aaf international installation, operation and maintenance manual · 2015-11-13 · this document...

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™ W

2 RotoClone® W

© 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 ........................................................................................................................... 5

2 SAFETY .............................................................................................................................................. 5

2.1 Safety statement ................................................................................................................. 5 2.2 Safe working practices and staff training ............................................................ 5 2.3 Dust explosions .................................................................................................................... 6

2.3.1 NFPA 654 and referenced codes and standards .......................................................................... 7

2.3.2 Other requirements ............................................................................................................................................ 8

2.4 Electrical hazards ................................................................................................................ 9 2.5 Rotating equipment ........................................................................................................... 9 2.6 Safety guards ........................................................................................................................ 9

3 GENERAL PRODUCT INFORMATION .............................................................................. 10

3.1 Description ............................................................................................................................ 10 3.2 Purpose and intended use ........................................................................................... 10 3.3 Normal Operation .............................................................................................................. 10 3.4 Sizes .......................................................................................................................................... 13 3.5 Filter elements .................................................................................................................... 13 3.6 Weights ................................................................................................................................... 14 3.7 Food Quality RotoClone W ........................................................................................... 14 3.8 Range Hood and FM Controls ..................................................................................... 15

4 PRODUCT SHIPMENT .............................................................................................................. 16

4.1 How the product ships ................................................................................................... 16 4.2 Items that ship separately .......................................................................................... 16

5 PRODUCT RECEIPT AT THE DESIGNATED DELIVERY POINT .......................... 16

5.1 Responsibilities of the customer or the customer’s agent ....................... 16 5.2 Receiving ................................................................................................................................ 16 5.3 Inspection on arrival ....................................................................................................... 16 5.4 Damaged goods .................................................................................................................. 17 5.5 Missing goods ...................................................................................................................... 17

6 UNLOADING AND HANDLING ............................................................................................ 17

6.1 Unloading ............................................................................................................................... 17 6.2 Handling.................................................................................................................................. 18 6.3 Rigging and hoisting instructions ........................................................................... 18

7 STORAGE AND PROTECTION .............................................................................................. 18

8 SITE PREPARATION ................................................................................................................ 20

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8.1 Locating equipment ......................................................................................................... 20 8.2 Foundations .......................................................................................................................... 20

9 ASSEMBLY AND INSTALLATION ...................................................................................... 20

9.1 Introduction ......................................................................................................................... 20 9.2 Assembling and installing the structure ............................................................. 21

9.2.1 Arrangement A ..................................................................................................................................................... 21

9.2.2 Arrangement D ..................................................................................................................................................... 22

9.2.3 Bearings ..................................................................................................................................................................... 24

9.2.4 Drive ............................................................................................................................................................................. 25

9.2.5 Electrical Connections ..................................................................................................................................... 25

9.2.6 Water connections ............................................................................................................................................. 26

9.2.7 Ductwork Installation ...................................................................................................................................... 32

10 START-UP & OPERATION ..................................................................................................... 33

10.1 Start-up checklist .............................................................................................................. 33

11 MAINTENANCE ........................................................................................................................... 34

11.1 Record Keeping .................................................................................................................. 34 11.2 Lubrication ............................................................................................................................ 34 11.3 Nozzles and Strainer ....................................................................................................... 35 11.4 RotoClone Inlet (Arr. A) ................................................................................................ 35 11.5 Pre-cleaner Inlet (Arr. D) ............................................................................................ 36 11.6 RotoClone Impeller .......................................................................................................... 36 11.7 Drains ....................................................................................................................................... 36 11.8 Emergency Overflow (Arr. D only) ......................................................................... 37 11.9 Shaft Seal ............................................................................................................................... 37 11.10 Replacement of Shaft, Impeller or Water Cone .................................... 38

12 TROUBLESHOOTING................................................................................................................ 41

12.1 Water Entrainment ........................................................................................................... 41 12.2 Dust Entrainment .............................................................................................................. 42 12.3 Start/Stop Issues ............................................................................................................. 42

13 RECOMMENDED SPARE PARTS ......................................................................................... 43

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

assemble, install, operate, and maintain the AAF RotoClone® W filter system and

filters. 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® W filter system and

filters. 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 explosions

By its very nature the RotoClone® W 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.

Except as otherwise expressly provided in writing, AAF makes no representation or warranty in connection with explosion hazard equipment,

7 RotoClone® W


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 following documents unless specifically referenced by those documents. Review this list to determine if any of these codes and standards apply

to the particular use for which the RotoClone® W will be employed. If such is the

case the appropriate documents shall be reviewed and complied with in full.

NFPA 30B, Code for the Manufacture and Storage of Aerosol Products, 2015

edition.

NFPA 33, Standard for Spray Application Using Flammable or Combustible Materials, 2011 edition.

NFPA 61, Standard for the Prevention of Fires and Dust Explosions in

Agricultural and Food Processing Facilities, 2013 edition.

8 RotoClone® W


NFPA 85, Boiler and Combustion Systems Hazards Code, 2015 edition.

NFPA 120, Standard for Fire Prevention and Control in Coal Mines, 2015

edition.

NFPA 400, Hazardous Materials Code, 2016 edition. NFPA 484, Standard for Combustible Metals, 2015 edition.

NFPA 495, Explosive Materials Code, 2013 edition.

NFPA 655, Standard for Prevention of Sulfur Fires and Explosions, 2012 edition.

NFPA 664, Standard for the Prevention of Fires and Explosions in Wood

Processing and Woodworking Facilities, 2012 edition.

NFPA 1124, Code for the Manufacture, Transportation, Storage, and Retail Sales of Fireworks and Pyrotechnic Articles, 2013 edition.

