8.   Process Calculation With Selection

8.1 Calculation formula

Q = KQ ₀ m ³/h

K —The correction factor is determined based on factors such as the dust concentration in the treated air and the system’s leakage rate. Generally, it is selected... 1.1-1.2 For applications with high dust concentrations or significant air leakage rates, the upper limit should be selected; conversely, the lower limit should be chosen.

Q ₀ —Airflow required for the process

Q —Actual required air handling capacity

8.2 According to Q Multiply the recommended airflow for this unit by the load factor. ( or use Q Divide by the load factor and then use the recommended airflow for this unit. ) Select the appropriate model specifications; the load factor is related to the dust concentration in the air being processed. Generally, it is... 0.6-1 High dust concentration corresponds to a low load factor; low dust concentration corresponds to a high load factor.

8.3 When the airflow entering this unit contains a high concentration of dust and debris, or when site conditions permit, it is advisable to select a larger-sized model whenever possible. This can reduce the resistance of the dust filtration equipment, lower energy consumption, and save on operating costs.

8.4 As far as possible, do not select equipment specifications based on the maximum air volume of this unit. Otherwise, the resistance of the dust filtration equipment will reach its maximum value.

9. Machine installation and commissioning

9.1 Pre-installation Preparations

9.1.1 The installation site for the dust removal unit must be dry, well-ventilated, and spacious, with a level and solid cement floor. The floor’s unevenness should be ≤ 2 per 1000 。

9.1.2 During unit installation, field measurements and layout positioning should be carried out according to the unit’s specifications and dimensions. The equipment must have sufficient clearance from surrounding walls and objects to allow for proper operation and maintenance. The height of the machine room should generally be ≥ 3600mm。

9.1.3 The unit can be directly installed on a smooth concrete floor without the need for anchor bolts.

9.1.4 The foundation for the main fan installation must be constructed or anchor bolts pre-embedded according to the fan’s specifications and the requirements of the construction design.

9.2 Unit commissioning

9.2.1 Precautions Before Debugging

9.2.1.1 Check the entire unit for any missing or incorrect parts; if any are found, make timely adjustments.

9.2.1.2 Check whether the connections between the main unit and all auxiliary units are firm and reliable, and whether the connecting pipes and joints of each cabinet panel are properly sealed. Any areas with air leaks must be sealed thoroughly. All connection bolts must be fully installed and tightened.

9.2.1.3 All moving parts should operate smoothly and freely, without any signs of sluggishness or jamming. There shall be no foreign objects inside the fan casing.

9.2.1.4 Check whether the electrical wiring and connections are correct, tighten each connection bolt one by one, and ensure good grounding.

9.2.1.5 Remove all debris from inside the unit. Seal the bottom perimeter of the unit’s outer casing with cement mortar or sealant, and only start up the unit after the sealant has fully cured.

9.2.2 Primary pre-filter adjustment

9.2.2.1 Adjust the distance between the large nozzle’s suction port and the mesh surface according to the application scenario and process requirements; typically, this value is: 10-30mm For dust removal systems with a higher content of short fibers and fewer fibers, use the lower value. ( Such as Qinghua and air-jet spinning dust removal, etc. ) , take the larger value for those with more long fibers. ( Such as carding and fine combing for dust removal, etc. ) ; The gap between the nozzle and the mesh surface shall be uniform throughout, with a deviation no greater than. 5mm。

9.2.2.2 Adjust the position of the reducer for the primary nozzle drive motor so that the V-belt remains straight and has appropriate tension.

9.2.2.3 Adjust the middle section of the primary suction nozzle so that there is a tight seal between the air inlet and the nozzle outlet, with no rubbing or contact.

9.2.2.4 The fiber compactor has been adjusted before leaving the factory and generally does not require further adjustment. However, if you notice mesh fouling during unit operation, you will need to adjust the fiber compactor. When making adjustments, slightly tighten or loosen the locking nut to appropriately reduce and ensure uniform clearance between the screw shaft blades and the copper strips inside the mesh cylinder—observe carefully as you make these adjustments. ( Ensure safety ) The process is complete once the meshing phenomenon has been eliminated. ( When adjusting, avoid friction between the blades and the copper strips. )。

9.2.3 Secondary dust filter adjustment

9.2.3.1 Check that the gap between the nozzles installed on each suction arm and the dust cage filter slots is uniform. Rotate the drive spindle once, observing four to six points during the rotation. If any misalignment is detected, loosen the connecting pipe positioning screws and adjust the suction pipe to the proper position.

