INSTALLATION, OPERATION AND

Transcription

THE WORLD LEADER IN CLEAN AIR SOLUTIONS
AAF® INTERNATIONAL
INSTALLATION, OPERATION
AND MAINTENANCE MANUAL
RotoClone N
™
TO ORDER SPARE & REPLACEMENT PARTS
Call 1-800-477-1214 Email:
[email protected]
Parts Sales
Power & Industrial
AAF International
9920 Corporate Campus Drive
Suite 2200
Louisville, KY 40223-5000
USA
Internet: http://www.AAFParts.com
© 2015 American Air Filter Company, Inc. Any use of the text or images
this document contains, without permission of American Air Filter
Company, Inc., is prohibited. RotoClone, AAF, REDClean, REDFiltration,
and Reliable Efficient Durable are registered trademarks of American Air
Filter Company, Inc. d/b/a AAF International.
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RotoClone N
TABLE OF CONTENTS
1
INTRODUCTION ........................................................................................................................... 6
2
SAFETY .............................................................................................................................................. 6
2.1 Safety statement ................................................................................................................. 6
2.2 Safe working practices and staff training ............................................................ 6
2.3 Dust explosion hazard ...................................................................................................... 7
2.3.1 NFPA 654 and referenced codes and standards .......................................................................... 8
2.3.2 NFPA 484, Light Metals .................................................................................................................................... 8
2.3.3 Other requirements ............................................................................................................................................ 9
2.4 Electrical hazards ................................................................................................................ 9
2.5 Rotating equipment ........................................................................................................... 9
2.6 Safety guards ...................................................................................................................... 10
3
GENERAL PRODUCT INFORMATION .............................................................................. 10
3.1 Description ............................................................................................................................ 10
3.2 Purpose and intended use ........................................................................................... 11
3.2.1 Collection of explosive dusts ..................................................................................................................... 11
3.2.2 Collection of other dry dusts ..................................................................................................................... 11
3.2.3 Collection of damp, wet, oily or sticky dusts ................................................................................ 12
3.3 Normal Operation.............................................................................................................. 12
3.4 Sizes and Arrangements ............................................................................................... 14
3.4.1 Manual Sludge Removal (Arr. B) ........................................................................................................... 15
3.4.2 Sludge Ejector (Arr. C) .................................................................................................................................. 15
3.4.3 Continuous Sluicing (Arr. D) ..................................................................................................................... 15
3.5 Filter elements .................................................................................................................... 16
3.6 Weights ................................................................................................................................... 16
4
PRODUCT SHIPMENT .............................................................................................................. 19
4.1 How the product ships ................................................................................................... 19
4.2 Items that ship separately .......................................................................................... 19
5
PRODUCT RECEIPT AT THE DESIGNATED DELIVERY POINT .......................... 19
5.1
5.2
5.3
5.4
5.5
6
Responsibilities of the customer or customer’s agent ............................... 19
Receiving ................................................................................................................................ 20
Inspection on arrival ....................................................................................................... 20
Damaged goods .................................................................................................................. 20
Missing goods ...................................................................................................................... 20
UNLOADING AND HANDLING ............................................................................................ 20
6.1 Unloading ............................................................................................................................... 20
6.2 Handling.................................................................................................................................. 21
6.3 Rigging and hoisting instructions ........................................................................... 21
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7
STORAGE AND PROTECTION.............................................................................................. 22
8
SITE PREPARATION ................................................................................................................ 23
8.1 Locating equipment ......................................................................................................... 23
8.2 Foundations and anchor bolts ................................................................................... 23
9
ASSEMBLY AND INSTALLATION ...................................................................................... 24
9.1 Introduction ......................................................................................................................... 24
9.2 Assembling and installing the structure ............................................................. 24
9.2.1 Shipping Arrangements ................................................................................................................................. 24
9.2.2 Foundation Installation and Levelling ................................................................................................ 25
9.2.3 Field Fan Connection ....................................................................................................................................... 25
9.2.4 Chevron Mist Eliminator Installation (Sizes 1-1⁄2 through 6 Only) ........................... 26
9.2.5 Assembly of RotoClone N Sizes 8 through 48 ............................................................................. 28
9.2.6 Assembly of Sizes 16 through 48 Hopper and Collecting Sections............................. 28
9.2.7 Lubrication ............................................................................................................................................................... 28
9.2.8 Electrical connections ...................................................................................................................................... 29
9.2.9 Water supply connections............................................................................................................................ 30
9.2.10
Drain Connection for RotoClone N Arrangement B ............................................................. 32
9.2.11
Drain Connection for RotoClone N Arrangement C ............................................................. 32
9.2.12
Drain Connection for RotoClone N Arrangement D ............................................................ 32
9.2.13
Fan Drain.............................................................................................................................................................. 35
9.2.14
Ductwork Installation ................................................................................................................................. 36
10 WATER LEVEL CONTROL OPTIONS................................................................................. 36
10.1 RotoClone N Arrangements B and C Water Level Controls ...................... 37
10.1.1
Model “SV” Control ....................................................................................................................................... 37
10.1.2
Model “SV” Control with Low Water Safety .............................................................................. 37
10.1.3
Model “A” Control .......................................................................................................................................... 38
10.2 RotoClone N Arrangement D Water Level Controls ...................................... 39
10.2.1
Model “SV-HV” Control .............................................................................................................................. 39
10.2.2
Model “SV-HV” Control with Low Water Safety ..................................................................... 40
10.3 Flow Control Valve ........................................................................................................... 40
11 START-UP & OPERATION ..................................................................................................... 45
11.1 To
11.2 To
11.3 To
11.4 To
11.5 To
11.6 To
11.7 To
Fill the RotoClone N .................................................................................................. 45
Start RotoClone N Arrangement B ................................................................... 47
Start RotoClone N Arrangement C ................................................................... 47
Start RotoClone N Arrangement D ................................................................... 47
Stop RotoClone N Arrangement B .................................................................... 47
Stop RotoClone N Arrangement C .................................................................... 47
Stop RotoClone N Arrangement D .................................................................... 48
12 MAINTENANCE ........................................................................................................................... 48
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12.1 Record Keeping .................................................................................................................. 48
12.2 Water Level Control Box ............................................................................................... 48
12.3 Eliminator Plates ............................................................................................................... 49
12.4 RotoClone Housing ........................................................................................................... 49
12.5 Metering Drain Orifice (Arr. D) ................................................................................. 49
12.6 Sludge Ejector (Arr. C)................................................................................................... 49
12.7 Lubrication ............................................................................................................................ 50
12.8 Fan ............................................................................................................................................. 51
12.9 Replacement Part Stock ................................................................................................ 51
12.10
Sludge Collector (Arr. C) ..................................................................................... 51
13 TROUBLESHOOTING................................................................................................................ 51
13.1 Reduction in airflow at exhaust hoods ................................................................ 51
13.2 Reduced dust collection efficiency ......................................................................... 52
13.3 Water entrainment in fan discharge...................................................................... 53
14 RECOMMENDED SPARE PARTS LIST .............................................................................. 53
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RotoClone N
1
INTRODUCTION
This document contains the information necessary to properly receive,
assemble, install, operate, and maintain the AAF RotoClone® N filter system. The
purchaser, installer, and operator of the filter system MUST read and comply with
this document in its entirety prior to installation of the equipment and its
operation. Failure to comply with the requirements of this manual may void
the product warranty. The information and guidelines contained in this manual
are not exhaustive, and additional or alternative precautions, measures, training,
etc. may be needed depending on the specific circumstances.
CAUTION
These instructions are specific to the AAF RotoClone® N filter system. All
ancillary tasks including, but not limited to, electrical and mechanical work,
equipment handling, and safety procedures must be performed in
accordance with industry accepted practice and all relevant local, state, and
