POZZI LEOPOLDO S.r.l.

I-20841 Carate Brianza – Italy

Phone +39 0362.90811
Fax +39 0362.901901
www.pozzi.it info@pozzi.it

USER
MANUAL

Machine: Rotating Heat Exchanger RCR/EOP

Type: RCR-20/SE
Serial Number : R-5272N
Production Year: 2011
Electric Power Supply: X 400V ±10% - 50 Hz
Mechanical Seal Type: TuCa
Special High Tank (+H)
Maximum Clean Water Pressure: 3 bar

I
Revisione Data Autore Commenti
1.00 05/12/05 SF Revisione iniziale da documentazione esistente
Aggiunto pedice con nome revisione
1.01 21/12/05 SF Unificata descrizione giunto rotante.
Corretti refusi
1.02 01/03/06 GB Sostituzione guarnizione feltro con anello di tenuta.
(aggiornati alla revisione E il Dis.101F18484 ed alla
revisione B il Dis.101F32784).
Modificata geometria troppo pieno unificando le
dimensioni per tutti gli RCR.
Unificato dimensione giunti rotanti e ingresso/uscita acqua
pulita per RCR10 ed RCR15.
Unificata dimensione scarico per tutti gli RCR.
1.50 08/03/06 SF Riscrittura parziale, conversione totale a .DOC –
Leggibilità alcuni disegni ancora da perfezionare.
1.51 10/03/06 SF Errori ortografia, conversione immagini.
1.52 07/07/06 SF Aggiornamento legenda disegni
1.53 08/11/06 GB Aggiornamento dichiarazione di conformità (estesa alla
normativa europea 2002/95)
1.54 17/01/07 GB Aggiornati schemi 101F32784B e 101F18484E assegnando
loro un nuovo numero : 101F34529A e 101F34530A.
Aggiornata lista ricambi pag.24.
1.55 06/02/07 GB Aggiornato Machine Data Summary in copertina con
l’indicazione della pressione massima acqua pulita
1.56 17/04/07 GB Aggiornata dichiarazione di conformità con
Dirett..2006/42/CEE
1.57 21/06/07 GB Aggiunta nota al paragrafo 7.3.4.2
1.58 28/09/07 DB Nuovo giunto rotante 2”
1.59 11/01/08 SF Rivista procedura 7.8.2.1
1.60 17/02/09 FP Variato tipo di tenuta meccanica – aggiornamento disegni
1.61 22/10/2009 GB Aggiornato dichiarazione di conformità
2.00 11/08/2010 AP Revisione totale
2.01 21/02/2011 MAL Revisione IT conforme a Manuale EN 2010

II
 Dichiarazione di conformità
Declaration of conformity
Déclaration de conformité
Declaración de conformidad
Konformitätserklärung

Noi/We/Nous/Nosotros/Wir: POZZI LEOPOLDO S.r.l.

Via Cavour, 63
I-20841 CARATE BRIANZA (MB)
dichiariamo sotto nostra unica responsabilità, che il prodotto,
declare under our sole responsibility that the product,
déclarons sous notre seule responsabilité que le produit,
declaramos, bajo nuestra sola responsabilidad, que el producto,
erklären, in alleiniger Verantwortung, dass dieses Produkt,

Scambiatore di calore rotante tipo:

Rotating heat exchanger type: RCR 20/SE
Echangeur de chaleur rotatif type:
Intercambiador de calor tipo: N° R – 5272N
Rotierender Wärmetauscher Typ:

a cui si riferisce questa dichiarazione è conforme alle seguenti norme o documenti normativi
to which this declaration relates is in conformity with the following standards or other normative documents
Auquel cette déclaration se réfère est conforme aux normes ou aux documents normatifs
al que esta declaración se refiere es conforme a las normas u otros documentos normativos
auf das sich diese Erklärung bezieht, mit den folgenden Normen oder Richtlinien übereinstimmt

Direttiva 2006/95 CEE - 89/336 CEE - 2006/42 CEE - 93/68 CEE e 2002/95 CEE
Directive 2006/95EEC - 89/336 EEC - 2006/42 EEC - 93/68 EEC and 2002/95 EEC
Directive 2006/95CEE - 89/336 CEE - 2006/42 CEE - 93/68 CEE et 2002/95 CEE
Directiva 2006/95CEE - 89/336 CEE - 2006/42 CEE - 93/68 CEE y 2002/95 CEE
Richtlinie 2006/95 EWG - 89/336 EWG - 2006/42 EWG - 93/68 EWG und 2002/95 EWG

La sopra citata azienda conserva archiviata la seguente documentazione tecnica a Vostra disposizione:
The above-mentioned company keeps the following technical documentation on file for inspection:
L'entreprise surmentionnée a les documentations techniques suivantes à votre disposition:
La compañía arriba mencionada tiene la siguiente documentación técnica a su disposición:
Die obengenannte Firma hat folgende technische Dokumentationen zur Einsicht bereit:

Fascicolo tecnico della costruzione (parte A+ parte B)

Technical construction booklet (part A + part B)
Dossier technique de construction (partie A + partie B) n. CE 94001
Fasciculo tecnico de la construcción (parte A + parte B)
Technische Lieferung vom Maschinenbau (Teil A + Teil B)

Agliate di Carate Brianza, 2011 Flavio Convento POZZI LEOPOLDO S.r.l.

