Carel KLINGENBURG Rotor Cleaning Device User manual

Read this manual carefully before use!
Keep for future use!

2
Rotor Cleaning Device ·KLINGENBURG
Klingenburg GmbH
Brüsseler Straße 77
45968 Gladbeck
GERMANY
Telephone: [phone]
E-Mail: [e-mail]
Internet: www.klingenburg.de
Original operating manual
Klin-64121-DE
© 2023 Klingenburg GmbH

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Rotor Cleaning Device ·KLINGENBURG
Information about this manual This manual enables safe and efficient handling of the machine. This
manual is part of the machine and must be kept accessible to the staff
(Chapter 2.3 Personnel qualification on page 12) at all times. The staff
must carefully read and have understood this manual before starting any
work on or with the machine. Basic requirement for safe working is
compliance with all specified safety notices and instructions in this manual.
In addition, the local accident prevention regulations and safety regulations
for the area of application of the machine also apply.
Illustrations in this manual are for basic understanding and may differ from
the actual design.
Applicable documents In addition to this manual, the following documents must also be taken into
account:
Manual of the building management system
Supplier documentation
Limitation of liability All information and instructions in this manual were prepared taking into
account the applicable standards and provisions, the state of the art and
our many years of findings and experience.
The manufacturer accepts no responsibility for damage due to:
•Non-compliance with this manual
•Improper use
•Deployment of untrained personnel
•Unauthorised modifications
•Technical changes
•Use of unapproved spare parts
The actual scope of delivery may vary from the explanations and
representations shown here in the event of special versions, the utilisation
of additional ordering options or due to the latest technical changes.
The obligations agreed in the supply contract, the manufacturer’s general
terms and conditions and delivery conditions and the applicable legal
regulations at the time the contract is concluded apply.
Copyright Transferring this manual to third parties, reproducing it in any form – in
whole or in part – and utilising and/or disclosing its content are not
permitted without the express written consent of Klingenburg GmbH
(referred to in the following as the “manufacturer”), except for internal
purposes. Contraventions shall be subject to compensation for damages.
The manufacturer reserves the right to assert further claims.
The manufacturer retains the copyright.
© Klingenburg GmbH 2023

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Rotor Cleaning Device ·KLINGENBURG
Table of Contents
1. Unpacking and checking scope of delivery ..................................................................... 6
2. Before you begin – safety ................................................................................................ 10
2.1. Symbols in this manual..................................................................................... 10
2.2. Intended use ..................................................................................................... 11
2.3. Personnel qualification ..................................................................................... 12
2.4. Personal protective equipment ......................................................................... 14
2.5. Working and danger areas ............................................................................... 15
2.6. Residual risks ................................................................................................... 15
2.6.1. Electrical hazards........................................................................... 15
2.6.2. Hazards from moving parts ............................................................ 16
2.6.3. Tripping and slipping hazards ........................................................ 16
2.6.4. Hazards from pressurised media ................................................... 16
2.6.5. Noise hazards ................................................................................ 17
2.7. Operator’s obligations....................................................................................... 18
2.8. Safety devices .................................................................................................. 19
2.9. Securing against being switched on again ....................................................... 19
3. Packing .............................................................................................................................. 20
4. Technical specifications................................................................................................... 21
4.1. Cleaning rail...................................................................................................... 21
4.2. Control units...................................................................................................... 22
4.3. Stepper motor................................................................................................... 25
4.4. Media supply..................................................................................................... 26
4.4.1. Compressed Air ............................................................................. 26
4.4.2. High pressure water ....................................................................... 26
4.5. Compressed air solenoid valve ........................................................................ 27
4.6. Sensors............................................................................................................. 29
5. Layout and function.......................................................................................................... 31
5.1. Function layout ................................................................................................. 31
5.2. Functional description....................................................................................... 32
5.3. Operating and display elements ....................................................................... 33
5.4. Sensors............................................................................................................. 34
5.5. Connections...................................................................................................... 34
6. Installation ......................................................................................................................... 38
6.1. Safety instructions for the installation ............................................................... 38
6.2. Mechanical installation ..................................................................................... 39
6.2.1. Cleaning rail ................................................................................... 39
6.2.2. Drip pan.......................................................................................... 51
6.2.3. Cleaning rail cover ......................................................................... 53

