate CAUTION Edges of the vent panel are sharp Avoid excessive flexure of the vent 3 Place the vent panel over the protruding bolts in the housing wall The vent panel must be oriented correctly The panel ruptures on three sides and hinges on the fourth The hinge side is indicated by a v notch in the edge Place the panel with the v notch to the left and the 1 D tag at the bottom as shown in Figure 4 6 The dome must protrude outward as shown or the panel will not function 4 Place the hold down frame over the bolts making sure that an even pressure is brought to bear on the panel 5 Tighten nuts evenly and use an alternating pattern to prevent damage to the vent panel Tighten nuts to 20 25 ft lbs of torque It is not necessary to use an excessive amount of pressure to clamp the panel securely Excessive tightening may damage fasteners or the explosion vent panel CAUTION Ductwork and Accessories CLEAN AIR DUCT HIGH ENTRY INLET TANGENTIAL INLET AIRLOCK OR OTHER OUTPUT ACCESSORY Figure 4 7 Location of Ductwork and Accessories Connect the inlet duct to the high entry inlet or tangential inlet on the filter 2 Connect the clean air duct to the exhaust located at the top of the filter housing Ductwork must be constructed to withstand the system design pressure The ductwork must be independently supported the MCF filter is not2. 2 Excessive temperature in blo wer a Too much oil in gear case or drive cover b Clogged filter or e muffler C Worn impeller clearances 3 Impeller end or tip drag a Incorrect clear ances b Case or frame e distortion C Excessive opera tion pressure 4 Lack of air volume a Slipping belts b Worn clearances C Leak in system e 5 Excessive bearing or gear wear a Improper lubri e cation b Worn filter e 6 Loss of oil a Vents plugged e b Worn seals Replace bearing and or head plate per manufactures manual Reduce oil level to recommended levels Remove clog or replace component Restore clearances per manufactures recom mendations Restore clearances per manufacturers recom mendations Relieve pipe loads on pump and adjust belt tension If all other aspects of the filter system are ok then reduce drive speed to provide 7 psi max pressure Correct belt tension Restore clearances per manufactures recom mendations Check for leaks in pipe lines and connection from pump to cleaning mechanism Repair as needed Correct oil level and follow lubrication schedule Replace filter Check and replace vents in headplate gear case or drive cover Check for leakage around head plate and gear case Replace leaking seals The above is intended as a quick reference for common problems that may be encountered with a dust filter If you are experiencing any diffi
3. Dirt and scale will effect the operation of the filter cleaning mechanism 38 POSITIVE DISPLACEMENT PUMP OTOR 40 DRIVEN SHEAVE 41 BELTS 42 DRIVER SHEAVE 43 OUTLET SILENCER 44 PRESSURE GAUGE 45 UNITARY BASE 46 INLET FILTER PUMP PACKAGE Figure 4 9 Pump Package Electrical Controls and Wiring Electrical Connections Distributor arm Drive is a 1 HP motor refer to label on motor for power requirements It is accessible to conduit through a 1 NPT coupling located in filter sidewall above the service door In high temperature units operating above 165 F the drive and motor are located outside of the unit The distributor arm rotation must be clockwise when looking down from above Reverse operation could result in damage to the index mechanism or Backing off of threaded components CAUTION Pump package Motors vary from 2 HP to 15 HP all are 230 460 volt 3 phase 60 Hz unless specifically ordered otherwise Airlock See airlock service manual Fan See fan service manual Only trained and authorized persons should be permitted to service or maintain electrical components It is the buyer s installer s responsibility to ensure that all applicable electrical codes are met NOTE The motors should be interlocked such that they start and shut down in the following sequence Start up 1 Airlock and discharge auger 2 Distributor arm drive and pump package 3 Main system fan Shut down 1
4. NOTE Full rated pressure is full pressure differential from inlet flange to discharge flange Read and Understand Safety Decals Several safety labels are located on this piece of equipment to warn the operator s of potentially hazardous situations Decal Locations The following figure shows typical locations for safety decals on the MCF filter The locations of decals for your particular filter may vary from those indicated Inspect your filter for locations of all decals lorN Y NS 8 A Ll UNE G O Figure 2 2 Typical Locations of Safety Decals see next page for description of decals Safety Decals Safety decals and other information labels may include but are not necessarily limited to the examples shown below Locate all of the safety decals on your equipment and know their meaning prior to operating this dust filter Free replacement decals are available ask for decal kit P N 413468 A SAFETY INSTRUCTIONS CONFINED SPACE Hazards may exist End User must determine hazard level for entry permit requirements Entry permit may be required Consult safety administrator for requirements Publication MAN3001E T Moving parts can cause serious injury Do NOT operate with doors open Lockout tagout before servicing 1999 HCS Inc 800 748 0241 Reorder No 8053 01 WVBZ ENTRAPMENT HAZARD
5. System fan 2 After variable time delay 0 15 min pump package and distributor arm drive 3 Airlock and discharge auger Optional MCF filter control panel is designed to make the task of start up and shut down simpler faster and more efficient The control logic is such that all motors are started in order by pushing the system start button and will stay running until one of the following occur 1 The stop button is depressed and the system goes into a shut down period The main fan stops immediately and the rest of the system continues to run for an adjustable time before stopping MAC Equipment Inc 6 2 Any one of system motors is overloaded the system will go into a shut down cycle To restart troubleshoot and correct the problem then push the overloaded motor starter reset button and restart the system If the filter is being used to vent a gas fired dryer to prevent fires and explosions the main exhaust fan must be interlocked with the gas burner in such a way as to allow the fan to operate an adequate period of time to purge the dust collector of combustible gases before turning on the burner The installation of a gas detection device in the system should be investigated and evaluated for each application Magnehelic Gauge or Photohelic Switch Gauge A magnehelic differential pressure gauge is available as an option The gauge indicates the difference in pressure between the input and discharge sides of the filter An
6. DRY FILL WITH MANUFACTURER S RECOMMENDED LUBRICANT BEFORE OPERATING 107972 Extreme conditions may cause failure and allow packing material into the airstream Do NOT weld or flame cut on silencer Use on clean air only Do NOT place in material conveying line Maximum temperature is 300 F Maximum continuous pressure is 15 PSIG Inspect periodically A DANGER MOVING BLADES LOCK OUT power before servicing this equipment A WARNING If you can read this sign a guard has been removed Do not operate with guard removed MAC Part No 393207 Equipment may be remotely controlled Moving drive components can cause injury Check lubricant level before initial startup Do not weld or flame cut on silencer May cause packing to enter into air stream and cause damage to cleaning mechanism Moving blades will cause severe injury Do not operate equipment with guards removed In addition if your filter is equipped with an explosion vent the following figure shows typical locations for other safety decals RUPTURE STYLE EXPLOSION VENT PVC STYLE EXPLOSION VENT Figure 2 3 Typical Locations of Safety Decals for Explosion Vents H SAFETY INSTRUCTIONS REPLACE steel shipping bolts with plastic bolts See instruction manual Failure to follow this instruction
7. LOCK OUT power before entering P O Box 205 Sabetha Kansas 66534 Serial Number Model Number Customer_P O Number PATENTED 1987 U S 4655799 PATENTED 1989 CANADA 1257552 CRUSH HAZARD Rotating parts inside can cause serious injury LOCK OUT power before entering 1994 HCS Inc 800 748 0241 1 800 821 2476 ROTATION gt NOILVLOH 107999 ENTANGLEMENT HAZARD LOCK OUT power before removing cover or guard Do NOT step on cover or guard MAC Equipment Inc Equipment has moving blades shaft rotor or arm which may cause injury It may also have valves discharging compressed gases Equipment can start without warning Exhaust fan can create enough force to close and hold service door closed Typical MAC Equipment Inc nameplate Typical MAC Equipment Inc MCF Filter Patent Numbers Equipment can start without warning Cleaning Mechanism rotation can cause entrapment under cleaning arm which will induce serious injury Typical MAC Equipment logo Equipment must rotate in direction indicated on rotation arrow Equipment has rotating screw conveyor which may cause injury Operate only when covers are in place AUTOMATIC START STAY CLEAR This equipment may start without warning AWARNING LOCK OUT Power before servicing this equipment REPLACE guards doors and covers before operating UNIT SHIPPED
