1-800-214-7716 ME-MAN—06
[Link]
INSTALLATION DO NOT STORE GRAY PVC MIST
OPERATION ELIMINATORS IN DIRECT SUNLIGHT
MAINTENANCE
• MistMasterTM In-Line Mist Eliminators
• Terminator™ Exhaust Hood
• Horizontal MW-400
Vertical In-Line
Mist Eliminator
PO Box 5319
281 Hughes Drive
Traverse City, MI 49686 Horizontal In-Line
Mist Eliminator
Ph:231-941-5865
Fax: 231-941-1636
mapco@[Link]
JOB NO:
CUSTOMER:
APPLICATION:
INDEX
Caution Notes………………………………………………………………….3
Washdown Schedule………………………………………………………....4
Introduction…………………………………………………………………….6
Safety
Receiving and Inspection
Handling and Storage
Duct Connections
Operating Temperatures
Materials of Construction
Installation Instructions……………………………………………………..7
Drain and Supply Piping
Washdown Notes
Spray Nozzles……………………………………………………...……….…8
Mesh Pads Filter Media
Trouble Shooting……………………………………………………...….…..9
Mist-MasterTM Parts Drawing………………………………………..….....10
TerminatorTM Exhaust Hood Parts Drawing.,…………………….…....11
MW-400 Parts Drawing………………………………………………….…..12
2
CAUTION
Responsible Personnel must be assigned to the installation, operation and maintenance of
this unit. Read complete manual prior to operating this unit. DO NOT WASH FINAL STAGE
WITH FAN RUNNING. Observe fan discharge stack immediately after start-up and also on a
regular basis thereafter. If excessive misting is present, shut down system immediately and
notify MAPCO. Serious damage could occur to property if unit is run under this condition.
Before putting mist eliminator into operation:
1. Check all mesh pads for separation between hood side wall and/or mesh pad retainer. Also
check mesh pad for voids. Any opening or gap in mesh pad could allow mists to bypass mesh
pads.
2. Plumbing: Make sure all plumbing is installed to code. Check for leaks.
3. Velocity/CFM: External static pressure for the proposed system may vary depending on actu-
al field conditions. Make sure exhaust fan is exhausting proper volume (CFM). Deviation from
design could cause excessive misting at the mist eliminator.
4. Spray Pattern: Check spray nozzles upon start-up for good spray pattern. Debris lodged in
filter media could become dislodged during transit. Without a filtering device, debris could be-
come lodged in spray nozzle causing little or no flow.
Any malfunction of the mist eliminator should be reported to MAPCO immediately for repair or
service instructions.
Start-Up Service:
In addition to this installation, operation and maintenance manual, MAPCO offers a factory
trained service representative to perform, assist or advise in the installation and start-up of
this equipment. The cost for this service is charged per man at the following rates:
A. First eight (8) hours of a single day Call Mapco for current Service rates.
B. Overtime hours in a single day Call Mapco for current Service rates.
C. Sunday or Holiday Call Mapco for current Service rates.
D. Other expenses such as airfare, hotel, car rental, meals, parts, tax, freight, etc. if applicable
will be charged at cost plus 15% administration fee.
E. Company Vehicles
1. Company car or truck @ $.75/mile
2. Company truck and trailer @ $1.75/mile
Note: MAPCO assumes the "End User" is knowledgeable of this equipment and fully understands the
risks associated with the installation, operation and maintenance of the equipment purchased.
3
WASHDOWN SCHEDULE 24 HR DAY
MW-400 MIST ELIMINATOR WASHDOWN SCHEDULE
PHASE DELIVERY FREQUENCY DURATION GALLONS GALLONS RINSE
GPM (SECONDS) (PER CYCLE) (PER DAY) TYPE
Stage I
Stage II
NOTES:
MistMasterTM INLINE MIST ELIMINATOR WASHDOWN SCHEDULE
PHASE DELIVERY FREQUENCY DURATION GALLONS GALLONS RINSE
GPM (SECONDS) (PER CYCLE) (PER DAY) TYPE
Stage I
Stage II
NOTES:
TerminatorTM Exhaust Hood WASHDOWN SCHEDULE
PHASE DELIVERY FREQUENCY DURATION GALLONS GALLONS RINSE
GPM (SECONDS) (PER CYCLE) (PER DAY) TYPE
Stage I 5.3 gpm 4 to 6 hrs 30 to 60 2.65 to 5.3 10.6 Fresh D.I.