NFPA 1125, Code for the Manufacture of Model Rocket and High Power

Rocket Motors, 2012 edition.

2.3.2 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 apply 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.

http://www.nfpa.org/

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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 W acts as a dust collector and as a fan. The impeller may

rotate at nominal speeds approaching 3600 rpm and has the potential to cause severe injury. The collector’s impeller can be accessed through the collector from

the air inlet if the ductwork is removed, from the outside of the collector through

the collector discharge, and through various access panels. All due care should be exercised to avoid any contact with the operating collector’s impeller. Under no

circumstances should the collector ever be allowed to operate when any of the access panels on the dust collector 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 housing prevents access to the impeller blades. All access panels and the inlet duct shall remain bolted in place while the collector is

operating. Prior to the removal of any access panels, 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 impeller will continue to rotate for

a period of time before coasting to a stop.

Multiple outlet options are available at the outlet of the RotoClone W. These

outlet options are bolted to the outlet flange of the collector. Under no circumstances should these be removed while the collector is in operation or when

there is electrical power connected to the dust collector.

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3 GENERAL PRODUCT INFORMATION 3.1 Description

The RotoClone W is a complete dust collector. It comprises a combination

fan and dust collector in a single compact device. Dust is separated from the airstream and the concentrated material is continuously discharged in a slurry

form. The RotoClone W can be applied in a variety of applications involving the collection of dry, damp, wet, or sticky dusts and where space is limited. The

distinguishing features of the RotoClone W are the combination of multiple high

power water sprays, special blade design, and dynamic precipitation.

The RotoClone W has been designed to operate automatically and requires very little maintenance. However, as is the case with any mechanical equipment, it

should be operated, and regularly maintained and serviced in accordance with these instructions to ensure long life and trouble free performance and use. 3.2 Purpose and intended use

The RotoClone W is a wet dust collector that is intended to be used for dust

collection. Typical product applications include mining, coal handling, food

processing, chemical handling, and general nuisance dusts. 3.3 Normal Operation

Dust laden air enters the RotoClone W where it is wetted by a fine conical water spray. The water and the dust, being heavier than air, impinge on the

blades of the impeller which are covered by a flowing water film which is sprayed separately onto and covers all blade surfaces. The water and dust are directed into

the water cone by the special blade design and the centrifugal force generated by

the rotating impeller. The mixture of dust and water forms a slurry which is emitted from the collector through the sludge chute and also from the drain in the

bottom of the RotoClone expansion chamber.

Similar to a fan, the rotating impeller and blades impart energy to the cleaned air, which being lighter than the water and dust, is discharged in front of

the water cone and continues to the clean air outlet.

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Arrangement A

The RotoClone W Arrangement A is recommended for the collection of airborne granular dusts and mist up to loadings of 2 grains per cubic foot of inlet

air.

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Arrangement D

The RotoClone W Arrangement D is designed to collect heavy concentrations of airborne granular dust up to loadings of 10 grains per cubic foot of inlet air. The

Arrangement D is equipped with an integral wet centrifugal pre-cleaner, which removes a high percentage of the incoming dust from the airstream. The

differential pressure in the wet pre-cleaner section is approximately twice the

13 RotoClone® W


value of the inlet velocity pressure for a RotoClone Arrangement A of the same

size. Collected dust and water are continuously discharged as a slurry through a single hopper drain. 3.4 Sizes

The RotoClone W Arrangement A is available in 12 sizes and the RotoClone

W Arrangement D is available in 7 sizes as outlined in the table below. The table also shows the inlet dust load range for each Arrangement and the airflow range

from the smallest to largest size. The RotoClone W Arrangement A sizes represent

the inlet diameter of the collector in inches (1 inch = 25.4 mm), e.g. the Size 12 has a 12 inch inlet diameter. See 3.6 for a listing of sizes with weights.

Arrangement

*

Inlet Dust Loading Sizes

Offered*

Airflow Range (Depending on

Size)*

Grains/ft3 mg/m3 ft3/ minute m3/ hour

A 0 to 2 0 to 4576 12.0 1000 to 50,000

1699 to 84950

D 0 to 10 0 to

22,884 7.0

1000 to 15,000

1699 to 25,485

Review the purchase order and the product documentation supplied for the

arrangement, size and airflow rating of the equipment supplied.

3.5 Filter elements

There are no disposable filter elements associated with the standard

RotoClone W. Occasionally, but rarely, after-filters may be supplied to provide

additional filtration efficiency on very small particulates. Review the purchase order and the product documentation supplied for details of any after-filters.

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3.6 Weights

Table 1. RotoClone W Shipping and Operating Weights

Size

Arrangement A Arrangement D

Shipping Weight

(lbs.)

Operating Weight

(lbs.)

Shipping Weight

(lbs.)

Operating Weight

(lbs.)

8 225 425 1725 2625

10 360 610 1810 3010

12 630 880 2030 3380

14 990 1340 2790 5320

16 1260 1710 3760 6310

20 1620 2270 5420 9650

24 1890 2590 7190 13290

27 2970 3720

30 3870 5020

33 4860 6360

36 5850 7350

45 13500 16000

Notes: 1. Shipping weight does not include motor and drive.

2. Operating Weight includes estimated weight for motor and drive for Arrangements

A and D.

3. Operating weight also includes an additional 100 lb. per cubic foot of hopper

volume for the Arrangement D, in the event that the drain line becomes plugged.

3.7 Food Quality RotoClone W

“Food Quality” refers to features on the RotoClone W that make it readily accessible for interior cleaning, and exterior finishing to facilitate wash-down by

minimizing surfaces that can collect and trap material or water. These features include quick opening access doors in the Inlet Section, Expansion Chamber, and

90° Elbow Outlet or Centrifugal Outlet (if supplied in lieu of the standard Straight Outlet); exterior welds ground smooth; and construction features to eliminate or

minimize flat, horizontal surfaces. Additionally, nozzles are installed in the Expansion Chamber and the 90° Elbow Outlet or Centrifugal Outlet (if supplied in

lieu of the standard Straight Outlet), to facilitate removal of buildup in the drain area.