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Rotor Cleaning Device ·KLINGENBURG
6.2.4. High-pressure water supply ........................................................... 54
6.2.5. Compressed air supply .................................................................. 54
6.2.6. Clock sensor .................................................................................. 58
6.2.7. Rotor cleaner control...................................................................... 60
6.2.8. Rotor cleaner drive......................................................................... 62
6.3. Electrical installation ......................................................................................... 63
6.3.1. Rotor cleaner control...................................................................... 63
6.3.2. Rotor cleaner drive......................................................................... 72
7. Commissioning and operation ........................................................................................ 79
7.1. Menu structure and menu navigation ............................................................... 79
7.2. Basic settings and calibration ........................................................................... 80
7.3. Settings............................................................................................................. 84
7.3.1. Open submenu “setup” .................................................................. 84
7.3.2. Change language........................................................................... 86
7.3.3. Set carriage step size..................................................................... 87
7.3.4. Set maximum rotor speed .............................................................. 88
7.3.5. Set minimum rotor speed ............................................................... 89
7.3.6. Set length tolerance ....................................................................... 90
7.3.7. Set drying cycles ............................................................................ 91
7.3.8. Perform calibration ......................................................................... 92
7.3.9. Perform hardware test.................................................................... 93
7.4. Scheduler.......................................................................................................... 98
7.5. Starting and stopping cleaning ....................................................................... 101
7.6. Status indicators ............................................................................................. 105
7.7. Fault indications.............................................................................................. 109
8. Maintenance .................................................................................................................... 116
8.1. Maintenance safety instructions ..................................................................... 116
8.2. Maintenance table .......................................................................................... 117
9. Troubleshooting.............................................................................................................. 118
10. Disassembly and disposal ............................................................................................. 124

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Rotor Cleaning Device ·KLINGENBURG
1. Unpacking and checking scope of delivery
Delivery
The
rotor cleaning device is delivered with the full scope of delivery in
packaging adapted to the transport route and delivery location.
Checking the delivery
Check delivery for transport damage and ensure it is complete
immediately upon receipt. If it is incomplete or if there are
defects, note the extent of the damage on the transport
documents and lodge a complaint immediately.
Scope of delivery
Fig.
1: Cleaning rail and accessories
Fig.
2: Deflection roller and toothed belt

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Rotor Cleaning Device ·KLINGENBURG
Fig.
3: Cleaning carriage with nozzles
Fig.
4: Inductive proximity sensors
Fig.
5: Compressed air hose and 3/2-way compressed air solenoid valve

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Rotor Cleaning Device ·KLINGENBURG
Fig.
6: Drip pan
Fig.
7: Cleaning rail cover
The scope of delivery includes:
•
Pre-assembled cleaning rail (Fig. 1/8) with stepper motor (Fig. 1/1), two
deflection rollers (Fig. 2/1), toothed belt (Fig. 2/2), cleaning carriage (
Fig.
3/1) with high-pressure hot water nozzle (Fig. 3/2) and compressed air
nozzle (Fig. 3/3) and two inductive proximity sensors (Fig. 4/1)
•
Clock sensor (Fig. 1/2)
•
Clock sensor holder with fasteners (Fig. 1/3)
•
RS-485 modbus cable (Fig. 1/4)
•
Cleaner Control (Fig. 1/5)
•
Cleaner Drive (Fig. 1/6)
•
Stepper motor cable with connector (Fig. 1/7)
•
3 m polyurethane compressed air hose (Fig. 5/1)
•
3/2-way solenoid valve (Fig. 5/2)
•
Drip pan (Fig. 6)
•
Cleaning rail cover (Fig. 7)