8. Monthly or at manufacturer s recommended intervals 1 Check the filter bags for signs of excessive wear or damage Six Months 1 Check for evidence of moisture or dust buildup inside the filter housing 2 Check oil in all gear motors Do not overfill 3 Check belt tension on all V belt drives Bag Replacement The filter bags are the heart of the filter and need a program of inspection cleaning and replacement to maintain high operating efficiency 1 Shut down the system and lockout tagout the electrical and compressed air service 2 Remove cage and inspect for rust or damage and replace if necessary 3 Remove the bag and inspect for excessive wear replace if necessary 4 Reinstall clean filter bags as described in the Installation section Bag Cleaning Natural fiber fabrics wool or cotton are subject to shrinkage when wet with water These fabrics must be dry cleaned Synthetic filter fabrics Orlon Dacron Nomex polypropylene and Teflon should also be dry cleaned MAC Equipment Inc 12 1 Thoroughly vacuum clean the filter bags to remove the bulk of the dust 2 Dry clean the bags using a standard dry cleaning procedure Use pure dry cleaning solvent Do not use dry cleaning detergents and or additives that require the addition of water as these may cause fabric shrinkage 3 Dry the bags Drip drying is the recommended drying method Tumble drying if used must be done at low temperatures Industrial d
9. PVC Style Vents The filter is shipped with the PVC style explosion vent panel temporarily mounted with four steel bolts The vent must be disassembled and re installed using the plastic bolts provided Refer to Figure 4 5 ee HOUSING SPONGE GASKET 3 8 PLASTIC BOLTS TYPICAL Figure 4 5 Typical PVC Style Explosion Vent Remove the four steel bolts and discard Remove the vent panel 2 Seal the housing with the 1 8 thick x 1 1 2 wide sponge gasket supplied 3 Bolt vent panel in place with 3 8 plastic bolts provided by MAC Equipment Inc Torque to approximately 30 inch pounds 4 Make sure that the two retaining chains are tightly fastened to the housing and to the vent panel Be sure that all bolts are MAC supplied plastic NEVER USE STEEL BOLTS IN THE EXPLOSION VENT PANEL Steel bolts will not allow the vent to function as designed and could result in injury to personnel and considerable damage to the filter in the event of an explosion CAUTION MAC Equipment Inc 5 Installing Domed Rupture Panel Style Vents The installation of the rupture panel style vent should be performed by two people Refer to Figure 4 6 below VENT OPENING IN FILTER HOUSING VENT MOUNT MOUNTING BOLTS RUPTURE STYLE VENT Y HOLDDOWN FRAME TAG Figure 4 6 Typical Rupture Style Explosion Vent Remove the hold down frame from the vent mount on the side of the filter VENT I D
10. TIMING SPROCKET SPAC SMALL TIMING SPROCKET CLAMP BANDS RUBBER SLEEVES ALUMINUM TUBE HOSE TO PIPE ADAPTOR 1 2 TUBE amp FITTINGS PRESSURE RELIEF VALVE PIPE TEE PIPE NIPPLE Cleaning Mechanism Spare Parts List yu aaaak kk oe Item No Part No Description 149217 Top Shaft Bearing 1 3 8 4 Bolt Flange Quad Rings amp Bushings Publication MAN3001E MAC Equipment Inc 13 628710 10 Diaphragm MCF 112 153 255 416 14 122270 10 tapas Sping er 112 153 255 436 15 473049 Dmememwm EE CN mem memes 19 402069 near 24 424732 Tmo sproken Top Removal Bags 5 diameter i gp Ta lt AQ Bag Length 16 Oz Dacron 14 Oz Polypropylene 96 119849 119881 120 119822 119873 144 118915 119857 Top Removal Cages 5 diameter Galvanized Cage Length and Part Number 105473 105481 105490 A u u s G u u 6v0 uu u vv e eu 6u _ 6 V vee ee m _y Y e Top Removal Bags 6 2 diameter i Tea 1 Bag Length 16 Oz Dacron 14 Oz Polypropylene 96 101451 101524 120 101443 101516 144 101435 101508 Top Removal Cages 6 2 diameter Galvanized Cage Length a
11. W OPTIONAL VIEW PORT AIRLOCK POSITIVE DISPLACEMENT PUMP TANGENTIAL INLET AND AIRLOCK DISCHARGE OSEPARATION OF LARGE PARTICLES SUCH AS WOOD INSPECTION OPENING W OPTIONAL VIEW PORT DISCHARGE AUGER AIRLOCK STRUCTURAL FRAME AND COLUMNS WITH HIGH ENTRY INLET AND AUGER DISCHARGE SUSED FOR LIGHT NON ABRASIVE MATERIALS WITH LOW TERMINAL VELOCITIES Figure 1 1 Typical MCF Dust Filter Receiving Your Equipment As soon as the equipment is received it should be carefully inspected to make certain the unit is in good condition and all items listed on the packing list are received Even though the equipment is mounted on heavy shipping skids at our plant it is possible for it to be damaged in shipment All damages or shortages should be noted on the Bill of Lading The purchaser must take immediate steps to file reports and damage claims with the carrier All damages incurred to the unit in transit are the responsibility of the common carrier since it is the policy of MAC Equipment Inc to make shipment F O B from its factory Ownership passes to purchaser when the unit is loaded and accepted by carrier Any claims for in transit damage or shortage must be brought against the carrier by the purchaser If the unit is not going to be assembled and installed soon after arrival it should be stored in a warm dry location to protect against corrosion Filter bags and cages or cartridges must be stored in a dry rodent proof
12. arm The cleaning arm has a series of nozzles correlated to the tube sheet layout Cleaning air exits these nozzles and enters the bags This action cleans the bags by 1 creating a shock wave that pops the bag and 2 forcing a momentary reverse flow of air through the bags MCF Timing The unique feature of the MCF filter is its patented timing mechanism Once adjusted this device assures a blast of cleaning air is injected directly into the center of the bag regardless of the rotational speed of the cleaning arm This device is mechanical and does not require electrical power to internal solenoids for firing Through the proper selection of gear ratios and rotational speeds the cleaning frequency can be adjusted Positive Displacement Blower The MCF Filter requires a rotary positive displacement blower to supply the cleaning air This blower has two figure eight impellers rotating in opposite directions As the impeller lobes pass the blower inlet they trap a quantity of air This entrapment occurs four times per revolution moving the entrained air around the case to the blower outlet Timing gears accurately position the impellers in relation to each other maintaining the minute clearances so vital to the high volumetric efficiency of the rotary positive displacement blower For further information on this equipment refer to the appendix Variable Cleaning Control Options Air Diverter Valve The Air Diverter Valve ADV cleaning cycle c
13. designed to support ductwork 3 Attach any auxiliary equipment such as an airlock or screw conveyor to the discharge flange of the hopper Discharge Auger Assembly The discharge auger assembly includes transitions with bolted inspection opening discharge auger and optional airlock and is typically shipped assembled Install the assembly after the filter has been erected on its support structure 9 DIA FLARED TROUGH SCREW CONVEYOR AUGER SPROCKET AIRLOCK T SENSE AIRLOCK GEARMOTOR SPROCKET SPROCKET MAC D12x10 ROTARY AIRLOCK 9 DISCHARGE AUGER WITH AIRLOCK Figure 4 8 Discharge Auger Assembly Publication MAN3001E To install the auger assembly 1 Determine the correct orientation for the auger discharge The transition may be rotated through 360 degrees in 15 degree increments 2 Apply a bead of silicone caulk to the transition flange and bolt it to the hopper flange with 3 8 16UNC x 1 1 4 bolts with lock washers Pump Package Pump package is shipped without lubricant Refer to lubrication section under Start up and Operation To install the pump package 1 Locate package on concrete pad with pressure discharge side to left of ladder when facing filter 2 Air supply line connection is located to left side of and above service door 3 Install piping from pump discharge silencer to filter piping is normally not supplied by MAC Be sure that there is no foreign material in the piping
14. should have maintenance manuals and manufacturer s documentation for all components readily available He she should be thoroughly familiar with the manuals so as to be able to pinpoint trouble should it occur The individual responsible for the system should follow a regular schedule of inspection and maintenance The exact schedule will depend on the particular system and the number of hours it operates per day or week A typical maintenance schedule is shown below Sample Maintenance Schedule Disconnect and properly lockout tagout the electrical and compressed air service before performing any maintenance or service procedures on the filter WARNING Weekly Check and record magnehelic or photohelic gauge readings on all filters Adverse operating conditions can be detected by a change in pressure drop 2 Check for dust in clean air outlet from filter 3 Check filter hoppers for continuous discharge of dust 4 Check fan and motor bearings for excessive heat or vibration 5 If pressure pneumatic conveying equipment is used to dispose of dust check the positive displacement pump for vibration overheating and proper lubrication Also compare reading on the pressure gauge with previous readings Clean air inlet filter or replace as necessary It is important to follow the manufacturer s recommendation on equipment of this nature 6 Check explosion vent s if provided for damage broken bolts or damaged panel