Responsabile Tecnico Leopoldo Pozzi – Amministratore Unico

III
IV
 Contents
1 Take Over Certificate 1
2 Delivery Inspection 2
3 Machine Identification 3
4 Warranty 4
5 Machine Description and Working Principle 5

6 Dimensions and Ratings 7

6.1 Weights 7
6.2 Hydraulic Ratings: Flowrate and Pressure 8
6.3 Thermal Exchange Data 9

7 User Specifications for Each Step of Machine Operation 10

7.1 Handling 10
7.2 Transport and Storage 11
7.3 Installation 11
7.3.1 Site Requirements 11
7.3.2 Connections to Networks of Fluids 12
7.3.3 Primary Fluid Connections 13
7.3.4 Secondary Fluid Connection 14
7.3.4.1 Safety Valve and Pressure Precautions 14
7.3.4.2 Rotary Joints 16
7.3.4.3 Mechanical Seals 17
7.3.5 Electrical Connections 18
7.4 Start-Up 19
7.5 Malfunction/Damage/Fault 20
7.6 Warning of Movement and Electric Danger 20
7.7 Cleaning 21
7.7.1 Tank Cleaning 21
7.7.2 External Cleaning of the Rotor 22
7.7.3 Internal Cleaning of the Rotor 22
7.8 Maintenance 23
7.8.1 Ordinary Maintenance 23
7.8.1.1 Bearings Lubrication 24
7.8.1.2 Gearbox Lubrication 24
7.8.2 Extraordinary Maintenance 25
7.8.2.1 Disassembly and Reassembly of Support on
Motor Side 26
7.8.2.2 Disassembly and Reassembly of Support on the
Side Opposite to the Motor 28
7.8.2.3 Maintenance and Repair of Rotating Joint 29

8 Emergency Button 30
9 Spare Parts 32
10 Golden Rules for Installing a RCR/EOP System 34
11 Drawings 35

V
VI
 1. Take Over Certificate
Dear Customer,

This RCR heat recovery unit has been conceived and built according to indications of
EC LWA 89/336 CEE - 2006/42/ CEE and 93/68.
Therefore, in order to assess its conformity, an ID plate is placed on the machine with
the mark CE (see section 3).

The machine, when used according to instructions given by POZZI LEOPOLDO S.r.l., is
not dangerous for the operator.

Before installing the machine, we recommend that you carefully read this User
Manual and consider that the safety of the machine may result in serious damage
if the procedures indicated in it are not correctly followed.

Furthermore, you must follow these guidelines:

 In order to install and put the machine to work, workers using this Manual must
have a good knowledge of the machine and of all its components.
 The machine must be installed in an easy-to-reach place with wide lateral
clearance required for operation and maintenance.
 The installation site must be well-lit and properly ventilated.
 The machine is provided with an identification plate and without such plate the
machine may not be operated.
 The machine can't be used outside its project characteristics without specific
written authorisation issued by the producer.
 The operation of the machine must be supervised by trained operators who must
be able to perform the correct proceedings; the operators must be aware of the
possible risks involved in running the unit.
 This User Manual remains property of POZZI LEOPOLDO S.r.l. which reserves
all rights.
 This Manual is intended only for the user of the machine; no other use is
authorised.
 Reproduction in any form of any part of this Manual is forbidden.
 Laws and regulations for workers safety which are effective in the country of final
installation of the machine have to be abided; as for Italy, especially the articles
contained in D.P.R. 27-04-55 n.547 and D.L. 19-09-94 n.626 and following
revisions.

1
 2. Delivery Inspection

Picture 1 : Delivery inspection

Upon receiving the machine it is necessary to check that:

 The wooden case is complete and undamaged;

 The delivery data (delivery address, number of packages, purchase number)
referring to transport documents are correct.
 Damage to fragile components must be verified and claimed within 5 days from
delivery.

In case of damages or missing parts please inform immediately the forwarding agent,
POZZI LEOPOLDO S.r.l. or its agent.

2
 3. Machine Identification

The machine and its details are identified by a serial number shown on a plate on the
machine and on the cover of this Manual.

Note: you have to relay this serial identification number to POZZI LEOPOLDO
S.r.l. for all maintenance requests and whenever instructed to do so.

Picture 2: Example of identification plate and its position

3
 4. Warranty
The heat recovery unit is tested and inspected as follows:

· Size check of each part.

· All seals on the external surfaces of the rotating axle are tested for absence of
leakages with an inner pressure of 3 bar.
· Double-check of concentricity and perpendicularity of all assembled pieces with
regard to the rotation axis.