Stage II
NOTES:
1. Mist Eliminator washdowns will be initiated by programmable timer, plating machine cycle, independent PLC and/
or plating tank level control.
2. The washdown schedule suggested above is a recommended starting point only. Should concentrated chemical
accumulate inside the equipment, or effluent from periodic washdowns not run clean or nearly clean at the end of
the washdown cycle, a need for more frequent or longer duration washdowns will be required.
Continued operation of mist eliminator with inadequate washdowns may result in damage to the mist elimi-
nator and a concentrated discharge at the exhaust stack.
4
INITIAL WASHDOWN PROGRAM FORM
START-UP DATE: CUSTOMER: JOB NO:
TIME CHANNEL 1 CHANNEL 2 CHANNEL 3 CHANNEL 4
STAGE I STAGE II
5:30 AM
6:00 AM
6:30 AM
7:00 AM
7:30 AM
8:00 AM
8:30 AM
9:00 AM
9:30 AM
10:00 AM
10:30 AM
11:00 AM
11:30 AM
12:00 PM
12:30 PM
1:00 PM
1:30 PM
2:00 PM
2:30 PM
3:00 PM
3:30 PM
4:00 PM
4:30 PM
5:00 PM
5:30 PM
6:00 PM
6:30 PM
Programmed washdowns to occur between 6:00 AM and 5:30 PM
5
INTRODUCTION—The performance of every
Mist Eliminator depends on many factors. The pur-
pose of this manual is to make you aware of these
factors so you will obtain the utmost efficient and
dependable performance.
Providing that proper care is exercised in installing
this equipment, and if it is given reasonable
maintenance, you can be assured of trouble free
operation.
It is important that you study this manual prior to
installing this equipment to assure safe installation
and operation.
SAFETY - The very nature of air handling equip-
ment and accessories present a hazard to person-
nel during installation and maintenance. The fol-
lowing precautions should be observed prior to in-
stalling, starting or maintaining this equipment. RECEIVING AND INSPECTION - Upon receipt of
shipment, check first to see that all items on bill of
1. Inspect the name plates or other tags for spe- lading and/or packing slip have been received. By
cial instructions. careful inspection determine whether damage has
occurred in transit. Any shortage or damage
2. It is recommended that this equipment be in- should be noted and a claim should be filed imme-
stalled by personnel familiar with the installa- diately.
tion of this type of equipment.
3. All motors should be locked out until installa- Equipment manufactured by Midwest Air
tion is complete. This is accomplished by pad- Products Co., Inc. has been inspected at our
locking the disconnect switch in the off posi- factory in Traverse City, MI.
tion. Inspect the hood interior for debris or
loose parts. HANDLING AND STORAGE - If installation of the
equipment is delayed and storage is made out-
4. Inspect ductwork for leakage of harmful or
doors, provide reasonable weather protection.
corrosive fumes.
When transporting or installing this equipment
5. Never discharge corrosive or harmful fumes exercise care to avoid breakage of PVC. Never
from the fan. The mist eliminator should pick this equipment up by the flanges.
always be operated with the proper amount of
water. Follow good safety practices when DUCT CONNECTIONS - Duct loads can cause
installing or maintaining this equipment. distortion with consequent damage. Support duct-
work independently of the mist eliminator.
OPERATING TEMPERATURES - The mist elimi-
nator is fabricated from PVC. When constant tem-
perature exceeds 130o F the unit will distort caus-
ing severe damage.
MATERIALS OF CONSTRUCTION - The mist
eliminator body is typically fabricated from 1/8”,
3/16”,1/4" and 3/8” Type I, Grade I corrosion re-
sistant, unplasticized PVC. Access doors and re-
moval doors are 3/8" thick PVC.
It is recommended that all chrome control equip-
ment be set up with some form of secondary
containment should a leak occur.
6
INSTALLATION INSTRUCTIONS
1. Prior to installation, inspect mesh pads for dam OPERATION IMPORTANT - The polypropylene
age during transit. This is accomplished by mesh pads supplied with this unit may contain re-
looking through the inspection door, hood sidual lubricating oil that is used on the knitting
outlet or inlet/outlet with the aid of a flashlight. needles during pad construction.