15. 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 5 Lower the cage into the bag When in position the flange will rest on the tubesheet 6 Insert all bags and cages in their proper position Do not use bent or rusted cages CAUTION Installation Instructions MAC Bags With Grounding Straps for Grounding Metal Cages Proper installation of bags and cages is required to ensure that the metal cages are not isolated from ground with the tubesheet cell plate in applications that have potential for an explosion hazard The effectiveness of a grounding mechanism depends upon proper installation and connection of the grounding mechanism to an adequately collector component Failure to properly install and connect grounding mechanism or maintain grounding of the collector component may result in static electricity discharge and possible explosion of dust stream within the collector and serious property damage and or bodily injury Proper installation must be verified per Section B of these instructions prior to operating collector WARNING MAC Equipment Inc 7 Section A Bag Installation Section B Verification of Proper Grounding The two grounding straps at the top of the bag are intended to ground the cage to the tubesheet Proper installation must be confirmed by testing to verify 1x1 0 1 megohm maximum r
16. to pump troubleshooting guide Clean or replace lines If installation is several years old replacement of lines may be necessary Check internal filter on differential pressure port on filter housing Replace if blocked Normally the gauge will fluctuate during cleaning pulse If needle does not move replace the gauge Inspect bag dust cake High humidity and condensation will cause dust cakes that are difficult to remove Run filter with exhaust fan off and without dust load for 15 to 30 minutes until cake is removed Preheat filter on start up to avoid condensation If air stream is extremely humid then review application with MAC Equipment Inc If condensation is a recurring problem start and operate the system with no dust load until the filter reaches ambient temperature It may also be necessary to operate the system with no dust load for a time at shut down Check air flow of system and compare with design values If air flow is too high review application with manufacturer 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 72 of fabric at any position Tight bags will not allow the bags to flex properly for cleaning If bags are too tight replace the
17. INGS TEMPERATURE OPERATION 250 TO INTERNAL ewes owes owes GEAR BOXES EXTERNAL AREA ee AEREO BEARINGS 12 WEEKS 8 WEEKS 4 WEEKS AU uu su u u v vVvv v V Vu b 0 u 8 uu c dd k k vv ee cc d c c c k RX GEAR BOXES 12 WEEKS MCF Cleaning Mechanism How the Cleaning Mechanism Works The success of the MAC MCF Filter centers around its positive controlled cleaning mechanism Every bag is cleaned the same number of times with the same amount of cleaning air Bag cleaning is accomplished using medium pressure 6 9 psig reverse air in a completely controlled manner DRIVE MOTOR REDUCER PRESSURE INLET TEE PRIMARY AIR SUPPLY DIAPHRAGM FROM PUMP VALVE PACKAGE CLEAN AIR RESERVOIR SECONDARY DIAPHRAGM CLEANING __ ARM INDEX SENSOR TUBESHEET Figure 6 1 Typical Cross Section of Cleaning Mechanism The cleaning or distribution arm is formed to correspond with the pie shaped sections of the tube sheet The tube sheet is the punched hole plate where the filter bags are attached As the distribution arm rotates clock wise looking down on tube sheet pressure builds in the cleaning air reservoir As the arm passes over each fifth tube sheet segment the pneumatic index sensor mechanism vents the pilot air line of the secondary diaphragm valve This caus
18. If you do not understand the contents of the manual bring it to the attention of your supervisor This manual contains important safety instructions concerning the maintenance use and operation of this product Failure to follow these instructions may result in serious injury or death NO haga funcionar este equipo hasta haber leido y comprehendido el contenido de este manual Si aiguna partre del contenido del manual queda sin comprehender notifiqueselo a su supervisor Este manual contiene instrucciones importantes en cuanto al anterimiento uso y funcionamiento sequros de este producto El no seguir las instrucciones contenidas en este manual podria ocasionar lesiones graves GENERAL INTRODUCTION Congratulations on your selection of a MAC MCF Dust Filter As the owner operator of this unit you have an important responsibility to see that it is operated and maintained in a safe manner The unit will require very little attention to keep it in good operating condition This manual has been prepared to aid you in that effort Throughout this manual reference may be made to various components which may or may not be part of your particular system They are included in the interest of fully describing typical MCF filter systems AIR SUPPLY LINE FROM PD PUMP ELECTRICAL CONNECT I ON 1 NPT SERVICE DOOR DIFFERENTIAL GAGE PORT 1 8 NPT SERVICE PLATFORM WITH LADDER AND SAFETY CAGE EXPLOSION VENT INSPECTION OPENING
19. MCF DUST FILTER INSTALLATION OPERATION amp MAINTENANCE MANUAL Fouipment Inc MAC EQUIPMENT INC P O Box 205 SABETHA KS 66534 SALES PARTS amp SERVICE 1 888 821 2476 www macequipment com Publication MAN3001E Revision Date 11 10 05 TABLE OF CONTENTS DESCRIPTION PAGE General Mod er 1 A O Dee ee eee 1 Principle of OperatiON cccccccccccnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnononononoos 3 WS LAU ALION ee EE E 4 System Start Up amp Operation sess 12 Minim 12 ITOUDIESNODUN GE 18 SALE dtes in ee Eee ee ee ee 19 LIST OF FIGURES Page Figure 1 1 Typical MCF Dust Filter ooooocccccccccnnnnnnnoo 1 Figure 2 1 Lockout and Tagout of Electrical Service and Compressed Air 1 Figure 2 2 Typical Location of Safety Decals 2 Figure 2 3 Typical Locations of Safety Decals For Explosion Vents ccccccccecceeessseeseeeeeeeeeeeeeees 3 Figure 3 1 Principle of Operation sseeesss 3 Figure 4 1 Typical Support Structure 4 Figure 4 2 Typical High Entry Inlet ssuuuse 4 Figure 4 3 Typical Front Access Service Platform and Ladder Assembly 5 Figure 4 4 Typical Side and Front Access Service Platform and Ladder Assembly 5 Figure 4 5 Typical PVC
20. Style Explosion Vent 5 Figure 4 6 Typical Rupture Style Explosion Vent 6 Figure 4 7 Location of Ductwork and Accessories 6 Figure 4 8 Discharge Auger Assembly 6 Figure 4 9 Pump Package cccccccccceeeeeesseeeeeeeeeeeeeeeeenaeeeees 6 Figure 4 10 Installation of Differential Pressure Gauge 7 Figure 4 11 Jumpers and Wiring of the Photohelic Switch Gauge cc ssccccecccceceeceeessesssscsccesceenees 7 Figure 6 1 Typical Cross Section of Cleaning Mechanism 13 Figure 6 2 Typical Distribution Arm Detail 13 Figure 6 3 Typical MCF Index Sensor 14 Figure 6 4 Typical Alignment Illustration 14 Figure 6 5 Typical MCF Larger Diaphragm Details 14 Figure 6 6 Typical Tightening Sequence 15 Figure 9 1 Typical Cleaning Mechanism 20 It is the owner s responsibility to maintain the safety features included with this equipment The safety features may include but not necessarily be limited to guards access doors and covers explosion vents warning decals caution decals and advisory decals Replacement safety features are available from MAC Equipment Inc WARNING DO NOT attempt to operate this equipment until you have read and understood the contents of this manual
21. all operators of the equipment are aware of them and understand their meaning Replacement decals are available free of charge from your MAC Equipment Service Representative or by calling MAC Equipment Inc at 1 888 821 2476 This piece of equipment may contain one or more safety guards to protect the operator s from injury It is the owner operator s responsibility to maintain the integrity of these guards and ensure that they are in place when the equipment is in operation DO NOT attempt to operate this equipment with any guard removed Replace damaged guards WARNING Lockout Tagout Requirements Before inspecting or servicing this equipment perform an approved lockout tagout procedure on the electrical service the compressed air or other WARNING gas supply or any other energy source ELECTRICAL POWER COMPRESSED AIR OR GAS Figure 2 1 Lockout and Tagout of Electrical Service and Compressed Air or other gas Control of this equipment must be in accordance with OSHA Standard 1910 147 The control of hazardous energy lockout tagout This standard requires employers to establish a program and utilize procedures for affixing appropriate lockout devices or tagout devices to energy isolating devices and to otherwise disable machines or equipment to prevent unexpected energizing start up or release of stored energy in order to prevent injury to employees For further information on Lockout Tagout requirements see your compa
22. ature operating conditions use any good quality SAE 40 non detergent oil 2 In cold climates use SAE 20 during the winter months 3 Use No 2 bearing grease in all climates NOTE For additional information on positive displacement pump consult the manufacturers manual included with pump package Lubrication Fluids Table EQUIPMENT AMBIENT MEDIUM HIGH TEMPERATURE TEMPERATURE TEMPERATURE LUBRICANT LUBRICANT LUBRICANT T 125 F 125 T 225 F 225 T 475 F Airlock gear SEE AIRLOCK NOT NOT reducer MANUAL RECOMMENDED RECOMMENDED Positive SEE PUMP MFR NOT NOT displacement LITERATURE RECOMMENDED RECOMMENDED Cleaning Arm Hub City Gear Lu Hub City All Tem NOT Drive bricant GL 150 perature Synthetic RECOMMENDED 8 58 00 01 010 Gear Lubricant O ARPA E EPA Cleaning NO 2 Bearing DOW BR2 PLUS DOW 41 EXTREME Mechanism grease MULTIPURPOSE HIGH Lower Bearing E P GREASE TEMPERATURE Pt GREASE Lubrication Schedule i COMPONENT TO DAILY SERVICE p BE SERVICED AMBIENT 8 HOURS 16 HOURS 24HOURS OPERATION X E PUMP 26 WEEKS 13 WEEKS 8 WEEKS PUMP BEARINGS 9 WEEKS 4 WEEKS 3 WEEKS GEAR BOXES 6 MONTHS 22 WEEKS 14 WEEKS INTERNAL BEARINGS YEARLY 8 MONTHS 6 MONTHS HIGH TEMPERATURE OPERATION 150 TO GEAR BOXES 16 WEEKS 12 WEEKS 8 WEEKS l INTERNAL AS EE ASES ESAS GEAR BOXES 6 MONTHS 22 WEEKS 14 WEEKS EXTERNAL l Publication MAN3001E BEAR
