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AAF INTERNATIONAL
INSTALLATION, OPERATION
AND MAINTENANCE MANUAL
RotoClone N
TO ORDER SPARE & REPLACEMENT PARTS
Parts Sales
Power & Industrial
AAF International
9920 Corporate Campus Drive
Suite 2200
Louisville, KY 40223-5000
USA
Internet: http://www.AAFParts.com
2015 American Air Filter Company, Inc. Any use of the text or images
this document contains, without permission of American Air Filter
Company, Inc., is prohibited. RotoClone, AAF, REDClean, REDFiltration,
and Reliable Efficient Durable are registered trademarks of American Air
Filter Company, Inc. d/b/a AAF International.
2 RotoClone N
TABLE OF CONTENTS
1 INTRODUCTION ........................................................................................................................... 6
2 SAFETY .............................................................................................................................................. 6
2.1 Safety statement ................................................................................................................. 6
2.2 Safe working practices and staff training ............................................................ 6
2.3 Dust explosion hazard ...................................................................................................... 7
2.3.1 NFPA 654 and referenced codes and standards .......................................................................... 8
2.3.2 NFPA 484, Light Metals .................................................................................................................................... 8
2.3.3 Other requirements ............................................................................................................................................ 9
2.4 Electrical hazards ................................................................................................................ 9
2.5 Rotating equipment ........................................................................................................... 9
2.6 Safety guards ...................................................................................................................... 10
3 GENERAL PRODUCT INFORMATION .............................................................................. 10
3.1 Description ............................................................................................................................ 10
3.2 Purpose and intended use ........................................................................................... 11
3.2.1 Collection of explosive dusts ..................................................................................................................... 11
3.2.2 Collection of other dry dusts ..................................................................................................................... 11
3.2.3 Collection of damp, wet, oily or sticky dusts ................................................................................ 12
3.3 Normal Operation.............................................................................................................. 12
3.4 Sizes and Arrangements ............................................................................................... 14
3.4.1 Manual Sludge Removal (Arr. B) ........................................................................................................... 15
3.4.2 Sludge Ejector (Arr. C) .................................................................................................................................. 15
3.4.3 Continuous Sluicing (Arr. D) ..................................................................................................................... 15
3.5 Filter elements .................................................................................................................... 16
3.6 Weights ................................................................................................................................... 16
4 PRODUCT SHIPMENT .............................................................................................................. 19
4.1 How the product ships ................................................................................................... 19
4.2 Items that ship separately .......................................................................................... 19
5 PRODUCT RECEIPT AT THE DESIGNATED DELIVERY POINT .......................... 19
5.1 Responsibilities of the customer or customers agent ............................... 19
5.2 Receiving ................................................................................................................................ 20
5.3 Inspection on arrival ....................................................................................................... 20
5.4 Damaged goods .................................................................................................................. 20
5.5 Missing goods ...................................................................................................................... 20
6 UNLOADING AND HANDLING ............................................................................................ 20
6.1 Unloading ............................................................................................................................... 20
6.2 Handling.................................................................................................................................. 21
6.3 Rigging and hoisting instructions ........................................................................... 21
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.
3 RotoClone N
7 STORAGE AND PROTECTION.............................................................................................. 22
8 SITE PREPARATION ................................................................................................................ 23
8.1 Locating equipment ......................................................................................................... 23
8.2 Foundations and anchor bolts ................................................................................... 23
9 ASSEMBLY AND INSTALLATION ...................................................................................... 24
9.1 Introduction ......................................................................................................................... 24
9.2 Assembling and installing the structure ............................................................. 24
9.2.1 Shipping Arrangements ................................................................................................................................. 24
9.2.2 Foundation Installation and Levelling ................................................................................................ 25
9.2.3 Field Fan Connection ....................................................................................................................................... 25
9.2.4 Chevron Mist Eliminator Installation (Sizes 1-12 through 6 Only) ........................... 26
9.2.5 Assembly of RotoClone N Sizes 8 through 48 ............................................................................. 28
9.2.6 Assembly of Sizes 16 through 48 Hopper and Collecting Sections............................. 28
9.2.7 Lubrication ............................................................................................................................................................... 28
9.2.8 Electrical connections ...................................................................................................................................... 29
9.2.9 Water supply connections............................................................................................................................ 30
9.2.10 Drain Connection for RotoClone N Arrangement B ............................................................. 32
9.2.11 Drain Connection for RotoClone N Arrangement C ............................................................. 32
9.2.12 Drain Connection for RotoClone N Arrangement D ............................................................ 32
9.2.13 Fan Drain.............................................................................................................................................................. 35
9.2.14 Ductwork Installation ................................................................................................................................. 36
10 WATER LEVEL CONTROL OPTIONS................................................................................. 36
10.1 RotoClone N Arrangements B and C Water Level Controls ...................... 37
10.1.1 Model SV Control ....................................................................................................................................... 37
10.1.2 Model SV Control with Low Water Safety .............................................................................. 37
10.1.3 Model A Control .......................................................................................................................................... 38
10.2 RotoClone N Arrangement D Water Level Controls ...................................... 39
10.2.1 Model SV-HV Control .............................................................................................................................. 39
10.2.2 Model SV-HV Control with Low Water Safety ..................................................................... 40
10.3 Flow Control Valve ........................................................................................................... 40
11 START-UP & OPERATION ..................................................................................................... 45
11.1 To Fill the RotoClone N .................................................................................................. 45
11.2 To Start RotoClone N Arrangement B ................................................................... 47
11.3 To Start RotoClone N Arrangement C ................................................................... 47
11.4 To Start RotoClone N Arrangement D ................................................................... 47
11.5 To Stop RotoClone N Arrangement B .................................................................... 47
11.6 To Stop RotoClone N Arrangement C .................................................................... 47
11.7 To Stop RotoClone N Arrangement D .................................................................... 48
12 MAINTENANCE ........................................................................................................................... 48
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.