federal government codes, laws, and policies.
2
SAFETY
2.1 Safety statement
The air cleaning equipment supplied by AAF International ranges from very
large multiple-component assemblies which require significant and complex,
rigging, handling and assembly on-site, to small compact assemblies that are
easily handled and maneuvered. In addition to size, many of the dust collectors
will require electrical connections, compressed air connections, and will feature
high speed rotating equipment.
At all times, when dealing with industrial equipment such as dust collection
equipment personnel safety must be the highest priority of all involved, from
riggers, installers, operators, users, and maintenance personnel. Those
responsible on-site shall review the details of the equipment beforehand and
develop a plan for dealing with all stages of the installation from receipt of the
equipment on-site to start-up, commissioning, and hand-over. All applicable
health, safety, and environmental (“HSE”) rules, regulations and legislation shall
be fully complied with at all times.
2.2 Safe working practices and staff training
AAF International is fully committed to the safety of its employees and those
of its customers. In this spirit the following guidelines are offered for the
consideration of those responsible:
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RotoClone N
All personnel shall receive safety training specific to the site, the task, and
the conditions under which the work will be conducted.
All personnel shall be equipped with appropriate safety apparel and
equipment, such as clothing, footwear, hard-hats, gloves, ear protection, eye
protection, and safety harness.
All personnel involved in any stage of the process shall have been trained for
the tasks in which they will be involved and at all times shall be under the direct
supervision of experienced supervisors and managers.
All personnel shall be equipped with appropriate tools and equipment to
safely and efficiently complete their task.
Adequate lighting shall be supplied at all times while work is being
conducted.
A work perimeter shall be set up to define the limits of the area within which
the work will be conducted and outside which there will be no threat to the safety
of personnel or plant. The perimeter shall be taped-off and marked appropriately
to prevent accidental ingress of uninvolved personnel or equipment. When the
work area impedes into existing access ways or traffic routes for which no practical
alternative is available, barriers, wardens and flaggers shall be employed to safely
control crossing traffic and personnel.
At any time only those personnel directly involved in completing the task at
hand shall be allowed within the work perimeter.
2.3 Dust explosion hazard
By its very nature the RotoClone® N is intended to be used to capture
airborne particulate matter, otherwise known as dust.
Many dusts have the potential to be explosive. Dust explosions constitute a
serious industrial hazard and may result in death, serious injury, and devastating
property damage. It is the responsibility of the user to identify the nature of the
dust generated during any process or activity, whether or not it poses an explosive
hazard, and to properly mitigate this hazard.
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Except as otherwise expressly provided in writing, AAF makes no
representation or warranty in connection with explosion hazard equipment,
including, but not limited to, the necessity or effectiveness of explosion hazard
equipment or to the design, installation, operation, and performance of such
equipment.
The basic standards for dealing with explosive dust applications are
published by the National Fire Protection Agency (“NFPA”). The user shall be fully
conversant with the provisions of the particular codes and standards that apply to
the specific application and equipment used, and shall comply in full with all of the
requirements of the applicable codes and standards.
2.3.1 NFPA 654 and referenced codes and standards
The owner shall review and comply with NFPA 654: Standard for the
Prevention of Fire and Dust Explosions from the Manufacturing,
Processing, and Handling of Combustible Particulate Solids, and those other
documents referenced therein. NFPA 654 pertains to “all phases of manufacturing,
processing, blending, conveying, repackaging, and handling of combustible
particulate solids or hybrid mixtures, regardless of concentration or particle size,
where the materials present a fire or explosion hazard”. The purpose of the
standard “is to prescribe technical requirements for safety to life and property
from fire and explosion and to minimize the resulting damage from a fire or
explosion”. The user shall be fully conversant with the provisions of NFPA 654 and
shall comply in full with all of its requirements and those of all applicable
referenced codes and standards.
Note that NFPA 654 does not apply to the specific applications or materials
covered by the other NFPA documents unless specifically referenced by those
documents.
2.3.2 NFPA 484, Light Metals
There are various methods for dealing with a dust explosion hazard. The
RotoClone™ N is particularly appropriate for the collection of dust generated by
the working of light metals such as aluminum, titanium and magnesium. These
dusts are highly explosive and the RotoClone™ N uses water as a medium for
neutralizing the development of a potentially explosive dust cloud and for
eliminating the possibility of ignition. The specific standard that applies to these
applications is NFPA 484: Standard for Combustible Metals. This standard
applies to “the production, processing, finishing, handling, recycling, storage, and
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RotoClone N
use of all metals and alloys that are in the form that is capable of combustion or
explosion1”. When the RotoClone N is used to collect dust from the working of light
metals, the user shall be fully conversant with the provisions of NFPA 484 and
shall comply in full with all of its requirements.
2.3.3 Other requirements
The use of a dust collector for the collection of explosive dust is only one
part of a safe dust prevention and mitigation program. Dust shall not be allowed to
accumulate or build up on the surfaces of the dust collector, on the air intakes or
in the surrounding area. The owner’s attention is directed particularly to the
“Housekeeping” chapters in NFPA 654 (Chapter 8 in the 2013 edition) or NFPA 484
(Chapter 7 in the 2015 edition). If any of the other codes and standards
referenced above applies, consult the appropriate chapters in those documents.
The editions referenced here were current at the time of writing. Be aware
that they may have changed. When referring to NFPA standards, the user shall
ensure that they are working with the most current edition.
For information on NFPA® standards, go to http://www.nfpa.org/ . NFPA
provides free on-line read-only access to its codes and standards. Standards may
also be purchased.
2.4 Electrical hazards
Before doing any work on the AAF equipment make sure that all potential
electrical hazards have been identified and that all electric current connected to
the equipment, and to any connected or associated equipment, has been properly
disconnected and securely locked-out to prevent accidental reconnection prior to
completion of the work. All electrical work shall be done in full accordance with the
current edition of NFPA 70, the National Electrical Code, and all other applicable
laws, rules, and regulations. All electrical work shall be performed by a licensed
electrician. Only original AAF parts shall be used as replacements for ongoing
maintenance and repair.
2.5 Rotating equipment
The RotoClone™ N incorporates a fan which is close-coupled and installed on
top of the RotoClone N, or installed separately (typically ground mounted) and
ducted to the outlet of the RotoClone N. The fan impeller (fan wheel) may rotate
at nominal speeds approaching 3600 rpm and has the potential to cause severe
1
Ref: NFPA 484: Standard for Combustible Metals, 2015 Edition, Paragraph 1.1, Page 484-8
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RotoClone N
injury. The fan impeller can be accessed through the collector from inside the
cabinet if the moisture eliminator is removed, from the outside of the collector
through the collector discharge, or from the connecting inlet or outlet ductwork. All
due care should be exercised to avoid any contact with the operating fan. Under
no circumstances should the fan ever be allowed to operate when any of the
access panels on the dust collector, silencer, or connecting ductwork have been
removed. The fan must be disconnected and locked out prior to the performance
of any maintenance work, see paragraph 2.4.
2.6 Safety guards
The dust collector cabinet prevents access to the fan inlet. All access panels
and ducts shall remain bolted in place while the fan is operating. Prior to the
removal of any access panel or ducts the electrical power to the collector shall be
disconnected and locked out, see paragraphs 2.4 and 2.5.
After electrical power is disconnected the fan impeller will continue to rotate
for a period of time before coasting to a stop. Do not access the fan until the fan
wheel has come to a complete stop.
3
GENERAL PRODUCT INFORMATION
3.1 Description
The RotoClone N is a wet dust collector which uses water as the medium to
separate dust from air by means of a unique stationary impeller. When installed
and operated properly, the RotoClone N operates automatically and will require
very little maintenance. However, as is the case with any mechanical equipment, it
should be operated, maintained and serviced in accordance with these instructions
to ensure long life and trouble free performance and use.
The RotoClone N is, for the most part, a factory assembled, fully selfcontained dust collector except that the top-mounted fan ships separately for
installation on-site.
The dust generated by the particular operation for which the RotoClone N is
employed is drawn into the collector through the inlet ductwork, into a water bath,
and then through AAF’s unique static impeller which through a combination of
induced aerodynamic and hydrostatic forces causes the dust to mix thoroughly
with the water and separate from the air. The cleaned air is then emitted from the
dust collector through the fan and the separated dust settles to the bottom of the
10 RotoClone N
water bath. The dust forms a sludge which is then periodically removed from the
collector.
The RotoClone N can only be operated when it is filled with water to the
correct level. A low water level would result in by-pass of unfiltered air. Automatic
cut-out devices prevent operation of the fan if the water level is too low.
3.2 Purpose and intended use
The RotoClone N is intended to be used to collect a wide range of dust
produced in industrial applications. It is particularly effective for the collection of
dusts that are potentially explosive such as light metal dusts (aluminum, titanium,
or magnesium) and coal dust, or dusts that are damp, wet, sticky or oily. Contact
AAF International for assistance with your application.
3.2.1 Collection of explosive dusts
As mentioned, the RotoClone N is primarily particularly effective for the
collection of dust generated by the working of light metals such as aluminum,
titanium, and magnesium, and for the collection of other explosive dusts such as
coal dust. Such dusts have the potential to be highly explosive if not dealt with
correctly. See paragraph Error! Reference source not found. “Dust explosion
hazard” for further details.
The RotoClone N neutralizes the threat of a dust explosion by encapsulating
the captured dust in water and preventing the development of both a dust cloud
that might reach the explosive limit and of any potential ignition source.
It bears repeating here that the use of a dust collector for the collection of
explosive dust is only one part of a safe dust prevention and mitigation program.
Dust shall not be allowed to accumulate or build up on the surfaces of the dust
collector, on the air intakes or in the surrounding area. The owner’s attention is
directed particularly to the “Housekeeping” chapter in NFPA 484 (Chapter 7 in the
2015 edition) and in NFPA 654 (Chapter 8 in the 2013 edition).
3.2.2 Collection of other dry dusts
The RotoClone N can also be used to collect dust generated by the working
of other metallic and non-metallic materials that may not present an explosion
hazard.
11 RotoClone N
3.2.3 Collection of damp, wet, oily or sticky dusts
The RotoClone N is an effective collector of dusts that are difficult or even
impossible for other collectors, particularly dry collectors such as cartridge and bag
collectors, to collect. Damp, wet, sticky or oily dusts can clog the pores of paper
and fabric media. In pulse clean or shaker style self-cleaning dust collectors, these
dusts will not release from the cartridges or bags, causing the dust collector to
clog and quickly fail.
3.3 Normal Operation
The RotoClone™ N cleans the air by the combined action of centrifugal force
and a thorough mixing of water and dust laden air. The dust is separated from the
air by means of a water curtain, created by the flow of air through a partially
submerged stationary impeller (see Figure 1). Air flowing through the impeller at a
high velocity conveys water with it in a very turbulent sheet. Additional water is
introduced at the narrowest portion of the impeller through a specially designed
slot in the bottom. Since there is a certain differential pressure through the
impeller, the water flows upward through the slot in an attempt to reach the water
level on the clean air side. This water flow upward through the slot creates
increased interaction between the dust and water, thus, increased collection
efficiency. Since the water flows upward in an attempt to reach the water level on