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Rotor Cleaning Device ·KLINGENBURG
Option
al:
•
Cross beam for cleaning rail mount
Handling packaging material
The individual packages are packed according to the expected transport
conditions.
The packaging provide
s protection against transport damage, corrosion and
other damage. For this reason, do not destroy the packaging and do not
remove it until shortly before use.
Dispose of packaging material in accordance with the applicable statutory
provisions and local re
gulations.
ENVIRONMENT!
Danger to the environment due to incorrect disposal!
Packaging materials are valuable raw materials and can, in
many cases, be further utilised or appropriately reconditioned
and recycled. Incorrect disposal of packaging materials can be
hazardous to the environment.
•Dispose of packaging materials in an environmentally
sound manner.
•Observe the locally applicable disposal regulations. If
necessary, engage the services of a specialist company
with regard to disposal.
Storage
Store packages under the following conditions:
•
Do not store outdoors.
•
Store in a dry and dust-free place.
•
Do not expose to aggressive media.
•
Protect from sun exposure.
•
Avoid mechanical shocks.
•
If stored for more than 3 months, regularly check the general condition
of all parts and the packaging.
There may be storage instructions on the packages that go
beyond the requirements mentioned here. Comply with these
accordingly.

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Rotor Cleaning Device ·KLINGENBURG
2. Before you begin – safety
This chapter provides an overview of
all important safety aspects for
protecting personnel and for ensuring safe and fault
-free operation. Further
task
-specific safety instructions can be found in the sections of the individual
chapters.
2.1. Symbols in this manual
Safety instructions
Safety
instructions are indicated by symbols in this manual. The safety
instructions are in
troduced by signal words that indicate the degree of danger.
DANGER!
This combination of symbol and signal word indicates an
imminently dangerous situation which, if not avoided, will
result in death or serious injury.
WARNING!
This combination of symbol and signal word indicates a
potentially dangerous situation which, if not avoided, could
result in death or serious injury.
CAUTION!
This combination of symbol and signal word indicates a
potentially dangerous situation which, if not avoided, could
result in slight or minor injuries.
NOTICE!
This combination of symbol and signal word indicates a
potentially dangerous situation which, if not avoided, could
result in damage to property.
ENVIRONMENT!
This combination of symbol and signal word indicates potential
dangers to the environment.
Safety instructions in specific
instructions
Safety instructions may refer to specific, individual
instructions. Such safety
instructions are integrated into the instruction so that they do not interrupt the
flow of reading when carrying out the task. The signal words described above
are used.

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Rotor Cleaning Device ·KLINGENBURG
Example:
1.
Loosen the screw.
2.
CAUTION!
Risk of pinching by cover!
Close the cover carefully.
3.
Tighten the screw.
Tips and recommendations
This symbol highlights useful tips and recommendations as
well as information designed to ensure efficient and smooth
operation.
Other markings
The following markings
are used in this manual in order to highlight
instructions, outcomes, lists, references and other elements:
Marking Explanation
Outcomes of steps
Reference to sections of this manual and to
other applicable documents
Lists without fixed order
[Button] Controls (e.g. buttons, switches), indicators
(e.g. signal lamps)
„Display“ Display elements (e.g. on-screen ads)
„Menu“ →
„Submenu“ →
„Setting“
Shortened description of navigation:
Call up menu, call up submenu, change
settings
2.2.Intended use
Intended Use
The rotor cleaning device is used to clean the storage mass of rotary heat
exchangers and is intended exclusively for installation in rotary heat
exchangers of the
Klingenburg RRS and RRT series.
The machine must
be integrated into the safety concept of the building
management system at the place of use.
Intended use also includes compliance with all information in this manual.