23. c 2 19 2 50 2 56 2 93 4 49 4 63 2 19 2 50 2 06 2 93 4 63 4 69 2 50 56 63 64 75 114 117 119 56 63 64 75 114 117 119 64 INCHES mm _ 157 40 194 48 157 40 194 48 Dass 86 MODEL RCA25TD 17 TROUBLESHOOTING The items listed below are intended as a quick reference for common problems that may be encountered with a dust filter If you are experiencing any difficulties not covered or have any questions concerning your MAC filter contact your local MAC representative or MAC Equipment Inc WARNING Disconnect and properly lockout tagout the electrical and compressed air service before performing any maintenance or service procedures on the filter It is imperative that the control panel enclosure be secured at all times unless access is required Troubleshooting Filter Cleaning Mechanism POSSIBLE CAUSE 1 High differential pressure across tube sheet 5 H20 and rising Publication MAN3001E Cleaning pump not running Low pump pressure Clogged or deteriorated gauge line Bad gauge Bags blinding System air vol ume too high Dust particle size too small Bag fit on cages too tightly Cleaning mechanism timing unsynchronized Cleaning mechanism malfunction SOLUTION See section on pump to determine fault Check gauge on pump normal pressure is 6 to 8 psi if low refer
24. ck washers flat washers wedge washers and nuts Tighten all bolts before removing the crane Ladder Safety Cage and Ladder Stand off Ladder and safety cages will come in pre assembled 6 ft 4 ft or 3 ft lengths and 1 8 ft section without a safety cage attached To assemble ladder and safety cages see figure 4 3 1 Position ladder and safety cage assemblies on ground end to end with the entry section at either end Note If ladder rungs are not 12 apart flip section end for end 2 Join ladder side rails together with splice plate as provided 3 8 UNC bolts and locknuts 3 Join lower safety cage bars to upper safety cage hoop using 3 8 UNC bolts and locknuts Note safety bars should be on the inside of safety hoop 4 After all sections are joined together lift ladder into position and attach to service platform 5 Position stand off clips over holes with weld ons located below service door and secure in position with 72 UNC as provided bolts and lockwashers 6 Attach ladder stand off to clips with UNC as provided bolts nuts and flatwashers Level stand off and clamp to ladder rail Pilot drill through hole in stand off into ladder rail on both sides Secure stand off to ladder rail with 72 UNC as provided bolts nuts and flatwashers Note Stand off to ladder connection can be welded or bolted 7 Measure distance from bottom of ladder rung to ground Cut 8 ft section to this length Note Check to
25. culties not covered above or have any questions concerning your MAC filter contact your local MAC representative or the MAC Equipment Service Center at 1 888 821 2476 Publication MAN3001E ORDERING SPARE PARTS To order by Phone dial 1 888 821 2476 When placing an order for spare parts always give the following 1 Model Number 2 Serial Number 3 Part Description 4 Part Number 5 Quantity Required 6 MAC Job Number or Sales Order Number P O Box 205 Sabetha Kansas 66534 Serial Number Model Number Customer P O Number Order Acknowledgement SALES ORDER NO RVSN DATE PAGE ORDER DATE SALES CAT TAXABLE METHOD OF SHIPMENT F O B PPD S A MAC Equipment Inc 19 Model Designations 96MCF 153 140 Li Filter Style Length of bags Cleaning Mechanism MCF FILTER CLEANING MECHANISM MCF 572 AND SMALLER Figure 9 1 Typical Cleaning Mechanism 1 2 3 4 5 6 T B 9 10 11 12 13 14 15 16 17 18 19 3 Unit supplied with 140 Bags Unit capable of handling153 bags AC MOTOR GEAR REDUCER REDUCER MOUNT ANGLE COUPL ING SUPPORT CHANNELS DRIVE SHAFT UPPER BEARING BEARING MOUNT INLET TEE BUSHING INLET TEE QUAD RINGS TANK AND ARM ASSEMBLY DIAPHRAGM COVER D 1 APHRAGM SPRING INLET TEE GOYEN VALVE INDEX PLUNGER LOWER BEARING INDEX ASSEMBLY INLET TEE SHAFT DIAHPRAGM WASHER SET COLLAR LOWER SUPPORT SHAFT LARGER
26. es a chain reaction the secondary diaphragm opens and the large primary diaphragm rapidly opens off of its seat allowing compressed air from the air reservoir to flow into the distribution arm Venturi nozzles located on the under side of the distribution arm are positioned over the filter bag centers as cleaning air is released into the wag bags u Venturi y Nozzles Rolled Flange Top cage No Tool Snap e Ring Bag and Cage Assembly C S a amc E de Figure 6 2 Typical Distribution Arm Detail Adjustment Do not enter the cleaning mechanism compartment when the cleaning arm and or the main exhaust fan are rotating or energized DANGER MAC Equipment Inc 13 Remotely started equipment can operate without warning DANGER Before attempting to make any adjustments on the cleaning mechanism read and understand all instructions thoroughly The motor powered rotating arm has sufficient power to cause severe injury and the close confines of the compartment limits personnel movement Read and understand the other safety information contained in this booklet before attempting any maintenance or adjustments In order for the cleaning mechanism to function properly the cleaning pulse must occur as the venturi nozzles pass directly over the centerlines of the individual filter bags Adjustment of the index sensor assembly clamp controls cleaning air pulse timing Refer to t
27. esistance Ensure that the hole is cleaned to remove dust and corrosion buildup Install bag in hole and at 500 volts between cage and tubesheet cell plate insert cage MEOGER 14002 Top load collector testing resistance between cage and tubesheet In addition to the proper installation and grounding of bags and cages the end user should select an appropriate filter media for use in bags Refer to the National Fire Protection Association NFPA Recommended Practice on Static Electricity NFPA 77 2000 edition for more information www nfpa org For blank out placement see the illustrations on the following pages The blank out plugs must be pressed in the tube sheet hole so that its flange is flush on the tube sheet On larger MCF units follow the general pattern of the smaller units Locate the plugs in the numbered priority as shown Publication MAN3001E MAC Equipment Inc 8 MCF 153 HIGH ENTRY INLET MCF 112 TANGENTIAL INLET MCF 153 TANGENTIAL INLET Publication MAN3001E MAC Equipment Inc MCF 255 HIGH ENTRY INLET F 25 TANGENTIAL INLET MCF 361 TANGENTIAL INLET Publication MAN3001E MAC Equipment Inc 10 MCF 416 MCF 494 HIGH ENTRY INLET HIGH ENTRY INLET MCF 416 TANGENTIAL INLET MCF 494 TANGENTIAL INLET 11 MAC Equipment Inc Publication MAN3001E SYSTEM START UP AND OPERATION The following inspection should be made before the init
28. etween inlet and outlet is considered a most suitable configuration for dust collector applications The design offers ease of installation low restriction to air flow and so provides an excellent cleaning pulse The valves can be operated by either integral pilot solenoids CA models or remote pilot solenoids RCA models CONSTRUCTION Body and cover are pressure diecast aluminium General purpose diaphragms are made from a Buna N elastomer reinforced with nylon mesh and are suitable for temperatures ranging from 180 deg F 82 deg C down to 40 deg F CAO deg C High temperature diaphragms are made from reinforced Viton and are suitable for temperatures up to 450 deg F 232 deg C All seals are designed to meet the same operating criteria SPECIFICATION Pilot Connections Ve Exhaust Connection Tapered Pipe Threads COT Ve eoT Ya 39 45 50 6e2T Ye 76T Vo Maximum working pressure 860Kpa 8 6 Bar 125 psi Recommended working pressure 7 60Kpa 7 6 Bar 110psi Recommended pilot for RCA models RCAGD2T ELECTRICAL Solenoid coil on CA models Type QR or QD Protection Class OR Nema 4 IP65 DIN Socket QD Nema 1 IP31 Conduit thread STANDARD VOLTAGES AVAILABLE ARE 100 120 Volt 50 60 Hz 200 240 Volt 50 60 Hz 24 Volt DC SPARE PARTS Part numbers of diaphragm repair kits are shown in Table for both standard Buna N and high temp erature Viton elastomers Spare parts
29. excessively high reading indicates that filter media are becoming clogged and that more frequent cleaning pulses are required A photohelic switch gauge is a second option The photohelic switch gauge indicates differential pressure and controls the cleaning operation When an electronic circuit in the switch gauge detects differential pressure in excess of a predetermined set point it provides a dry contact closure which initiates the cleaning cycle When differential pressure drops to a predetermined set point the switch gauge opens the contact thus stopping the cleaning cycle This method of control reduces compressed air needed and increases bag life To install either type of gauge refer to Figure 4 10 below and to the manufacturers documentation LOW PRESSURE PORT HIGH PRESSURE PORT Figure 4 10 Installation of Differential Pressure Gauge notaning the Magnehelic Differential Pressure Gauge Mount the gauge in a convenient place for easy viewing A Install the tubing fittings in the pressure ports of the magnehelic pressure gauge and in the ports on the filter The filter ports are normally located on the right side of the filter from the service door 3 Run the plastic tubing supplied from the filter ports to the gauge ports The low pressure line runs from the filter port above the tube sheet to the low pressure port usually the lower port on the gauge The high pressure line runs