4 RotoClone N
12.1 Record Keeping .................................................................................................................. 48
12.2 Water Level Control Box ............................................................................................... 48
12.3 Eliminator Plates ............................................................................................................... 49
12.4 RotoClone Housing ........................................................................................................... 49
12.5 Metering Drain Orifice (Arr. D) ................................................................................. 49
12.6 Sludge Ejector (Arr. C)................................................................................................... 49
12.7 Lubrication ............................................................................................................................ 50
12.8 Fan ............................................................................................................................................. 51
12.9 Replacement Part Stock ................................................................................................ 51
12.10 Sludge Collector (Arr. C) ..................................................................................... 51
13 TROUBLESHOOTING................................................................................................................ 51
13.1 Reduction in airflow at exhaust hoods ................................................................ 51
13.2 Reduced dust collection efficiency ......................................................................... 52
13.3 Water entrainment in fan discharge...................................................................... 53
14 RECOMMENDED SPARE PARTS LIST .............................................................................. 53
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.
5 RotoClone N
1 INTRODUCTION
This document contains the information necessary to properly receive,
assemble, install, operate, and maintain the AAF RotoClone N filter system. The
purchaser, installer, and operator of the filter system MUST read and comply with
this document in its entirety prior to installation of the equipment and its
operation. Failure to comply with the requirements of this manual may void
the product warranty. The information and guidelines contained in this manual
are not exhaustive, and additional or alternative precautions, measures, training,
etc. may be needed depending on the specific circumstances.
CAUTION
These instructions are specific to the AAF RotoClone N filter system. All
ancillary tasks including, but not limited to, electrical and mechanical work,
equipment handling, and safety procedures must be performed in
accordance with industry accepted practice and all relevant local, state, and
federal government codes, laws, and policies.
2 SAFETY
2.1 Safety statement
The air cleaning equipment supplied by AAF International ranges from very
large multiple-component assemblies which require significant and complex,
rigging, handling and assembly on-site, to small compact assemblies that are
easily handled and maneuvered. In addition to size, many of the dust collectors
will require electrical connections, compressed air connections, and will feature
high speed rotating equipment.
At all times, when dealing with industrial equipment such as dust collection
equipment personnel safety must be the highest priority of all involved, from
riggers, installers, operators, users, and maintenance personnel. Those
responsible on-site shall review the details of the equipment beforehand and
develop a plan for dealing with all stages of the installation from receipt of the
equipment on-site to start-up, commissioning, and hand-over. All applicable
health, safety, and environmental (HSE) rules, regulations and legislation shall
be fully complied with at all times.
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.
6 RotoClone N
All personnel shall receive safety training specific to the site, the task, and
the conditions under which the work will be conducted.
All personnel 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.
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.
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.
7 RotoClone N
Except as otherwise expressly provided in writing, AAF makes no
representation or warranty in connection with explosion hazard equipment,
including, but not limited to, the necessity or effectiveness of explosion hazard
equipment or to the design, installation, operation, and performance of such
equipment.
The basic standards for dealing with explosive dust applications are
published by the National Fire Protection Agency (NFPA). The user shall be fully
conversant with the provisions of the particular codes and standards that apply to
the specific application and equipment used, and shall comply in full with all of the
requirements of the applicable codes and standards.
Note that NFPA 654 does not apply to the specific applications or materials
covered by the other NFPA documents unless specifically referenced by those
documents.
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.
8 RotoClone N
use of all metals and alloys that are in the form that is capable of combustion or
explosion1. When the RotoClone N is used to collect dust from the working of light
metals, the user shall be fully conversant with the provisions of NFPA 484 and
shall comply in full with all of its requirements.
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.
1 Ref: NFPA 484: Standard for Combustible Metals, 2015 Edition, Paragraph 1.1, Page 484-8
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.
9 RotoClone N
injury. The fan impeller can be accessed through the collector from inside the
cabinet if the moisture eliminator is removed, from the outside of the collector
through the collector discharge, or from the connecting inlet or outlet ductwork. All
due care should be exercised to avoid any contact with the operating fan. Under
no circumstances should the fan ever be allowed to operate when any of the
access panels on the dust collector, silencer, or connecting ductwork have been
removed. The fan must be disconnected and locked out prior to the performance
of any maintenance work, see paragraph 2.4.