9.2.3.2 Check the nozzle and straw. ( Double-sided ) Is the suction nozzle aligned vertically with the filter media? If there is any misalignment, loosen the clamp securing the suction tube, rotate the suction tube to achieve the desired alignment, and then tighten the clamp again.

9.2.3.3 Check whether the vacuum hose connection is secure.

9.2.3.4 Adjust the main spindle drive belt to ensure it is properly tensioned.

9.2.4 Adjustment of the motor's rotation

9.2.4.1 Press the start buttons for the dust collection and dust discharge fans separately to ensure that their rotation directions are completely correct.

9.2.4.2 Individually jog the fiber compactor and dust compactor motors to ensure that the screw shafts are rotating in the correct direction.

9.2.4.3 Individually jog the motors of the primary suction nozzle and the secondary suction arm, and observe the rotation of the nozzle and the suction arm.

10. Operation of the dust removal system

10.1 System startup

First, start the dust removal unit. After it is running normally, then start the main fan, and finally start the process equipment.

10.2 System parking

To properly shut down the system, you must first stop the process equipment and then press the button for the dust removal unit.

11. Operation, management, and maintenance of the crew.

11.1 Operations Management

11.1.1 During normal operation of the equipment, each 2 Check the operating status of the main and auxiliary machinery once per hour. If any abnormalities are detected, stop the machinery immediately and address the issue.

11.1.2 Regularly remove the fibers and dust discharged by the fiber compactor and dust compactor in the cleaning unit. However, it is strictly prohibited to manually clean out debris from the dust compactor, as this could cause reverse airflow and lead to malfunctions in the dust collection system.

11.1.3 During each shift, check the primary suction nozzle for cotton pickup, ensure the mesh surface is clean, and verify that there is no fiber entanglement inside or outside the nozzle. If any fiber entanglement is found, clean it promptly.

11.1.4 Inspect each class to ensure that there is no fiber winding around the shaft on the fiber compactor; if any such issue is found, clean it promptly.

Attention: When inspecting or cleaning, be sure to turn off the power supply to the fiber compactor to prevent accidental injuries.

11.1.5 Inspect the operation of the secondary dust filters in each shift, check whether the rubber strips on the small suction nozzles are damaged, verify that the oscillation mechanism is functioning properly, confirm that the vacuum hose is intact, and ensure that the dust inside the dust bin has been completely removed. Any issues found must be promptly analyzed and addressed.

11.1.6 Each class performs a cleaning of the unit’s baseplate once, and the unit’s interior is thoroughly cleaned of accumulated dust once a week.

11.2 Maintenance and upkeep

11.2.1 Monthly check whether the secondary nozzle inlet is perpendicular to the dust cage filter media, and whether the rubber strips on both sides of the inlet are damaged. If any misalignment or damage is found, adjustments, repairs, or replacements must be carried out immediately.

11.2.2 The electrical department conducts cleaning and inspection of the electrical control cabinets once a month and performs a comprehensive overhaul annually to ensure safety and reliability.

11.2.3 The electrical department should clean the bearings and replace the grease of all motors in the dust removal equipment once a year.

11.2.4 Replace the dust-laden filter media when the secondary resistance noticeably increases or when the long-fiber filter media has severe dust accumulation and wear. The decision to replace the filter media should be made based on the specific situation.

1) 1. Remove the pressure plate of the filter frame and the bolts connecting the filter frame to the rear frame, then take off the filter frame.

2) Loosen the filter media at both ends of the filter frame. You Secure the plastic card with a fixed steel wire and... You Remove the plastic card;

3) Tear open the nylon fastener from the bottom of the filter frame;

4) Remove the plush filter media from the upper part of the filter frame. Y Extract from the shape card;

5) Replace the spare filter media and install the filter frame. The installation sequence is the reverse of the removal sequence.