In all cases the machine is covered by the following warranty conditions:

1. All POZZI LEOPOLDO S.r.l. products are covered by warranty for twelve months as
of delivery date.
2. POZZI LEOPOLDO S.r.l. will solve any anomaly assessed by its technicians, when
due to defects in materials or workmanship that can arise within the time limits
indicated in point 1above.
3. For each identified defect the buyer must give written notice to POZZI LEOPOLDO
S.r.l. within eight (8) days from discovery.
4. All transport costs and insurance fees related to defective parts and/or repaired
parts, or of parts delivered as substitution, included customs duties, must be paid by
the customer.
5. The repair or the substitution of defective parts is a complete satisfaction of warranty
duties.
6. The warranty does not include any direct and/or indirect damage caused by the
machine to the installation where it is mounted.
7. This warranty does not include POZZI LEOPOLDO S.r.l. technicians’ manpower, if
requested, and any material subject to normal wear and tear.

This warranty does not include those parts that become damaged because of
customer’s inaccuracy or incorrect use, wrong maintenance and/or damages
occurred by transport or any other cause which can’t be referred to material or
production defects.

The warranty excludes all cases arising from an incorrect use, wrong application, use
with fluids not compatible with the declared material of construction and/or from failure
to comply with the rules contained in this Manual.

Warranty claim procedure

All parts subject to a warranty claim shall be sent back to the manufacturer in order to
obtain a replacement or a repair, following indications of point 4.
POZZI LEOPOLDO S.r.l. will repair or ship a replacement part under “tentative sale”
conditions.
Upon receipt of the damaged part, POZZI LEOPOLDO S.r.l. will issue an analysis report
stating whether the part has to be considered either a free replacement under warranty
or the sale of a spare part, in which case a bill will be issued to the customer.

POZZI LEOPOLDO S.r.l.

4
 5. Machine Description and Working Principle

The heat recovery unit consists of:

 One ROTATING HEAT EXCHANGING ELEMENT made of AISI 316 stainless

steel. The whole ROTOR is electrochemically mirror-polished. The rotation
provides for the self-cleaning action of the surfaces.
 One EXTERNAL TANK with protection lid and all other parts in contact with the
operating fluids made of stainless steel AISI 316. The tank has connections for
discharge water outlet and inlet, overflow pipe and tank emptying valve.
 ROTATING JOINTS for fresh water inlet and outlet connected to the rotor.
 One SAFETY VALVE on the fresh water circuit.
 One MOTOR GROUP consisting of one or two motoreducers with pulleys and
toothed belts.

Note: No start/stop motor device is included in the machine.

Warning: The machine will operate as soon as you connect it to electrical power.

The hot discharge water (primary fluid) which can be contaminated with both chemical
and physical pollutants, coming from tanks or directly from discharges of continuous
machines, is introduced with a constant flow rate in the external tank, through flanged
connections.

The flow of discharge waters runs through the tank using gravity only (the height
difference between inlet and outlet) and it is flown around the rotor by means of
especially shaped deflectors.
The fresh clean water (secondary fluid), coming from the hydraulic network at a max.
pressure of 3 bar, is fed inside the rotor through the flexible manifold and the rotating

5
joints. The rotor is made of many shell-shaped elements, inside which a canalisation is
created so that water circulates in a perfect counter-current flow running against the
discharge water.

The rotor is activated by a motoreducer; the speed of the elements inside the water
causes a turbulent movement which increases the thermal exchange efficiency and
avoids the physical pollutants deposit on the exchanger walls.

The clean water, after having run across the rotor, exits from the rotating joint as heated
water.
The discharge water, on the contrary, has been cooled off since it has transferred its
thermal content to the fresh water. The two circuits have opposite counter-current
directions, so to optimize the thermal exchange.

6
 6. Dimensions and Ratings
The rotating heat exchanger comes in several models depending on the required heat
exchanging surface.
Apart from size, double connections and motors of large units, all RCR/EOP units share
the same constructive details and hydraulic circuits.

Picture 3: Machine diagram

TYPE A [mm] B [mm] B [mm] (+H) C [mm]

RCR 10 1900 735 885 725
RCR 15 2440 735 885 725
RCR 20 2890 735 885 725
RCR 25 3320 735 885 725
RCR 30 3680 735 885 725
RCR 40 3000 735 885 1350
RCR 50 3420 735 885 1350
RCR 60 3700 735 885 1350

6.1 Weights
Version Net weight [kg] Gross weight [kg]
(in wooden case)
RCR 10 370 450
RCR 10H 400 490
RCR 15 510 630
RCR 15H 550 670
RCR 20 600 695
RCR 20H 660 770
RCR 25 695 815
RCR 25H 755 885
RCR 30 790 900
RCR 30H 850 1000
RCR 40 1230 1470
RCR 40H 1360 1600
RCR 50 1470 1720
RCR 60 1550 1815
RCR 60H 1700 2000
7
 6.2 Hydraulic Ratings: Flowrate and Pressure

Version Qmax Qmax Δp1max Δp2max Pmax [bar] Pi [kW]

[L/min] [m3/h] [bar] [bar]
RCR 10/10H 100 6 0.005 0.45 3 0.55
RCR 15/15H 150 9 0.005 0.4 3 0.55
RCR 20/20H 200 12 0.005 0.4 3 0.55
RCR 25/25H 250 15 0.006 0.5 3 0.55
RCR 30/30H 300 18 0.007 0.6 3 0.55
RCR 40/40H 400 24 0.005 0.4 3 2 x 0.55
RCR 50 500 30 0.007 0.6 3 2 x 0.55
RCR 60/60H 600 36 0.007 0.6 3 2 x 0.55

Max. flow rate Qmax (in L/min. or in m³/h)

Note: Flow rates are generally considered equal to both circuits (primary and
secondary), it is however possible to choose different flow rates (included between 0 e
QmaX) for the two circuits: the choice must be done so to optimize the thermal
recovery, by privileging, according to user needs, either the maximisation of the exit
temperature or that of the flow-rate of the “cold” secondary fluid tfu

Δp1max is the maximum pressure difference on the primary circuit.