15 RotoClone® W


3.8 Range Hood and FM Controls

A RotoClone W provided with Range Hood or FM controls has slightly different inlet piping and controls than the standard RotoClone W. The Range Hood

RotoClone W has two (2) flow switches, two (2) solenoid valves, extra inlet nozzle(s); and no pressure switch. Additionally, there is an electrical control box

that houses relays and terminal strips, and a temperature switch to be installed in the ductwork upstream of the RotoClone W. The piping assembly with the solenoid

valves and flow switches, pressure gauge, and strainer, ship loose along with the temperature switch and electrical control box - see the specific wiring diagram in

the electrical control box (or in the envelope with the other documents) for proper wiring, and sequence of operation. See Figure 1.

Figure 1. Flow Switches and Solenoid Valves

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4 PRODUCT SHIPMENT 4.1 How the product ships

Typically, size 24 and smaller RotoClone W dust collectors will ship upright

on a wooden skid. Larger sizes will ship on 4x4 wooden runners. Size 16 units and smaller will ship using LTL (less than truckload shipping) unless otherwise agreed

with the buyer. Consult AAF International for information on carrier arrangements for all larger sizes. 4.2 Items that ship separately

To reduce freight costs, AAF International may ship some items separately. The customer will be notified which particular equipment items ship separately

when the order is placed. Items that ship separately may arrive at the designated receipt point at different times. Those items that arrive early should be set aside in

an area that is clean, dry, and secure, where the equipment will be safe and protected.

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 includes 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 the 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 and fully understand all laws, codes and regulations that

apply before installation starts. 5.2 Receiving

Remove crates, tarps, shipping straps, etc. along with any loose items or

equipment before unloading the AAF RotoClone W.

5.3 Inspection on arrival The AAF RotoClone W is normally shipped by truck and should be checked

for damage that may have occurred in route. Compare the product received to the

17 RotoClone® W


description and/or drawing of the product ordered. Immediately report any

missing items or differences to the product ordered to AAF International. Remove loose items or components before lifting the collector from the truck.

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.

Connect the lifting sling to at least four lifting points, if possible, distributing the load evenly.

Use clevises, not hooks, on the lifting sling.

Use of spreader bars is recommended on all lifting slings.

Check the drawings of the specific RotoClone W ordered for dimensions and

weights to ensure proper lifting and installation equipment.

18 RotoClone® W


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 W may be moved using a forklift to lift the product using its shipping pallet, if available.

The RotoClone W 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.

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.

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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 manufactured by Ashland Inc., 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.

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.

20 RotoClone® W


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.

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 W.

Locate the RotoClone W in a location so that maintenance to the collector can be handled easily. See collector drawing for cartridge clearance.

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 W. See section 3.6 for net weights of the RotoClone W.

9 ASSEMBLY AND INSTALLATION 9.1 Introduction

Safe and efficient operation of the RotoClone W depends on proper

installation.

AAF recommends that the ductwork going into the collector be as straight as possible, with at least 5 duct diameters of straight run recommended.

Authorities with jurisdiction should be consulted before installing the RotoClone W 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.

21 RotoClone® W


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 Arrangement A Refer to Installation Diagram - Figure 2. Assembly of the RotoClone should

proceed in the following manner sealing all joints using gaskets and bolts included with shipment. Some RotoClone, size 16 and smaller, have inlet, outlet, and

expansion chamber welded to housing in lieu of flanged and bolted connections.

1. Bolt RotoClone outlet connection to RotoClone outlet. Be sure that the

bottom of the outlet piece is even with the bottom of the RotoClone outlet and that no gasket material is protruding inside as this will cause water

carryover.

2. Bolt RotoClone on foundation. If vibration isolators are used, a sub-base must be used to support the exhauster with the isolators located at each

corner of the sub-base. Connecting ductwork requires flexible connections when vibration isolators are used.

3. Bolt RotoClone inlet connection to RotoClone inlet. (Note: Eliminate

elbows and other inlet obstructions if at all possible. Sharp elbows at the fan inlet or other disturbances will seriously reduce the air volume and

can affect the RotoClone dust collection efficiency. A minimum of 4-5 inlet

diameters of straight duct prior to the RotoClone is recommended to evenly distribute airflow.)

4. Bolt expansion chamber to water outlet.

22 RotoClone® W


Figure 2. Installation Diagram

9.2.2 Arrangement D Refer to Arrangement D Erection Diagram - Figure 3. Assembly should

proceed in the following manner, using gaskets and bolts included with shipment for each joint. Some RotoClone, sizes 16 and smaller, may have inlet, outlet, and

expansion chamber welded to housing in lieu of flanged and bolted connections.

1. Place hopper section on foundation and anchor.

2. Bolt pre-cleaner section to hopper top. (Note: On RotoClone sizes 8 through 20, the hopper and pre-cleaner sections are normally shipped

assembled.)

23 RotoClone® W


3. Bolt RotoClone outlet connection to RotoClone outlet. Be sure that the bottom of the outlet piece is even with the bottom of the RotoClone outlet

and that no gasket material is protruding inside as this will cause water carryover.

4. Bolt RotoClone to pre-cleaner top. (Note: On RotoClone sizes 8 and

10, RotoClone® is shipped assembled to pre-cleaner and hopper.)

5. Bolt pre-cleaner outlet connection to pre-cleaner section. (Note: On RotoClone sizes 8 through 16, the pre-cleaner outlet connection and pre-

cleaner are shipped assembled.)