After electrical power is disconnected the fan impeller will continue to rotate
for a period of time before coasting to a stop. Do not access the fan until the fan
wheel has come to a complete stop.
The RotoClone N is, for the most part, a factory assembled, fully self-
contained dust collector except that the top-mounted fan ships separately for
installation on-site.
The dust generated by the particular operation for which the RotoClone N is
employed is drawn into the collector through the inlet ductwork, into a water bath,
and then through AAFs unique static impeller which through a combination of
induced aerodynamic and hydrostatic forces causes the dust to mix thoroughly
with the water and separate from the air. The cleaned air is then emitted from the
dust collector through the fan and the separated dust settles to the bottom of the
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.
10 RotoClone N
water bath. The dust forms a sludge which is then periodically removed from the
collector.
The RotoClone N can only be operated when it is filled with water to the
correct level. A low water level would result in by-pass of unfiltered air. Automatic
cut-out devices prevent operation of the fan if the water level is too low.
It bears repeating here that the use of a dust collector for the collection of
explosive dust is only one part of a safe dust prevention and mitigation program.
Dust shall not be allowed to accumulate or build up on the surfaces of the dust
collector, on the air intakes or in the surrounding area. The owners attention is
directed particularly to the Housekeeping chapter in NFPA 484 (Chapter 7 in the
2015 edition) and in NFPA 654 (Chapter 8 in the 2013 edition).
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.
11 RotoClone N
3.2.3 Collection of damp, wet, oily or sticky dusts
The RotoClone N is an effective collector of dusts that are difficult or even
impossible for other collectors, particularly dry collectors such as cartridge and bag
collectors, to collect. Damp, wet, sticky or oily dusts can clog the pores of paper
and fabric media. In pulse clean or shaker style self-cleaning dust collectors, these
dusts will not release from the cartridges or bags, causing the dust collector to
clog and quickly fail.
The water in the reservoir is continually reused and since the water curtain
is produced by the air flow, no pumps or nozzles are required. The water level is
maintained by the overflow weir in the control box as long as a small amount of
fresh water is supplied through the make-up water connection or by electrical
controls that automatically add water, as needed to compensate for evaporation
and water lost as the collected dust is removed from the unit.
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.
12 RotoClone N
The RotoClone N has the ability to operate at a flange to flange differential
pressure from 5.0 to 12.0 w.g. This allows for operation of the unit at the exact
differential pressure and efficiency required for each application. The differential
pressure of this unit is determined by two parameters: airflow rate and water flow
rate through the impeller. The RotoClone N has a certain standing water level
within the unit determined by an overflow weir within the water level control box.
It is possible to increase the water flow rate through the stationary impeller by
simply raising the water level within the unit. That is, raise the weir height within
the control box. This will result in a higher differential pressure and efficiency for a
given flow rate.
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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.
13 RotoClone N
Figure 2. Operating Lines for Given Airflows
Notes:
1. Figure 2, the pressure drop chart, shows the total pressure losses through the
RotoClone N in relation to the flow rate through the impeller for a given operating
line. The RotoClone N must operate on one of the operating lines shown.
2. The total pressure losses are measured by subtracting the static pressure at the
collector outlet flange from the static pressure at the inlet flange.
The 100% nominal flow level is equal to 1,000 acfm per foot of impeller.
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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.
14 RotoClone N
There are three different arrangements: Arrangement B (Flat Bottom Manual
Sludge Removal), Arrangement C (Automatic Sludge Removal with Conveyor), and
Arrangement D (Continuous Sluicing with Bottom Drain).
In units with a single impeller, one side of the reservoir is sloped to facilitate
removal of the collected material. With the double impeller units, it is usually
necessary to drain the reservoir for sludge removal. Access door location and
interior headroom is provided to facilitate shoveling collected material to a tote
box or sludge chute.
Steep sides in the hopper minimize material build-up, while the sludge
ejector mechanism provides easy removal of collected material. The ejector
assembly is designed for heavy-duty service and driven by a small geared motor.
The chain and sprockets of the ejector are fabricated from wear-resistant alloys. A
slow chain speed, approximately two feet per minute, combined with a long steep
ejector chute assures effective dewatering of the solid material as it is ejected.
Scrubbing water is conserved and make-up water is reduced.
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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.
15 RotoClone N
To maintain the scrubbing water at the proper operating level, a constant
supply of make-up water and drainage is required.
3.6 Weights
Table 1. RotoClone N, Arr. B Shipping and Operating Weights
Erecting Weight
Maximum Normal Water
Size Operating Operating Wt. Capacity RotoClone Exhauster
Wt. (lbs) (lbs) (Gallons) Only Only
1.5 2600 2200 90 1300 300
2.5 2800 2400 90 1300 750
4 4200 3700 140 1800 900
6 5900 4800 220 2400 1500
8 8200 6700 295 3400 2000
12 11200 9000 440 4000 2900
16 14000 11500 510 5000 3450
20 17900 14200 730 5900 4200
24 21900 17500 880 6800 4220
28 24900 19800 1025 7900 6020
32 NA NA NA NA NA
36 NA NA NA NA NA
40 NA NA NA NA NA
44 NA NA NA NA NA
48 NA NA NA NA NA
1. Weight based on maximum sludge capacity with a sludge weight of 100 pounds per
cubic foot.