30. from the filter port below the tube sheet to the high pressure port usually the upper port on the gauge 4 Verify that the filter is installed inside the housing on the high pressure port Installing the Photohelic Differential Pressure Switch Gauge Install the photohelic switch gauge and run air piping as for the magnehelic gauge as described above In addition 1 Connect electric power to contacts labeled L1 and L2 on the switch gauge Refer to the label on the switch gauge for power requirements 2 Connect contacts labeled NO and C on the switch gauge to contacts labeled Pressure Switch on the timer board Remove jumper between the Pressure Switch contacts if any 3 Install jumpers on the switch gauge according to the Figure 4 11 below PHOTOHELIC RED MW TO MOTOR STARTER ON DISTRIBUTOR ARM amp PUMP PACKAGE TO POWER SOURCE POWER TO COIL Figure 4 11 Jumpers and Wiring of the Photohelic Switch Gauge Bag and Cage Installation Filter bags and cages are shipped loose and are installed after the MCF filter has been assembled and set in place Installation of bags and cages is made from inside the unit Install bags and cages as follows Publication MAN3001E 1 Lower bottom of bag through hole in tube sheet 2 Fold snap band bag top to insert it into tube sheet hole 3 Fit the groove of snap band to the edge of the tube sheet and allow band to snap in place 4 Check
31. g on drive shaft Replace if needed and correct problem that caused shear Repair or replace line Visually inspect for loose parts and wear Remove sensor and bench test valve Connect 7 psi air line to valve and manually actuate Replace if plunger will not seal Disassemble and inspect diaphragm for tears and wear Replace if damaged Remove cover to diaphragm Inspect for tears and wear Replace if damaged High temperatures chemical content and dust composition will affect bag life Poor inlet design practices such as high inlet velocities and elbows on the inlet can cause accelerated abrasion on bags Consult MAC Equipment Inc for guidance Damaged corroded or bent cages can wear on bags Replace cages Coated or stainless steel cages are available Moisture will cause acids to form in some applications which weaken the filter media Check moisture level and composition of dust and air stream Consult MAC Equipment Inc for review of application Check air to cloth ratio and compare to original specifications Review cleaning procedures Improper cleaning can shorten bag life Allow filter to run for 48 to 96 hours Replace worn bags Check all blank out plugs for tight fit SOLUTION Reset timing per manufacturers manual Relieve pipe loads on pump and adjust belt tension Replace timing gears per manufacturers manual Replace bearings per manufacturers manual 18 e Worn bearing fit
32. ghten all bolts Bolts must be tightened before allowing the structure to support the weight of the filter 8 Touch up paint on the support structure as needed Assembly should be complete and all bolts tightened prior to painting High Entry Inlet This inlet may be mounted with the filter horizontal To install the high entry inlet 1 Remove the bolted shipping cover from the high entry inlet opening 2 Apply a bead of silicone caulk around the inlet assembly flange Lift inlet into position and bolt with 1 2 13 x 1 lg bolts with flat washers NOTE The sloped end of the inlet assembly must be toward the filter bottom FILTER HOUSING SILICONE CAULK REMOVE SHIPPING COVER Figure 4 2 Typical High Entry Inlet With the inlet mounted the filter will be unbalanced when lifted to the vertical position CAUTION Tangential Inlet The tangential inlet requires only the addition of the fourth side of the inlet flange To install the tangential inlet angle 1 Locate a 2 1 2 x 2 1 2 angle with bolt holes in both legs One leg will match the bolt pattern drilled into the outside of the inlet 2 Apply a bead of silicone caulk and bolt the angle in place with 1 2 13UNC x 1 lg bolts with flat washers Service Platform see figure 4 3 and 4 4 Platform may be mounted with the filter horizontal To install the front access service platform see figure 4 3 1 Align holes in service platform with h
33. he illustration at right and item number 19 in Figure 9 1 on the cleaning mechanism illustration located in section 9005 This mechanism is rough timed at the factory but requires fine tuning once the baghouse is installed in the field All models of MCF baghouses from the Compact to the large Panelized units utilize the same method and similar parts for initiating the cleaning pulse Timing adjustment procedure is the same for all units Figure 6 3 Typical MCF Index Sensor Be sure the main system fan has been de energized and locked out before opening the door of the cleaning mechanism compartment DO NOT ENTER the compartment observe operation of the rotating cleaning arm and timing of the cleaning pulse while standing OUTSIDE the compartment Be extremely careful while operating the arm when the access door is open When making adjustments shut off and lockout all power to the rotating arm system fan and positive displacement blower before entering the compartment CAUTION Determining if the index sensor assembly needs adjustment requires observation of the operating cleaning arm with the positive displacement pump running Observe the position of the distribution arm nozzles when the mechanism pulses Observe all nozzles because it is possible for some nozzles to line up while others are misaligned See the tube sheet illustration How The Index Sensor Assembly Works The index sensor assembly serves tw
34. hed to this valve Remove two 5 16 bolts clamping the assembly to the tank shaft and remove the assembly Install new sensor assembly and replace air lines Magnehelic Gauge 1 Most filters are designed to operate at a differential pressure of 3 to 5 inches of water When starting a new filter the differential pressure may be less than 1 inch until a mat of dust begins to build on the fabric Once the filter reaches equilibrium pressure the magnehelic gauge becomes an indicator of the operation of the entire system So long as the gauge reads between 3 and 5 inches of water the system will be delivering design volume flow When differential pressure exceeds the upper limit the filter should be checked for malfunction See Troubleshooting Section If none is found the excessive pressure means the bags should be cleaned or replaced Normally the bags should not require attention until after many months of operation When the filter differential pressure falls below the lower limit the system again should be checked for malfunction See Troubleshooting Section Publication MAN3001E MAC Equipment Inc 15 Publication MAN3001E GOYEN CONTROLS TECH SPEC CAS 1 T SERIES DIAPHRAGM VALVES The 94 T series was the first Goyen valve to be offered to the industry The series has now grown to include 7 sizes ranging from 94 20mm up to 3 76mm All of these valves have right angle bodies as the 90 deg angle b
35. hen ordered with 4 steel bolts These bolts must be replaced with special plastic bolts before operating the filter Do not cut weld or grind on the filter while it is in operation dust laden air may be highly explosive Refer to the proper National Fire Protection Association Manual for information on cutting welding or grinding in hazardous areas The work area is clean and orderly free of debris materials tools etc Operating personnel are wearing proper ear and eye protection and have secured loose hair clothing jewelry etc Failure to follow these instructions may result in death personal injury and or property damage WARNING Installation and Operation Cautions The MCF Cleaning arm timing is critical to the correct and efficient operation of these filters Refer to the maintenance section for correct placement and adjustment of the timing BLOWERS and GEAR BOXES are shipped without lubrication oil do not operate before lubricating Refer to the maintenance section for the lubrication schedule All system piping must be clean internally before connecting to blower Check lubrication level only when the equipment is stopped Keep inlet filter clean Keep belts properly tensioned and aligned Keep pressure relief valves in good condition so that maximum pressure is not exceeded Never attempt to regulate air flow by restricting intake or exhaust of a positive displacement blower
36. ial start up of the system and for normal operation thereafter Disconnect and properly lockout tagout all electrical connections before performing any inspection procedures WARNING Cleaning Mechanism 1 Gear reducer is shipped dry Install proper level of lubricant Refer to the Lubrication Fluids Table for the proper lubricants required for this units 2 Bearings are pre lubricated and should not require lubrication at start up 3 Drive coupling Item 4 ships disengaged Loosen set screws and slide couplings together Tighten set screws Refer to Figure 9 1 for illustration 4 Jog the drive motor on and off quickly to check direction of rotation The proper direction of the cleaning arm is CW as viewed from the top Listen for sounds of unwanted mechanical contact Pump Package 1 Pump package is shipped dry Install proper level of lubricant Refer to the Lubrication Fluids Table for the proper lubricants required for this units Refer to the maintenance section for procedures and quantities of lubricant Further information is also contained in the pump package manual 2 Remove belt guard and check belts for alignment and tension 3 Rotate pump by hand to check freedom of rotation and binding Jog the drive motor on and off quickly to check direction of rotation The proper direction is indicated by a decal on the drive guard Listen for sounds of unwanted mechanical contact If pump knocks do not start See Tro