6. Bolt RotoClone inlet connection to RotoClone inlet and pre-cleaner outlet connection.

7. Connect hose from water drain in RotoClone outlet connection to

nipple provided in hopper using fittings provided.

24 RotoClone® W


Figure 3. Arrangement D Erection Diagram

9.2.3 Bearings

RotoClone bearings are of the ball or roller-bearing type and are packed with proper amounts of grease before leaving the factory. Additional grease need not

be added at the time of installation. Both a “fixed” and “floating” bearing are used. For optimum life, the “fixed” bearing is located on the outboard position (drive

side).

25 RotoClone® W


9.2.4 Drive RotoClone W units are belt-driven. Motor, if supplied by others, should be

equipped with adjustable slide base. Short center V-belt drives, if provided by others, are the preferred arrangement. V-belt drives are usually mounted by the

factory in an Arrangement 9 motor mounting. Where the motor mounting is Arrangement 1 or the motor and drive are too large to be shipped mounted on the

unit, refer to belt manufacturer’s recommendations for belt tension, or call AAF for instructions. Improper tension will affect performance and life of the drive and

bearings. 9.2.5 Electrical Connections 9.2.5.1 Pressure Switch

A switch is supplied with the RotoClone which will stop the RotoClone motor automatically when water supply fails or water pressure falls below 28 psi. This

pressure switch should be mounted in the water supply line as shown in Figure 2 and wired as shown in the wiring diagram supplied with the unit. (Note: this switch

is not supplied, when “Range Hood” controls are supplied - see Section 9.2.6.1 for Range Hood controls.)

When switch has stopped RotoClone motor because the water pressure has

dropped below 28 PSI, RotoClone cannot be started again until water pressure has returned to not less than 30 PSI.

Switch has been adjusted at factory to operate in the range described

above. Switch setting may be checked against pressure gage reading. To readjust,

remove cover and turn adjustment screw to right or left, using pressure gage as a guide. 9.2.5.2 FM Range Hood Controls

These controls are designed to prevent fires in kitchen range hoods beyond

the RotoClone outlet when wired according to Drawing U48P-46209 (except NY), U48P-1427848 (NY), U48P-1653872 (Canada), or the specific wiring diagram

supplied with the unit. These controls, when supplied, include two solenoid valves, two flow control switches (these replace the pressure switch), Fenwal Detect-A-

Fire switch, and relays. (See Section 3.8 for additional details on this option.)

26 RotoClone® W


9.2.5.3 Auxiliary Impeller Flushing

An auxiliary flushing nozzle is supplied with a manual valve or automatic

solenoid valve to provide extra cleaning for the impeller while it coasts down to a stop after the motor is de-energized.

The automatic solenoid valve option includes a timer/relay in a separate

(shipped loose) box. Refer to the wiring diagram supplied with the unit for connection directions. The timer/relay is interlocked with the motor starter to open

the solenoid when the “STOP” button is pushed. After the timer runs its preset

time, the solenoid closes, shutting off water to the RotoClone.

NOTE: The valve should not remain open while the RotoClone® is running.

The extra water may cause water entrainment in the exhaust airstream. 9.2.6 Water connections

Arrangement A - RotoClone piping may be shipped loose to prevent

damage during shipping. Connect the two lines from the “cross” to the two connections on the RotoClone inlet. The third outlet from the cross connects to the

pressure gauge supplied and the front leg should be connected to the water supply line. Supply line should be ¾” size for RotoClone through size 14; 1” size for size

16 RotoClone® and larger and designed for supply line water pressures.

Connect the water supply line to strainer located near RotoClone inlet, using pipe at least as large as the strainer connection. The Solenoid Valve should be

installed between the strainer and cross, and should be wired in parallel with the RotoClone motor per the wiring diagram supplied with the unit. Solenoid valves

should always be installed with the coil in the top, vertical position. Finished piping

should be per Figure 2. It is recommended that a manual shut-off valve be installed in the supply line, to be able to do maintenance on the solenoid valve.

The water connection must be capable of supplying the volume listed in 9.2.6.11, Table 2 to the spray nozzles at 40 to 60 psi pressure.

Arrangement D - Instructions same as Arrangement A, strainer located

near Pre-cleaner inlet. Refer to Figure 3 for Pressure Gage Installation.

A by-pass connection with manual valve per Figure 4 (both Arrangement A and D) may be included to safeguard operation of

RotoClone in case of solenoid valve failure or for strainer maintenance.

27 RotoClone® W


Figure 4 - Piping Diagram, Arrangements A and D

9.2.6.1 Range Hood and FM Controls

The temperature switch comes attached to its own conduit box. The switch

should be installed in an unobstructed portion of the ductwork between the RotoClone inlet and the Exhaust hood, where the thermal path is not hindered. It

must be installed in the top of the ductwork so that the temperature switch/probe is hanging vertically. The switch/probe is installed in the duct by screwing the

switch/probe through the duct and into the bushing in the conduit box until tight. This secures both the switch/probe and the conduit box to the duct.

9.2.6.2 Spray Nozzles

Arrangement A - Nozzles are installed at the factory. Connect the nozzle piping to the fittings provided. From the strainer, the main pipe leads to the

conical spray nozzle fitted in the RotoClone inlet connection. The small branch line leads to auxiliary flat spray nozzle within the RotoClone housing. Refer to

28 RotoClone® W


installation diagram, Figure 2. Flat spray should be in the 7 o’clock position with

“fan” parallel to the blades of the impeller.