2. Weight based on weight of water of 62.4 pounds per cubic foot.
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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.
16 RotoClone N
Table 2. RotoClone N, Arr. C Shipping and Operating Weights
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.
17 RotoClone N
Table 3. RotoClone N, Arr. D Shipping and Operating Weights
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.
18 RotoClone N
4 PRODUCT SHIPMENT
4.1 How the product ships
RotoClone N sizes 1.5 through 6, units are shipped fully assembled.
RotoClone N sizes 8 through 48 are shipped with the transition, motor, and
exhauster disassembled from the RotoClone.
RotoClone N sizes 1.5 through 6, are normally shipped by single drop or LTL.
RotoClone N sizes 8 through 48, are normally shipped by a double drop or by a
specialized hauler.
When shipment is in major subassemblies, the gasket for the flange between
the RotoClone and clean air transition outlet and fan are packed in a box with the
necessary bolts. The nominal 5/8 gap between the transition piece outlet and fan
inlet should be sealed with the three inch sealing tape which is also included in the
box of bolts.
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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.
19 RotoClone N
5.2 Receiving
Remove crates, tarps, shipping straps, etc. along with any loose items or
equipment before unloading the AAF RotoClone N.
20 RotoClone N
Connect lifting sling to at least four cabinet lifting lugs, if possible,
distributing the load evenly.
Check the drawings of the specific RotoClone N ordered for dimensions and
weights to ensure proper lifting and installation equipment.
All lifting operations must be made in compliance with the relevant HSE
legislation.
6.2 Handling
Only personnel experienced in handling equipment shall be employed for this
task.
The RotoClone N also has lifting lugs mounted on the top. These may be
used to hoist the product instead of lifting it using the shipping pallet. All lifting
lugs must be used when hoisting the product. When using the top mounted lifting
lugs use spreader bars at all times. Position the spreader bars so that the force
applied to each lifting lug is vertical and not angled. Also make sure that lifting
straps or cables do not come into contact with any other part of the product to
prevent the possibility of damage from abrasion. Before hoisting make sure that
the load is properly balanced. At the beginning of the lift, hoist the product slowly
and carefully.
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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.
21 RotoClone N
7 STORAGE AND PROTECTION
If not installed immediately, the equipment shall be retained and stored in a
protective environment until immediately prior to installation. This environment
shall be clean, dry, and temperature and humidity-controlled.
At all times the equipment shall be protected from exposure to weather and
from standing water.
Block all openings to prevent rodents and small animals from nesting
inside.
Insert silica gel desiccant in control boxes and motor junction boxes.
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.
22 RotoClone N
If the unit has been in use and prolonged storage is anticipated, the unit
shall be cleaned on the inside and outside of dust and water to prevent damage to
the interior and exterior of the collector.
8 SITE PREPARATION
8.1 Locating equipment
When locating the RotoClone N, the design engineer shall consider the many
factors associated with site selection including, but not limited to, seismic design
category and site class, flood design data, design load bearing value of soils,
serviceability, risk category, and load combinations, including dead loads, live
loads, snow loads, wind loads, and earthquake loads. Such factors and values are
typically defined by the building codes and standards imposed by the local
authority with jurisdiction for buildings and structures.
Provide adequate clear space around the RotoClone N for access and
maintenance.
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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.
23 RotoClone N
for the Arrangement D must be designed to accommodate this drain. See section
9.2.7 for further details.
AAF recommends that the ductwork going into the collector be as straight as
possible, with at least 5 diameters of straight run recommended.
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.
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.
24 RotoClone N
Chevron mist eliminator bundles ship loose for installation at the
jobsite
RotoClone N Sizes 16 thru 48 may be shipped with the collecting section and
hopper section disconnected.
Place a spirit level on the leveling strips welded on two or more sides of the
hopper. The RotoClone N must be accurately levelled in both orthogonal
directions (along axes 90 degrees apart).
Fill the RotoClone N with water until the level reaches the entering edge of
the impeller (Figure 1). On RotoClone N with double impellers (sizes 8 and
above) this will apply to both impellers simultaneously. The entering edge of
each impeller must be level with the water along its entire length with a
maximum allowable variation of plus or minus 18 of an inch. On RotoClone
N with single impellers (sizes 6 and below), the RotoClone will still need to
be leveled in the other direction.
When the RotoClone N has been properly levelled, fix the equipment in
position using shims and anchor bolts and then grout beneath the structural
support elements to ensure that the equipment is fully supported.
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.
25 RotoClone N
the 58 inch nominal gap between the clean air transition and the exhauster inlet.