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Rotor Cleaning Device ·KLINGENBURG
Misuse
Any use that deviates from the intended use, in particular use on machines
other than rotary heat exchangers of the
Klingenburg RRS and RRT series
and use in potentially explosive environments is misuse.
WARNING!
Danger from misuse!
Misuse of the machine can lead to serious injuries or even
death.
•Only operate the machine after it has been integrated into
the building management system at the place of use and
the required safety devices have been installed. The
safety devices are to be designed and installed by the
operator.
•Only use the machine as intended.
•Strictly comply with all information in this manual.
•Do not operate the machine without first calibrating it.
•Only operate the machine on rotary heat exchangers from
the Klingenburg RRS and RRT series.
•Never operate the machine in an explosive environment.
•Do not rebuild, convert or change the design of the
machine with the aim of changing the area of application.
•Refrain from converting or changing the construction or
individual pieces of equipment with the aim of changing
the area of application or the usability.
•Do not operate the machine outside the range of the
technical specifications.
Claims of any kind for damage due to misuse are excluded.
The operator alone is liable for any damage caused
by improper use.
2.3.Personnel qualification
Risk of injury for unqualified
personnel and unauthorized
persons
WARNING!
Risk of injury for unqualified personnel and unauthorized
persons!
Persons who do not meet the personnel qualifications listed in
this section do not know the dangers of the individual work
and danger areas Chapter 2.5 Working and danger areas
on page 15. If personnel without the required qualifications
perform work on or with the rotor cleaning device or if such
persons are present in the danger zone while work is being
performed, dangers arise that could cause serious injuries
and considerable property damage.
•Have all tasks performed by suitable qualified personnel
without exception.
•Keep unqualified personnel away from the danger zones
and work areas.

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Rotor Cleaning Device ·KLINGENBURG
List of personnel qualificati
ons
The qualifications of the personnel required to carry out the activities on the
machine are defined below
.
The definition of personnel
qualifications depends on their main focus. A
distinction is made here between the personnel who operates the machine
(user), the personnel who prepares the machine for operation (
service
technician
, electrician) and the operator, who bears the legal product
responsibility for the protection of personnel or third parties.
User
:
The
user has been verifiably trained by the operator to handle the machine
and is aware of the potential risks associated with improper use.
The
user performs the following tasks on the machine:
•
Manually starting and stopping the cleaning process
•
Setting the cleaning parameters
Service technician
:
The service technician is able to work on industrial machinery because of his
technical training, knowled
ge and experience and knowledge of the relevant
standards and regulations.
The service technician is specially trained for his working environment and is
aware of the relevant standards and regulations.
He has been demonstrably instructed by the
operator to handle the machine.
In addition to the work performed by the
user, the service technician may
perform the following tasks:
•
Assembly work
•
Complex set-up work
•
Complex maintenance work
•
Complex troubleshooting tasks
Electrician:
Due to his training,
knowledge, experience and knowledge of the relevant
standards and provisions
, the electrician is able to carry out the following
work on electrical systems professionally and safely:
•
Planning and connecting electrical systems on the basis of circuits and
circuit diagrams
•
Assembling cables and connecting electrical components
•
Analysing, measuring and testing electrical systems and functions
•
Carrying out safety checks on electrical systems, components and
devices
•
Analysing and troubleshooting electrical systems

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Rotor Cleaning Device ·KLINGENBURG
Operator:
The o
perator is a natural or legal person who operates the rotor cleaning
device for commercial or economic purposes themselves, or make
s it
available for a third
-party to use, and who bears the legal responsibility for
the product vis
-à-vis protection of personnel and third parties during
operation.
2.4.Personal protective equipment
Personal protective equipment protects people from impairments of safety
and health at work.
The operator must identify the specific hazards at the site and
prescribe the appropriate protective equipment. Unless
otherwise prescribed by the operator, wear the protective
equipment specified in this chapter.
The staff must wear personal protective equipment
during the various works
on and with the machine, referred to separately in the individual sections of
this manual.
Description of personal protective
equipment
The different types of personal protective equipment are detailed
below:
Protective
clothing
Protective work clothing is close
-fitting work clothing
with low tear resistance,
tight sleeves and no protruding parts.
Safety shoes
Safety shoes protect feet from bruises, falling parts and slipping on slippery
surfaces.
Protective
gloves
Protective gloves protect hands from friction, abrasions, punctures or deeper
injuries and from touching hot surfaces.