If media is separated from sidewall, consult
factory immediately. Mapco knows of no instance where these oils pre-
sented a problem involving contamination of the
2. Inspect all plumbing connections for breakage or plating bath. To avoid any possibility of plating
leaks.
Inadequate washdown procedures and/ or concen-
3. If flanges are not drilled, the bolt holes should be trations of chemicals may considerably shorten the
drilled on 4" to 6" centerlines. Use either 1/4" or service life of polypropylene mesh pads. Mapco
3/8" bolts with a flat washer under both bolt offers a more expensive alternate mesh pad con-
head and nut. It is important that a caulking or structed of Kynar™. Kynar™ offers a higher de-
gasket material which is compatible with the gree of resistance to chromic acid and should sig-
process chemicals be used. Mapco recom- nificantly increase the life expectancy of the first
mends the use of an adhesive backed teflon phase pad. These pads are offered as an option
type gasket. and are not standard equipment. Replacement
Kynar™ mesh pads cost run three to five times
DRAIN AND SUPPLY PIPING - Follow proper that of polypropylene.
plumbing codes when installing plumbing. Double
wall containment may be required. DO NOT tap WASHDOWN SCHEDULE
into potable drinking water for supply of clean (FREQUENCY AND DURATION)
water. Use the proper back- The mist eliminator is designed with one, two or
flow valves, etc. to prevent three stages. The first stage will collect the highest
cross-contamination. percentage of larger chemical droplets and there-
fore will require more washdown cycles. The last
1. The drain is marked with a stage (if so equipped) will require the least amount
tag. It is good practice to of washdown cycles.
install a trap and valve on
the drain line. DO NOT reduce the drain line The first stage in most cases will require a wash-
diameter. Unit could overflow and cause dam- down every two to three hours. The duration of the
age. washdown will last from 30 seconds to one minute.
This can be determined by visual inspection of the
2. The supply line should be plumbed using sch. effluent. When the water is clean the washdown
80 PVC or CPVC as a minimum. DO NOT re- duration will be established.
duce the supply line. Reducing supply line
could cause higher head pressure and reduced The second stage (if so equipped) will require a
flow. Pipe supports should be installed to in- washdown every three to four hours. The duration
sure solid installation. of the washdown could last from 10 seconds to
one minute. This can be determined by visual in-
3. In order to minimize plugging of the spray noz- spection of the effluent. When the water is clean
zles, a filtering device should be installed on the washdown duration will be established.
the supply line. If not installed, the nozzles will
eventually become plugged and cause the Proper washdown of the mesh pad will be indicat-
mesh pads to plug. This could create undue ed when effluent produced from washdown runs
stress on the mesh pads and allow chemical to clear at the end of the wash cycle. For situations
bypass the system. involving very light loadings, it may be possible to
decrease washdown frequency or duration or both.
bath contamination, effluent from initial pad wash- A lightly colored effluent will indicate the need for
downs should be sent to waste treatment until more frequent or longer duration washdown of the
foamy brown traces of oil disappear. mesh pad depending on what you plan to do with
the effluent..
7
NOTE: Use the appropriate safety equipment, or other particles are present in the plant air, the
clothing and eye protection. Follow manufactures mesh pads will eventually plug and/or deteriorate.
recommended safety procedures for safe handling If mesh pad becomes plugged, remove and clean
of all chemicals and other potential hazards. immediately. MAPCO recommends at a minimum,
bi-annual removal and inspection of the Mist Elimi-
A. SPRAY NOZZLES nating components. A decreased exhaust volume
Spray nozzles should be checked for proper may indicate plugging of the mesh pad.
spray pattern. The spray pattern should give
the appearance of a full cone for each nozzle. The mesh pad and pad retainer can be immersed
If the pattern appears to be erratic, the spray in a rinse tank to remove accumulated deposits.
header and nozzle assembly should be re- Eventual replacement of the mesh pad may be
moved from the unit and cleaned. Improper or necessary. Typical 1st stage pad life ranges from
no spray can cause severe plugging and dete- two to four years with proper wash down. MAPCO
rioration of the mesh pads. Mapco recom- recommends a spare mesh pad and retainer as-
mends the use of a strainer in the main header sembly be kept on hand.
line to minimize nozzle plugging.