The tape is packed in a separate box with other loose components.
b. Tilt the top of the eliminator forward until it rests on housing above
the door opening using a lever.
c. Lift the bottom of the eliminator over the lip of the impeller plate.
f. After all eliminators have been installed, slide all of them to the side
opposite the blank-off baffle.
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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.
26 RotoClone N
As a guide, the correctly installed location of the eliminator sections is
painted on the inside surface of the RotoClone N wall. Confirm that the installation
of the eliminators coincides with these markings.
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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.
27 RotoClone N
9.2.5 Assembly of RotoClone N Sizes 8 through 48
As previously noted (see 9.2.3), the clean air transition supplied for
RotoClone N sizes 8 thru 48 ships separately for installation at the jobsite. The
gasket material for sealing the flange between the RotoClone base section and the
clean air transition section is packed in a separate box with other loose
components.
c. Lower the cleaning section carefully onto the flange of the hopper
section, watching for interference between intermediate sheets and
impellers. The walls of the interior center section, formed by the two
intermediate sheets, must be inside the impeller bolting surface. Set the
cleaning section in place so that its bolting flange matches the hopper
flange.
d. Bolt the outside flanges of the cleaning section and hopper section.
9.2.7 Lubrication
All bearings are ball bearings and were packed with grease before leaving
the factory. Do not add more grease during installation.
The gear reducer on the sludge ejector drive (supplied with the RotoClone
Arrangement C only) was filled with oil before shipment. Check for proper oil level.
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.
28 RotoClone N
NOTE: To prevent loss of oil while units are in transport, the
reducers are shipped with a brass pin in vent or filler plug. This pin must
be removed before the reducer is operated.
The exhauster motor, the exhauster motor starter, the solenoid valve, the
flow switch, and on the RotoClone N Arrangement C only, the sludge ejector motor
and controls. Each electrical connection shall be made in accordance with the
appropriate wiring schematic enclosed with the RotoClone N instruction packet.
Also note the following:
1. Exhauster motor: The motor nameplate will show the connection hook-
up of the motor leads.
2. Exhauster motor starter: The exhauster motor starter may or may not
be supplied by AAF. The AAF Control Center, if ordered, will include the
appropriate motor starter. Otherwise, the motor starter will be engineered,
selected and supplied by others.
3. Sludge ejector motor: A sludge ejector motor is supplied only with the
RotoClone N Arrangement C. It is a fractional horsepower, 230/460/60/3,
TEFC motor. The lead connection diagram will be found either on the motor
nameplate or inside the cover of the motor.
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and Reliable Efficient Durable are registered trademarks of American Air
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29 RotoClone N
operation of the RotoClone until the solenoid water valve is opened. In the
event of a water supply failure, the flow switch contacts open and the
RotoClone shuts down.
CAUTION: Any change made in the water supply rate will usually require
changing the orifice in the drain valve. Select a new orifice by referring to Table 5.
Always supply enough water to provide a small flow over the weir in the control
box plus the drain volume.
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30 RotoClone N
Figure 3. Supply Piping, Arrangement D.
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31 RotoClone N
9.2.10 Drain Connection for RotoClone N Arrangement B
Each time water is drained from the RotoClone, clean the elements after
collected material has been removed from the RotoClone housing. A drain is
supplied with the RotoClone N Arrangement B for draining the water from the
equipment for cleaning and maintenance. The drain valve will remain closed during
normal operation. Connect the 1-1/2 drain line from the RotoClone N
Arrangement B to the customers drain line or sewer at the tee connection
provided on the base of the equipment. The customers drain or sewer line MUST
be equal to or larger in size to the drain from the RotoClone N.
Water flow rates can be obtained from Tables 5a, 5b, and 5c. The standard
orifice size and associated flow rates for the different RotoClone N Arrangement D
sizes are shown in Table 5a. Variations in the drainage rates can be obtained by
referring to Table 5b and selecting a non-standard orifice size. The flow through
the control box can be obtained from Table 5c.
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32 RotoClone N
Figure 4. Typical RotoClone N Design.
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33 RotoClone N
Hoppers per Hopper Drain
RotoClone Orifice Head Control
RotoClone N Volume (Gallons
Size Diameter (feet) Box
Arrangement D per Minute)
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34 RotoClone N
Orifice Area Sq Head in Feet
Diameter In.
