aaf international installation, operation and … · the dust collector through the fan located on...

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™ LVN

2 RotoClone LVN GDED-IOM-175

© 2017 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 and REDClean 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.AAFIntl.com

mailto:[email protected]

http://www.aafintl.com/






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For best results, discuss the use and application of this equipment with an AAF International representative. For optimal product performance, use only AAF International replacement parts.

WARNING: Process owners/operators must determine if their process creates a combustible dust, fume, or mist before installing or operating a dust or mist collection product. Process owners/operators are solely responsible for ensuring proper precautions have been taken to prevent and avoid catastrophic damages, injuries and/or deaths related to the operation of this dust collector in a

combustible dust, fume, or mist application. At a minimum, process owners/operators should:

Comply with all applicable local, state, and federal codes and standards.

Ensure all NFPA standards have been met.

o Note that current NFPA standards require owners/operators of processes that

involve potentially combustible materials to have a current Hazard Analysis.

Prevent all ignition sources from entering into any dust or mist collection equipment

Design, select, and implement fire and explosion mitigation, suppression, and isolation

strategies that are appropriate for the risks associated with their processes

Develop, implement, and maintain proper work place maintenance procedures to

maintain a safe operating environment that ensures combustible dust, fume, or mist

does not accumulate within the work environment

When combustible materials are present, AAF International recommends that all process owners/operators consult with experts to make certain all responsibilities are met. AAF International can provide assistance in the selection of the filtration technology however,

process owners/operators retain all responsibility for the suitability of fire and explosion hazard mitigation, suppression, and isolation strategies. AAF International assumes no responsibility or liability for the suitability of any fire and/or explosion mitigation strategy, or any items incorporated into a collector as part of an owner/operators hazard mitigation strategy.

Improper operation of a dust control system may contribute to conditions in the work area or facility that could result in severe personal injury and product or property damage. Check that all dust and mist collection equipment is properly selected and sized for the intended use.

DO NOT operate this equipment until you have read and understand the instruction warnings in the Installation, Operation, and Maintenance Manual.

Product Information:

Model ____________________________

Serial Number _____________________

Installation Date ___________________






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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 explosions ................................................................................................................ 7 2.4 Electrical hazards ............................................................................................................ 7 2.5 Rotating equipment ....................................................................................................... 8 2.6 Safety guards .................................................................................................................... 8

3 GENERAL PRODUCT INFORMATION .............................................................................. 8

3.1 Description ......................................................................................................................... 8 3.2 Purpose and intended use .......................................................................................... 8 3.3 Normal Operation ............................................................................................................ 8 3.4 Sizes and Arrangements .............................................................................................. 9 3.5 Filter elements .................................................................................................................. 9 3.6 Weights .............................................................................................................................. 10

4 PRODUCT SHIPMENT .......................................................................................................... 10

4.1 How the product ships ................................................................................................ 10

5 PRODUCT RECEIPT AT THE DESIGNATED DELIVERY POINT .......................... 10

5.1 Responsibilities of the customer or customer’s agent ............................... 10 5.2 Receiving ........................................................................................................................... 10 5.3 Inspection on arrival ................................................................................................... 10 5.4 Damaged goods.............................................................................................................. 10 5.5 Missing goods .................................................................................................................. 11

6 UNLOADING AND HANDLING ......................................................................................... 11

6.1 Unloading .......................................................................................................................... 11 6.2 Handling ............................................................................................................................. 11

7 STORAGE AND PROTECTION .......................................................................................... 11

8 SITE PREPARATION ............................................................................................................ 12

8.1 Locating equipment ..................................................................................................... 12 8.2 Foundations...................................................................................................................... 12

9 ASSEMBLY AND INSTALLATION ................................................................................... 13

9.1 Introduction ..................................................................................................................... 13 9.2 Assembling and installing the structure ........................................................... 13

9.2.1 All Arrangements ......................................................................... 13






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9.2.2 Lubrication .................................................................................. 13

