groundbreaking innovations have produced new...

DUST

Groundbreaking innovations have produced new technology that will have you re-thinking the way you process your airborne contaminants.

SOLUTIONSCOLLECTION

®

We offer more.

FPE Automation is an award-winning, fully stocking distributor of the industry's premier products.

The products in this catalog are just a portion of what

FPE Automation has to offer. Turn to the inside back

cover of this catalog for automation products, controls,

pneumatic supplies and more.

It doesn't end there. We also provide custom value-

added solutions designed to save you time, resources

and money. Ask your solution specialist for details or visit

www.fpeautomation.com

Dust Collection Solutions

FPE Automation Presents:

The MAC Pulse Valve Advantage

Dust Collection SolutionsThe Patented MAC Pulse Valve:

Game-changing Design

• MAC’s vastly improved technology is changing dust collection methodology

• Designed for high effi ciency

• Eliminates known failure points

• Lowers maintenance costs

• Makes conversion quick and easy with a bolt-on design

• Optimized for harsh environments

• Signifi cantly decreases energy costs

DUST COLLECTION SOLUTIONS CASE STUDY: CONSTANTLY CHANGING FILTERS

Before: The fi lters are

packed with caked-on

bakery fl our and other

contaminants.

After: With the MAC pulse

valve in place, the fi lter

stays substantially cleaner.

Before

After

The fi x? The old valve was replaced with a MAC Pulse Valve: The failing valve was removed, and a new MAC pulse valve was used instead. After just two pulses, the customer realized that the change was “dramatic” and remarked that the new MAC solution “will “drastically reduce the number of fi lter changes in the plant”. Note how clean the fi lter remains.

The facility in this case study, a large bakery, was changing fi lters every two to three weeks. It seemed like they could never keep up with the accumulation of product. Little did they know, the problem was their pulse valve. It was under-performing and not properly cleaning the fi lters. That’s a buildup of fl our and other dust that you see on the fi lter.

The MAC Pulse ValveHarsh Environment Compatible

Balanced pilot technology ensures fast, repeatable pulses. Bonded spool

technology in the main valve results in superior reliability beyond existing

diaphragm technology. A checked accumulator and main spool with

memory spring are used to ensure a shift back to the home position, for

times when air supply may not be adequate. A line of adapter plates has also

been released to replace existing diaphragm pulse valves with a direct drop-

in, without disturbing existing plumbing.

DUST COLLECTION SOLUTIONS CASE STUDY: THE EQUIPMENT COULD NOT KEEP UP

• The compressor supplying the air has to compensate with more air. The result is far more electricity usage (much higher cost of ownership).

• A diaphragm valve not functioning correctly can cause negative performance in other valves on the manifold.

• A small leak can occur after the diaphragm is in place just a very short time.

• When leaks don’t result in a catastrophic tear, they can be diffi cult to detect. Undetected, they can result in thousands of dollars of increased costs before they are discovered and rectifi ed.

• Case study after case study has shown there is a 20-30% increased expenditure in energy costs to operate a diaphragm valve, versus a MAC pulse valve.

Diaphragm Valves Tear. Here’s What Happens When They Do:

Before

AfterAfter Installation of the MAC Pulse Valve: All equipment can be run at the same time. The clean-up time on processed pieces has been drastically reduced and they are able to work normal schedules and still meet their scheduled delivery dates. They also found that after initial start-up, the old valves weren’t cleaning as well as the MAC pulse valves. They purged quite a bit of old debris. That allowed the dust collection system as a whole to operate at a higher effi ciency.

At the facility in this case study, when the dust collection system was turned on, other things had to be turned off . This caused added time in prepping material for shipment after it was processed. That resulted in working longer hours and potentially delaying shipments to customers.