3.4 4.4 4.8 5.3 5.4 6.1 6.3 6.4 7.2
Hopper Drain Volume (Gallons per Minute)
1/4" 0.491 1.3 1.5 1.6 1.7 1.7 1.8 1.8 1.8 2.0
3/8" 0.110 3.1 3.5 3.6 3.8 3.8 4.1 4.2 4.2 4.5
1/2" 0.196 5.5 6.3 6.5 6.8 6.9 7.3 7.5 7.5 8.0
5/8" 0.307 8.6 9.8 10.3 10.7 10.9 11.5 11.7 11.8 12.5
3/4" 0.442 12.4 14.1 14.7 15.5 15.6 16.6 16.9 17.0 18.1
7/8" 0.602 16.9 19.2 20.1 21.1 21.3 22.3 23.0 23.2 24.6
1" 0.785 22.0 25.1 26.2 27.5 27.8 29.5 30.0 30.3 32.1
1 1/4" 1.227 34.5 39.2 40.9 42.6 43.4 46.2 46.9 47.3 50.2
1 1/2" 1.767 49.6 56.5 59.0 62.0 62.6 66.5 67.6 68.1 72.3
These Figures are based on Q = CA 2gh
C= 0.61 x 3.12 (Conversion factor for units)
Table 5b. RotoClone N Arrangement D Hopper Drain Volumes for Various Standard
and Non-Standard Orifice Sizes
Control Boxes
Standard High
Height of Flow
Volume Volume
Over Weir
(S) (H)
7.5 GPM 19 GPM
Floods 30 GPM
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35 RotoClone N
pipe from the fan and caulk it to the RotoClone roof to close off the annulus
formed by the drain pipe and hole in the roof of the RotoClone N.
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.
It is critical for the proper operation of the RotoClone N that the correct
operating water level be maintained at all times. For this reason, make-up water
must be supplied to the RotoClone N at all times.
There are three types of water level controls available on the RotoClone N
Arrangements B and C, and two types of water level controls available on the
RotoClone N Arrangement D. Check the product documentation supplied for
information on the type of control provided with the equipment.
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36 RotoClone N
10.1 RotoClone N Arrangements B and C Water Level Controls
10.1.1 Model SV Control
See Figure 5. This is the standard water level control for the RotoClone N. It
prevents operation of the RotoClone when there is insufficient water flow. It also
allows a continuous water flow over the running level weir, down the drain pipe,
and into the overflow. The water level supply system contains a fill valve, solenoid
valve, strainer, flow switch and flow control valve. As long as the solenoid valve
remains open, there will be a constant water flow into the control box.
The air pressure equalizing hose is connected directly to a port in the top of
the control box. This connection permits the air pressure on the clean air side of
the RotoClone N to equal the air pressure in the control box. Consequently, the
water level on the clean air side of the RotoClone N and in the control box will be
the same.
The low water safety control prevents operation of the RotoClone N if the
water level in the equipment is too low.
The electrode and holder are installed in one of the ports on the top of the
control box. This low water safety device is designed to maintain continuous
contact with the water in the control box. If the water level in the control box
drops below the electrode, a 3 minute timer relay activates. The water level must
reach the electrode within 3 minutes or the RotoClone fan will shut down
automatically and the RotoClone operation stops.
As long as the equipment operates, the solenoid remains open. When the
fan stops, the solenoid valve closes and the water flow to the control box stops.
The air pressure equalizing hose is attached to a separate port on the top of
the control box. This keeps the air pressure on the clean air side of the RotoClone
the same as in the control box. This ensures that the water level in the RotoClone
and the control box will be the same.
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and Reliable Efficient Durable are registered trademarks of American Air
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37 RotoClone N
Whenever makeup water is needed in the RotoClone N, water continuously
drains into the equipment through the hose connection in the bottom of the water
level control box.
Similarly to the SV Control, the Model SV Control with Low Water Safety
provides a continuous flow of water over the control box weir.
The water supply system contains a fill valve, strainer, solenoid valve,
electrode, electrode holder, and a timing relay.
The electrode and holder are installed in one of the ports on the top of the
box. This low water safety device is designed to be in continuous contact with the
water in the control box. When the water level drops below the electrode, the
solenoid valve opens to supply the required makeup water to the system. When
the control box water level is again in contact with the electrode, the solenoid
valve closes and stops the flow of makeup water. This prevents water from
continuously overflowing the weir.
If for any reason the water level does not make contact with the electrode
within three (3) minutes, the timer will turn off the RotoClone exhauster and stop
the RotoClone operation.
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38 RotoClone N
Aluminum, magnesium, and titanium oxidize and resulting in a high
hydrogen ion content. A high H content equals a low pH value. A suggestion for
maintaining the pH in the 6.0 to 6.5 range is to add an automatic purge system,
using solenoid valves on both the drain and makeup lines, to allow fresh water into
the system every one to four hours. For each gallon of fresh water added a gallon
of low pH water should be released.
The air pressure equalizing hose is connected directly to a port in the top of
the control box. This connection permits the air pressure on the clean air side of
the RotoClone N to equal the air pressure in the control box. Consequently, the
water level on the clean air side of the RotoClone N and in the control box will be
the same.
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39 RotoClone N
10.2.2 Model SV-HV Control with Low Water Safety
See Figure 8. This control should be used for light metal dusts such as
aluminum, magnesium, and titanium, and other explosive dusts. In addition to the
standard SV-HV control, this control contains an electrode, electrode holder, and
a timing relay. It does not use the flow switch.
The low water safety control prevents operation of the RotoClone N if the
water level in the equipment is too low.
The electrode and holder are installed in one of the ports on the top of the
control box. This low water safety device is designed to maintain continuous
contact with the water in the control box. If the water level in the control box
drops below the electrode, a 3 minute timer relay activates. The water level must
reach the electrode within 3 minutes or the RotoClone fan will shut down
automatically and the RotoClone operation stops.