the clean air side of the impeller, the impeller opening can be decreased (resulting
in higher differential pressure and collection efficiency) by raising the water in the
unit. This is accomplished by a unique and patented variable water level control
box. The centrifugal force exerted by the rapid changes in direction of flow causes
the dust particle to penetrate the water film and become permanently trapped.
(Figure 1)
Any entrained moisture in the cleaned air is removed by specially designed,
wide spaced chevron eliminators made in removable sections for sizes 1 ½
through 6, and curved entrained baffles for sizes 8 and larger.
The water in the reservoir is continually reused and since the water curtain
is produced by the air flow, no pumps or nozzles are required. The water level is
maintained by the overflow weir in the control box as long as a small amount of
fresh water is supplied through the make-up water connection or by electrical
controls that automatically add water, as needed to compensate for evaporation
and water lost as the collected dust is removed from the unit.
12 RotoClone N
The RotoClone N has the ability to operate at a flange to flange differential
pressure from 5.0 to 12.0” w.g. This allows for operation of the unit at the exact
differential pressure and efficiency required for each application. The differential
pressure of this unit is determined by two parameters: airflow rate and water flow
rate through the impeller. The RotoClone N has a certain standing water level
within the unit determined by an overflow weir within the water level control box.
It is possible to increase the water flow rate through the stationary impeller by
simply raising the water level within the unit. That is, raise the weir height within
the control box. This will result in a higher differential pressure and efficiency for a
given flow rate.
13 RotoClone N
Figure 2. Operating Lines for Given Airflows
Notes:
1. Figure 2, the pressure drop chart, shows the total pressure losses through the
RotoClone N in relation to the flow rate through the impeller for a given operating
line. The RotoClone N must operate on one of the operating lines shown.
2. The total pressure losses are measured by subtracting the static pressure at the
collector outlet flange from the static pressure at the inlet flange.
The 100% nominal flow level is equal to 1,000 acfm per foot of impeller.
3.4 Sizes and Arrangements
The RotoClone N is available in 15 sizes, operating from 900 to 57,600 cfm
(1530 to 97,865 m3/hr).
14 RotoClone N
There are three different arrangements: Arrangement B (Flat Bottom Manual
Sludge Removal), Arrangement C (Automatic Sludge Removal with Conveyor), and
Arrangement D (Continuous Sluicing with Bottom Drain).
3.4.1 Manual Sludge Removal (Arr. B)
RotoClone N, Arrangement B, is designed for reduced height and low initial
cost. Since collected material must be removed manually, this arrangement is
appropriate for applications where dust loadings are light, such as, the exhaust of
buffing, polishing, and metal working; packaging, sorting, and weighing
operations; and chemical products.
In units with a single impeller, one side of the reservoir is sloped to facilitate
removal of the collected material. With the double impeller units, it is usually
necessary to drain the reservoir for sludge removal. Access door location and
interior headroom is provided to facilitate shoveling collected material to a tote
box or sludge chute.
3.4.2 Sludge Ejector (Arr. C)
RotoClone N, Arrangement C, is designed to reduce manual removal of
collected material. It is recommended for moderate and heavy dust loads, for
applications requiring continuous 24-hour service, and where manual removal of
the sludge would be unreliable or cost prohibitive. This arrangement is frequently
used for foundry sand handling applications; abrasive cleaning, buffing, and
grinding; material handling; and dryer and process exhaust.
Steep sides in the hopper minimize material build-up, while the sludge
ejector mechanism provides easy removal of collected material. The ejector
assembly is designed for heavy-duty service and driven by a small geared motor.
The chain and sprockets of the ejector are fabricated from wear-resistant alloys. A
slow chain speed, approximately two feet per minute, combined with a long steep
ejector chute assures effective dewatering of the solid material as it is ejected.
Scrubbing water is conserved and make-up water is reduced.
3.4.3 Continuous Sluicing (Arr. D)
RotoClone N, Arrangement D, is designed to sluice collected material
through the hopper into a process or disposal point. Sluicing may be continuous or
intermittent. This arrangement is recommended for material handling applications
in the chemical and rock products industries; and dust abatement on crushers,
screens, and transfer points for mining and rock products.
15 RotoClone N
To maintain the scrubbing water at the proper operating level, a constant
supply of make-up water and drainage is required.
3.5 Filter elements
There are no disposable filter elements associated with the RotoClone N, as
the water and impeller acts as the filtering elements. Separate after-filters can be
installed downstream of the RotoClone N if additional air cleaning efficiency is
required.
3.6 Weights
Table 1. RotoClone N, Arr. B Shipping and Operating Weights
Erecting Weight
Size
Maximum
Operating
Wt. (lbs)
Normal
Operating Wt.
(lbs)
Water
Capacity
(Gallons)
RotoClone
Only
Exhauster
Only
1.5
2600
2200
90
1300
300
2.5
2800
2400
90
1300
750
4
4200
3700
140
1800
900
6
5900
4800
220
2400
1500
8
8200
6700
295
3400
2000
12
11200
9000
440
4000
2900
16
14000
11500
510
5000
3450
20
17900
14200
730
5900
4200
24
21900
17500
880
6800
4220
28
24900
19800
1025
7900
6020
32
NA
NA
NA
NA
NA
36
NA
NA
NA
NA
NA
40
NA
NA
NA
NA
NA
44
NA
NA
NA
NA
NA
48
NA
NA
NA
NA
NA
1. Weight based on maximum sludge capacity with a sludge weight of 100 pounds per
cubic foot.
2. Weight based on weight of water of 62.4 pounds per cubic foot.
16 RotoClone N
Table 2. RotoClone N, Arr. C Shipping and Operating Weights
Erecting Weight
Water Capacity
(Gallons)
RotoClone Exhauster
Only
Only
Size
Maximum
Operating
Wt. (lbs)
Normal
Operating Wt.
(lbs)
1.5
6300
4800
300
2000
300
2.5
6400
4900
300
2000
750
4
9500
7100
470
2700
900
6
11400
8700
540
3600
1500
8
13200
10500
530
5300
2000
12
16500
13200
650
6500
2900
16
28500
21600
1370
8000
3450
20
33600
25300
1650
9400
4200
24
40300
30500
1950
11000
4220
28
46000
34800
2220
12400
6020
32
51100
38500
2500
13700
6020
36
56300
42400
2775
14800
7400
40
64500
49200
3050
19300
7400
44
70200
53500
3330
21300
8700
48
76100
58000
3610
23400
8700
Notes
1. Weight based on maximum sludge capacity with a sludge weight of 100 pounds
per cubic foot.
17 RotoClone N
Table 3. RotoClone N, Arr. D Shipping and Operating Weights
Size
Maximum
Operating
Wt. (lbs)
Normal
Operating
Wt. (lbs)
Water
Capacity
(Gallons)
Erecting Weight
RotoClone
Complete
Exhauster
Only
3700
2960
120
2000
300
1.5
3900
3140
120
2200
750
2.5
5200
4250
180
2800
900
4
8100
6520
330
3800
1500
6
10700
8560
390
5300
2000
8
15000
10765
605
5700
2900
12
20800
16250
900
8800
3450
16
26800
20700
1250
10300
4200
20
31400
25120
1290
14400
4220
24
36800
28310
1510
15800
6020
28
43500
33610
1925
17600
6020
32
50000
37850
2250
19100
7400
36
58300
55850
2500
24100
7400
40
62900
45600
2690
26400
8700
44
67400
52650
2880
28700
8700
48
Notes
1. Weight based on maximum sludge capacity with a sludge weight of 100 pounds per
cubic foot.
18 RotoClone N
4
PRODUCT SHIPMENT
4.1 How the product ships
RotoClone N sizes 1.5 through 6, units are shipped fully assembled.
RotoClone N sizes 8 through 48 are shipped with the transition, motor, and
exhauster disassembled from the RotoClone.
RotoClone N sizes 1.5 through 6, are normally shipped by single drop or LTL.
RotoClone N sizes 8 through 48, are normally shipped by a double drop or by a
specialized hauler.
When shipment is in major subassemblies, the gasket for the flange between
the RotoClone and clean air transition outlet and fan are packed in a box with the
necessary bolts. The nominal 5/8” gap between the transition piece outlet and fan
inlet should be sealed with the three inch sealing tape which is also included in the
box of bolts.
4.2 Items that ship separately
To reduce freight costs, AAF International may ship items separately. The
customer will be notified which equipment ships separately when the order is
placed. Items that ship separately should be set aside in an area that is clean, dry,
and in a place where damage to the equipment will not occur, see section 7 for
information on storage and protection.
5
PRODUCT RECEIPT AT THE DESIGNATED DELIVERY POINT
The people of AAF International take pride in the quality of the products that
we supply and it is our intention that our customer’s experience with our products
and services be positive and satisfying. This process begins at delivery. It is
important to ensure that the product delivered is what was ordered and that it
arrives at its destination in perfect condition. Adequate preparation on the part of
the buyer, together with a structured approach to receipt and inspection, will
ensure that if problems exist they are communicated swiftly and efficiently
through the proper channels allowing them to be resolved in the shortest possible
time.
5.1 Responsibilities of the customer or customer’s agent
Ensure all loading/unloading equipment and safety equipment is on site at
the time of delivery. Safe and efficient operation of the collector depends on
proper installation. Know proper laws, codes and regulations before installation
starts.
19 RotoClone N
5.2 Receiving
Remove crates, tarps, shipping straps, etc. along with any loose items or
equipment before unloading the AAF RotoClone N.
5.3 Inspection on arrival
The AAF RotoClone N is normally shipped by truck and should be checked for
damage that may have occurred in route. Compare the collector(s) received to the
description and/or drawing of the collector(s) ordered. Immediately report any
differences or missing items from the order to AAF International. Remove loose
items or components before lifting the collector from the truck.
A qualified installation and service company should complete installation of
the collector and accessories.
5.4 Damaged goods
If there is any visible damage to the packaging or the equipment, notify the
carrier and AAF before proceeding further and, if appropriate, file an immediate
claim with the carrier against such damage. Be aware that damage to packaging
may indicate hidden damage to the product that is not immediately discernable.
Digital color photographs must be taken of any damage to the packaging
and the equipment immediately on discovery. The nature of any damage must
also be documented in writing. Adequate documentation will be critical to support
any claims.
Contact AAF International for claim filing procedure.
5.5 Missing goods
Any missing goods should be noted on the delivery receipt, and the carrier
and AAF notified immediately. Contact AAF International for claim filing procedure.
FOR ASSISTANCE: Contact AAF International at 1-800-477-1214. Have the
AAF control number available. The control number can be found on the
shipping papers.
6
UNLOADING AND HANDLING
6.1 Unloading
Failure to lift the collector correctly can result in severe personal injury,
property damage, or even death.
20 RotoClone N
Connect lifting sling to at least four cabinet lifting lugs, if possible,
distributing the load evenly.
Use clevises, not hooks, on lifting sling.
Use of spreader bars is recommended on all lifting slings.
Check the drawings of the specific RotoClone N ordered for dimensions and
weights to ensure proper lifting and installation equipment.
All lifting operations must be made in compliance with the relevant HSE
legislation.
6.2 Handling
Only personnel experienced in handling equipment shall be employed for this
task.
If lifted by its shipping pallet, attention must be paid to properly balancing
the load and strapping it to the handling device. Care shall be taken to ensure that
the equipment is not dropped or subjected to any impact loads.
6.3 Rigging and hoisting instructions
Only personnel experienced in rigging and hoisting equipment shall be
employed for this task.
It is recommended that each item of equipment remain on its pallet until it
has been moved to its final installation location. The RotoClone N may be moved
using a forklift to lift the product using its shipping pallet, if available.
The RotoClone N also has lifting lugs mounted on the top. These may be
used to hoist the product instead of lifting it using the shipping pallet. All lifting
lugs must be used when hoisting the product. When using the top mounted lifting
lugs use spreader bars at all times. Position the spreader bars so that the force
applied to each lifting lug is vertical and not angled. Also make sure that lifting
straps or cables do not come into contact with any other part of the product to
prevent the possibility of damage from abrasion. Before hoisting make sure that
the load is properly balanced. At the beginning of the lift, hoist the product slowly
and carefully.
21 RotoClone N
7
STORAGE AND PROTECTION
If not installed immediately, the equipment shall be retained and stored in a
protective environment until immediately prior to installation. This environment
shall be clean, dry, and temperature and humidity-controlled.
At all times the equipment shall be protected from exposure to weather and
from standing water.
All equipment shall be stored on its original shipping pallet so that it is
elevated above grade.
The equipment shall be clearly labelled and be stored in a location that is
easily and readily accessible.
If prolonged storage (greater than 30 days) is anticipated, the equipment
shall be covered with plastic to prevent the accumulation of surface dust and
include the following:

Motor shaft and flanges to be coated with easily removable rust
preventative Tectyl No.502-C, or equal.

Block all openings to prevent rodents and small animals from nesting
inside.

Insert silica gel desiccant in control boxes and motor junction boxes.

Cover units completely to exclude dirt, dust, moisture, and other
foreign materials. If possible, insert motor in strong, transparent
plastic bag. Attach moisture indicator to side of motor, place several
bags of silica gel inside, then seal plastic bag. If motor cannot be
placed in plastic bag and relative humidity exceeds 50%, use space
heaters to keep motor at least 10F above ambient air temperature.

Rotate motor shaft at least 10 revolutions every month; re-lubricate
bearings after each year of storage.

Check desiccant bags and rust prohibitive monthly; replace desiccant
and recoat with rust preventative as required. Also check operation of
space heaters.
22 RotoClone N
If the unit has been in use and prolonged storage is anticipated, the unit
shall be cleaned on the inside and outside of dust and water to prevent damage to
the interior and exterior of the collector.
8
SITE PREPARATION
8.1 Locating equipment
When locating the RotoClone N, the design engineer shall consider the many
factors associated with site selection including, but not limited to, seismic design
category and site class, flood design data, design load bearing value of soils,
serviceability, risk category, and load combinations, including dead loads, live
loads, snow loads, wind loads, and earthquake loads. Such factors and values are
typically defined by the building codes and standards imposed by the local
authority with jurisdiction for buildings and structures.
The equipment installation, including supports, must be selected and
designed to adequately resist all external loads, and combinations of loads, acting
on the equipment at all times.
Take appropriate precautions to reduce operating equipment noise levels to
levels mandated by the relevant legal authorities.
Take appropriate precautions necessary for all phases of manufacturing,
processing, blending, conveying, repackaging, handling and disposal of hazardous
materials as mandated by the relevant legal authorities.
The RotoClone N is not intended to be used as a load bearing structure and
all connecting components, including ducts, must be supported separately.
Provide adequate clear space around the RotoClone N for access and
maintenance.
8.2 Foundations and anchor bolts
The foundations supplied must be level and rigid, must fully support the
RotoClone N during operation, and prevent vibration. Sufficient anchor bolts shall
be supplied to connect all RotoClone N support points. The anchor bolts shall be
designed and selected to adequately resist all forces between the RotoClone N and
the foundation. See section 3.6 for net weights of the RotoClone N. Note that the
RotoClone Arrangement D is equipped with a bottom outlet drain. The foundation
23 RotoClone N
for the Arrangement D must be designed to accommodate this drain. See section
9.2.7 for further details.
9
ASSEMBLY AND INSTALLATION
9.1 Introduction
Safe and efficient operation of the RotoClone N depends on proper
installation.
AAF recommends that the ductwork going into the collector be as straight as
possible, with at least 5 diameters of straight run recommended.
Authorities with jurisdiction should be consulted before installing the
RotoClone N to ensure local installation laws, codes, regulations and procedures
are followed.
A qualified installation and service agent must complete installation and
service of the dust collector and equipment.
Ensure all covers from shipping and loose materials are removed from the
collector before installation. Failure to do so can result in failure of the dust
collector.
Ensure the hardware on the dust collector assemblies are properly installed
and tight before installation.
9.2 Assembling and installing the structure
9.2.1 Shipping Arrangements
The equipment delivered to the site will arrive in one of a number of various
arrangements depending on the size and style of the product supplied and the
customer’s particular needs and requirements. Review the product documentation
supplied, especially the sales drawing, for details. A brief summary of the potential
arrangements is as follows:
RotoClone N Sizes
following arrangements:

With fan and

With fan and

With fan and
1 1⁄2 through 6 will ship mostly assembled in one of the
drive installed
drive shipped loose for field installation
drive supplied by others
24 RotoClone N

Chevron mist eliminator bundles ship loose for installation at the
jobsite
RotoClone N Sizes 8 thru 48 are shipped disassembled
subassemblies as follows:

RotoClone base section

Clean air transition

With fan and drive shipped loose for field installation

With fan and drive supplied by others
in
major
RotoClone N Sizes 16 thru 48 may be shipped with the collecting section and
hopper section disconnected.
9.2.2 Foundation Installation and Levelling
Install the RotoClone N base onto the prepared foundation using
appropriately selected anchor bolts. Adjust the base until the equipment is
completely level in all directions. This operation is critical, the RotoClone
N will not operate properly if not level. There are two recommended methods
for achieving this:
Place a spirit level on the leveling strips welded on two or more sides of the
hopper. The RotoClone N must be accurately levelled in both orthogonal
directions (along axes 90 degrees apart).
Fill the RotoClone N with water until the level reaches the entering edge of
the impeller (Figure 1). On RotoClone N with double impellers (sizes 8 and
above) this will apply to both impellers simultaneously. The entering edge of
each impeller must be level with the water along its entire length with a
maximum allowable variation of plus or minus 1⁄8 of an inch. On RotoClone
N with single impellers (sizes 6 and below), the RotoClone will still need to
be leveled in the other direction.
When the RotoClone N has been properly levelled, fix the equipment in
position using shims and anchor bolts and then grout beneath the structural
support elements to ensure that the equipment is fully supported.
9.2.3 Field Fan Connection
For RotoClone Sizes 1-1⁄2 through 6, which are not shipped with exhausters,
or for all RotoClone Sizes 8 and larger, three-inch sealing tape is furnished to seal
25 RotoClone N
the 5⁄8 inch nominal gap between the clean air transition and the exhauster inlet.
The tape is packed in a separate box with other loose components.
9.2.4 Chevron Mist Eliminator Installation (Sizes 1-1⁄2 through 6 Only)
As previously noted, the chevron mist eliminators for sizes 1-1⁄2 through 6
are shipped loose for installation at the jobsite. Install these into the RotoClone N
as follows (see the illustration below):
a.
Slide the mist eliminator assembly through the door, supporting it
from the bottom.
b.
Tilt the top of the eliminator forward until it rests on housing above
the door opening using a lever.
c.
Lift the bottom of the eliminator over the lip of the impeller plate.
d.
Slide the eliminator under the blank off baffle.
e.
Repeat with the remaining eliminators.
f.
After all eliminators have been installed, slide all of them to the side
opposite the blank-off baffle.
26 RotoClone N
As a guide, the correctly installed location of the eliminator sections is
painted on the inside surface of the RotoClone N wall. Confirm that the installation
of the eliminators coincides with these markings.
27 RotoClone N
9.2.5 Assembly of RotoClone N Sizes 8 through 48
As previously noted (see 9.2.3), the clean air transition supplied for
RotoClone N sizes 8 thru 48 ships separately for installation at the jobsite. The
gasket material for sealing the flange between the RotoClone base section and the
clean air transition section is packed in a separate box with other loose
components.
9.2.6 Assembly of Sizes 16 through 48 Hopper and Collecting Sections
As previously noted (see section 9), the hopper (lower level) and collecting
section (upper level) supplied for RotoClone N sizes 16 thru 48 may be shipped
separately for installation at the jobsite. If this is the case field assembly of these
sections will be as follows:
a.
Locate the hopper section on it foundation and secure it in position.
b.
Install the supplied gaskets on top of the hopper external flange.
c.
Lower the cleaning section carefully onto the flange of the hopper
section, watching for interference between intermediate sheets and
impellers. The walls of the interior center section, formed by the two
intermediate sheets, must be inside the impeller bolting surface. Set the
cleaning section in place so that its bolting flange matches the hopper
flange.
d.
Bolt the outside flanges of the cleaning section and hopper section.
e.
The impellers are bolted to intermediate sheets. Before tightening the
impellers into place, the entering edge (Figure 1) of the impellers must form
a straight line. The impellers were aligned at the factory and each impeller
section matched drilled with holes in the connecting intermediate sheet.
Check the alignment before tightening the remaining bolts, both the slotted
holes in impellers and the drilled holes in the intermediate sheets.
9.2.7 Lubrication
All bearings are ball bearings and were packed with grease before leaving
the factory. Do not add more grease during installation.
The gear reducer on the sludge ejector drive (supplied with the RotoClone
Arrangement C only) was filled with oil before shipment. Check for proper oil level.
28 RotoClone N
NOTE: To prevent loss of oil while units are in transport, the
reducers are shipped with a brass pin in vent or filler plug. This pin must
be removed before the reducer is operated.
9.2.8
Electrical connections
The normal set of electrical components that may be supplied with the
RotoClone N may comprise of the following:
The exhauster motor, the exhauster motor starter, the solenoid valve, the
flow switch, and on the RotoClone N Arrangement C only, the sludge ejector motor
and controls. Each electrical connection shall be made in accordance with the
appropriate wiring schematic enclosed with the RotoClone N instruction packet.
Also note the following:
1.
Exhauster motor: The motor nameplate will show the connection hookup of the motor leads.
CAUTION: After connecting the motor leads, ensure that the
exhauster rotates in the proper direction as indicated by the arrow on the
exhauster housing.
2.
Exhauster motor starter: The exhauster motor starter may or may not
be supplied by AAF. The AAF “Control Center”, if ordered, will include the
appropriate motor starter. Otherwise, the motor starter will be engineered,
selected and supplied by others.
3.
Sludge ejector motor: A sludge ejector motor is supplied only with the
RotoClone N Arrangement C. It is a fractional horsepower, 230/460/60/3,
TEFC motor. The lead connection diagram will be found either on the motor
nameplate or inside the cover of the motor.
4.
Solenoid valve: This valve is normally supplied in the water supply
line. A solenoid valve is furnished with RotoClone N Sizes 1-1/2 through 48
on the model “SV” control, the model “SV” with lower water safety control,
and Model ‘A’ control.
5.
Flow Switch: The flow switch is a protective electrical interlocking
device wired in series with the exhauster starter holding coil circuit. It is
used only on the model “SV” water level control. The flow switch prevents
29 RotoClone N
operation of the RotoClone until the solenoid water valve is opened. In the
event of a water supply failure, the flow switch contacts open and the
RotoClone shuts down.
CAUTION: For some applications, such as incinerators and dryers,
damage to the process or equipment could occur if the RotoClone is shut
down during its operating cycle. In such cases, the flow switch MUST be
wired to a monitored alarm to indicate a water supply failure. It is the
responsibility of the customer to supply this alarm.
9.2.9
Water supply connections
Connect a 1” water supply connection line to RotoClone N sizes 1-1/2.5
through 6, or a 2” water supply connection line for sizes 8 and larger at the
location shown in Figure 3. Supply piping with standard volumes and orifice sizes
are shown in Table 4 and Figure 3. Variations in the supply volume can be
provided by changing the flow switch and flow control valve.
CAUTION: Any change made in the water supply rate will usually require
changing the orifice in the drain valve. Select a new orifice by referring to Table 5.
Always supply enough water to provide a small flow over the weir in the control
box plus the drain volume.
30 RotoClone N
Figure 3. Supply Piping, Arrangement D.
31 RotoClone N
9.2.10 Drain Connection for RotoClone N Arrangement B
Each time water is drained from the RotoClone, clean the elements after
collected material has been removed from the RotoClone housing. A drain is
supplied with the RotoClone N Arrangement B for draining the water from the
equipment for cleaning and maintenance. The drain valve will remain closed during
normal operation. Connect the 1-1/2” drain line from the RotoClone N
Arrangement B to the customer’s drain line or sewer at the tee connection
provided on the base of the equipment. The customer’s drain or sewer line MUST
be equal to or larger in size to the drain from the RotoClone N.
9.2.11 Drain Connection for RotoClone N Arrangement C
A drain is supplied with the RotoClone N Arrangement C for draining the
water from the equipment for cleaning and maintenance. The drain valve will
remain closed during normal operation. Connect the 2” drain line from the
RotoClone N Arrangement C Sizes 1-1/2 through 12, or the 4” drain line from the
RotoClone N Arrangement C Sizes 16 and larger, to the customer’s drain line or
sewer at the connection provided on the base of the equipment. The customer’s
drain or sewer line MUST be equal to or larger in size to the drain from the
RotoClone N.
9.2.12 Drain Connection for RotoClone N Arrangement D
A drain valve is supplied with the RotoClone N Arrangement D. The valve is
intended to allow continuous sluicing of water from the equipment during
