AAF INTERNATIONAL INSTALLATION, OPERATION AND MAINTENANCE MANUAL · 2016-05-27 · AAF® INTERNATIONAL INSTALLATION, OPERATION AND MAINTENANCE MANUAL RotoClone ™ N. ... 3.4.1 Manual

T H E W O R L D L E A D E R I N C L E A N A I R S O L U T I O N S

AAF® INTERNATIONAL

INSTALLATION, OPERATIONAND MAINTENANCE MANUAL

RotoClone™ N

2 RotoClone N

© 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.

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

mailto:[email protected]

http://www.aafparts.com/

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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 Responsibilities of the customer or customer’s agent ............................... 19 5.2 Receiving ................................................................................................................................ 20 5.3 Inspection on arrival ....................................................................................................... 20 5.4 Damaged goods .................................................................................................................. 20 5.5 Missing goods ...................................................................................................................... 20

6 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 Fill the RotoClone N .................................................................................................. 45 11.2 To Start RotoClone N Arrangement B ................................................................... 47 11.3 To Start RotoClone N Arrangement C ................................................................... 47 11.4 To Start RotoClone N Arrangement D ................................................................... 47 11.5 To Stop RotoClone N Arrangement B .................................................................... 47 11.6 To Stop RotoClone N Arrangement C .................................................................... 47 11.7 To 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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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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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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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

http://www.nfpa.org/

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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 self-contained 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

11 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.

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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.

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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.

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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).

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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.

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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

Size

Maximum

Operating Wt. (lbs)

Normal

Operating Wt. (lbs)

Water

Capacity (Gallons)

Erecting Weight

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.

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Table 2. RotoClone N, Arr. C Shipping and Operating Weights

Size Maximum Operating

Wt. (lbs)

Normal Operating Wt.

(lbs)

Water Capacity (Gallons)

Erecting Weight

RotoClone Only

Exhauster Only

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.


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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

1.5 3700 2960 120 2000 300

2.5 3900 3140 120 2200 750

4 5200 4250 180 2800 900

6 8100 6520 330 3800 1500

8 10700 8560 390 5300 2000

12 15000 10765 605 5700 2900

16 20800 16250 900 8800 3450

20 26800 20700 1250 10300 4200

24 31400 25120 1290 14400 4220

28 36800 28310 1510 15800 6020

32 43500 33610 1925 17600 6020

36 50000 37850 2250 19100 7400

40 58300 55850 2500 24100 7400

44 62900 45600 2690 26400 8700

48 67400 52650 2880 28700 8700

Notes 1. Weight based on maximum sludge capacity with a sludge weight of 100 pounds per

cubic foot.


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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.

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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.

21 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.

22 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.

23 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

24 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 1 1⁄2 through 6 will ship mostly assembled in one of the following arrangements:

With fan and drive installed With fan and drive shipped loose for field installation

With fan and drive supplied by others

25 RotoClone N


Chevron mist eliminator bundles ship loose for installation at the

jobsite

RotoClone N Sizes 8 thru 48 are shipped disassembled in major 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

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

26 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.

27 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.

28 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.

29 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 hook-up 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

30 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.

31 RotoClone N


Figure 3. Supply Piping, Arrangement D.

32 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.

33 RotoClone N


Figure 4. Typical RotoClone N Design.

34 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

35 RotoClone N


Orifice

Diameter

Area Sq

In.

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

Control Boxes

Height of Flow

Over Weir

Standard Volume

(S)

High Volume

(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

36 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. Cross-

section 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.

37 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.

38 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.

The electrode and holder are installed in one of the ports on the top of the

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.

10.1.3.1 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.

39 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.

40 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.

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.

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.

41 RotoClone N


Figure 5. Model “SV” Water Level Control

42 RotoClone N


Figure 6. Model “SV” Water Level Control with “Low Water Safety Control” or Model “A” Water Level Control

43 RotoClone N


Figure 7. Model “SV-HV” Water Level Control

44 RotoClone N


Figure 8. Model “SV-HV” Water Level Control with “Low Water Safety Control”

45 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.

46 RotoClone N


Figure 7. Cutaway view of standard Water Level Control “SV”.

47 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.

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.

11.4 To Start RotoClone N Arrangement D


Open drain valve in hopper drain.

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.

11.5 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

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.

48 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

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.

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 1.5-

6.

49 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.

50 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.

51 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:

52 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 failureto 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 flow control valve. Contact AAF representative for

replacement.

4. 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).

53 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.

Sales Offices:

Reliable, Efficient, Durable

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 InternationalAPC-

Europe, Middle East & Africa

AAF Ltd Bassington Lane, CramlingtonNorthumberland, NE23 8AF UKTel: +44 1670 713 477Email: [email protected]

AAF, S.A. C/ Urartea, 11Polígono Ali-Gobeo01010 Vitoria, SpainTel: +34 945 214851Email: [email protected]

AAF FranceRue Wiiliam DianB.P.327620 Gasny, FranceTel: +33 2 32 53 60 60Email: [email protected]

AAF SriVia Lario, 122070 – Fenegrò (CO), ItalyTel: +39 031 35 25 311Email: [email protected]

AAF Luftreinigungssysteme Gesmbi-iCampus 21Europaring F12 4012345 Brunn am Gebirge, AustriaTel: +43 (0) 2236 677 628 0Email: [email protected]

AAF – Lufttechnik GmbHCentroalle 263 bD 46047Oberhausen, GermanyTel: +49 208 828423 0Email: [email protected]

AAF – Environmental Control Epe1, Ifaistou & Kikladon15354- Glika Nera, GreeceTel: +30 2106632015Email: [email protected]

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Asia

America Air Filter Manufacturing Sdn Bhd(Asia Regional Office)Lot 6, Jalan Pengapit 15/19Seksyen 15 40000 Shah AlamSelangor Darul Ehsan, MalaysiaTel: (60) 3 5039 7777 +603 5039 7732Email: [email protected]

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North & South America

AAF International9920 Corporate Campus Drive, Suite 2200Louisville, KY 40223-5000, USATel: 1 502 637 0011Toll Free: 1 800 477 1214Email: [email protected]

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Documents

AAF INTERNATIONAL INSTALLATION, OPERATION AND MAINTENANCE MANUAL · 2016-05-27 · AAF® INTERNATIONAL INSTALLATION, OPERATION AND MAINTENANCE MANUAL RotoClone ™ N. ... 3.4.1 Manual