9.2.3 Electrical connections ................................................................... 13

9.2.4 Water supply connections ............................................................. 14

9.2.5 Drain Connection ......................................................................... 14

9.2.6 Ductwork Installation ................................................................... 14

10 WATER LEVEL CONTROL ................................................................................................... 15

10.1 Model “A” Control ......................................................................................................... 15 10.2 Wiring diagram ............................................................................................................... 16

11 START-UP & OPERATION.................................................................................................. 18

11.1 To Fill RotoClone ............................................................................................................ 18 11.2 To Start RotoClone........................................................................................................ 18 11.3 To Stop RotoClone ........................................................................................................ 18

12 MAINTENANCE ....................................................................................................................... 19

12.1 Record Keeping .............................................................................................................. 19 12.2 Removal of Collected Material ................................................................................ 19 12.3 Draining the RotoClone .............................................................................................. 19 12.4 Cleaning the RotoClone .............................................................................................. 19 12.5 RotoClone Maintenance ............................................................................................. 19

12.5.1 Water Level Control Box ............................................................... 20

12.5.2 Water Eliminator .......................................................................... 20

12.5.3 RotoClone Housing ....................................................................... 20

12.5.4 Fan ............................................................................................ 20

13 TROUBLESHOOTING............................................................................................................ 21

13.1 Reduction in airflow at exhaust hoods............................................................... 21 13.2 Reduction in dust collection efficiency .............................................................. 21 13.3 Water entrainment in exhaust discharge ......................................................... 21

14 RECOMMENDED SPARE PARTS LIST ........................................................................... 22






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1 INTRODUCTION This document contains the information necessary to properly receive, assemble, install,

operate, and maintain the AAF® RotoClone® LVN 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 different precautions, measures, training, etc. may be needed depending on the specific circumstances.

CAUTION These instructions are specific to the AAF RotoClone® LVN 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, water supply, 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:

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






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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 explosions Dust explosions constitute a serious

industrial hazard and may result in death, serious injury, and/or devastating property damage. It is the responsibility of the user to identify the nature of the dust and whether or not it poses an explosive hazard and to properly mitigate this hazard. 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

standard for dealing with explosive dust applications is from the National Fire Protection Agency (“NFPA”), NFPA 69: Standard on Explosion Prevention Systems. This standard applies to the design, installation, operation, maintenance, and testing of systems for the prevention of explosions by means of various methods. The user shall be fully conversant with the provisions of NFPA 69 and shall comply in full with all of its requirements.

By its very nature AAF equipment is intended to be used to capture airborne particulate matter, otherwise known as dust. There are various methods for dealing with a dust explosion in a dust collector. These can include, but are not limited to, the use of

properly designed explosion vents, explosion

suppression systems, or flameless vents. The user shall understand which method is being used and who is responsible for the design and supply of the equipment required.

When an explosive dust has been properly identified to AAF, the dust collector may be structurally designed to withstand the internal pressure generated during the explosive event and fitted with an explosion vent, or

with multiple vents, designed to safely discharge the pressure and the resulting fireball. The user shall review the purchase order and the documents referenced within it

to determine if explosion protection equipment has been supplied by AAF International. Where this is the case, review the appropriate sections of this manual that

deal with the installation, operation and maintenance of the equipment ordered.

When explosion protection systems are

supplied by multiple vendors, it is the responsibility of the user to coordinate between suppliers to ensure that the equipment supplied by each vendor will work

together to achieve the required protection. For instance, if an explosion suppression system is being supplied by parties other than AAF, it is incumbent on the user to ensure that the dust collection equipment has been

ordered to resist the internal pressure defined by the suppression equipment supplier.

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






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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 LVN will operate with a

fan which is installed either on the ground or on the top of the dust collector. The fan wheel

rotates at a nominal speed of 3,600 rpm and has the potential to cause severe injury. The fan wheel could be accessed from inside the cabinet through the air inlet if the moisture eliminator is removed, and from outside the cabinet through the fan discharge. 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, or the silencer, 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 shall

remain bolted in place while the fan is operating. Prior to the removal of any access panel 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 wheel 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 LVN is a complete dust control unit. Designed to perform its various functions automatically, the RotoClone requires very little maintenance. Like any other mechanical equipment, however, it

should have regular attention and be operated according to instructions to insure long life and trouble-free service.

