AAF RotoClone W, Installation, Operation And Maintenance Manual

Page 1: ...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 OPERATION AND MAINTENANCE MANUAL RotoClone W ...

Page 2: ...toClone 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 APCSales AAFINTL com Parts Sales Power Industrial AAF International 9920 Corporate Campus Drive Suite 2200 Louisville KY 40223 5000 USA Internet http www AAFParts com ...

Page 3: ...s 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 RECEIP...

Page 4: ...ture 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 Impe...

Page 5: ...med 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 ma...

Page 6: ...et 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...

Page 7: ...renced 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 t...

Page 8: ...les 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...

Page 9: ... 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 eve...

Page 10: ...hanical 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 nuisan...

Page 11: ... 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 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 ...

Page 12: ...arks of American Air Filter Company Inc d b a AAF International 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 pr...

Page 13: ...d 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 00...

Page 14: ...erating 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 ...

Page 15: ...dard 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 shi...

Page 16: ...rotected 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 destina...

Page 17: ...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 immediatel...

Page 18: ...een 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 spread...

Page 19: ...hland 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 pl...

Page 20: ...ge 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 ...

Page 21: ...ing 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 is...

Page 22: ...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...

Page 23: ...s 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 clea...

Page 24: ...stered trademarks of American Air Filter Company Inc d b a AAF International 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 bear...

Page 25: ...ally 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...

Page 26: ...nnect 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 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 ...

Page 27: ...ctwork 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 ...

Page 28: ...re 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 ...

Page 29: ...xhaust 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 connect...

Page 30: ... is a FPT on the valve 9 2 6 11Water 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 ...

Page 31: ... 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 Re...

Page 32: ...er 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 ...

Page 33: ...ion 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 RotoC...

Page 34: ...spections 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 RotoC...

Page 35: ...ically 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 ...

Page 36: ... 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 velo...

Page 37: ... 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 sh...

Page 38: ...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 ...

Page 39: ...croll 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 tighte...

Page 40: ...ks of American Air Filter Company Inc d b a AAF International 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...

Page 41: ...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 obs...

Page 42: ...rainer 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 S...

Page 43: ...urable are registered trademarks of American Air Filter Company Inc d b a AAF International 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 w...

Page 44: ... 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 ...

Page 45: ... 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 an...

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