Δp2max is the maximum pressure difference allowed on the secondary (rotor) circuit.

Pmax is the maximum pressure allowed inside the rotor.

Warning:
Even transient pressure peaks will damage
the rotor.
Care has to be taken that no hammering effect on the rotor arises due to the hydraulic
design of the downhill circuit.

Pi is the power of the motor.

8
6.3 Thermal Exchange Data

Picture 4: Thermal diagram

tfi (°C) temperature of secondary fluid (“cold” fluid) inlet

tci (°C) temperature of primary fluid (“hot” fluid) inlet
tfu (°C) temperature of secondary fluid (“cold” fluid) outlet
tcu (°C) temperature of primary fluid (“hot” fluid) outlet
Q (m3/h) flow-rate at design condition
Qrec(kcal/h – MW) recovered heat
Version Q [m3/h] tfu [°C] tcu [°C] Qrec [kcal/h] Qrec [MW] ε
RCR 10 6.0 60.9 30.7 275000 0.32 71%
RCR 10 4.2 62.2 29.5 198000 0.23 73%
RCR 10 2.4 64.1 27.8 118000 0.14 76%
RCR 15 9.0 60.6 30.9 410000 0.48 70%
RCR 15 6.3 61.9 29.8 295000 0.34 72%
RCR 15 3.6 63.8 28.1 176000 0.20 75%
RCR 20 12.0 61.0 30.6 552000 0.64 71%
RCR 20 8.4 62.3 29.4 397000 0.46 73%
RCR 20 4.8 64.2 27.7 236000 0.27 76%
RCR 25 15.0 60.9 30.6 689000 0.80 71%
RCR 25 10.5 62.3 29.4 497000 0.58 73%
RCR 25 6.0 64.2 27.7 295000 0.34 76%
RCR 30 18.0 60.6 31.8 821000 0.95 70%
RCR 30 12.6 62.0 29.7 592000 0.69 72%
RCR 30 7.2 64.0 27.9 353000 0.41 75%
RCR 40 24.0 61.0 30.6 1104000 1.28 71%
RCR 40 16.8 62.3 29.4 795000 0.92 73%
RCR 40 9.6 64.2 27.7 472000 0.55 76%
RCR 50 30.0 60.9 30.6 1377000 1.60 71%
RCR 50 21.0 62.3 29.4 993000 1.15 73%
RCR 50 12.0 64.2 27.7 590000 0.69 76%
RCR 60 36.0 60.6 31.8 1642000 1.91 70%
RCR 60 25.2 62.0 29.7 1184000 1.38 72%
RCR 60 14.4 64.0 27.9 706000 0.82 75%

9
 7. User Specifications for Each Step of Machine Operation
7.1 Handling

Warning: The machine does not have any handle, hook or protrusion intended for
handling or lifting.

The machine must always be handled (and especially lifted) using belts positioned on
the bottom of the tank so that they do not affect rotating and power groups when
tensioned as shown in Picture 5.

Picture 5 : Handling without wooden case

If the unit is delivered in a wooden or cardboard case, this can be handled with belts
fixed at the two ends or by a fork-lift as shown in Picture 6.

Picture 6: Handling with wooden case and forklift

10
7.2 Transport and Storage

Warning: before transportation and long term storage, the internal rotor may have
to be blocked to avoid damage.
Units without a special wooden case cannot be stacked one on top of the other. Note
that the unit is usually shipped in a strong cardboard box supported by a wooden pallet.

Warning: when the unit is not packed, extreme caution should be paid to the
rotating joints and moto-reducer parts.
If stacking is requested, you have to order special wood-case shipping: units enclosed
in a proper wooden Pozzi Leopoldo supplied case can be stacked upon each other up
to a maximum of three cases.

NO UP TO
STACKING THREE
WOODEN
CASES

Picture 7: Stacking

7.3 Installation
7.3.1 Site Requirements

The area where the RCR will be installed has to fulfil the following requirements:

Once running, machine surfaces can become very hot, therefore it is mandatory that
proper protecting fences are available to avoid any accidental contact with surfaces and
to prevent operators from eventual burning.
However, such protections must allow for maintenance and/or temporary cleaning of the
unit, so the following minimum clearances are required: 0.5m on motoreducer side, free
access to the side where the identification plate is installed, and 0.1m on the opposite
long side.

11
During the installation it is possible to foresee a light inclination (20-30 mm.) towards the
primary fluid outlet (i.e. to the side of the moto-reducer). This is to allow for complete
drainage of the trough.