The RotoClone LVN is a factory assembled, fully self-contained unitary dust collector. The dust generated by operations is drawn into the collector by ductwork, into a

water bath and then through AAF’s unique static impeller which 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 located on top of the collector and separated dust settles to the bottom of the 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. Automatic cut-out devices prevent

operation of the fan if the water level is too low.

3.2 Purpose and intended use The RotoClone LVN is intended to be

used to collect dust that can be explosive,

such as metal dusts, dusts that tend to cause dry collectors to have problems, such as oily or moisture laden dust, or dusts that can be easily collected using a water bath. Contact

AAF International for assistance on your application.

3.3 Normal Operation The RotoClone LVN 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. 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






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between the dust and water, thus, increased

collection efficiency. 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.

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 water level probe in the

control box as long as a small amount of fresh water is supplied through the make-up water connection as needed to compensate for evaporation and water lost as the collected dust is removed from the unit.

Figure 1. Cross Section of the RotoClone LVN Impeller.

3.4 Sizes and Arrangements The RotoClone LVN is available in 2

sizes, operating from 1000 to 2000 cfm (1700-3400 m3/hr).

3.5 Filter elements There are no disposable filter elements

associated with the RotoClone LVN, as the water and impeller acts as the filtering elements. After filters can be utilized with the RotoClone LVN as efficiency is needed.






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3.6 Weights Table 1. RotoClone LVN Shipping and Operating Weights

RotoClone LVN Shipping and Operating Weights

Size

Maximum Operating Wt.

(lbs)

Normal Operating Wt.

(lbs)

Water Capacity

(Gallons)

Erecting

Weight (lbs)

1000 1700 1600 61 1075

2000 2400 2200 102 1360

Notes

1. Weight based on maximum sludge capacity with a sludge weight of 80 pounds per cubic foot.

2. Weight based on weight of water as 62.4 pounds per cubic foot

4 PRODUCT SHIPMENT 4.1 How the product ships

The RotoClone LVN is shipped fully assembled.

5 PRODUCT RECEIPT AT THE DESIGNATED DELIVERY POINT

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.

5.2 Receiving Remove crates, tarps, shipping straps,

etc. along with any loose items or equipment

before unloading the AAF RotoClone LVN.

5.3 Inspection on arrival The AAF RotoClone LVN 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.

WARNING

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.






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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

CAUTION Failure to lift the collector correctly can result in severe personal

injury, property damage, or even death.

Check the drawings of the specific

RotoClone LVN 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 CAUTION 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.

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






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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.

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

The dust collector site location must take into account the wind and seismic loadings. See collector specifications to ensure proper site location.

WARNING Ensure local laws, codes and regulations are followed for the materials being collected. Noise

levels should be considered when selecting the proper location of the RotoClone LVN.

Locate the RotoClone LVN in a location so that maintenance to the collector can be

handled easily. See collector drawing for cartridge clearance.

CAUTION In the case of hazardous dust, consult your local authorities, laws,

codes, or regulations for the location of the unit.

8.2 Foundations Foundations must be true, level, and

rigid enough to prevent vibration and support the weight of the RotoClone LVN with its maximum dust and water load. See section

3.6 for net weights of the RotoClone LVN.






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9 ASSEMBLY AND INSTALLATION 9.1 Introduction

Safe and efficient operation of the RotoClone LVN 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.

WARNING Authorities with jurisdiction should

be consulted before installing the RotoClone LVN to insure 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 All Arrangements

1. Set RotoClone on foundation and adjust base until unit is

level. Place spirit level on the leveling strips welded on two

or more sides of the hopper. Use care in leveling both

directions as the operation of the RotoClone depends on

the accuracy of the leveling

function.