Arrangement D - Nozzles are installed at the factory. Connect nozzle piping to the fittings provided. Refer to erection diagram, Figure 3. From the strainer, the

main line branches into two connections, one leading to two or more vertical flat spray nozzles fitted at the pre-cleaner inlet and the other one to a conical spray

nozzle fitted into the RotoClone inlet connection. From this line, a small branch leads to an auxiliary flat spray nozzle within the RotoClone® housing.

9.2.6.3 Sludge connection

Arrangement A - The expansion chamber and outlet connection drains

should discharge to an open funnel, so if drain piping plugs up, water will run over

funnel and not back up in RotoClone which may cause damage. See Figure 2. Piping from funnel should be equal or larger in size than expansion chamber

nipple. This connection can run to (1) sewer or drain line, (2) process, (3) settling tank, or (4) other locations dependent on local conditions/regulations and the

amount of material collected by the RotoClone.

Arrangement D - The hopper drain should discharge into an open funnel. See Figure 3. Piping from the funnel should be equal or larger in size than the

hopper drain opening. The sludge can be disposed the same as suggested under Arrangement A.

9.2.6.4 Drain Connection

Arrangement A - The drain from the outlet connection, see Figure 2, should be connected to the sludge pipe from expansion chamber or directly to a

drain. Full size piping should be used. Refer to installation diagram Figure 1. Note that a funnel is shown under the drain. This provides easy access to the drain if an

obstruction should occur. A plugged drain can cause the water level in the collector to rise into the impeller and the impeller tips will break.

Arrangement D - The drain from the outlet connection should be piped

back into the RotoClone hopper (see Figure 3).

9.2.6.5 Emergency Overflow (arrangement D only)

Connect pipe nipple located on hopper side to open drain funnel using same

size pipe. See Figure 3. Connection from funnel to sludge line must be no smaller than main drain connection at bottom of RotoClone hopper.

29 RotoClone® W


9.2.6.6 Food Quality RotoClone W

Installation and Operation procedure is the same as shown in Sections 9.2

and 10 of this IOM, with the exception of the requirement for extra water connections. Additional, valved, 40 psi, water supply connections should be made

for the spray nozzle connections (screwed coupling(s) - see general Arrangement drawing for location(s)) in the Expansion Chamber and 90° Elbow or Centrifugal

Outlet (if other than the Straight Outlet is supplied). It is recommended that the valves be opened intermittently, for a brief period, during RotoClone operation and

at shutdown, to facilitate flushing of material that can accumulate and plug the

drains. Frequency and duration of the water spray must be determined individually for each RotoClone application. (Provision can be made for automatic operation, by

installing solenoid valves, actuated by timers.)

NOTE: Leaving the water “on” during operation of the RotoClone can result in water carryover in the exhaust duct; and, will result in excessive water

consumption. An empirically determined timed sequence should be adequate to keep drains free-flowing, and is the recommended operational approach.

9.2.6.7 Flow Switches for Range Hood and FM Controls

Flow switches are shipped assembled on the external piping assembly, which is shipped loose. They are referred to as FS-1 and FS-2. Flow switch FS-1 is

connected to the standard inlet nozzle and the impeller flushing (auxiliary) nozzle. Flow switch FS-2 is connected to the emergency spray nozzle(s). Flow switches are

set at the factory and should not be field adjusted. Each flow switch is set for a specific flow and is not interchangeable. The flow switches need only be wired up

according to the separate wiring diagram.

9.2.6.8 Solenoid Valves for Range Hood and FM Controls

The solenoid valves (SV-1 and SV-2) are shipped assembled on the external

piping assembly, which is shipped loose. The solenoid valves are identical and interchangeable; and need only be wired up according to the separate wiring

diagram.

9.2.6.9 Water connection for Range Hood and FM Controls

The “shipped loose” piping assembly is attached to the RotoClone at the two

unions on the end of the loose piping and connecting pieces on the RotoClone. Connect the water supply line to the strainer on the other end of the RotoClone

piping assembly. It is recommended that a manual shut off valve (supplied by others) be installed in the supply line to facilitate maintenance on the flow

30 RotoClone® W


switches and solenoid valves. The water connection should be capable of supplying

the volume listed in Table 2 at a pressure of 40 psi.

9.2.6.10 Auxiliary Impeller Flushing

The manual or solenoid valve should be piped up to the water line that supplies the RotoClone, after the strainer. The connection size is a ½" FPT on the

valve.

9.2.6.11 Water Usage Table

Table 2. Normal Water Supply Rates

RotoClone Size

Arrangement A Arrangement D

GPM Supplied GPM Supplied

40 50 60 40 50 60

8 1.1 1.2 1.3 2.1 2.2 2.5

10 1.5 1.6 1.8 3.1 3.4 3.8

12 1.8 2 2.2 4.8 5.4 5.9

14 2.3 2.5 2.9 5.3 5.9 6.5

16 3.5 3.9 4.3 7.5 8.4 9.2

20 4.5 5 5.5 8.5 9.5 10.4

24 5.5-6.0 6.2-6.7 6.8-7.3 13.5-14.0 15.1-15.6 16.6-17.1

27 7.0-7.5 7.9-8.4 8.7-9.2

30 8 8.9 9.8

33 12 13.4 14.7

36 14.0-15.0 14.7-15.7 16.7-17.1

45 21.0-22.0 23.6-24.6 25.9-26.9

Notes: 1. Decreased or increased water requirements can be provided by changing

nozzle size.

2. For air temperatures in excess of 300F, cooling spray nozzles should be

provided in inlet duct to compensate for evaporation. A safe

approximation will be 0.2 GPM if additional water per 1000 CFM for each

100°F temperature reduction.