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Rotor Cleaning Device ·KLINGENBURG
2.5.Working and danger areas
During normal operation, it is not necessary for personnel to be in the area of
the rotor cleaning device.
Personnel only needs to be in the area of the rotor
cleaning device for adjustment and maintenance work and for
troubleshooting.
In this case, the areas of the rotor cleaning device and the
cleaner control are regarded as workspace.
The exit area of the compressed
air nozzle and the high
-pressure warm water nozzle as well as the inside of
the cleaning rail are regarded as danger areas
.
2.6.Residual risks
2.6.1. Electrical hazards
Electric
al voltage
DANGER!
Risk of fatal injury from electric current!
In case of contact with live parts, there is a risk of fatal injury
through electric shock.
•Only qualified electricians may work on electrical
components.
•Before doing any work on the electrical system, switch it
off and secure it against being switched on again.
•Even after the electrical system has been switched off,
dangerous electrical voltage is still present on internal
ciruit components. Wait at least 5 minutes for the residual
voltage to dissipate before working on electrical
components.
•Check that there is no voltage before any intervention.
•In case of damage to the insulation switch off power
supply immediately and arrange for repairs.
•Keep away moisture from live components.
Circuit protection
DANGER!
Risk of electric shock due to insufficiently secured
circuits!
In the case of incorrectly secured circuits unintentional
currents may flow and cause serious injury or death.
•Only operate the electrical system with proper grounding.
•Never take fuses out of service or bypass them.

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Rotor Cleaning Device ·KLINGENBURG
2.6.2. Hazards from moving parts
Cleaning carriage
WARNING!
Danger of being crushed and drawn in by the cleaning
carriage!
Body parts can be crushed or hair and limbs pulled in on the
cleaning carriage.
•Do not reach into the cleaning carriage when it is running.
•Only operate the cleaning carriage with mounted lid.
•Before carrying out any work on the cleaning carriage,
switch off the machine and secure it against being
switched on again.
2.6.3. Tripping and slipping hazards
Power cords and supply lines
CAUTION!
Tripping hazard from power cords and compressed air
and water supply lines!
There is a risk of tripping if the power cables and supply lines
are not laid properly.
•Lay power cables and supply lines in such a way that
tripping hazards are avoided.
Fluid accumulations
CAUTION!
Danger of slipping due to accumulation of liquid!
Fluid buildup increases the risk of slipping and falling.
•Clean up any accumulations of liquid immediately.
•Fix any leaks.
•Check the position of the drip pan and adjust if
necessary.
2.6.4. Hazards from pressurised media
Pressuri
sed water
WARNING!
Risk of injury from water spraying out!
If there is a leak in the high-pressure hot water line, water can
spray out under high pressure and cause injury.
•Wear protective goggles when working near the line
connections.
•In the event of leaks, switch off the Rotor Cleaning Device
and repair the damage.
•Do not reach into the liquid jet.

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Rotor Cleaning Device ·KLINGENBURG
Pressuri
sed supply lines
WARNING!
Risk of injury from pressurised supply lines!
During and after operation, the compressed air and water
lines are under pressure. Working on pressurised components
can lead to serious injuries.
•Prior to any work on the compressed air and water lines,
depressurise them.
High pressure jets
WARNING!
Risk of injury from compressed air and water escaping at
high pressure from the nozzles!
Compressed air and water escaping at high pressure from the
nozzles of the cleaning carriage during the cleaning process
can lead to serious injuries.
•Do not reach into the compressed air or water jet.
•Wear protective goggles when working near the nozzles.
•Before doing any work on the nozzles, switch off the
machine and secure it against being switched on again
and disconnect it from the media supply.
2.6.5. Noise hazards
Compressed air and water escaping
under high pressure and high
speed
WARNING!
Risk of injury from noise!
The noise level caused by the compressed air and water
escaping from the nozzles at high pressure and velocity can
cause serious hearing damage.
•Stay in the danger area only for as long as necessary.
•Wear hearing protection in the danger area during the
cleaning process.