Note: This level can be checked by filling the unit with water until the level reaches the entering edge

(Figure 1) of the impeller. This entering edge should be level with the water along its entire length with maximum variation of 1⁄16" plus or

minus.

9.2.2 Lubrication All motor bearings are ball bearings

and packed with grease before leaving the factory. Do not add more grease during installation.

Some motors have lubrication plugs.

They should be removed and replaced with grease fittings. Lubricate every six months under dusty operating conditions, and every 12 months under reasonably clean conditions.

9.2.3 Electrical connections Customer’s connection is made to the

control box’s L1, L2, L3 and ground. Disconnect device is provided by customer. The following page includes the wiring diagram.

CAUTION Ensure that motor voltage matches line voltage, and wiring is per diagram on motor.

After connecting the motor

leads, ensure that the motor rotates in a clockwise

direction as viewed from the top of the unit.

Sequence of operation:

1. Water level control 'WLC' is energized when power is turned on at the disconnect switch.

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2. When '2PB' start button is pressed, fan

motor starter 'M' is energized and roto-clone starts.

3. If water level falls below the electrode

'EL', after a 2 min. Delay, water level control 'WLC' contacts #1 & #3 close, energizing timer 'TR' and opens water solenoid valve 'SV'. When water level reaches electrode 'EL', water level

control 'WLC' contacts #1 & #3 open, de-energizing timer 'TR' & closes water valve 'SV'. If water level does not reach electrode 'EL' within 3 min. (field

adjustable) while roto-clone is operating, timer 'TR' contacts #1 & #3 open, de-energizing fan starter 'M' stopping roto-clone & closing water

solenoid valve 'SV'. 4. When '1PB' stop button is pressed, or if

overload relay 'OL' trips, roto-clone fan

motor starter 'm' is de-energized. RotoClone fan will stop & water solenoid valve 'SV' closes.

9.2.4 Water supply connections Units are supplied with a 1” (FPT)

quick fill valve and ¼” (FPT) solenoid valve for automatic water makeup. Connect supply piping to both.

9.2.5 Drain Connection A 2” (FPT) drain valve is supplied at

the bottom of the hopper. Drain piping,

should be attached here and to the 1” (FPT)

overflow coupling on the side of the sludge chute.

9.2.6 Ductwork Installation In order to prevent surging within the

RotoClone, four to five 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.






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10 WATER LEVEL CONTROL Supply water makeup for the

RotoClone is required because of water losses due to evaporation and sludge removal. Makeup water will maintain the proper water level in the unit by entering the RotoClone through the RotoClone/Control box connection.

The Model A control is the only water

level control available on the RotoClone LVN.

10.1 Model “A” Control This control box is used when there

can be no water overflow from the RotoClone. Makeup water will be added to the system only when the requirement exists. This

control also prevents the RotoClone from operating when there is insufficient water level.

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 makeup

water flow. This prohibits a continuous water overflow at the weir.

If the water level has not reached the electrode within three (3) minutes, the timer will turn off the RotoClone exhauster and stop the RotoClone operation. NOTE: Since make-up water is only added to replace evaporated water losses and sludge removal water losses, dissolved solids will build up in the scrubbing water which can cause increased rates of corrosion. It is recommended that the reservoir be purged occasionally and pH readings be taken once a week (with litmus paper) and adjusted to 6.5–7.5.

This range is appropriate for most

dusts except aluminum, magnesium, and titanium, which oxidize and leave a high

hydrogen ion content. A high H content equals a low pH. This can be kept in the 6–6.5 range with an automatic (solenoid valves on drain and makeup) purge system which

lets in fresh water once each one to four hours. For each gallon of fresh water, a gallon of low pH water is released.

Be aware that most collected dusts are either inert or biodegradable. However, dusts which are toxins or heavy metals may not be purged to the sewage system. Be sure to follow the applicable regulations on this matter.






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10.2 Wiring diagram






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Figure 3, Wiring diagram






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11 START-UP & OPERATION 11.1 To Fill RotoClone

1. Close drain valve or insert drain plug (on older units without drain valve), and open any manual valves in the supply piping.