31 RotoClone® W


Table 3. Spray Nozzles

RotoClone Size

Inlet Nozzle (GPM)1

Impeller

Auxiliary Nozzle

(GPM)2

Arr. D Pre-

cleaner Nozzles

(GPM)2

Total Water

Requirements @ 40 psi

Arr. A Arr. D

8 0.6 0.5 0.5 1.1 2.1

10 1.0 0.5 0.8 1.5 3.1

12 1.0 0.8 1.5 1.8 4.8

14 1.5 0.8 1.5 2.3 5.3

16 2.0 1.5 2.0 3.5 7.5

20 3.0 1.5 2.0 4.5 8.5

24 3.5-4.0 2.0 4.0 5.5-6.0 13.5-14.0

27 5.0-5.5 2.0 7.0-7.5

30 6.0 2.0 8.0

33 8.0 4.0 12.0

36 10.0-11.0 4.0 14.0-15.0

45 15.0-17.0 6.0 21.0-22.0

Notes: 1 Hollow Cone Nozzle with 70 to 90 degree spray pattern

2 80 to 90 degree flat spray pattern

Table 4. Water Requirements for Range Hood and FM Controls

RotoClone Size

8 10 12 14 16 20 24 27 30 33 36 45

Normal (GPM)

1.1 1.5 1.8 2.3 3.5 4.5 6.0 7.5 8.0 12.0 14.0 22.0

Emergency

(GPM) 1.3 4.0 4.0 3.2 4.0 6.0 6.0 12.0 12.0 14.0 14.0 30.0

Combined

(GPM) 2.4 5.5 5.8 5.5 7.5 10.5 12.0 19.5 20.0 26.0 28.0 52.0

32 RotoClone® W


9.2.7 Ductwork Installation

Arrangement A - Inlet and discharge ducts must be supported from floor, wall, or ceiling, and not by the RotoClone. The joint between the RotoClone inlet

and exhaust main must be water-tight. Inlet duct should slope downward with bottom of duct no lower than bottom of RotoClone inlet. There should be at least

four (4) duct diameters of straight run leading to the inlet of the RotoClone or performance may be impaired. Discharge duct should extend above roof line and

should discharge the air vertically upward. It should be of same diameter as the RotoClone inlet and seams must be soldered or welded water-tight. A gasket (not

furnished) should be placed between the outlet connection and the discharge duct to make joint water-tight. A weather hood is not required. Expansion chamber

should be vented per Figure 5, where recirculation of discharge air is not permitted.

Figure 5- Expansion Chamber Venting Diagram

Arrangement D - Instructions same as Arrangement A except on arrangement D, the joint between Pre-cleaner inlet and exhaust main must be

water-tight.

33 RotoClone® W


10 START-UP & OPERATION To make sure the impeller is free, turn shaft by hand before starting the

RotoClone. THE DIRECTION OF ROTATION MUST BE COUNTERCLOCKWISE when

viewed from the drive side of RotoClone, NOTE ARROW ON HOUSING.

Flush strainer to remove pipe scale and solids from supply line. Paper, wood, and other foreign materials are frequently left in exhaust system during erection.

Inspect RotoClone impeller through inspection doors located at RotoClone inlet and

rear housing before operating the unit and after 24 hours operation. Remove any such accumulations conveyed to the RotoClone impeller, and check all drains for

blockage.

10.1 Start-up checklist TO START RotoClone:

1. Open valve in water supply line (unless automatically controlled).

2. Start RotoClone motor.

TO STOP RotoClone:

1. Stop RotoClone motor.

2. Close valve in water supply line (unless automatically controlled).

CAUTION: Pressure in water supply line to spray nozzles must be maintained at 40 lb. per square inch (psi) or higher during RotoClone

operation.

Do not permit paper, waste, or similar large pieces of material to be thrown into suction hoods because they will plug the RotoClone and cause water and dust

to escape through the clean air discharge or will plug drains, allowing water to build up and damage the impeller.

34 RotoClone® W


11 MAINTENANCE 11.1 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.

11.2 Lubrication

Flush and refill pillow block bearings on RotoClone shaft per attached schedule. Using amounts listed below. #2 S.R.I. type grease is recommended.

For 2 piece split bearings, 12 hours/day, 5 days/week operation, the

bearings should be lubricated every 6 months, as follows (Note: this type of bearing should not be over greased).

Table 5. Bearing Lubrication

RotoClone Size 8 10 12 14 16 20 24 27 30 33 36

Oz. of grease per Bearing 2 2 3 4 10 10 16 22 28 32 36

For single piece bearings, the following minimum schedule should be

followed for 12 hours/day, 5 days/week operations. This type of bearing can be greased until old grease is forced out of seals.

Table 6. Shaft Seal Lubrication Interval

35 RotoClone® W


Lubrication Interval

RotoClone

Size

Cu. In.

Grease

6mos 4mos 2mos

Max Operating Speed

(RPM)

8 0.3 2400 3600 5000

10 0.3 2400 3600

12 0.4 2000 3000

14 0.8 1700 2500

16 0.8 1450 2200

20 0.8 1450 2200

24 1.2 1300 1900

27 1.7 1200 1800

30 2.3 1100

33 3.1 1000

36 3.1 1000

45 4.3 900

Grease shaft seal at same time as bearings. Water leakage is an indication of insufficient grease. 11.3 Nozzles and Strainer

Flush out strainer periodically and inspect spray nozzles for proper water

delivery and pattern. Since water quality varies, a monthly inspection, for the first

year of operation is recommended, in order to determine a maintenance schedule.

On a Food Quality RotoClone W, special attention should be paid to the spray nozzles and areas where there are quick opening access doors. These areas often

require more frequent cleaning. It is recommended that a preventative maintenance schedule be developed specific to each W RotoClone.