37. inutes to clean and remove all of the dust cake on the bags 3 Dust emission may occur from exhaust at start up but it should disappear after a new dust cake is formed on the bags This should only take a few hours If the dust emission persists the filter bags should be rechecked to be certain that they seat properly in the tube sheet System Parameters Use this page to record the operating conditions of the system once start up is complete and you have made the final adjustments You will find this information very valuable for future reference when troubleshooting the system or when monitoring its performance DUST MATERIAL DUST PARTICLE SIZE FILTER MODEL FILTER S N AIR CLOTH RATIO AIR FLOW CFM Publication MAN3001E PHOTOHELIC GAUGE SET POINTS if provided High H20 Low H20 DIFFERENTIAL PRESSURE H20 after the filter has stabilized FAN MODEL MANUFACTURER FAN S N FAN RPM FAN DESIGN CFM O SP BHP Notes High Temperature Units For MCF units encountering high temperatures in excess of 400 degrees F the cleaning arm and pump should be operated during the preheat cycle This will prolong the life of temperature sensitive materials in the cleaning mechanism by cooling them NOTE AIR DIVERTER VALVES should be in the closed clean position during preheat cycles MAINTENANCE It is recommended that one individual be assigned to monitor the operation of the dust collection system The individual assigned
38. kits for pilot solenoid valves consist of ferrule tube plunger and spring The part num bers for these kits are M1131B Buna N and M1167B Viton These kits service all CA valves AC or DC voltages MAC Equipment Inc ORDERING When ordering T Series valves the following need to be specified e valve size diameter e CA or RCA coil type voltage Hz for CA models A typical valve might be specified as follows CA40T QR 240 50 DIAPHRAGM VALVES With integral pilot control CA for remote pilot control RCA Pipe ORIFICE REPAIR KITS pra FR Inches mm Buna N Viton CARCA2OT E MERE 25 M11838 M1887 Tacas mme oe 42 m1581 50 xs 100 195 Single diaphragm models Kv 86 Cv 16 T SERIES DIAPHRAGM VALVES DIMENSIONS all diaphragm valve models ORIFICE A BH INCHES mm INCHES INCHES mm INCHES mm _ Reas im 40 475 1808 866 os 437 115 RoAdSTB 1 40 841 138 478 385 498 126 Peas e so 811 206 806 154 785 184 moase ew 82 825 20 681 173 725 184 cass 1 es 418 104 495 185 325 83 cass T4 40 475 M8 878 nae 437 411 caase e 40 841 138 871 175 498 188 caser PX e 825 20 878 20a 725 184 4 13 ALL RCA T MODELS ALL CA T MODELS Publication MAN3001E MAC Equipment In
39. location SAFETY INFORMATION Do not attempt to operate or maintain this piece of equipment until you have read and thoroughly understood all of the safety information contained in this manual All such information must be taken seriously This piece of equipment contains moving parts and potential pinch points which can cause serious injury or death If you do not understand anything in this manual seek assistance from your supervisor before operating this equipment WARNING Recognize Safety Information The symbol at left is used to alert you to important safety messages located throughout this manual It also appears on the equipment to alert you to potential hazards When you see this symbol you must read understand and heed the information that accompanies it Understand Signal Words DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury and or property damage Publication MAN3001E Warning Decals And Guards This piece of equipment contains several warning decals located in many different locations It is the owner operator s responsibility to maintain the integrity of these decals and to ensure that
40. ly Secondary Diaphragm Primary Diaphragm Tubing to Index Sensor Figure 6 5 Typical MCF Larger Diaphragm Details 1 Lock out all power before entering filter 2 Disconnect 1 2 bleed line at secondary valve head 3 Remove nuts around large valve head and remove it Be careful of large diaphragm spring to avoid dropping it down a bag MAC Equipment Inc 14 4 Remove old diaphragm assembly Some older MCF Models have fabricated diaphragms which require a rebound cushion on the valve head New MCF Models have one piece molded diaphragms that do not require this cushion ring This ring should be removed when upgrading your filter with the molded diaphragm 5 Clean flanges on tank and valve head Apply a thin even coat of silicone caulk to both flanges 6 Place the new diaphragm on the studs with the side of the diaphragm marked tank side towards the tank 7 With diaphragm spring in place in valve head place valve head on studs Be sure that secondary valve is oriented correctly exhaust points down 8 Tighten all nuts until snug against the valve head 9 In an alternating pattern torque all nuts to 28 foot pounds CAUTION To insure a proper torque reading move the torque wrench ina slow and smooth manner Do not jerk the torque wrench Ned FIGURE 6 6 Typical tightening sequence 10 Recattach 1 2 line CAUTION Torque all nuts to 28 foot pounds to reduce the risk of fatigue failure By pre l
41. m Bags which have been cleaned or washed may shrink and must be checked for proper fit on cage Refer to maintenance section for correct timing adjustment Listen to filter for the distinct cleaning pulse 3 to 7 sec cycle If pulse is not heard see Cleaning Mechanism Malfunction 2 Low differential pressure less than 1 2 H20 a Check items 1a and 1b b Holes in bags c Incorrect bag installation causing leakage 3 Cleaning mechanism malfunction a Cleaning arm not running b Leak in air line from secondary valve to index valve c Index sensor malfunction d Secondary valve malfunction e Primary diaphragm malfunction 4 Poor bag life a b Incorrect filter media Abrasion Damaged cages Moisture in air stream Excessive air to cloth ratio Improper cleaning 5 Dust in exhaust air a Troubleshooting Pump Package Normal for start up period and new bags Holes in bags Blank out plugs installed incorrectly POSSIBLE CAUSE 1 Knocking a b Unit out of time Housing distortion due to external strains from pipes and or drive tension Worn gears Worn bearings MAC Equipment Inc Verify lines to magnehelic gauge are properly connected Replace worn bags Look for dust in clean air plenum Refer to bag installation procedure Check motor Check power supply Make necessary repairs to get motor running Check shear couplin
42. make sure what end will maintain the 12 distance from rung to rung and cut the opposite end Join ladder side rails together as described in step 2 8 Position ladder foundation clip by clamping to the bottom of the ladder rail and pilot drill through 2 holes in foundation clip into ladder rail on both sides Secure stand off to rail with 3 8 UNC as provided bolts and locknuts Secure foundation clip to ground Note Foundation clips to ladder connection can be welded or bolted SUPPORT SERVICE PLATFORM FLAT BAR SUPPORT PLATFORM ADAPTER LADDER CAGE ASSEMBLY EN i gt SUPPORT E lt CLIP EA LADDER 3l Y ENTRY STAND OFF SECTION SPLICE IL PLATE lle 8 FT LADDER PN SECTION FOUNDATION CLIP Figure 4 3 Typical Front Access Service Platform and Ladder Assembly Publication MAN3001E SIDE ACCESS PLATFORM ADAPTER SUPPORT SUPPORT CLIP ENTRY y SECTION E AAA SUPPORT CLIP 2 FLAT BAR SUPPORT Y 7 STING N LADDER STAND OFF xe Lf FRONT ACCESS SERVICE PLATFORM TA LAA PLATFORM ADAPTER SPLICE PLATE 8 FT LADDER SECTION FOUNDATION CLIP Figure 4 4 Typical Side and Front Access Service Platform and Ladder Assembly Explosion Venting Venting Guidelines This section is intended as a general guide only For further information refer to NFPA Standard 68 Explosion Venting and consult with your insurance carrier Ex
43. may result in PERSONAL INJURY or PROPERTY DAMAGE EXPLOSION HAZARD Stay clear of relief panel Never use steel bolts in the explosion vent panel Steel bolts will not allow the vent to function as designed Stay clear of explosion vent During an explosion flame explosive gases or flying material will be released The following ISO decals may appear on your MCF Filter Publication MAN3001E Disconnect lockout and tagout electrical and all other energy sources before inspecting cleaning or performing maintenance on this filter This warning sign reminds operators and other users that they must read and understand the Operator Manual before storing installing inspecting cleaning or servicing the filter This filter may be remotely controlled It can start without warning unless it is properly locked out at the motor starter or local disconnect Do not rely on the control system for safe lockout Equipment can start without warning This access port should be equipped with safety lock oPec PRINCIPLE OF OPERATION The MCF filter is a top bag removal pneumatically controlled medium pressure high volume pulse cleaning dust filter Cleaning air is generated by a positive displacement blower MCF models range in size from a MCF112 with 1 086 sq ft of cloth to a MCF494 with 7 163 sq ft of cloth Clean Air Out 1111 Cleaning Mechanism Tubesheet E ttttt Filter Bags WAM PD Blowe
44. nd Part Number Filter Style MCF MPH 105341 105333 ka eel 20 Miscellaneous Spare Parts rr c uu u d e eq _ _ Vx _ u u u v v kkk V_ v b k k kb u V u u u un u _ 0Y ev o a Item Part No Description No EN 111090 Magnehelic Gauge 0 15 WC Publication MAN3001E 1 MAC Equipment Inc 21