DUST COLLECTION SOLUTIONS CASE STUDY: PREVIOUS VALVES WERE BARELY WORKING

Measureable and remarkable results: After 10 minutes, the

Mac pulse valves had collected around 4’ of airborne carpet

dust. On the side of the hopper underneath the diaphragm

valves, there was approximately 8” of collected material. The

bags above the Mac valves remained cleaner as well.

Like most carpet and rug manufacturers, eff ective management of airborne dust in the manufacturing process was mandatory and a contaminant-free atmosphere is crucial.

There are 14 bags at this facility. Each is 6” x 10’ long. At the top of this photo, you’ll notice the material clinging to the bags. It was left over from the diaphragm valves that were in place before.

The hopper was cleaned and prepared for the test.

The results were dramatic. The dust collection system was started and the entire system of valves run for 10 minutes. for the purpose of this test, no other devices were operating. The augar and air cannons remained off .

The depth of the material collected underneath the Mac valves is approximately four feet deep. The portion of the hopper underneath the diaphragm valves had about eight inches of collected material. The old valves were consuming energy, but doing next to nothing. The Mac pulse valves collected approximately 83% more under identical conditions.

The higher impact force of their pulses allowed the cycle to complete fully, with the dust released into the bottom of the augar, where it belonged, instead of clinging to the bags. That higher impact force has a number of benefi ts, including better cleaning, less pulsing, improved bag and fi lter life and air savings.

• Improved pulse effi ciency has direct, measurable results on energy costs. MAC valves = energy savings.

• High impact force has a number of benefi ts, including better cleaning, less pulsing and improved bag and fi lter life.

• Mac’s whip action produces shorter pulse duration. That results in air savings.

• Diaphragm valves spend more time in the “on” position:Average “on time” for Pulse Valve up to 1-1/2” NPT: 120-150 msAverage “on time” for Pulse Valve over 1-1/2” NPT: 150-250 ms

Diaphragm Valves are less effi cient. Here’s why that matters:

DIAPHRAGM VALVES MAC PV SERIES VALVES

The MAC Pulse ValveDesign Advantages

D-seal technology isolates the solenoid: As a result of MAC’s innovative solution, contamination, sticking and burning are reduced and the valve has a longer life.

4-way pilot: Maximizes shifting forces.

Lifting solenoid: Consistent response.

Substantially longer life: Many years of service with no maintenance.

Easy conversion: a wide variety of custom adapter plates are available by request.

There are many, signifi cant advantages of a MAC spool design:

Bonded = dynamic, longer life.Wiping action = self cleaning.Balanced design = repeatable purges.Precision ground spool = air savings

Contaminated air passed through an unbalanced solenoid. The result? Sticking and burning, inconsistent pulses.

A small, fi xed orifi ce. It’s a fl awed design. The orifi ce can quickly become blocked by contaminants.

They don’t last as long. Diaphragm valves are rated at 1 million cycles. The MAC pulse valves are rated at 10 million cycles.

A diaphragm design that has several disadvantages: Diaphragms are prone to cracking and ruptures. They shorten the life of the valve. Cracks result in wasted air. There is frequent routine maintenance, resulting in high cost of ownership.

MAC Pulse Valve Performance CurveMeasurable Energy Savings

DUST COLLECTION SOLUTIONS CASE STUDY: EVEN MORE EFFICIENCY OVER TIME

This manufacturer of building materials performed a review of their new project using MAC’s high effi ciency valves for dust collection. It was a routine follow-up meeting to track the progress. The review took place 19 days after the project had been implemented. Here’s what they found.

By redefi ning the pulse fi lter cleaning valve system— migrating from traditional diaphragm valve technology to Mac spool valves— they were able to make their entire dust collection process more effi cient.

How much more effi cient?

They nominated the idea for an award in their Supplier Innovation Program. Competition was stiff . It was up against some other exceptionally innovative ideas that year.

The MAC Valve dust collection project won 1st place.

The MAC Valve advantage,

after 19 days.