Note: The machine is not adequate for outdoor installation.

7.3.2 Connections to Networks of Fluids

The connection to the networks of fluids must be made as shown in

Picture 8, so that the two fluids circulate counter-current one opposite to the other. This
means that the secondary fluid (“cold” fluid) comes into the rotor from the moto-reducer
side and the primary fluid (“hot” fluid) comes into the tank from the opposite side.

Picture 8: Connections to networks of fluids

12
The following table gives the type and dimensions of the connections for each
inlet/outlet depending on the machine model:

Version Tfi Tfu Tci Tcu

RCR 10/10H Ø1½" gas Ø1½" gas DN100 DN100
RCR 15/15H Ø1½" gas Ø1½" gas DN100 DN100
RCR 20/20H Ø2" gas Ø2" gas DN125 DN125
RCR 25/25H Ø2" gas Ø2" gas DN125 DN125
RCR 30/30H Ø2" gas Ø2" gas DN125 DN125
RCR 40/40H 2 x Ø2" gas 2 x Ø2" gas DN175 DN175
RCR 50 2 x Ø2" gas 2 x Ø2" gas DN175 DN175
RCR 60/60H 2 x Ø2" gas 2 x Ø2" gas DN175 DN175

7.3.3 Primary Fluid Connections

The primary fluid generally consists of the waste fluid coming out of a continuous
processing machine that could be operating while the heat exchanger needs cleaning or
maintenance. Therefore, we recommend that a by-pass circuit is created to allow
exclusion of the RCR.

Picture 9: Overflow and tank empty

When the heat exchanger is off-line, its tank can be emptied using the valve (reference
B in Picture 9).
An overflow device (reference A in Picture 9) is installed into the heat exchanger tank
and it is provided for connection to a discharge pit, should overflow conditions arise.

Sizes of connections A and B are as follows:

13
 Version External Ø A [mm] Internal Ø B [mm]
RCR 10/10H 88.9 2" gas
RCR 15/15H 88.9 2" gas
RCR 20/20H 88.9 2" gas
RCR 25/25H 88.9 2" gas
RCR 30/30H 88.9 2" gas
RCR 40/40H 88.9 2" gas
RCR 50 88.9 2" gas
RCR 60/60H 88.9 2" gas

7.3.4 Secondary Fluid

The secondary circuit connects the heat exchanging element (the rotor) to the fresh
water network.
We advise this fluid (water) to be softened and filtered, in order to avoid deposits and
sedimentations caused by water hardness.

7.3.4.1 Safety Valve and Pressure Precautions

To protect the rotor from high pressure, a safety valve is installed on the water inlet of
the rotor side.

Note: The safety valve is factory regulated to 3 bar and may not be tampered
with.

Warning: In some setups, very quick transient pressure variations may happen. In
these cases, the response of the provided safety valve is not fast enough and the
machine rotor could fail because of fatigue damage. It is necessary to eliminate any
pressure variation in order to operate the machine properly.

Note: All flow-rate regulations on the secondary circuit have to be carried on

upstream with respect to the exchanger rotor. For maintenance purposes, we strongly
recommend adding a shut off valve before the RCR and/or a complete bypass circuit.

Warning: To avoid pressure peaks and overpressures inside the rotor, no valves
are allowed downstream on the secondary circuit, except valves specially approved by
POZZI LEOPOLDO S.r.l. for this use.

14
Picture 10: Safety valve

15
 7.3.4.2 Rotary Joints
On both sides of the secondary circuit, there are a rotary joint and a flexible pipe which
must be handled with care.

Warning: Rotary joints contain fragile components and neither axial nor radial
force must be applied to them while operating.

Note: All units require flexible pipes to be connected to the rotary joints before the
unit may start operating. This is to safeguard the life of the RCR/EOP itself.

Picture 11:: Rotary joints

In order to avoid damages to the rotating joints, we recommend that the connections of
the secondary circuit are installed according to
Picture or in a similar manner, so that no pull is exerted by bracket B on the joint D.

Note: No device must be connected directly to the rotary joint D except for the
flexible pipe C.

Note: The two bends attached to the flexible pipe are part of the RCR.
Removal will void the warranty.

16
 7.3.4.3 Mechanical Seals

Inside the tank, on both sides of the rotor, a mechanical seal is installed.

Correct positioning and condition of the mechanical seals must be verified before use as
follows:

Picture 12: Mechanical seal

Warning: Before starting the rotor, you must ensure that the level of water inside
the tank is above the mechanical seals in order to avoid irreversible damages on the
mechanical seals surfaces.

17
7.3.5 Electrical Connections

The following steps are required for proper and safe operation:

1. Connect the exchanger to the ground with the special connection indicated by
the label; you must use a cable (yellow-green) with a section equal to or bigger
than 16 mm² (See Picture 13).

Picture 13: Grounding

2. Connect the electric power to the emergency push button box as shown in
Picture 14.

Picture 14 : Electric connection

18
 3. Verify that the axle rotates in the direction shown by the arrow on the carter (see
Picture 15 ). If the direction is not correct, check the connections you made in the
previous step.