CAUTION NOTE:
1. Shut off water supply to spray header. Follow
proper safety procedures to insure against Mapco assumes no responsibility or liability for
header discharge while working on spray problems resulting from mesh pad replacement by
header. other. Only qualified persons should replace mesh
pads when necessary. It is extremely important
2. Remove bolts securing header flange to side- that the replacement fit as snug as the original.
wall of scrubber. Break apart union connection
at main spray header. Take all necessary pre-
cautions to avoid spillage of solution. Be sure
solution has completely drained from header.
Pry header away from backing plate.
Exercise caution to avoid breaking header
flange when removing or prying. Remove
header from unit.
3. Remove threaded end cap and/or all spray
nozzles from spray header. Remove all debris
from nozzles and header.
4. Reverse above steps and re-install. Make sure
header flange and backing plate are secured
and leak proof. Mapco recommends the use of
a 100% silicone caulking and /or Teflon gasket.
B. MESH PAD FILTER MEDIA
Mesh pads should be checked for plugging,
build-up or separation from retainer. Under nor-
mal circumstances, the mesh pad filter media
requires minimal maintenance, provided, the
spray nozzles, washdown schedule, and wash-
down concentration are maintained. Other fac-
tors that may accelerate plugging are minerals
in the washdown liquor such as calcium or
small dust particles present in the plant air from
grinding operations, etc. Should the unit be
operated for periods without water,
8
TROUBLE SHOOTING
PROBLEM POSSIBLE CAUSE
POOR SPRAY PATTERN • Spray Nozzles plugged up
• Spray Headers plugged up
• Pump suction blocked
• Pump discharge piping too small
• Insufficient water in sump
• Pump running backwards
• Total head requirement exceeds that of pump
UNIT WILL NOT DRAIN • Drain line to tank is not submerged or trapped
• Drain line is not sloped towards tank
• Drain line plugged
• Drain line too small
MOISTURE AFTER UNIT - Some • Re-Entrainment due to excessive washdown duration
moisture will be evident with • Gap or void in mist eliminator
only one mesh pad. • Mist Eliminator damaged
• Velocity too high through mist eliminator
• Droplet size too small
• Build-up of chemical on Mist Eliminator
LOW REMOVAL EFFICIENCY • Insufficient or no water to spray nozzles
• Mist Eliminator plugged or shifted
• Velocity too high or too low
• Inlet concentration too high
DETERIORATION OF MESH • No water to spray nozzles
PAD • Spray nozzles plugged
• Concentrated chemical build-up
• Plating bath includes chemicals not compatible with polypro-
pylene
DECREASED EXHAUST • Insufficient air make-up in building
VOLUME • Mesh pads are plugged
• System static pressure too high
• Fan belts loose
• Duct dampers are closed or broken
OILY SOLUTION IN PLATING • Residual oils used in manufacture of mesh pads. Run sev-
BATH eral washdown cycles on each phase until clean.
NOTE: Due to the high efficiency of composite mesh pads, plugging can occur from the following
sources:
1. Grinding dust, blasting grit. Airborne dust and dirt.
2. Mineral deposit from water supply.
3. Flux from soldering or welding process.
4. Oil mist from machining operations.
9
MIST- MASTER™ INLINE MIST ELIMINATOR
Removable
Mesh Pad
Flanged Inlet and
Outlet
Drain
Removable
Spray Head-
er
10
TERMINATOR™ EXHAUST HOOD
Magnehelic
Gauge
Removable
Mesh Pad
Removal
Door
Removable
Spray Head-
er
11
MW-400 HORIZONTAL MIST ELIMINATOR
Removal
Removable Door
Mesh Pad
Outlet
Transition
Flanged Inlet and
Outlet
Removable
Spray Headers
Inlet
Transition
Painted
Steel Base
12
Highest Value Corrosion Resistant PVC Duct
Exhaust and Pollution CorzanTM Duct
Control Equipment Fiberglass Overlaid Duct
Turnkey
Installations
“old
school CorzanTM
Duct
quality
old
school
service”
Motorized Dampers
TerminatorTM
Composite Mesh Pad
Exhaust Hoods
13