operation. The drain MUST remain open during normal operation. An orifice
located in the base plate of the valve provides a constant drainage rate.
Water flow rates can be obtained from Tables 5a, 5b, and 5c. The standard
orifice size and associated flow rates for the different RotoClone N Arrangement D
sizes are shown in Table 5a. Variations in the drainage rates can be obtained by
referring to Table 5b and selecting a non-standard orifice size. The flow through
the control box can be obtained from Table 5c.
The drain valve from the RotoClone N Arrangement D should never be
directly connected to the drain line but should feed into an open funnel or trough.
This provides visual observation that the RotoClone is draining properly, provides a
constant head, and ensures that the water will not back-up into the collector in the
event of a drain or sewer blockage. The drain line from the control box or boxes
can feed the same disposal point.
32 RotoClone N
Figure 4. Typical RotoClone N Design.
33 RotoClone N
RotoClone
Size
Hoppers per
RotoClone N
Arrangement D
Orifice
Diameter
Head
(feet)
Hopper Drain
Volume (Gallons
per Minute)
Control
Box
1.5
1
3/8”
3.4
3.1
S
2.5
1
3/8”
3.4
3.1
S
4
1
½”
3.4
5.5
S
6
1
½”
4.4
6.3
S
8
1
5/8”
4.8
10.3
S
12
1
5/8”
5.4
10.9
S
16
1
¾”
6.1
16.6
H
20
1
¾”
6.4
17
H
24
2
5/8”
5.3
21.6
2H
28
2
¾”
5.3
31
2H
32
2
¾”
6.3
33.8
2H
36
2
¾”
6.3
33.8
2H
40
2
¾”
6.3
33.8
2H
44
3
¾”
7.2
54.3
3H
48
3
¾”
7.2
54.3
3H
Table 5a. RotoClone N Arrangement D Hopper Drain Volumes for Standard Orifice
Sizes
34 RotoClone N
Head in Feet
3.4
4.4
4.8
5.3
5.4
6.1
6.3
6.4
7.2
Hopper Drain Volume (Gallons per Minute)
1/4"
0.491
1.3
1.5
1.6
1.7
1.7
1.8
1.8
1.8
2.0
3/8"
0.110
3.1
3.5
3.6
3.8
3.8
4.1
4.2
4.2
4.5
1/2"
0.196
5.5
6.3
6.5
6.8
6.9
7.3
7.5
7.5
8.0
5/8"
0.307
8.6
9.8 10.3 10.7 10.9 11.5 11.7 11.8 12.5
3/4"
0.442
12.4 14.1 14.7 15.5 15.6 16.6 16.9 17.0 18.1
7/8"
0.602
16.9 19.2 20.1 21.1 21.3 22.3 23.0 23.2 24.6
1"
0.785
22.0 25.1 26.2 27.5 27.8 29.5 30.0 30.3 32.1
1 1/4"
1.227
34.5 39.2 40.9 42.6 43.4 46.2 46.9 47.3 50.2
1 1/2"
1.767
49.6 56.5 59.0 62.0 62.6 66.5 67.6 68.1 72.3
These Figures are based on Q = CA √2gh
C= 0.61 x 3.12 (Conversion factor for units)
Table 5b. RotoClone N Arrangement D Hopper Drain Volumes for Various Standard
and Non-Standard Orifice Sizes
Orifice
Diameter
Area Sq
In.
Control Boxes
Standard
High
Height of Flow
Volume Volume
Over Weir
(S)
(H)
¼”
7.5 GPM
19 GPM
7/16”
14 GPM
26 GPM
½”
Floods
30 GPM
9/16”
Floods
Floods
Table 5c. RotoClone N Arrangement D Control Box Drain Volumes for Various
Heights Above the Weir
9.2.13 Fan Drain
When the fan is mounted on the RotoClone N, a drain pipe from the fan
drain should be installed back into the top of the RotoClone using the hole that is
supplied in the top of the RotoClone. Slide an “oversized washer” over the drain
35 RotoClone N
pipe from the fan and caulk it to the RotoClone roof to close off the annulus
formed by the drain pipe and hole in the roof of the RotoClone N.
9.2.14 Ductwork Installation
In order to prevent surging within the RotoClone, three to four duct
diameters length of straight run prior to the inlet will provide uniform distribution
at the inlet. If an elbow is required due to space constraints, turning vanes must
be used in the elbow to evenly distribute the air and prevent surging.
Inlet and exhaust ductwork must be supported from the floor, wall or
ceiling; not from the RotoClone or fan exhauster. Depending on the application
and local conditions, the discharge from the exhauster may be either returned to
the workroom or discharged to the atmosphere. It may be desirable to have both
outside and inside discharges fitted with a selective damper. This will save heat in
the winter with recirculation and aid ventilation by discharging outside during the
summer months. When a discharge duct is required, it should extend above
adjacent roof lines and should discharge vertically upward. As long as there is a
drain in the fan housing, a drain cap or weather hood should not be used. Crosssection of the discharge duct should not be less than the exhauster outlet area.
10
Water Level Control Options
Water loss can occur in the RotoClone N for a variety of reasons. These
include:
 Evaporation
 Overflow through the control box
 Sludge removal
 Continuous sluicing through the hopper drain (RotoClone N
Arrangement D only)
It is critical for the proper operation of the RotoClone N that the correct
operating water level be maintained at all times. For this reason, make-up water
must be supplied to the RotoClone N at all times.
There are three types of water level controls available on the RotoClone N
Arrangements B and C, and two types of water level controls available on the
RotoClone N Arrangement D. Check the product documentation supplied for
information on the type of control provided with the equipment.
36 RotoClone N
10.1 RotoClone N Arrangements B and C Water Level Controls
10.1.1
Model “SV” Control
See Figure 5. This is the standard water level control for the RotoClone N. It
prevents operation of the RotoClone when there is insufficient water flow. It also
allows a continuous water flow over the running level weir, down the drain pipe,
and into the overflow. The water level supply system contains a fill valve, solenoid
valve, strainer, flow switch and flow control valve. As long as the solenoid valve
remains open, there will be a constant water flow into the control box.
The air pressure equalizing hose is connected directly to a port in the top of
the control box. This connection permits the air pressure on the clean air side of
the RotoClone N to equal the air pressure in the control box. Consequently, the
water level on the clean air side of the RotoClone N and in the control box will be
the same.
10.1.2
Model “SV” Control with Low Water Safety
See Figure 6. This control should be used for “light metal” dusts such as
aluminum, magnesium, and titanium, and other explosive dusts. In addition to the
standard “SV” control, this control contains an electrode, electrode holder, and a
timing relay. It does not use the flow switch.
The low water safety control prevents operation of the RotoClone N if the
water level in the equipment is too low.
The electrode and holder are installed in one of the ports on the top of the
control box. This low water safety device is designed to maintain continuous
contact with the water in the control box. If the water level in the control box
drops below the electrode, a 3 minute timer relay activates. The water level must
reach the electrode within 3 minutes or the RotoClone fan will shut down
automatically and the RotoClone operation stops.
As long as the equipment operates, the solenoid remains open. When the
fan stops, the solenoid valve closes and the water flow to the control box stops.
The air pressure equalizing hose is attached to a separate port on the top of
the control box. This keeps the air pressure on the clean air side of the RotoClone
the same as in the control box. This ensures that the water level in the RotoClone
and the control box will be the same.
37 RotoClone N
Whenever makeup water is needed in the RotoClone N, water continuously
drains into the equipment through the hose connection in the bottom of the water
level control box.
Similarly to the “SV” Control, the Model “SV” Control with Low Water Safety
provides a continuous flow of water over the control box weir.
10.1.3
Model “A” Control
See Figure 6. This control box is used when there can be no water overflow
from the RotoClone N. Makeup water will be added to the system only when
needed. This control also prevents the RotoClone N from operating when there is
not sufficient water in the equipment.
The water supply system contains a fill valve, strainer, solenoid valve,
electrode, electrode holder, and a timing relay.
box. This low water safety device is designed to be in continuous contact with the
water in the control box. When the water level drops below the electrode, the
solenoid valve opens to supply the required makeup water to the system. When
the control box water level is again in contact with the electrode, the solenoid
valve closes and stops the flow of makeup water. This prevents water from
continuously overflowing the weir.
If for any reason the water level does not make contact with the electrode
within three (3) minutes, the timer will turn off the RotoClone exhauster and stop
the RotoClone operation.
Model “A” Control and Water Quality
In the case of the Model “A” Control, make-up water is only added to replace
evaporated water losses and sludge removal water losses. As a consequence,
dissolved solids will build up in the scrubbing water. This can result in accelerated
rates of corrosion of those surfaces in contact with the scrubbing water. It is
recommended that pH readings be taken once a week (with litmus paper) and the
reservoir pH be adjusted to within a range of 6.5 to 7.5 for the majority of dusts
and within a range of 6.0 to 6.5 for aluminum, magnesium, and titanium dusts
(see below). It is also recommended that, based on the equipment’s operational
history, the water in the reservoir be purged occasionally.
10.1.3.1
38 RotoClone N
Aluminum, magnesium, and titanium oxidize and resulting in a high
hydrogen ion content. A high H content equals a low pH value. A suggestion for
maintaining the pH in the 6.0 to 6.5 range is to add an automatic purge system,
using solenoid valves on both the drain and makeup lines, to allow fresh water into