As long as the equipment operates, the solenoid remains open. When the
fan stops, the solenoid valve closes and the water flow to the control box stops.
The air pressure equalizing hose is attached to a separate port on the top of
the control box. This keeps the air pressure on the clean air side of the RotoClone
the same as in the control box. This ensures that the water level in the RotoClone
and the control box will be the same.
Similarly to the SV-HV Control the Model SV-HV Control with Low Water
Safety provides a continuous flow of water over the control box weir.
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40 RotoClone N
Figure 5. Model SV Water Level Control
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41 RotoClone N
Figure 6. Model SV Water Level Control with Low Water Safety Control or
Model A Water Level Control
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42 RotoClone N
Figure 7. Model SV-HV Water Level Control
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43 RotoClone N
Figure 8. Model SV-HV Water Level Control with Low Water Safety Control
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44 RotoClone N
11 START-UP & OPERATION
11.1 To Fill the RotoClone N
Be certain the drain valve in the RotoClone hopper is closed.
Open the Fill Valve and add water until it reaches a point 2 inches below the
running level weir in the water level control box. This level is marked on the
outside of the control box.
1. First bring water level to the entering edge of the impeller, see Figure 1,
and check that the RotoClone was properly leveled during erection.
2. Pour one gallon of water down the control box drain pipe to make an air
seal at the bottom of the pipe. See Figure 7.
Close and tighten control box cover. It must be air tight or an incorrect
water level in the RotoClone N will result.
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45 RotoClone N
Figure 7. Cutaway view of standard Water Level Control SV.
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46 RotoClone N
11.2 To Start RotoClone N Arrangement B
Check the control box cover and be certain it is tight.
Press start button for the RotoClone exhauster. Solenoid valve in the water
supply line should be interlocked to open simultaneously with the fan start-up.
Press start button for the RotoClone exhauster. Solenoid valve in the water
supply line should be interlocked to open simultaneously with the fan start-up.
Press start button for the RotoClone exhauster. Solenoid valve in the water
supply line should be interlocked to open simultaneously with the fan start-up.
Press the stop button for the RotoClone exhauster. The solenoid valve in the
water supply should be interlocked to close simultaneously with the fan stoppage.
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47 RotoClone N
Do not stop ejector for two hours after the RotoClone has stopped. If the
automatic sludge ejector timer control is provided, the sludge ejector will stop
automatically at the end of two hours or after the interval set with the timer.
12 MAINTENANCE
12.1 Record Keeping
It is suggested that a record be kept of operational data and that all
servicing maintenance be recorded.
CAUTION: DO NOT open the portlight when the unit is running because air
leakage will alter water level.
Open the portlight each week while RotoClone is stopped and remove any
accumulations in the box, check air equalizing port for plugging, check running
water level weir, electrode (if supplied), and drain pipe for build-up and wear.
Clean cover glass and secure portlight, carefully tightening hold downs.
Remove strainer in water makeup line after first 24 hours of service and
clean. Clean monthly thereafter. Strainer is located in solenoid valve on sizes 1.5-
6.
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48 RotoClone N
12.3 Eliminator Plates
Inspect each week and remove any accumulations. Cleaning methods will
vary with material collected. Hosing in place is effective for many materials,
Removal of plates and scraping or washing may be necessary. After cleaning,
install correctly, see 9.2.4.
The Type L2 is used on RotoClone Sizes 16 thru 48. It has two submerged
shaft assemblies.
a. Chain Tension:
49 RotoClone N
b. Submerged Shafts: Check Type W2 and L2 shafts, sprockets, and
bushings when unit is drained.
c. Upper Shafts: Grease bearings on the upper ejector and paddle scraper
shaft each week.
e. The oil in the speed reducer should be drained at the end of the first
ten days for 24 hours per day operations or at the end of 30 days when
operation is 8 hours per day. The case should then be thoroughly flushed
with light flushing oil. Fill to oil level with new oil of the proper grade. After
this, change oil every 2500 hours or every six months whichever comes first.
1. To prevent loss of oil while units are in transport, the reducers are
shipped with a brass pin in vent or filler plug. This pin must be removed
before the reducer is operated.
2. A drain plug, at or near the bottom (base flange) of the reducer housing,
is provided for oil removal.
f. Once each month inspect the paddle scraper for correct positioning
against ejector paddle; the scraper bumpers, ejector chain and sprockets for
wear.
12.7 Lubrication
All bearings on the sludge ejector are ball bearings packed with grease
before leaving the factory. Do not add grease during installation. See Maintenance
Instructions, A-4 for greasing instructions and schedules.
Gear reducer on sludge ejector drive was filled with oil before shipment.
Check for proper oil level.
NOTE: To prevent loss of oil while units are in transport, the reducers are
shipped with a brass pin in vent or filler plug. This pin must be removed
before the reducer is operated.
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and Reliable Efficient Durable are registered trademarks of American Air
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50 RotoClone N
12.8 Fan
Check the fan for excessive vibration each month while checking V-belt
drive. Be certain the fan is rotating in the proper direction.