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Rotor Cleaning Device ·KLINGENBURG
2.7.Operator’s obligations
The
rotor cleaning device is used in the commercial sector. The operator of
the rotor cleaning device is therefore subject to the statutory obligations
pertaining to occupational safety.
In addition to the safety instructions in t
his manual, the applicable safety,
occupational safety and environmental protection regulations for the rotor
cleaning device’s area of application must be adhered to.
The following specifically applies in this regard:
•
Operators must familiarise themselves with the applicable occupational
safety regulations and, as part of a risk assessment, determine
additional dangers that arise as a result of the specific operating
conditions at the operating site of the rotor cleaning device. This risk
assessment must be implemented in the form of safety instructions for
operation of the rotor cleaning device.
•
During the entire time the rotor cleaning device is in use, the operator
must check whether the safety instructions reflect current regulations
and, if necessary, the operator must change the instructions
accordingly.
•
The operator must clearly define and regulate responsibilities for all
work on and with the rotor cleaning device. The authority and
responsibilities of personnel regarding installation, operation,
troubleshooting, maintenance and cleaning must be clearly defined.
•
The operator must ensure that all persons handling the machine have
read and understood these instructions. In addition, he must train the
staff at regular intervals and inform them about the dangers.
•
The operator must provide the personnel with the necessary protective
equipment and must instruct them to wear the necessary protective
equipment.
Furthermore, the operator is responsible for ensuring that the
rotor cleaning
device
is always in perfect technical condition. Therefore the following
applies:
•
The operator must ensure that the maintenance intervals described in
this manual are observed.
•
The operator must have all safety devices checked regularly for
functionality and completeness.
•
The operator must install emergency stop devices for the rotor cleaning
device and integrate them into the safety chain of the higher-level
control.

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Rotor Cleaning Device ·KLINGENBURG
2.8.Safety devices
Location of safety devices
The machine does not have its own safety
devices.
The operator must install
emergency stop devices for the rotor cleaning device and integrate them into
the safety chain of the
higher-level control.
Int
egration in an emergency stop
concept
The rotor cleaning device is intended for attachment to rotary heat
exchangers that are controlled via
a higher-level control system at their
respective place of use. The rotor cleaning device does not have an
autonomous emergency stop function.
Before co
mmissioning, install an emergency stop device for the rotor
cleaning device
and integrate it into the safety concept of the higher-level
control
system.
Connect the emergency stop device in such a way that in the event of an
interruption of the power supply or the activation of the power supply after an
interruption, dangerous situations for people and property are excluded.
The emergency stop devices must always be freely accessible.
2.9.Securing against being switched on again
WARNING!
Risk of fatal injury from unauthorised restarting!
If the power supply is switched on again without authorisation
during maintenance or troubleshooting, there is a risk of
serious or fatal injury for persons in the danger zone.
•Before starting any maintenance work or troubleshooting
work, switch off the power supply to the machine and
secure it against being switched on again Operating
manual for the building control system.

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Rotor Cleaning Device ·KLINGENBURG
3. Packing
Packaging unit cleaning rail
Fig.
8: Cleaning rail packing
Packaging unit accessories
Fig.
9: Accessories packing
The cleaning rail is delivered packed in bubble wrap. The bubble wrap
serves to protect the cleaning rail and the
components preassembled
on it from damage during transport.
A red tape on the bubble wrap
warns about highly sensitive electr
onic equipment.
The remaining delivery components
, such as the cleaner control, cleaner
drive etc.
, are delivered packed in a cardboard box. A red tape on the
cardboard box
warns about highly sensitive electronic equipment. On the
carton are the following instructions for safe handling of the packages.
Fragile
Marks packages with fragile or
sensitive content.
Handle the package with care, do not drop it and do not subject it to shocks.
Top
The arrowheads of the mark indicate the top of the package. They must
always point upwards, otherwise the contents could be damaged.
Protect from
moisture
Protect packages from moisture and keep them dry.