2. Fill the RotoClone with water to approximately 1⁄2" to 2" below the

electronic probe tip or the unit will be marked with a horizontal line indicating “Air (Fan) On” water level.

11.2 To Start RotoClone

1. Check that the water level is approximately 2" below the operating level on the level indicating tube.

2. Make sure sludge removal door is in place.

3. Press “start” button for exhauster motor.

4. Adjust water level to the correct operating level as shown on the level indicating tube, or until it just touches the electronic probe.

11.3 To Stop RotoClone 1. Press exhauster motor “stop” button.

2. Turn off water supply. Even on units supplied with solenoid valves, it is

recommended that a manual valve be placed in the water supply line, prior to the RotoClone, for maintenance purposes and occasions where the

RotoClone will be idle for extended periods of time.






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12 MAINTENANCE 12.1 Record Keeping

It is suggested that a record is kept of operational data and that all servicing maintenance is 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 Removal of Collected

Material In general, the RotoClone LVN is best

suited for light or moderate dust loadings

such that the interval between each sludge removal is of a reasonable length. The required cleaning interval can be determined for any given RotoClone installation by using

the rule shown below. Any material collected on the flat

surfaces, as well as material collected in the

RotoClone, should be removed at regular intervals.

NOTE: Cleanout interval established must be frequent enough to prevent

collected material from exceeding a depth of 6" (2" for light metals). The sludge depth may be checked by

probing through the access door periodically during the first week of operation. At the end of the week, inspect the unit to determine the depth of sludge accumulation. Based upon

this inspection, a fixed schedule should be established for regular sludge removal.

NOTE: The RotoClone may be cleaned

without draining.

12.3 Draining the RotoClone Ideally, the RotoClone should be shut

down for a few hours prior to draining to allow solids to settle.

Open the drain slowly such that flow

increases gradually. This will prevent a sudden rush of solids into the drain. Initially,

a small amount of the sludge layer will erode away in the vicinity of the drain. The cleaner water will then flow out and tends to leave the remainder of the sludge layer intact.

If the drain is plugged, backflush the

drain with a hose or manually back the sludge away from the drain in order to establish

flow. Drain pluggage is an indication that the frequency of cleaning should be increased.

12.4 Cleaning the RotoClone Collected material can be raked up the

sloping side through the main access door. Dust and metal chips can be easily removed with a 12" wide hoe.

Mud or sludge pumps are available from several manufacturers. They can be used to pump the settled material into a suitable container. Sometimes a “wet-vac”

type unit can be utilized. Once collected material is removed, fill

the RotoClone in section 0.

12.5 RotoClone Maintenance During the draining and cleaning of the

RotoClone, a routine inspection and cleaning

of water level control box and float switch, electronic probes if supplied, and RotoClone housing, should be done.

To ensure proper operation of the RotoClone, these procedures should be followed as a minimum. More frequent cleaning may be required for certain

applications.

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International.

12.5.1 Water Level Control Box Observe water level in sight tube

(electronic probe hose connection) frequently. Be certain that water level is at the running level. Verify that no blockage occurs in the connections of the tubing (or hose) to the RotoClone housing.

Clean water control box, sight tubing,

and connection hosing as needed. Wipe down electronic probe or float

switch.

12.5.2 Water Eliminator 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.

12.5.3 RotoClone Housing After one month’s operation, drain the

RotoClone and check for build-up on any surfaces. 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.

12.5.4 Fan

Check the fan for excessive vibration each month. Be certain the fan is rotating in

the proper direction. If vibration of the fan becomes excessive, the exhauster should be disassembled and thoroughly cleaned.

Inspect the fan wheel by removing the top assembly. Check for any dust accumulation every three (3) months.

Re-lubricate motor bearings every 12 months (more often if conditions require). Follow these steps:

1. Stop the motor. Lock out the switch.

2. Thoroughly clean off and

remove pipe plugs from the

bearing housing.

3. Remove hardened grease from

drains with stiff wire or rod.