45. nt range Refer to MAC Engineering Department for further details Air Exhaust Returning filtered exhaust air into a facility can present hazards The type of dust it s characteristics and the effect of a recirculation system malfunction must be considered If system design dictates that filtered air be returned into the facility the buyer is cautioned to take appropriate steps to monitor the air quality and provide appropriate safeguards as prescribed by OSHA NFPA Federal State and Local codes and regulations Never return filtered air to a habitable space or building without proper monitoring and precautions WARNING INSTALLATION The MCF filter housing and internal components are shipped factory assembled The support structure if provided magnehelic or photohelic pressure gauges bags and cages service platform and ladder safety cage are shipped loose and require field assembly Location Locate the MCF filter in a clear area away from normal personnel traffic on a flat and solid concrete or steel surface Locate the filter so as to minimize supply and exhaust ductwork and so that explosion venting if required can be directed so that injury to personnel and damage to property cannot occur Provide sufficient space for emptying the hopper and maintaining the unit During an explosion a vent will release flame explosive gases or flying material The explosion venting must be directed away from personnel to prevent inju
46. ny s Safety Director or refer to OSHA Standard 1910 147 Safety Precautions Do not operate inspect or service this equipment unless all the following safety precautions are in effect WARNING Guards access doors and covers are in place and secure The equipment has been wired and grounded in accordance with all applicable codes If air being filtered contains toxic materials all necessary precautions to protect personnel have been taken An approved lockout tagout procedure has been followed before the equipment is inspected disassembled and or serviced The equipment is automatically controlled and may start without warning unless energy supplies are properly disconnected and locked out tagged out The control panel enclosure is closed and secured except as is necessary for service or adjustment The service door is closed and secured Do not enter filter while the system exhaust fan is operating air flow can pull service door closed trapping personnel inside A confined space permit if required by authorities having jurisdiction has been obtained prior to personnel entering the unit Check with your company s safety director for special instructions testing prior to entry etc that may be required by the specific application MAC Equipment Inc 1 Explosion vents have been properly installed and ducted as described below in the Installation section MAC PVC style explosion vents are shipped w
47. o simple functions It 1 blocks off the pilot air line to the secondary diaphragm valve while the cleaning air reservoir builds up pressure and 2 vents the pilot air line opening the secondary and primary diaphragms allowing compressed air flow to the venturi nozzles See the illustrations at the beginning of this section for specific cleaning mechanism arrangements of the three major MCF collector variations A stationary index sprocket is mounted over the reservoir shaft flange bearing bolted directly to the tube sheet and this fixed sprocket is positioned just below the rotating cleaning air reservoir tank The adjustable index sensor bracket clamps to the rotating pivot shaft of the tank Rotation of the tank shaft causes the index cam sprocket to rotate As the index cam sprocket actuating lobe contacts the roller wheel the rocker arm pulls the plunger from its seat releasing the air that allows the diaphragm valves to open and vent permitting rapid air flow to the cleaning arm nozzles When the plunger return spring pushes the plunger back against its seat the PD pump air pressure resets closes the diaphragm valves and pressure begins to build in the cleaning air reservoir tank This cycle repeats as the index sensor passes over every fifth pie shaped tube sheet segment Changing position of the index sensor bracket relative to the stationary index sprocket changes the timing of the back flushing cleaning air Shifting the bracket opp
48. oading the bolts to 28 foot pounds the alternating stress exerted by the diaphragm firing on the bolts will be kept to a minimum Replace Shaft Seals On Air Inlet Tee 1 2 3 12 Lock out all power before entering filter Loosen hose clamps on the air supply line and remove it Disconnect the drive coupling between the gear reducer and the tank shaft Tie off the tank to the filter housing at the rings provided and place blocks under the ends of the cleaning arms to support the assembly Remove four bolts holding motor and reducer plate to channels and slide it over on the channels Use clamps to secure plate to channel temporarily Turn the lower drive plate below channels 90 and lift the drive plate and shaft out of the tank Loosen the shaft collar directly above the inlet tee and slide it off the tank Slide the air inlet tee off the tank shaft Remove old quad rings 2 and install new set Slip tee back on shaft with light coat of grease If tee still appears to be loose then bushings need replaced This can be done by removing tee and threading the bushings out of the tee NOTE Top bushing is right hand thread and bottom bushing has left hand thread Left hand thread bushing has notch in edge of bushing Reassemble by reversing the procedure above Replace Index Sensor 1 2 Lock out all power before entering filter Disconnect air line s from the sensor valve High temp units have two lines attac
49. oles in platform adapter located below service door 2 Bolt together with UNC as provided bolt nuts and lock washers 3 Position support clips over holes with weld ons on both sides of service door and secure in position with 72 UNC as provided bolts and lock washers 4 Attach 2 flat bar supports from clips to holes in both sides of service platform Secure in position with 72 UNC as provided bolts nuts lock washers and flat washers Publication MAN3001E MAC Equipment Inc 1 11 1 14 To install the side access service platform see figure 4 4 1 Align holes in service platform with holes in platform adapter located below service door 2 Bolt together with UNC as provided bolt nuts and lock washers 3 Position support clip over holes with weld ons below platform adapter and secure in position with 72 UNC as provided bolts and lock washers 4 Attach 2 angle supports from clips to angles on bottom side of service platform Secure in position with UNC as provided bolts nuts lock washers and flat washers Setting in Place It is recommended that a properly sized crane be used for unloading the filter and setting it in place Spreader bars are recommended to distribute the load evenly while lifting the filter WARNING To set up the MCF filter 1 Lift the filter housing and set in place on the support structure Bolt the filter to the structure with 5 8 UNC as provided bolts lo
50. on no further action is required Proceed with normal filter start up routine If the cleaning pulse does not hit the bag centerline the index sensor timing must be adjusted This is done by moving the index sensor assembly in relation to the distributor arm Note that the index sensor assembly is located entirely below the rotating tank and arm and does rotate with them ltis also on the same side of the tank and is approximately in line with the secondary valve When the cleaning pulse occurs before the nozzles reach the centerline of the bags timing must be retarded Loosen the two bolts in the clamp and move the assembly a small amount opposite from the direction of rotation Figure 6 4 Typical Alignment Illustration When the cleaning pulse occurs after the nozzles pass the centerline of the bags the timing must be advanced Loosen the two bolts in the clamp and move the assembly a small amount in the direction of rotation Repeat these adjustments as required to direct the cleaning pulse into the bag centerlines Be sure to tighten the index clamp bolts after final adjustment If the index sensor is grossly out of time it may be reset relatively easily 1 Disconnect drive coupling on drive gear box allowing the distributor arm to swing freely 2 Rotate the distributor arm to line up the arrow on the cleaning arm and the arrow on the housing wall Block the distributor arm in this position 3 Loosen the two inde
51. ontrol is offered as an option on the MAC MCF filters This valve provides an economical method of controlling the cleaning cycle of the filter The cleaning cycle can be extend from the base time to any cycle time desired above this base This is useful for filter applications that require a longer duration between cleaning pulses to prevent over cleaning the filter media To extend the cleaning cycle with the ADV a timer Photohelic gauge or PLC is required The ADV functions as a by pass valve to the cleaning system To initiate cleaning the valve is closed and air is allowed to flow to the cleaning mechanism The valve is left closed for the duration of one cleaning cycle To interrupt the cleaning cycle the valve is opened and cleaning air is exhausted to the atmosphere The frequency of the cleaning cycle is controlled by adjusting the duration of the open state of the valve Variable Frequency Drives Variable Frequency Drives VFD are offered as an alternate option for cleaning cycle control on the MAC MCF Filters This arrangement controls the speed of the rotating cleaning arm and blower which directly controls the frequency of the cleaning cycle Cleaning frequency is adjustable above and below the base cycle The extent of control is limited by the physical limitations of the drive and the motor With this type of control the filter is usually provided with a non standard base cleaning cycle falling in the center of the desired adjustme