Picture 15: Direction of rotation

7.4 Start-Up

Once connected to the fluids networks and to the electrical power, the exchanger can
work in continuous or batch mode.
To increase the energy recovery, continuous functioning is recommended, thus having
a constant flow-rate per hour distributed over time for as long as possible.
Motor rotation starts as soon as power is connected.

Warning: To avoid possible damage to gear/transmission it is necessary to limit

the number of on-off cycles per hour (no more than five start/stop cycles per hour).

Working is completely automatic and it doesn’t require any operator intervention.

Emergency stop can be achieved pressing the emergency button shown in Picture 14.

Even when the motor is switched off, thermal exchange will take place inside the
machine if the machine itself is not isolated (cut-off) from the primary and secondary
circuits.

Note: Thermal exchange is considerably reduced when the motor is not operating.

19
For normal operations, it is important to keep in mind the following:
:
 Hot water could get out of the tank from the overflow pipe, as shown in
Picture 9 when excessive flow-rate is applied.
 Pressure along the secondary circuit must not exceed the working conditions
specified in 6.2
 Shock related risks must be prevented by proper grounding as indicated in 0.
 Thermal risks must be prevented by the erection of suitable barriers/fences to
avoid accidental contacts as indicated in 7.3.1.

7.5 Malfunction/Damage/Fault

If the instructions for the connection to the fluid network are not accurately followed (see
Section 7.3), the machine could reach a critical status and the situation might result in
damage to the machine itself.
All tampering of the safety valve, positioned at the entrance of the rotor (secondary fluid
inlet), may cause irreversible damage to the discs of the rotor, invalidating warranty and
dramatically reducing the thermal efficiency of the exchanger without the user noticing
it.

7.6 Warning of Movement and Electric Danger

Limit as much as possible the number of start-up per hour of the motor. An excessive
number of start-up can damage the transmission system. Avoid, for instance,
connecting the rotating control device to a level probe which can be affected by the
“wave-effect”. To get the best energy recovery, the exchanger must operate distributing
fluid loads over a long period (ideally 24 hours).
The electrical setup must allow stopping the rotation at any time, so that the
maintenance operator can make sure that there is no chance of accidental start-up. For
this reason a removable key switch is highly recommended.
If the control device is activated by a more complex system, in which it is not possible to
disconnect the general switch (as per continuous machines, where the machine can
work even with the stopped exchanger), the electric line powering the exchanger must
be intercepted by a switch with key-lock.
When the primary fluid is pushed by a pump, you will need to provide a key-lock also for
the pump. In this case you can use the same key-lock for both the rotating control and
the pump.

Warning: Stickers placed on fixed protection elements (the lid and the carter
covering the transmission) remind you of the dangers of electricity and advise you to
disconnect power supply before removing the protection themselves. Should the
stickers deteriorate over time, they must be replaced.

20
7.7 Cleaning

Before any cleaning operation on the exchanger, the operator must follow these
instructions:

 Interrupt the power supply to the machine.

 Prevent the primary fluid (“hot” fluid) from entering the machine, using a by-pass
circuit, acting on a deviating valve or switching off the feed pump .
 If access to the secondary fluid circuit is required, be sure to interrupt the flow on
the secondary circuit by acting on the proper by-pass circuit, acting on a
deviating valve or switching off the feed pump.
 Place a sign in a visible position indicating that the machine is being serviced.

Only when you have followed all of the above steps, you can proceed further and
remove the protection lid (acting as safety device to the rotor) by using a spanner.

Picture 16: Lid removal

7.7.1 Tank Cleaning

The operator must wear heavy rubber gloves with hand and arm protection.
The operator should check for the presence of fibres, yarns, chemical polluting material
inside the baffles. This material may be cleaned off by using exclusively specific tools
that will not damage the tank surfaces.
This operation must be carried out periodically and the time between two consecutive
cleanings depends on how long the exchanger operates on a daily basis and on the
quality and quantity of pollutants in the primary fluid.

21
7.7.2 External Cleaning of the Rotor

To remove fouling from the external surface of the rotor we suggest using high
temperature high pressure water.

Warning: We advise against using mechanical tools for this purpose, as they
could damage the polished surface of the rotor.
For hard to remove fouling, a chemical washing may be required, by operating the rotor
when the tank is filled with the following solution:

Descaling solution
16 parts of water (volume)
3 parts of citric acid (volume)
9 parts of phosphoric acid (volume)
1 mL per liter of wetting agent
anti-foam agent as required

Once again, how often to carry out this procedure depends on the chemical composition
of primary fluid and its sedimentation speed.

7.7.3 Internal Cleaning of the Rotor

Since visual inspection of the internal parts of the rotor is impossible, fouling on the
internal part is only evident when the thermal efficiency decreases as indicated by
examining input and output temperatures.

Note: To prevent the build-up of fouling inside the rotor, we suggest softening the
secondary fluid.

Should the operator suspect that the described fouling has occurred, he may clean the
internal part of the rotor using the same descaling solution indicated in 7.7.2 by having it
circulate it with an arrangement similar to the one shown in Picture 17.