the system every one to four hours. For each gallon of fresh water added a gallon
of low pH water should be released.
The majority of collected dusts are either inert or biodegradable. However,
some dusts may comprise of toxins, heavy metals, or other hazardous waste
products. Such products will require special handling and disposal and must not be
purged to the sewer system. It is the responsibility of the user to be fully aware of
the nature of the products being collected and to comply with all applicable laws
and regulations regarding collection, handling and disposal.
10.2 RotoClone N Arrangement D Water Level Controls
The RotoClone N Arrangement D features continuous controlled sluicing of
water through the hopper outlet. For this reason the control options offered with
the RotoClone N Arrangement D, are “High Volume” or “HV” versions of the Model
“SV” control and Model “SV” Control with Low Water Safety.
A continuous flow of makeup water is required in the RotoClone N
Arrangement D. The water flows into the equipment through the pipe connection
to the air inlet chamber. Approximately 90% of the water drains through the
orifice located in the hopper bottom. The balance of the water flows into the
control box and over the weir to the drain.
10.2.1
Model “SV-HV” Control
See Figure 7. This is the standard water level control for the RotoClone N
Arrangement D. It prevents operation of the RotoClone when there is insufficient
water flow. It also allows a continuous water flow over the running level weir,
down the drain pipe, and into the overflow. The water level supply system contains
a fill valve, solenoid valve, strainer, flow switch and flow control valve. As long as
the solenoid valve remains open there will be a constant water flow into the
control box.
The air pressure equalizing hose is connected directly to a port in the top of
the control box. This connection permits the air pressure on the clean air side of
the RotoClone N to equal the air pressure in the control box. Consequently, the
water level on the clean air side of the RotoClone N and in the control box will be
the same.
39 RotoClone N
10.2.2
Model “SV-HV” Control with Low Water Safety
See Figure 8. This control should be used for “light metal” dusts such as
aluminum, magnesium, and titanium, and other explosive dusts. In addition to the
standard “SV-HV” control, this control contains an electrode, electrode holder, and
a timing relay. It does not use the flow switch.
The low water safety control prevents operation of the RotoClone N if the
water level in the equipment is too low.
control box. This low water safety device is designed to maintain continuous
contact with the water in the control box. If the water level in the control box
drops below the electrode, a 3 minute timer relay activates. The water level must
reach the electrode within 3 minutes or the RotoClone fan will shut down
automatically and the RotoClone operation stops.
As long as the equipment operates, the solenoid remains open. When the
fan stops, the solenoid valve closes and the water flow to the control box stops.
The air pressure equalizing hose is attached to a separate port on the top of
the control box. This keeps the air pressure on the clean air side of the RotoClone
the same as in the control box. This ensures that the water level in the RotoClone
and the control box will be the same.
Similarly to the “SV-HV” Control the Model “SV-HV” Control with Low Water
Safety provides a continuous flow of water over the control box weir.
10.3 Flow Control Valve
The Model “SV” and Model “SV” with low water safety switch contain a flow
control valve in the same makeup water controls (see Figure 5 or 6). It will deliver
a continuous water flow rate to the water level control box at a minimum water
pressure of 15 psig. Should the flowrate not maintain the water level due to the
amount of dust being out taken out or high evaporation losses, report to your AAF
representative who can provide a replacement.
40 RotoClone N
Figure 5. Model “SV” Water Level Control
41 RotoClone N
Figure 6. Model “SV” Water Level Control with “Low Water Safety Control” or
Model “A” Water Level Control
42 RotoClone N
Figure 7. Model “SV-HV” Water Level Control
43 RotoClone N
Figure 8. Model “SV-HV” Water Level Control with “Low Water Safety Control”
44 RotoClone N
11
START-UP & OPERATION
11.1 To Fill the RotoClone N
Be certain the drain valve in the RotoClone hopper is closed.
Open the Fill Valve and add water until it reaches a point 2 inches below the
running level weir in the water level control box. This level is marked on the
outside of the control box.
When filling for the first time:
1. First bring water level to the entering edge of the impeller, see Figure 1,
and check that the RotoClone was properly leveled during erection.
2. Pour one gallon of water down the control box drain pipe to make an air
seal at the bottom of the pipe. See Figure 7.
Close and tighten control box cover. It must be air tight or an incorrect
water level in the RotoClone N will result.
45 RotoClone N
Figure 7. Cutaway view of standard Water Level Control “SV”.
46 RotoClone N
11.2 To Start RotoClone N Arrangement B
Check the control box cover and be certain it is tight.
Check water supply.
Press start button for the RotoClone exhauster. Solenoid valve in the water
supply line should be interlocked to open simultaneously with the fan start-up.
11.3 To Start RotoClone N Arrangement C
Start ejector motor.
Check water supply.
11.4 To Start RotoClone N Arrangement D
Open drain valve in hopper drain.
Check water supply.
11.5 To Stop RotoClone N Arrangement B
For RotoClone N Arrangement B without a solenoid valve in the makeup
water line, close the lever-operated valve in the water line.
Press the stop button for the RotoClone exhauster. The solenoid valve in the
water supply should be interlocked to close simultaneously with the fan stoppage.
11.6 To Stop RotoClone N Arrangement C
47 RotoClone N
Do not stop ejector for two hours after the RotoClone has stopped. If the
automatic sludge ejector timer control is provided, the sludge ejector will stop
automatically at the end of two hours or after the interval set with the timer.
11.7 To Stop RotoClone N Arrangement D
Shut off the drain valve hopper drain.
12
MAINTENANCE
12.1 Record Keeping
It is suggested that a record be kept of operational data and that all
servicing maintenance be recorded.
Maintenance data to be recorded should include details of inspections and
any parts replaced.
More frequent cleaning may be required for certain applications.
12.2 Water Level Control Box
Observe water in the control box frequently. Be certain that water level is at
the running level weir. Observe frequently through glass portlight in control box
top.
CAUTION: DO NOT open the portlight when the unit is running because air
leakage will alter water level.
Open the portlight each week while RotoClone is stopped and remove any
accumulations in the box, check air equalizing port for plugging, check running
water level weir, electrode (if supplied), and drain pipe for build-up and wear.
Clean cover glass and secure portlight, carefully tightening hold downs.
Remove strainer in water makeup line after first 24 hours of service and
clean. Clean monthly thereafter. Strainer is located in solenoid valve on sizes 1.56.
48 RotoClone N
12.3 Eliminator Plates
Inspect each week and remove any accumulations. Cleaning methods will
vary with material collected. Hosing in place is effective for many materials,
Removal of plates and scraping or washing may be necessary. After cleaning,
install correctly, see 9.2.4.
12.4 RotoClone Housing
After one month’s operation, drain the RotoClone and check for build-up on
any surface. Check all impeller surfaces and hopper walls carefully and wash down
with water hose, if required. Frequency of this operation can be extended until
proper cycle for a given application has been determined.
12.5 Metering Drain Orifice (Arr. D)
If there is evidence of plugging, clean the hopper orifice. Check the
screening grid in the hopper to determine if it is clogged. (The screening grid is a
coarse grid which is positioned approximately 18 inches above the metering
orifice).
12.6 Sludge Ejector (Arr. C)
The two basic types of sludge ejectors are the Type “W2” and the Type “L2”.
The Type “W2” is used on RotoClone sizes 1 1⁄2 through 12 and has one
submerged shaft assembly.
The Type “L2” is used on RotoClone Sizes 16 thru 48. It has two submerged
shaft assemblies.
a. Chain Tension:
1.
Type “W2” ejector (Size 1 1⁄2 thru 12) chains should be checked
weekly. Take up slack in both ejector chains evenly by moving the upper
bearings from the lower bolt hole to the upper bolt hole (Figure 4). If the
slack remains, remove one link and move the bearing back to the lower bolt
hole. Each time the RotoClone is drained, check for condition of shaft
bushings and sprockets on the ejector.
2.
Type “L2” ejector (Size 16 thru 48) chains should be checked
periodically or when the unit is drained for cleaning. The ejector return run
of chain is suspended to maintain tension and reduce frequency of take-up.
If necessary, remove links from each chain before upper run sags enough to
interfere with lower run operation or entering edge of guide assembly.
49 RotoClone N
b. Submerged Shafts: Check Type “W2” and “L2” shafts, sprockets, and
bushings when unit is drained.
c. Upper Shafts: Grease bearings on the upper ejector and paddle scraper
shaft each week.
d. A shear pin protects the chain and paddle assembly.