11.2.5 Each year, all transmission mechanisms should be inspected, cleaned, and worn parts replaced.

11.3 After parking at the end of each shift, the machine interior should be cleaned to remove accumulated dust and fiber fluff. Pay particular attention to the first-stage disc and fiber separator, and carefully check the cleanliness of the filter media as well as whether the multi-tube rubber nozzles have been blocked by accidentally entrapped fiber fluff.

11.4 Pay attention to adjusting the tension of the drive belt as needed.

11.5 Check the reducer once a week for abnormal heating, unusual noises, and other abnormalities, and lubricate it with oil as needed.

11.6 Check the lubrication condition of the reciprocating screw every three months and replenish the grease on a regular basis.

12. Ordering Instructions

12.1 This unit must be positioned with sufficient clearance from surrounding walls and objects to allow for operation and maintenance. The clear height of the machine room should generally be ≥ 3600mm The front of the unit enclosure shall be ≥ to the wall. 1500mm The distance between the unit maintenance door and the wall ≥ 700mm。

12.2 This unit does not include external piping or the main fan; these must be ordered separately according to the dust removal system design requirements.

12.3 The external electrical conduits for this unit (including the power supply inlet to the electrical cabinet and all pre-embedded power cable conduits) shall be provided by the user.

12.4 Based on the process conditions (such as air handling capacity, process steps, equipment, raw materials, product types, etc.), reasonably select the model and specifications of the dust removal unit as well as the filter media; and determine the shape, size, and location dimensions of the inlet duct opening.

12.5 The air volume and pressure of the main fan shall be configured according to the system design requirements. Provided that the user supplies the corresponding and necessary technical documentation, our factory can offer technical consultation or system design services to the user.

12.6 This unit is supplied as a complete set (including the main unit, auxiliary equipment, electrical control cabinet, and all necessary wiring and ductwork within the unit). If the main fan requires a separate electrical control cabinet, please specify the technical requirements when placing your order.

12.7 Our factory can handle equipment shipping on behalf of our customers.

13. Faults and Their Troubleshooting

Common faults and troubleshooting methods for dust removal units during operation are shown below. ( Appendix 1) 。

14. Random technical document

14.1 Product Manual  

14.2 Packing List Certificate of Conformity  

14.3 Electrical Data

Appendix 1

Therefore     Obstacle	Original         Because	place   reason   square   Law
The primary mesh surface isn't being cleaned effectively by vacuuming.	1. Improper gap between the primary nozzle and the mesh surface	Adjust the gap
	2. Flower hanging and blockage inside the primary nozzle.	Remove hanging flowers and blockages.
	3. Fiber compactor meshing glue	Adjust the gap between the screw and the mesh cylinder.
	4. Primary dust removal fan failure	Check whether the fan’s rotation direction is correct and whether there are any obstructions.
Fiber compactor does not discharge. Fiber	1. Spiral rod winding flowers	Remove the brush from the spiral blade.
	2. Air leakage from the discharge port ( The spring door is malfunctioning. )	Check and repair the spring door; ensure it resets smoothly and flexibly.
	3. The screw rod doesn't turn.	Inspect electrical equipment and motors; inspect the reducer.
	4. The end of the spiral blade is severely deformed.	Inspect, repair, or replace the helical blades.
The secondary filter material cannot be thoroughly cleaned.	1. The nozzle inlet is not vertically aligned with the filter material.	Loosen the clamp and adjust the suction nozzle.
	2. The rubber strip of the nozzle is damaged.	Replace the nozzle rubber strip.
	3. The nozzle has uneven gaps in the middle of the filter tank.	Release the接管 and adjust the nozzle position.
	4. Dust collection fan reversing	Adjust the motor wiring.
	5. Vacuum hose damaged	Replace the vacuum hose.
	6. Dust collection bag clogged	Identify the cause, troubleshoot the issue, and remove blockages from the filter bags.
Dust collection bag clogged	1. Ash hopper blockage	Clean the dust bag and remove accumulated dust from the ash hopper.
	2. Oscillation mechanism failure	Identify the cause and eliminate the fault.
	3. Dust compactor malfunction: a. Wind the compressor.	Use waste cotton to block the ash outlet.
	b. The clamp doesn't turn.	Check the cause and eliminate it.