22
 Picture 17: Internal cleaning of the rotor

7.8 Maintenance
The maintenance operations are divided into:
 ordinary maintenance
 extraordinary maintenance
A detailed explanation of both follows.

7.8.1 Ordinary Maintenance

Ordinary maintenance operations merely consists in lubrication of the bearings inside
the side supports and the gearbox.

Picture 18: Ordinary maintenance

23
7.8.1.1 Bearings Lubrication

The bearings contained in side supports need ordinary lubrication.

This must be carried out every 300 working hours by a pump acting on the lubrication
devices positioned on the supports. See Picture 18.

Use grease with following characteristics:

 Specific gravity: 0,89 kg/dm³

 Drop point (Ubbelohde): > 230°C
 Ashes: 2,81%
 E.P.: 7.000 kg/cm²
 Soap base: Lithium
 NLGI number: 2

Examples:

 ORVIM 77/ADS (original filling)

 AGIP GR MU EP
 SHELL SUPER GREASE R2
 MOBIL MOBILPLEX 47
 KLUBER CENTOPELX 2EP

7.8.1.2 Gearbox Lubrication

Change lubrication oil in gear box of motoreducer every 5.000 working hours. Use one
of following lubricants:

 KLUBER SYNTHESO D 220 EP (original filling)

 AGIP BLASIA S 220
 SHELL TIVELA WB
 MOBIL GLYGOYLE 30

To change the oil in the reducer we suggest to dismount the motoreducer from the
machine and carry out the operation on the bench as follows:

 Remove the motor

 Remove the cap
 Empty the unit and properly dispose of the lubricant
 Put the cap on again
 Fill the oil chamber of the gearbox with about 0.6 liter of oil through the motor
hole.
 Verify that the oil covers the upper part of the gears and not completely cover the
chamber.
 Reinstall the motor

24
7.8.2 Extraordinary Maintenance

Note: We advise you to have all the necessary spare parts at hand before starting
these operations. For spares identification refer to section 0 in this Manual.

Extraordinary maintenance operations refer mainly to the external supports.

Picture 10: Checking for seal leakage

In the lower part of the supports there is a hole-indicator to show a possible loss of
water from the seals. As soon as leakages are noticed, we advise to replace the seals
to avoid water reaching the bearings and create damages also to the bearings.

Following this paragraph, you will find instructions to:

 disassemble and reassemble the support on the side of the motoreducer;

 disassemble and reassemble the support on the side opposite to the
motoreducer;
 disassemble and reassemble the rotating joint.

25
7.8.2.1 Disassembly and Reassembly of Support on Motor Side

 Refer to drawing “SPARE PARTS REDUCER SIDE” in section 11 of this Manual.

 Verify that you carried out the steps indicated in 7.6 and 7.7, i.e. the motor is
disconnected and the tank empty.
 Take off the protection guard.
 Remove the rotary joint (50) unscrewing the nut on the shaft.
 Loosen the screws that hold the gearbox as to be able to remove the toothed belt
(46).
 Support the rotor putting a piece of wood underneath it or with a fly-beam.
 Remove the pulley by unscrewing the grub screw on the back of the pulley.
 Remove the cover lid of the support (52) by unscrewing the 4 13mm screws.
 Set free the washer blocking the threaded ring of the bearing and unscrew it by
2-3mm.
 Gently hammer the ring in order to remove the adapter sleeve.
 Unscrew the 4 22mm screws that hold the support (52) to the tank and remove
the support together with the bearing from the shaft. Put it on the bench.
 Remove the flange (41) supporting the mechanical seal, together with the
stationary part of the seal (42) and the flange O-ring (55). Put it on the bench.
 Pull gently to remove the rotating part of the seal (42) from the shaft.
 Inspect the sleeve that terminates the shaft for signs of wearing.
 If the sleeve (49) requires replacement, proceed as follows: remove the 6 17mm
screws, and remove the sleeve. Replace the O-ring of the sleeve (56). Fit the
new sleeve and tighten the screws.

26
 Note: During installation double-check that you are replacing the mechanical
seal with the correct direction of rotation.

 Install the rotating part of the replacement mechanical seal onto the sleeve (49).
Help yourself by lubricating the sleeve a little bit. Verify that the ring can move
along the shaft.
 On the bench, replace the stationary part of the mechanical seal and the O-ring
(55) of flange (41). Carefully fit this assembly to the shaft without pushing against
the other side of the mechanical seal.
 On the bench, remove the old bearing (43) and the seal (54) from the support.
Clean the support with a solvent. Check that the drain hole is free. Replace the
seal (54). Grease the new bearing. Fit the adapter sleeve, the bearing, the
washer and the threaded ring into the support casing.
 Gently fit the support assembly onto the shaft sleeve (the drain hole must be on
the lower side).
 Match the support flange with the groove on the support casing.
 Push slowly the combined assembly against the rotating part of the seal until the
flange matches the wall of the tank.
 Screw the 4 22mm screws holding the support to the tank.
 Tighten the threaded ring of the adapter sleeve until the bearing is locked on the
shaft. Fold down one tooth of the washer to block it.
 Grease the support. Insert the spacer ring (58). Replace the seal (54) on the
cover and put it on again with the 13 mm screws.
 Re-position the pulley on the shaft and lock it.
 Re-position the toothed belt and screw down the gear-box in order to tighten the
belt. Check the alignment between the pulley and the gearbox.
 Re-position the rotary joint and fix it.
 Re-position the motor guard.