Whether you operate a pulse/

clean on demand system or

a timed cleaning system, the

eff ect upon energy savings

and valve life is substantial.

This performance curve

illustrates the signifi cant

impact of less frequent

pulsing.

DUST COLLECTION SOLUTIONS CASE STUDY: A SAFETY ISSUE

• Dust build-up causes a pressure drop across the fi lters. • That drop in pressure is constantly being monitored by

a Photohelic® switch/gauge.• When it exceeds a preset limit, the gage activates a

cleaning cycle.• The valves pulse. • A higher impact pulse results is less frequent intervals.

The system operates less often, which saves energy.

• A Magnehelic® gauge is used. It displays the static pressure inside the bag house.

• The timing of fi ring of the valves is pre-confi gured in the controller. It is normally set up based on time (ms) distributed across the number of pulse valves in the array.

• At the preset time, the timed sequence activates and the valves pulse.

• A higher impact pulse means the system can be programmed to operate less frequently, which saves energy.

What is timed cleaning?

It was employee safety (and the potential liability that comes with it) which fi rst captured the attention of this large manufacturer of aluminum castings.

The dust collection system is on the rooftop of the facility. So, whenever the previous valves failed, that was where the repair needed to take place. Because the system needed to be running at all times, that meant employees had to make that, somewhat risky, climb in all conditions; snow or rain, at times in the middle of the night. It presented a serious occupational hazard that needed to be minimized.

Ten MAC units were installed; PV03 and PV06. The facility managers were grateful that their safety issues had been drastically reduced.

They also realized that there were other benefi ts they hadn’t anticipated. Pulse on demand time went from every 8 seconds to every 22 seconds. Estimated energy savings is over $2000 per valve installed, a grand total of almost a quarter of a million dollars.

What is pulse/clean on demand?

MAC Pulse ValvePV03 Series

The MAC Pulse Valve PV03 series is designed to be a direct

drop-in replacement for existing pulse technology. The MAC

solution utilizes a long life, bonded-spool design, instead of the

traditional diaphragm style. MAC also uses a balanced, 4-way

pilot valve that isolates the solenoid from airline contamination.

Available with integral solenoid pilot as well as bleed pilot

confi gurations.

Direct Drop-InThe MAC Pulse Valve is available with various adapter options.

These adapter options allow the MAC valve to directly replace

the diaphragm technology with our bonded spool technology

without disturbing plumbing. The MAC bleed confi guration

works with existing remotely located solenoids.

Harsh Environment CompatibleStandard features include an aluminum die-cast body, stainless

steel fasteners, an environmentally protected solenoid, plus

Viton® seals for extreme temperature environments and

chemical resistance.

MaintenanceLower cost of ownership through reduction in downtime due

to high reliability. When necessary, maintenance is simplifi ed

with available spool kits.

Base AdaptersCustom base adapters available for most

competitive models. Additional confi gurations

available upon request.

SPOOL KITViton K-PV001-05

CHARACTERISTICS AND PERFORMANCEFlow Temperature Range Pressure Range

24Cv -20°F - 230°F-29°C - 100°C

30 - 120 PSI2.07 - 8.27 bar

MAC Pulse Valve PV03 Series Confi guration Options

P V 0 3 B - X X X - 4 6 L - D X X X - X X X = X X X X Integral Pilot

P V 0 3 B - X X X - 4 6 L - R B X X = X X X X Remote Bleed

INTERNAL/EXTERNAL PILOT0ABCD

Base OnlyInternal PilotExternal Pilot NPTF ThreadsExternal Pilot BSPPL ThreadsExternal Pilot BSPTR Threads

REMOTE BLEED111415

NPTF ThreadsBSPPL ThreadsBSPTR Threads

BASE PORT SIZE/THREAD TYPE0ABCDEF

Basic Valve No Base3/4” NPTF MAC Base1” NPTF MAC Base3/4” BSPPL MAC Base1” BSPPL MAC Base3/4” BSPTR MAC Base1” BSPTR MAC Base

Solenoid Valve Options

* Available with AC voltage (requires modifi cation).