11.4 RotoClone Inlet (Arr. A)

Open inspection door at RotoClone inlet connection and remove any accumulation in the inlet at the border line of the wet and dry section. The

frequency of cleaning varies for each installation and must be determined by frequent inspection when RotoClone is first placed in service. Clean out before

accumulation obstructs one-tenth of cross section area or inlet connection. Clean sludge from RotoClone inlet door before closing.

36 RotoClone® W


11.5 Pre-cleaner Inlet (Arr. D) Under certain operating conditions, a deposit of dust will occur at the border

line of the dry and wet zones in the pre-cleaner inlet. The removal of this deposit must become a part of regular maintenance. The frequency of removal can be

established only by periodic inspections when the RotoClone is first put in operation. The deposit should never be allowed to obstruct more than one quarter

of the area of the pre-cleaner inlet.

A door is provided at the pre-cleaner inlet to remove this accumulation. Be sure spray nozzle is not damaged or clogged and that nozzle orifice is vertical.

Gasket seal should be cleaned before closing inlet door. 11.6 RotoClone Impeller

Inspect the RotoClone impeller periodically for accumulations of foreign

material or obstructions in blade hooks. The blade hooks formed by the leading edge of the impeller blades convey the collected dust and water out of the

airstream. A buildup of dust within these hooks may be sufficient to cause pronounced vibration or dust and water entrainment. Such accumulations should

be removed either by flushing with high velocity water jet or scraping with long screw driver through access door in back of RotoClone housing and from front side

of impeller.

Flat spray of flushing nozzle located at impeller (7 o’clock position, viewed

from the inlet) should be parallel to blade edges. Check this spray with water on periodically to ensure proper positioning and spray pattern.

Certain accumulations in RotoClone impeller cause no difficulty and can be

disregarded. They include minor deposits on back of impeller blades, slight coating or small deposits on front side of blades, and slight deposits in blade hooks that do

not obstruct flow of dust and water.

11.7 Drains

Keep all drains clean. If necessary flush out periodically. A plugged drain can

cause damage to the impeller. Inspect grating in bottom of the Arr. D RotoClone hopper periodically and remove any accumulation.

37 RotoClone® W


11.8 Emergency Overflow (Arr. D only)

An emergency overflow is provided on side of hopper to drain off the water in case hopper drain pipe becomes clogged. This stoppage must be cleared

immediately.

11.9 Shaft Seal Other than routine greasing of the shaft seal (see 11.2 Lubrication), the

shaft seal requires no maintenance. Should the seal fail, replacement of the two seals as shown in Figure 6 may be necessary. Since the seals are “split”, it is

usually not necessary to remove anything, other than the seals, from the shaft itself, unless damage to the seal housing or metal spacer (located between the

two seals) is evident. On the smaller RotoClone, it may be necessary to loosen the bearing closest to the seal and move it back about 6 inches, to gain clearance to

remove the seal housing. Be certain that the position of the shaft in relation to the RotoClone is not changed in any direction when doing this.

1. Remove the seal housing by removing the nuts securing it to the scroll, and slide the housing back, exposing the seals and spacer. Discard old

seals.

2. Inspect the shaft and seal housing to ensure that they are clean and smooth. Remove any rust buildup with emery cloth or steel wool. Inspect

metal spacer; replace if necessary (this will require removing bearings to slip spacer off the shaft and install new spacer. Be sure to reposition impeller per

Figure 7, before tightening bearings back in place).

3. Place a small amount of silicone sealant between the radial cut on each seal.

4. Install the new seals on either side of the spacer with the radial cut at

the top and the garter springs circling the inner lip of each seal.

5. Ensure that the radial cut in the metal spacer is located directly below

the grease fitting in the seal housing to allow grease flow.

6. Install the seal housing and tighten the nuts.

7. Lubricate the seal thoroughly with No. 2 grease.

38 RotoClone® W


8. Replace any bearings, if removed, in original position and check

impeller clearance per Figure 7 before tightening bearings onto shaft.

Figure 6. Construction details of the RotoClone W shaft Assembly

11.10 Replacement of Shaft, Impeller or Water Cone Removal of the shaft, impeller, or water cone requires access to the front of

the scroll. This is most easily accomplished by removing the inlet piece and scroll inlet cone. The water piping should be disconnected before removing the inlet

sections. The water cone should be marked to indicate the bolt hole locations in relation to the scroll, before removal. The old water cone can be used to match

mark the replacement water cone, which comes undrilled. Note the distance from the back of the impeller to the scroll before removing the impeller. The impeller is

fastened to the shaft by a taper lock hub.

It is easiest to remove the impeller from the shaft by using a wheel puller,

after unbolting the hub; or one can reinsert the hub screws into the unused holes in the hub to “push” the shaft off of the hub. However, on units that have been in

service for years, this method may not provide the necessary force to “break” the hub away from the shaft, and the wheel puller will be necessary. Finally, the

bearings and driven sheave are taken off and the shaft can be removed.

Reinstallation is the reverse of removal. The shaft is replaced and the bearings and driven sheave tightened back onto it. New set screws should be

used, when single piece bearings are supplied, as the old ones will most likely have blunted ends that can no longer adequately secure the collar to the shaft. Be

39 RotoClone® W


sure to tighten the set screws to the proper torque as recommended by the

bearing supplier (or contact AAF for recommendation). The impeller is reattached to the shaft, but the taper lock hub screws are not tightened yet. All old gasket

material should be removed from the scroll and water cone. A new water cone gasket should be cemented to the water cone. The water cone is then reattached

to the scroll using the match marks to orient it in the same position as the original. The impeller is then checked for proper distance from the water cone edge using

Figure 7 and the Table 7.