4. Add grease to the inlet with a hand gun until small amount of

new grease is forced out the drain.

NOTE: For best results, grease should be a good grade of petroleum oil. It should be of No. 2 consistency and stabilized against oxidation. Operating

temperature range should be from —15

˚F to +250˚F for Class B insulation,

and to +300˚F for Class “F” and “H”.

Most leading oil companies have special bearing greases that are satisfactory.

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International.

13 TROUBLESHOOTING Most difficulties that may be

encountered in RotoClone operation will be discovered and corrected by one or more of the following:

13.1 Reduction in airflow at

exhaust hoods Reduced exhauster flow due to

pluggage. Clean out the collector. Accumulations in the ducts or hoods

due to sticky nature of dust, or settling in

ducts caused by low conveying velocities. Confirm airflow and duct velocities are enough to transport the dust to the collector without dropout.

Addition of more exhaust points to the

system, causing a higher static at the fan.

High water level in RotoClone. This can be observed at the level indicating tube. Drain water out of the unit until it reaches the correct level.

Pluggage at the eliminator shelves or accumulations in impellers or dirty air chamber. Clean of the moisture eliminators and unit.

Fan running backwards.

13.2 Reduction in dust collection

efficiency Extreme reduction in air flow, see 13.1

Low water level in RotoClone. The unit out of level.

Corrosion or abrasion to impeller sections.

Material buildup inside collector.

13.3 Water entrainment in exhaust discharge

Buildup of water in the fan plenum. There is a drain hole near the front of the fan discharge.

Excessive air flow through RotoClone.

To stop entrainment caused by excessive air flow, increase static pressure by partially closing the outlet slide damper located on top of the RotoClone.

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 or too high an external pressure resistance. Contact your local AAF sales representative for assistance.

Material buildup on mist eliminator

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International.

14 RECOMMENDED SPARE PARTS LIST Parts of the RotoClone will not require frequent replacement and spare part stock is seldom

necessary. When ordering any parts, give RotoClone size, type and serial number (see the Equipment

nameplate).

To obtain replacement parts: Call: 1-800-477-1214

Or email: [email protected].

Item Description Quantity

1 Water level sensor / probe 1 2 Solenoid valve 1 3 Manual water supply valve 1

4 Manual drain valve 1 5 6 7

8 9 10 11

Control panel Motor

Fan impeller

Fan inlet cone Peripheral door gasket

Impeller gasket Equipment Nameplate

1 1 1

1 1 1 1

Figure 4, Spare parts

Figure 5, Equipment Nameplate

mailto:[email protected]

Sales Offices:

Reliable, Efficient, Durable

The information in this document is the property of AAF® International 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 ©2016 AAF International

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 William Dian27620 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 GesmbHCampus 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]

AAF Hava Filtreleri ve Ticaret ASHürriyet MahallesiYakac1k D-100 Kuzey Yan Yol No: 49/1-234876 Kartal, Istanbul, TurkeyTel: +90 216 4495164/65Email: [email protected]

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Asia

America Air Filter Manufacturing Sdn Bhd(Asia Regional Office)Lot 6, Jalan Pengapit, 15/19,Seksyen 15, 40000 Shah Alam,Selangor Darul Ehsan, MalaysiaTel: +603 5039 7733Email: [email protected]

AAF (Wuhan) Co. Ltd., (China HQ)33 Che Cheng RoadWuhan Economic & TechnologicalDevelopment ZoneWuhan, Hubei Province PR,China 430056Tel: +86 27 8447 3671 +86 27 8447 3672Email: [email protected]

AAF International (Thailand) Co., Ltd.100 Moo 4 Soi Namdang – Bangplee 44Bangkaew Bangplee, Samutprakarn 10540, ThailandTel: +66 2738 7788Email: [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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American Air Filter Brasil Ltda.Rua Doutor Bacelar, 173-CJ. 121 Vila Clementino – São Paulo – BrazilCEP 04026-000Tel: +55 11 5567 3000Email: [email protected]

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