PILOT ONLY OPTIONS: BODIES AND ASSEMBLIES46LB-LR0-RBXX=XXXX (bleed pilot valve)46LB-LP0-DXXX=XXXX (solenoid operated pilot valve).

MODIFICATIONS - ONE SELECTION REQUIREDPVVTPVVRPV01PV02PV03PV04

Viton® (includes seals and spring) Viton® seals and AC voltage (rectifi ed)Viton® seals, silicone free greaseViton® seals, silicone free grease and AC voltage (rectifi ed)Viton® seals, FDA food grade greaseViton® seals, FDA food grade grease and AC voltage (rectifi ed)

4 6 L - D X X X - X X X

MANUAL OPERATOR*01

No operatorNon-locking

ELECTRICAL CONNECTORBA*BKCM*CN*JA*JBJC*JDJJ*JMKA*KBKDKEKCKJ*KK

GrommetGrommet w/diodeMetal conduit 1/2”Metal conduit w/ground 1/2”Square plug-inRectangular plug-inSquare plug-in w/lightRectangular plug-in w/lightSquare male onlyRectangular male onlyMini plug-inMini plug-in w/diodeMini plug-in w/lightMini plug-in w/light & diodeMini plug-in w/LED & diodeMini plug-in male onlyMini plug-in male only w/diode

DC VOLTAGEDAEWDF

24 VDC (5.4 W)24 VDC (8.0 W)24 VDC (12.7 W)

AC VOLTAGE (Requires Modifi cation)

DDDPEMGD

24 VAC (7.3 W)48 VAC (5.8 W)120 VAC (6.2 W)220 VAC (7.3 W)

LEAD WIRE LENGTHABCDEFJ

18”24”36”48”72”96”External Plug-in Lead

* Integral solenoid only.

Modifi cations (Required)

MODIFICATIONS See below.

SPOOL TYPE0A

Base OnlyN.C. Main w/Memory Spring.

MAC Pulse Valve PV03 Series Specifi cations

MAC Pulse Valve PV03 Series Base Options

Additional adapters available upon request.



drop-in replacement for existing pulse technology. The

MAC solution utilizes a long life, bonded-spool design,

instead of the traditional diaphragm style. MAC also uses a

balanced pilot valve that isolates the solenoid from airline

contamination. Available with integral solenoid pilot as well

as bleed pilot confi gurations.

Direct Drop-InThe MAC Pulse Valve is available with various adapter

options. These adapter options allow the MAC valve to

directly replace the diaphragm technology with our bonded

spool technology without disturbing plumbing. The MAC

bleed confi guration works with existing remotely located

solenoids.

Harsh Environment CompatibleStandard features include an aluminum die-cast body,

stainless steel fasteners, an environmentally protected

solenoid, plus Viton® seals for extreme temperature

environments and chemical resistance.

MaintenanceLower cost of ownership through reduction in downtime

due to high reliability. When necessary, maintenance is

simplifi ed with available spool kits.

Base AdaptersCustom base adapters available for most

competitive models. Additional confi gurations

available upon request. SPOOL KITViton K-PV002-05


53.2Cv -20°F - 230°F-29°C - 100°C

30 - 120 PSI2.07 - 8.27 bar


P V 0 6 B - X X X - 4 6 L - D X X X - X X X = X X X X Integral Pilot

P V 0 6 B - X X X - 4 6 L - R B X X = X X X X Remote Bleed






4 6 L - D X X X - X X X

MANUAL OPERATOR*01




DC VOLTAGEDAEWDF

24 VDC (5.4 W)24 VDC (8.0 W)24 VDC (12.7 W)


DDDPEMGD



18”24”36”48”72”96”External Plug-in Lead

* Integral solenoid only.