CAUTION: When shear pin breakage occurs, immediately investigate the
cause of trouble. Do not exchange proper shear pin with solid pin.
e.
The oil in the speed reducer should be drained at the end of the first
ten days for 24 hours per day operations or at the end of 30 days when
operation is 8 hours per day. The case should then be thoroughly flushed
with light flushing oil. Fill to oil level with new oil of the proper grade. After
this, change oil every 2500 hours or every six months whichever comes first.
1. To prevent loss of oil while units are in transport, the reducers are
shipped with a brass pin in vent or filler plug. This pin must be removed
before the reducer is operated.
2. A drain plug, at or near the bottom (base flange) of the reducer housing,
is provided for oil removal.
f. Once each month inspect the paddle scraper for correct positioning
against ejector paddle; the scraper bumpers, ejector chain and sprockets for
wear.
12.7 Lubrication
All bearings on the sludge ejector are ball bearings packed with grease
before leaving the factory. Do not add grease during installation. See Maintenance
Instructions, A-4 for greasing instructions and schedules.
Gear reducer on sludge ejector drive was filled with oil before shipment.
Check for proper oil level.
NOTE: To prevent loss of oil while units are in transport, the reducers are
shipped with a brass pin in vent or filler plug. This pin must be removed
before the reducer is operated.
50 RotoClone N
12.8 Fan
Check the fan for excessive vibration each month while checking V-belt
drive. Be certain the fan is rotating in the proper direction.
Check the fan wheel for any dust accumulation every three (3) months.
Check the belt tension of the V-belt drive (if applicable) each week for the
first month of operation; monthly thereafter. Loose belts reduce air flow through
the RotoClone and cause excessive belt wear.
12.9 Replacement Part Stock
Sludge ejector chains and sprockets are subject to considerable abrasion in
many applications. Life will vary from 6 months to more than 3 years.
Replacement of impeller and eliminator sections will be required at
prolonged intervals. Routine inspection will give ample warning for replacement
requirements.
12.10
Sludge Collector (Arr. C)
A suitable container must be provided under the sludge ejector to catch the
continuously ejected sludge. It should be water tight and arranged for ready
removal and easy dumping when filled.
13
TROUBLESHOOTING
13.1 Reduction in airflow at exhaust hoods
Reduced exhauster speed due to belt slippage.
Accumulations in ducts and hoods due to sticky nature of dust or settling in
ducts caused by low conveying velocities.
Addition of more exhaust points to the system
During winter, when doors and windows are closed, insufficient makeup air
to the exhaust system will create high negative pressure in the room.
High water level in the RotoClone can be observed through the closed
portlight in control box. Water level above running level weir can be caused by:
51 RotoClone N
1.
Plugged drain line from the control box.
2.
Open or leaky fill valve that allows water to flow into the RotoClone
raising level over running level weir ¼” or more.
3.
Air leak in control box due to portlight cover not closed tight or failure
to pour water in drain pipe to provide water seal.
4.
Malfunctioning solenoid valve on Model “A” control box.
Plugged eliminator plates or accumulations in impellers or dirty air chamber.
Plugged air equalizing hose or air leak in hose.
13.2 Reduced dust collection efficiency
Extreme reduction in air flow indicated in 13.1, above.
Corrosion or abrasion to impeller sections.
Low water level in RotoClone. Can be observed through closed portlight.
Water level below running level weir can be caused by:
1.
Open or leaky drain valve.
2.
Insufficient water supply due to plugged strainer in makeup water line.
Prolonged periods of low water pressure can reduce water supply rate below
water evaporation rate in RotoClone. Evaporation will be greatest on hot, dry
days.
3.
Incorrect
replacement.
4.
flow
control
valve.
Contact
AAF
representative
for
Solenoid valve sticking in closed position.
5.
Accumulation on electrode in Model “SV” with low water safety control
or Model “A”.
6.
The unit out of level. (See 13.1).
52 RotoClone N
13.3 Water entrainment in fan discharge
Rain or snow draining into exhauster housing during erection or shut down.
Incorrect position of water eliminator plates in Design 2 or 3.
Excessive air flow through RotoClone. Overrating can be checked by
measuring the differential pressure across the RotoClone. This can be done by
subtracting the static pressure directly upstream of the inlet of the RotoClone from
the static pressure directly downstream of the exhaust plenum (between the
RotoClone and the exhauster). If the differential pressure of the RotoClone
exceeds the maximum allowable for the particular operating line the RotoClone
was sized for (see product order details), this usually indicates excessive air flow.
The maximum allowable differential pressure for each operating line can be
determined from the operating line chart in Figure 2. The maximum allowable
differential pressure for a particular operating line occurs at its intersection with
the “maximum differential pressure” line.
To stop entrainment caused by excessive air flow, increase static pressure or
reduce exhauster speed.
A plugged air equalizing hose will cause the water level control box to
maintain a too-high water level in the unit. Clean the hose and readjust the water
level.
Surging of the RotoClone is a rocking of the water from end to end in the
unit. This can be caused by running the unit well below its rated capacity. Contact
the local AAF sales representative for assistance.
1.
Surging can also be caused by a duct elbow at the RotoClone inlet.
Four to five duct diameters length of straight run will give an even air flow at
the inlet. If an elbow is required due to space limitations, turning vanes in
the elbow will evenly distribute the air and eliminate surging.
If the unit is out of level water entrainment will result.
14
RECOMMENDED SPARE PARTS LIST
When ordering Replacement Parts, customer should state Serial Number and
Size of RotoClone, Part Name (when shown on drawing) and Item Number.
53 RotoClone N
Reliable, Efficient, Durable
Sales Offices:
Europe, Middle East
& Africa
AAF Ltd
Bassington Lane, Cramlington
Northumberland, NE23 8AF UK
Tel: +44 1670 713 477
Email: [email protected]
AAF, S.A.
C/ Urartea, 11
Polígono Ali-Gobeo
01010 Vitoria, Spain
Tel: +34 945 214851
AAF France
Rue Wiiliam Dian
B.P.3
27620 Gasny, France
Tel: +33 2 32 53 60 60
AAF Sri
Via Lario, 1
22070 – Fenegrò (CO), Italy
Tel: +39 031 35 25 311
AAF Luftreinigungssysteme
Gesmbi-i
Campus 21
Europaring F12 401
2345 Brunn am Gebirge, Austria
Tel: +43 (0) 2236 677 628 0
AAF – Lufttechnik GmbH
Centroalle 263 b
D 46047
Oberhausen, Germany
Tel: +49 208 828423 0
AAF – Environmental Control Epe
1, Ifaistou & Kikladon
15354- Glika Nera, Greece
Tel: +30 2106632015
AAF Hava Filtreleri ve Ticaret AS
Hürriyet Mahallesi
Yakac1k D-100 Kuzey Yan Yol No: 49/1-2
34876 Kartal, Istanbul, Turkey
Tel: +90 216 4495164/65
AAF International – Middle East
FZS1BC01-BC04, Jebel Ali Dubai, UAE
Tel: 009714 8894886
AAF Saudi Arabia Ltd.
P.O. Box 59336 Riyadh 11525,
Kingdom of Saudi Arabia
Tel: +966 1 265 0883
Asia
America Air Filter Manufacturing
Sdn Bhd
(Asia Regional Office)
Lot 6, Jalan Pengapit 15/19
Seksyen 15 40000 Shah Alam
Selangor Darul Ehsan, Malaysia
Tel: (60) 3 5039 7777 +603 5039 7732
AAF (Wuhan) Co. Ltd., (China HQ)
268 CheCheng Road
Wuhan Economic & Technological
Development Zone
Wuhan, Hubei Province PR,
China 430056
Tel: +86 27 8447 3671 +86 27 8447 3672
The information in this document is the property of American Air Filter Company, Inc. (AAFCI) and may not be
copied or distributed to any third party, or used for any purpose other than that for which it is supplied, without
the express written consent of AAFCI.
While the information herein is provided in good faith based on information available when the document was
created, it should not be relied upon as being complete or accurate, and the products advertised within this
document, and their components and accessories, are subject to change without notice. AAFCI provides this
information on an AS IS basis and makes no warranties, expressed or implied, or representations regarding
same. This document does not establish, and should not be taken as establishing, any contractual or other
commitment binding upon AAFCI or any of its subsidiaries or associated companies.
ISO Certified Firm ©2015 AAF International
APC-
AAF International (Thailand) Co., Ltd.
100 Moo 4 Soi Namdang – Bangplee 44
Bangkaew Bangplee, Samutprakarn
10540, Thailand
Tel: +66 2738 7788
Daikin Australia Pty Ltd
(AAF Australia & New Zealand Sales Office)
15 Nyadale Road Scoresby Victoria 3179,
Australia
Tel: +61 (0)3 9237 5562
North & South America
AAF International
9920 Corporate Campus Drive, Suite 2200
Louisville, KY 40223-5000, USA
Tel: 1 502 637 0011
Toll Free: 1 800 477 1214
AAF, S de RL de CV
Av. Primero de Mayo No. 85,
Col. San Andrés Atenco,
C.P. 54040 Tialnepantla Edo.
De Mexico, México
Tel: +52 55 5565 5200
American Air Filter Brasil Ltda.
Rua Doutor Bacelar, 173-CJ. 121
Vila Clementino – São Paulo – Brazil
CEP 04026-000
Tel: +55 11 5567 3000

INSTALLATION, OPERATION AND

Transcription

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