Check the fan wheel for any dust accumulation every three (3) months.
Check the belt tension of the V-belt drive (if applicable) each week for the
first month of operation; monthly thereafter. Loose belts reduce air flow through
the RotoClone and cause excessive belt wear.
13 TROUBLESHOOTING
During winter, when doors and windows are closed, insufficient makeup air
to the exhaust system will create high negative pressure in the room.
High water level in the RotoClone can be observed through the closed
portlight in control box. Water level above running level weir can be caused by:
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51 RotoClone N
1. Plugged drain line from the control box.
2. Open or leaky fill valve that allows water to flow into the RotoClone
raising level over running level weir or more.
3. Air leak in control box due to portlight cover not closed tight or failure
to pour water in drain pipe to provide water seal.
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52 RotoClone N
13.3 Water entrainment in fan discharge
Rain or snow draining into exhauster housing during erection or shut down.
A plugged air equalizing hose will cause the water level control box to
maintain a too-high water level in the unit. Clean the hose and readjust the water
level.
Surging of the RotoClone is a rocking of the water from end to end in the
unit. This can be caused by running the unit well below its rated capacity. Contact
the local AAF sales representative for assistance.
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53 RotoClone N
Reliable, Efficient, Durable
Sales Offices:
Europe, Middle East AAF Environmental Control Epe AAF International (Thailand) Co., Ltd.
& Africa 1, Ifaistou & Kikladon 100 Moo 4 Soi Namdang Bangplee 44
15354- Glika Nera, Greece Bangkaew Bangplee, Samutprakarn
AAF Ltd
Tel: +30 2106632015 10540, Thailand
Bassington Lane, Cramlington
Email: redfiltration@aafintl.com Tel: +66 2738 7788
Northumberland, NE23 8AF UK
Email: redfiltration@aafintl.com
Tel: +44 1670 713 477 AAF Hava Filtreleri ve Ticaret AS
Email: redfiltration@aafintl.com Hrriyet Mahallesi Daikin Australia Pty Ltd
Yakac1k D-100 Kuzey Yan Yol No: 49/1-2 (AAF Australia & New Zealand Sales Office)
AAF, S.A.
34876 Kartal, Istanbul, Turkey 15 Nyadale Road Scoresby Victoria 3179,
C/ Urartea, 11
Tel: +90 216 4495164/65 Australia
Polgono Ali-Gobeo
01010 Vitoria, Spain Email: redfiltration@aafintl.com Tel: +61 (0)3 9237 5562
Email: redfiltration@aafintl.com
Tel: +34 945 214851 AAF International Middle East
Email: redfiltration@aafintl.com FZS1BC01-BC04, Jebel Ali Dubai, UAE North & South America
Tel: 009714 8894886
AAF France AAF International
Email: redfiltration@aafintl.com
Rue Wiiliam Dian 9920 Corporate Campus Drive, Suite 2200
B.P.3 AAF Saudi Arabia Ltd. Louisville, KY 40223-5000, USA
27620 Gasny, France P.O. Box 59336 Riyadh 11525, Tel: 1 502 637 0011
Tel: +33 2 32 53 60 60 Kingdom of Saudi Arabia Toll Free: 1 800 477 1214
Email: redfiltration@aafintl.com Tel: +966 1 265 0883 Email: redfiltration@aafintl.com
Email: redfiltration@aafintl.com
AAF Sri AAF, S de RL de CV
Via Lario, 1 Asia Av. Primero de Mayo No. 85,
22070 Fenegr (CO), Italy Col. San Andrs Atenco,
America Air Filter Manufacturing
Tel: +39 031 35 25 311 C.P. 54040 Tialnepantla Edo.
Sdn Bhd
Email: redfiltration@aafintl.com De Mexico, Mxico
(Asia Regional Office)
Tel: +52 55 5565 5200
AAF Luftreinigungssysteme Lot 6, Jalan Pengapit 15/19
Email: redfiltration@aafintl.com
Gesmbi-i Seksyen 15 40000 Shah Alam
Campus 21 Selangor Darul Ehsan, Malaysia American Air Filter Brasil Ltda.
Europaring F12 401 Tel: (60) 3 5039 7777 +603 5039 7732 Rua Doutor Bacelar, 173-CJ. 121
2345 Brunn am Gebirge, Austria Email: redfiltration@aafintl.com Vila Clementino So Paulo Brazil
Tel: +43 (0) 2236 677 628 0 CEP 04026-000
AAF (Wuhan) Co. Ltd., (China HQ)
Email: redfiltration@aafintl.com Tel: +55 11 5567 3000
268 CheCheng Road
Email: redfiltration@aafintl.com
AAF Lufttechnik GmbH Wuhan Economic & Technological
Centroalle 263 b Development Zone
D 46047 Wuhan, Hubei Province PR,
Oberhausen, Germany China 430056
Tel: +49 208 828423 0 Tel: +86 27 8447 3671 +86 27 8447 3672
Email: redfiltration@aafintl.com Email: redfiltration@aafintl.com
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
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