INTERNAL/EXTERNAL PILOT0ABCD

Base OnlyInternal PilotExternal Pilot NPTF ThreadsExternal Pilot BSPPL ThreadsExternal Pilot BSPTR Threads

REMOTE BLEED111415


BASE PORT SIZE/THREAD TYPE0ACE

Basic Valve No Base1-1/2” NPTF MAC Base1-1/2” BSPPL MAC Base1-1/2” BSPTR MAC Base

SPOOL TYPE0A





drop-in replacement for existing pulse technology. The MAC

solution utilizes a long life, 2-way bonded main spool, instead

of the traditional diaphragm style. MAC also uses a balanced,

46 lifting series pilot valve, off ering all the benefi ts you have

come to expect from MAC valves: balanced design, high

shifting forces and longer life with greater repeatability. The

4-way pilot design allows for maximum shifting forces to both

the energized and de-energized positions for a dependable,

long-life valve. A main spool memory spring to ensure a shift

back to the home position, for times when air supply may not

be adequate.

Direct Drop-InThe MAC Pulse Valve is available with various adapter options.

These adapter options allow the MAC valve to directly replace

the diaphragm technology with our bonded spool technology

without disturbing plumbing. The MAC bleed confi guration

works with existing remotely located solenoids.

Harsh Environment CompatibleStandard features include an aluminum die-cast body,

stainless steel fasteners holding the pilot, an environmentally

protected solenoid, plus Viton® seals for extreme temperature

environments and chemical resistance.

MaintenanceLower cost of ownership through reduction in downtime due

to high reliability. When necessary, maintenance is simplifi ed

with available spool kits.

SPOOL KITViton S-PV005-05


100Cv -20°F - 230°F-29°C - 100°C

30 - 120 PSI2.07 - 8.27 bar

Integral Pilot

Remote Bleed


P V 0 9 B - X X X - 4 6 L - D X X X - X X X = X X X X

P V 0 9 B - X X X - 4 6 L - R B X X = X X X X

INTERNAL/EXTERNAL PILOT0ABCDEF

Base OnlyInternal Pilot NPTF ThreadsExternal Pilot NPTF ThreadsExternal Pilot BSPPL ThreadsExternal Pilot BSPTR ThreadsInternal Pilot BSPPL ThreadsInternal Pilot BSPTR Threads

REMOTE BLEED111415


BASE PORT SIZE/THREAD TYPE0ABCDEF

Basic Valve No Base2” NPTF MAC Base2 ½” NPTF MAC Base2” BSPPL MAC Base2 ½” BSPPL MAC Base2” BSPTR MAC Base2 ½” BSPTR MAC Base

SPOOL TYPE0A


4 6 L - D X X X - X X X


MANUAL OPERATOR01




DC VOLTAGEDAEW

24 VDC (5.4 W)24 VDC (8.0 W)


DDDPEMGD



18”24”36”48”72”96”External plug-in lead









SPOOL AND ADAPTER KITSK-PV003-05 Viton® (includes seals and spring) N-PV001-01 Solenoid adapter plate N-PV001-02 Remote bleed adapter plate N-PV002-02 PV09 check stem kit

FPE Automation, Inc.Since 1963

If you give any business the opportunity to say good things about

themselves, they’ll take it. We’re going to skip that part. We think the

partnership we’ve had with you and companies like yours, for more than a

half a century, says more about us than anything we can print here. We’ve

worked alongside you to create solutions that didn’t previously exist.

Solutions that streamlined, modernized and improved your operations.

They have increased your effi ciency, saved you money... and a lot of hassle.

Working together, we have strengthened American manufacturing, and

we intend to do all that we can to continue to do so. For more than 50

years, we’ve had the uniquely rewarding experience of watching solution

after solution come to life for the very fi rst time.

We’d like to thank you for the chance to be a part of all of that.

ACE ControlsShock absorbers, gas springs, rotary dampers & vibration control.