27
7.8.2.2 Disassembly and Reassembly of Support on the Side Opposite to the
Motor

 Refer to drawing “SPARE PARTS-DRIVEN SHAFT SIDE” in section 11 of this

Manual.
 Verify that you carried out the steps indicated in 7.6 and 7.7, i.e. the motor is
disconnected and the tank empty.
 Work as for support motor side (7.8.2.1) but being careful to let the bearing
free of sliding inside the support to follow rotor expansion caused by
thermal differences.
 The threaded bush must be screwed without completely blocking the conical gear
(53)
 Between bearing and lid do not insert a spacer ring, but leave instead a space
movement of at least 5 mm.

28
7.8.2.3 Maintenance and Repair of Rotating Joint

In case of water loss, suggesting seal replacement, proceed as follows:

Note: The rotary joint bearings don’t need lubrication.

 Refer to drawing “ROTARY JOINT” in section 11 of this Manual.

 Verify that you carried out the steps indicated in 7.6 and 7.7, i.e. the motor is
disconnected and the tank empty.
 Remove the flexible pipe.
 Remove the fixing grub screw (it might be underneath a label).
 Remove the old seals and carry out an accurate cleaning of the seats both in the
fixed part and on lid.
 Be careful not to damage the seats, especially the ones of the O-Ring.
 Re-position the new seals being sure not to damage the O-rings

29
 8. Emergency Button

EMERGENCY
PUSHBUTTON RESET PUSHBUTTON

Picture 20: Emergency button

The emergency pushbutton disconnects power supply to heat exchanger electric motor.
It may be pushed during emergency situations or during maintenance when, with other
safety precautions for operators, it's necessary to disconnect electric apparatus.

Operation of the emergency button:

EMERGENCY DEVICE RESET

Push the emergency 1. Rotate the button clockwise

button to stop motor 2. Gently pull the button to reach the original
position
3. Push the reset button (there are two of
them for RCR with two rotors)

30
Picture 21 : Electrical scheme of emergency button

31
 9. Spare Parts

Note: The support lower part has an inspection hole to show possible water loss
from the seals. Replace seals as soon as a loss is noticed to prevent water from
reaching the ball bearings as specified in section 7.8.2.

Note: If you ever need to ship the rotor for repair, in order to avoid extra damages,
use a packing rig as in the attached Drawing 101 F16001A of Section 11.

To select and order spare parts refer to the following specially designed website:

http://www.pozzienergy.it

32
Necessary spare parts should be readily available.
All spare parts are normally in our stock.
Refer to drawings 101F34529C and 101F34530C of Section 11.

Browsing the site you will be able to visually identify and select necessary spares.
By adding the selected parts to the cart, the procedure will collect your data, organize
them and automatically transfer your tentative order to our customer service.

At that point we will send you a formal order confirmation that, once approved, will
become your final purchase order.

33
 IMPORTANT!
10. Golden Rules for Installing a RCR/EOP System
For ECOLAB Customers

 Do not place an automatic driven valve between RCR/EOP and CBW. If such a
valve is there, it has to be placed in front of the RCR/EOP. The RCR/EOP must
have a free flow into the CBW or connected machine.

 In front of the RCR/ EOP only slowly moving valves have to be used in the fresh
water line. If possible use pneumatic actuators with an adjustable throttle valve.
Fast moving valves cause water hammers in the rotor and can lead to damage of
the equipment.

 Pulse water counters are always to be positioned in front of the RCR/EOP on the
cold water line. When connecting a CBW, the press water recycling never runs
through the pulse water counters.

 Turbometer and inductive flow meters with motor control valves are always
positioned behind the RCR/EOP on the hot line. The press water recycling runs
always through the turbometer and inductive flow meters.

 Place always a pressure regulator in the fresh water line in front of the RCR/EOP
and adjust it to 2,5 bars.

 Connect the motor of the EOP with the main switch of the CBW. Even a CBW
break-time should not stop the EOP. The EOP runs continuously without
interruption until the end of the production time.

34
 11. Drawings

SINGLE RCR DIMENSION 101 F 32782A

DOUBLE RCR DIMENSION 101 F 32781

REPAIR KIT “S” MODEL 000-1313

SPARE PARTS - REDUCER SIDE 101F34529C

SPARE PARTS – DRIVEN SHAFT SIDE 101F34530C

ROTOR PACKING 101F16001A-SOSTEG

35
36
37
 350°F/176.6°C
330°F/165.5°C
395°F/201.6°C

S50-310-01R is used for RCR 20-25-30-40-50-60

S40-310-01R is used for RCR 10-15

38
Pos CODE DESCRIPTION DESCRIZIONE

39
 Pos CODE DESCRIPTION DESCRIZIONE

Pos CODE DESCRIPTION DESCRIZIONE

40
41