The taper lock hub screws are tightened after confirming the proper position of the impeller. Note that the impeller may shift as the hub is tightened onto the

shaft; the impeller position should be checked while tightening the hub and repositioned as necessary. A wooden block and hammer can be used to “tap” the

impeller back if required. Recheck the impeller position and rotate the impeller to insure that it turns freely, once the impeller is locked onto the shaft. The inlet

pieces and piping can then be reattached. A waterproof caulking/gasket is used

between the inlet flanges; remove any old material before reinstalling, and be sure to encircle bolt holes with caulk, or leaks may result.

Figure 7. Field Replacement of RotoClone W Impeller

40 RotoClone® W


Table 7: Distance of Impeller from Water Cone

RotoClone

Size C = Cap Screws

F= Impeller

Clearance

8 3/8 - 16 x 1 5/16 - 7/16

10 3/8 - 16 x 1 7/16 - 9/16

12 3/4 - 10 x 1 9/16 - 11/16

14 3/4 - 10 x 1 9/16 - 11/17

16 3/4 - 10 x 1 5/8 - 7/8

20 3/4 - 10 x 1 13/16 - 1 1/16

24 3/4 - 10 x 1 1 1/8 - 1 3/8

27 3/4 - 10 x 1 1 1/8 - 1 3/8

30 5/8 - 10 x 1 1 5/16 - 1 11/16

33 3/4 - 10 x 1 1 5/16 - 1 11/16

36 3/4 - 10 x 1 1 5/8 - 1 15/16

45 3/4 - 10 x 2 3/4 2 - 2 1/2

41 RotoClone® W


12 TROUBLESHOOTING 12.1 Water Entrainment

Issue: Excessive discharge of water in the exhaust may be due to the following:

Fix:

Incorrect rotation (correct rotation is counter-clockwise, when

viewed form the drive end).

Incorrect size cone spray or auxiliary nozzles and incorrect spray pattern (i.e. flat spray at 7 o’clock position viewed from the inlet and

parallel to blades and cone spray to be centered at wheel).

Inlet spray should just miss inlet perimeter as it passes into the scroll.

Disturbances at inlet, such as elbows or branch entries, causing

unbalanced airflow or dust loading (see Section 2.3).

Bent blade tips and/or obstructions in impeller such as rags, collected material buildup, etc.

• Pluggage of drains.

Incorrect outlet piece location. The bottom of the outlet piece should never be above the bottom of the RotoClone® scroll. Any gasketing

that has squeezed out should be removed.

Improper gasketing of water cone, or damage/wear of the water cone.

• Incorrect water pressure.

42 RotoClone® W


12.2 Dust Entrainment

Issue: Excessive entrainment of dust with the cleaned air may be due to the following:

Fix:

• Equipment running dry or with insufficient water – because of clogged spray nozzles or strainer, or low water pressure, (40 lb.

minimum pressure required at nozzles).

• Obstructions in impeller blade hooks.

• On Arrangement D, spray nozzle in pre-cleaner turned. Flat spray must discharge in a vertical plane.

• Dust loading too heavy.

• Particulate size too small to be captured.

• Disturbances at inlet, such as elbows or branch entries, causing unbalanced airflow or dust loading (see Section 9.2.7).

12.3 Start/Stop Issues

Issue: Water pressure or flow insufficient to actuate flow switch/switches. Fix:

• Supply water pressure less than 40 psi

• Nozzles plugged

• Strainer plugged

• Water usage elsewhere causes momentary interruption in flow to

RotoClone

• Solenoid valve malfunctioning

Issue: Flow switch wired incorrectly

Fix:

• See Note under 9.2.6.7

43 RotoClone® W


Issue: Motor amperage exceeds nameplate full load amps

Fix: • Impeller turning backward

• Airflow or static pressure change in ductwork

• Drains plugged

• Motor and RotoClone sheaves reversed

13 RECOMMENDED SPARE PARTS When ordering Replacement Parts, customer must state Serial Number and

Size of RotoClone, Part Name (when shown on drawing) and Item Number.

44 RotoClone® W


45 RotoClone® W


RotoClone W Parts List:

1. Expansion Chamber Assembly

2. Impeller Shaft

3. Bearing, Shown on 4. Water Cone Assembly

5. Inlet Cone Assembly 6. Impeller Assembly

7. Inlet Connection 8. Cone Spray Nozzle

9. Piping Assembly 10. Monarch Figure 624 Nozzle

11. Housing Assembly

12. Outlet Connection

13. Impeller Hub 14. Hex. Head Cap Screws

15. Impeller Hub Cap 16. Taper Lock Bushing

17. Key 18. Seal Housing Assembly

19. Shaft Seal 2 20. Spacer

1. Standard RotoClone, sizes 16 and smaller, may have inlet, outlet, and

expansion chamber welded to housing in lieu of flanged and bolted connection.

2. Seal consists of two Buna-N pieces and two garter springs. Radial cuts

should be sealed with silicon caulk when installing new seal.

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-

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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]

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]

AAF International – Middle EastFZS1BC01-BC04, Jebel Ali Dubai, UAETel: 009714 8894886Email: [email protected]

AAF Saudi Arabia Ltd.P.O. Box 59336 Riyadh 11525,Kingdom of Saudi ArabiaTel: +966 1 265 0883Email: [email protected]

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]

AAF (Wuhan) Co. Ltd., (China HQ)268 CheCheng 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]

Daikin Australia Pty Ltd(AAF Australia & New Zealand Sales Office)15 Nyadale Road Scoresby Victoria 3179,AustraliaTel: +61 (0)3 9237 5562Email: [email protected]

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]

AAF, S de RL de CVAv. Primero de Mayo No. 85,Col. San Andrés Atenco,C.P. 54040 Tialnepantla Edo. De Mexico, MéxicoTel: +52 55 5565 5200Email: [email protected]

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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