52. osite to the cleaning arm rotation delays retards the pulse Moving the bracket in the same direction the arm turns advances the pulse firing Adjusting MCF Filter Index Sensor Timing MCF 112 through MCF 572 Each MCF Filter is rough timed at the factory and on start up will need to be fine tuned to achieve optimum operating efficiency For this procedure it will be necessary to energize the distributor arm drive and the pump package DO NOT ENTER the filter while the distributor arm is in motion Lock out power to the main system fan and secure the service door in the open position Fan can create enough force to close and hold the service door closed CAUTION Publication MAN3001E Start the distributor arm drive and the pump package From the service platform observe the location of the venturi nozzles when firing or pulsing takes place Pulsing will occur over every fifth pie shaped segment of the tube sheet Refer to Figure 6 4 for the correct position of the distributor arm and it s nozzles In addition to watching the nozzles over the bags timing arrows are located on the end of the cleaning arm and on the housing wall just inside the service door The cleaning mechanism should fire when the two arrows are aligned and the nozzles are directly over the centerline of all of the filter bags Observe the cleaning pulse for several rotations of the distributor arm If the cleaning pulse does occur in the correct positi
53. plosion venting is required whenever the filter will process explosive dusts as defined by NFPA Dust filters handling explosive dusts should be located outside of buildings wherever possible Explosion vents must not be obstructed in any way and must be protected from snow ice buildup Explosion vents must be oriented so that flame explosive gases or flying material cannot injure personnel or damage property Dust filters inside of buildings should be located next to an exterior wall the explosion vent s must be ducted to the outside of the building Vent ducts must be kept as short and straight as possible avoiding bends Such ducts must be capable of withstanding a pressure at least as high as that expected to develop inside the filter itself in the event of an explosion Ducts increase internal pressures inside the filter and special reinforcement of the filter may be required Consult MAC Equipment Inc Engineering Department regarding your specific application Any duct will decrease the effectiveness of the vent Explosion Vents General Explosion vents are available from MAC Equipment Inc in either PVC or domed rupture panel styles as part of the filter system The PVC style vent functions by breaking the plastic bolts holding it to the filter housing The rupture panel style functions by bursting the panel itself Explosion vents are installed after the filter unit is assembled on its support structure Installing MAC
54. r Cleaning Pulse Baffles AA Vortex Dust Laden Air In H Material Spiral Hopper Product Discharge Figure 3 1 Principle of Operation Air Flow through the Unit Dust laden air enters the MCF through the tangential inlet near the bottom of the unit A remote fan on the exhaust side draws air through the filter A majority of the dust entering the unit is captured by the spiral and directed into the hopper and out the discharge The remaining dust laden air is directed to the filter bags Vortex baffles just below the filter bags straighten the air to prevent excessive wear on the bags Filtered dust collects on the outside of the filter media The MPHV cleaning mechanism pulses the dust off the filter bags and it drops into the hopper Filtered air passes through the center of the filter bags and out through the clean air discharge at the top of the unit MPHV Cleaning The MCF filter is a continuously operating self cleaning filter It uses MEDIUM PRESSURE HIGH VOLUME MPHV air to clean the bags This air is supplied from a positive displacement blower located outside the unit Cleaning air is stored in a tank within the clean air plenum Cleaning air pressure climbs to approximately 7 psi within this tank before it is injected into the bags A high volume blast of air is delivered by means of the MAC diaphragm valve Cleaning air is channeled MAC Equipment Inc 3 to the bags through a rotating
55. ry DANGER Foundation The filter requires an adequate foundation designed by a qualified structural engineer Refer to the General Dimension drawings of your system for foot pad layout and weights When calculating the loading for the foundation the weight of the filter material collected and all auxiliary equipment must be considered together with snow wind and seismic loads Support Structure A support structure may be supplied by MAC Equipment Inc as part of your MCF filter system The figure below shows a typical structure which will vary from system to system depending on the size of the MCF filter Publication MAN3001E SPLICE PLATE BRACING Figure 4 1 Typical Support Structure To install the support structure 1 Review the components of the support structure 2 Set anchor bolts in the foundation according to the plan drawing Position four columns on anchor bolts as indicated Install nuts but do not tighten 3 Attach cross bracing to 4 sides with grade A325 UNC as provided bolts washers and nuts 4 On 10 ft 12 ft 13 ft and 14 ft diameter filters bolt halves of top channel frame together with grade A325 4 UNC bolts as provided washers nuts and splice plate both sides of channel 5 Lift channel frame onto columns and bolt together with grade A325 UNC as provided bolts wedge washers flat washers and nuts 6 Check the structure is square and plumb 7 Ti
56. ry cleaning establishments are available in many cities These companies specialize in filter bag cleaning and will normally provide the most satisfactory results Lubrication Gearmotors Located on distributor arm drive and optional airlock drive Refer to the Lubrication Fluids Table for lubricants Refer to the Lubrication Schedule for recommended replacement times Do not use lubricants containing sulfur and or chlorine extreme pressure additives which are corrosive to worm gear bronze Motors Standard motors are permanently lubricated and require no further attention Pump The positive displacement pump is shipped dry At the gear end the timing gear teeth are lubricated by being partially submerged The gear teeth serve as oil slingers for gear end bearings At the drive end the bearings are grease lubricated Filling Procedure Remove square head vented oil fill plug on gear end Remove oil level plug located in head plate Fill gear case until oil drips out of the oil level hole Add fresh oil as required to maintain proper oil level In typical 8 hour per day operation oil should be drained flushed and replaced every 6 months more often with increased operating time or severe conditions Bearings on drive end of blower require grease lubrication initially and every 2 months of operation in typical 8 hour days more often with increased operating time or severe conditions Recommended Oil amp Grease 1 Under ambient temper
57. uble Shooting Guide 5 Replace guard 6 Start pump and filter and operate for 15 minutes check for hot spots noise and other indications of interference Allow pump to cool to room temperature and recheck oil level 7 Start pump and filter Observe operation for the first hour a Monitor pressure at pump outlet it should be 6 to 8 PSIG when the filter pulses b Check amp draw in the motor See motor name plate for rating Pump Operation 1 Check oil level daily for first week of use then weekly thereafter 2 Check intake filter weekly or more often if dust conditions are severe Clean as required Filter element is a dry type element with a 1 4 polyester foam pre filter Pre filter may be cleaned by washing with mild soap and warm water 3 Check the drive belts tension after 24 hours of operation then check periodically Tighten if necessary Filter Bags 1 Check filter bags for proper installation 2 When the MCF Filter is started up in cold weather or if the unit is handling high temperature gases there is a danger of condensation forming on the filter bags and inside the housing This is a very undesirable situation and can be avoided by preheating the filter for about 30 minutes Preheating is accomplished by starting the fan and filter and allowing it to run without any dust loading Before doing this the MCF filter cleaning mechanism and pump package should be run alone with the main exhaust fan shut down for about 10 m
58. x clamp bolts until the index sensor can be moved easily by hand 4 With the nozzles on the distributor arm located directly over the bags rotate the index sensor assembly clockwise looking down on bags until the actuator lobe on the cam is centered on the 1 1 8 diameter roller wheel and is causing the plunger to open from its seat Tighten bolts on index sensor clamp 5 Re engage drive coupling remove block form distributor arm and check for proper firing sequence from outside the filter Fine tune the adjustment as previously directed NOTE If attempts at aligning the cleaning arm have been unsuccessful with this method disconnect power to the pump and the cleaning arm Remove the drive coupling Have one person start the pump while another person is at the plenum access door The cleaning arm should not be rotating Enter the filter plenum and rotate the arm by hand Observe where the firing takes place Turn off the pump and adjust the index sensor in the direction required as recommended previously Repeat as needed to fine tune the adjustment If the pump runs very long in this state the relief valve will open and there will be a very loud hissing noise from the pump area This is normal but ear protection is recommended for the person near the pump Watch the pressure gage on the pump and do not allow it to exceed 15 psi or damage to the CAUTION equipment may occur This will not happen if the relief valve is working proper
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