Beijer ElectronicsHuman machine interface (HMI).

BimbaPneumatic and electric motion devices, air cylinders & pinch valves*.

CamozziPneumatic fittings, flow controls and mechanical valves.

Carlo GavazziSensors, relays, switches.

CognexHandheld and fixed mount barcode readers, vision systems*.

ContiTechIndustrial air bags & air springs.

ContrinexProximity switches, inductive, photoelectric & capacitive sensors.

Dyadic/MiraiLow cost electric linear actuators.

Eaton B-lineEnclosures.

ElwoodHigh performance, food grade and explosion-proof servo and stepper motors.

FlairlineCylinders, flow controls, mufflers, check & needle valves.

Frame-WorldAluminim extrusions & structural framing components.

HypercylHydra-pneumatic cylinders and Servo presses.

JoulinVacuum grippers.

LegrisFittings, flow controls & check valves.

Leuze ElectronicSensors for industrial automation.

LinkTechQuick couplers; metal, plastic & NSF.

LinTechMechanical positioning components; linear and round bearing systems.

MurrelektronikConnectivity products and I-O systems.

MurrplastikPlotters, engravers, cable drag chains, cable entry & management solutions.

Omron Automation & SafetyPLC, HMI, Vision, Safety, Sensors, and other industrial control components.

Pendant Armor/RoboworldProtective robot suits and teach pendant cases.

PHDClamps, grippers, slides, escapements, rotary actuators, switches & sensors.

PHD+Electric actuators & slides.

PiabVacuum solutions, suction cups.

PneumadyneMechanical valves, fittings and manifolds.

QC IndustriesLow profile belt conveyors, stainless steel/sanitary conveyors.

RobotiqAdaptive grippers, wrist cameras and sensors for collaborative robots.

Smart Vision LightsMachine vision lighting.

StarcylPneumatic cylinders.

TolomaticElectric & pneumatic linear motion, actuators, brakes, power transmission.

TRDCustomizable pneumatic and hydraulic cylinders.*

Universal RobotsCollaborative robots.

WilkersonCompressed air treatment systems; filters, regulators & lubricators.

DalsaVision systems*.

MAC ValvesAir valves, small & large 3-way, 4-way, proportional air controlled valves.

Mead Fluid DynamicsPneumatic cylinders and mechanical valves*.

MencomIndustrial electrical connectors & panel interface.

MFDCompact cylinders, air preparation, grippers & thrusters*

LutzeCable, cord sets, wiring, network I/O suppressors & power supplies.

Yamaha RoboticsSCARA, cartesian, pick & place and single-axis robots.

Freelin-WadePneumatic tubing and coiled hose.

PanasonicPLC, HMI, sensors and laser markers.

* Not available in selected regions. Contact FPE Automation for details.

JVLIntegrated servo and stepper motors.

KB ElectronicsAC & DC speed controls, drives (inverters).

For many, dust collection is one of life's inconvenient

necessities. If failures go undetected, equipment, labor and

energy costs all go up. Maintenance and replacement is a bit of

a hassle. Even worse, a failure can result in downtime, loss of

production or product contamination.

The technological advances in recent years in the area of dust

collection have been nothing short of amazing. New innovations

take a lot of the hassle out of the process and offer better

cleaning results, while offering significant savings. Let's face it,

you don't often hear of better results and increased savings at

the same time.

In case study after case study, the reduction in air usage,

downtime, product contamination, leaks eliminated, reduced

labor costs and energy cost savings are significant. You have

nothing to lose, except a lot of excess dust.

Serving the state of Illinois,

Eastern Missouri/the

greater St. Louis area and

the Quad Cities, Iowa

region.

110 Gordon Street

Elk Grove Village, IL 60007

847-364-7455

12951 Gravois Road

Suite 120

Sunset Hills, MO 63127

314-842-0881

www.fpeautomation.com

#automationrevolution

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