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Form V372, Rev. 12 

- 1 - 

12/18, ECN4334 

 

SECTION 1: IMPORTANT SAFETY INFORMATION 

This  equipment  is  intended  for  installation  by  technically  qualified  personnel.  Failure  to  install  it  in 
compliance  with  national  and  local  electrical  codes,  building  codes  and  within  Vaughan  Co. 
recommendations  may  result  in  electrical  shock,  personal  injury  or  death,  fire  hazard,  unsatisfactory 
performance, and equipment failure. If further assistance is required contact your local representative 
or Vaughan Co. 

Keep this manual in a safe location for future reference.

 

 

 

Indicates a hazard, which, if not avoided, will result in death or serious injury. 

Indicates a hazard, which, if not avoided,

 

could result in death or serious injury. 

Indicates a hazard, which, if not avoided, may result in minor or moderate injury or 
damage to the equipment. 

Indicates special operation or maintenance information. 

 

Isolate  the  pump  hydraulically  and  electrically  before  servicing  or  inspecting  pump.  Lock  out  both  power 
source and isolation valves. 

 

This  pump may  handle  dangerous  or  contaminated  fluids.  There  are  sharp  corners,  edges  and  pinch  areas 
which  can  cause  serious  injury.  Be  careful;  wear  protective  gloves  whenever  possible.  If  you  cut  yourself, 
seek medical help immediately to avoid serious infection. 

 

This pump may start automatically if wired to float switches or other equipment. Before inspecting or making 
adjustments  disconnect  electrical  power  and  lock  out  circuit  breakers  to  pump  motor  and  associated 
equipment.  Duplex  pumps  with  alternating  relays  must  both  be  locked  out;  otherwise  the  pump  you  are 
w

orking on may not be isolated and could start as “the alternate”.  Visually confirm that the pump has come to 

a complete stop before proceeding. 

 

Motors  may  be  equipped  with  built-in  thermal  overloads  to shut off  the  motors  in  the  event the  temperature 
gets  too  high  (as  a  result  of  low  voltage,  poor  ventilation,  overloaded  lines,  etc.)  These  motors  can  restart 
automatically as the motor cools down. DO NOT work on the pump or motor without first disconnecting and 
locking out the power supply.  

 

Enter  tanks  or  pits  with  extreme  caution  and  only  after  an  instrument  check  of  the  pit/tank  has  been 
completed to verify the absence of dangerous gases and the presence of safe levels of oxygen. Never enter a 
tank or pit without a safety harness and lifeline, and an air pack. Never enter the pit without rescue personnel 
standing by. Follow all national and local requirements for confined space entry.  

 

Keep  all  pit  openings  covered  when  not  in  use.  In  addition  to  the  injuries  from  falling,  pits  may  contain 
poisonous gases or liquids. 

 

The  pump  and  nozzle  assemblies  are  to  always  be  lifted  using  adequate  crane  and  sling  capacity.  All 
applicable safe hoisting practices should be employed. When doing so, rig the load to prevent flipping. Do not 
use the motor lifting eyes to lift the assembled pump. Use the motor lifting eyes to lift the detached motor only. 
Cast-in  lifting  eyes  are  designed  for  lifting  individual  pump  components  or  sub-assemblies,  not  the  entire 
pump. Only base-mounted lifting eyes may be used to lift a pump and drive assembly. 

 

Lift  submersible  pump  and  motor  by  pump  lifting  bail  only.  Lifting  by  any  other  parts  of  this  equipment  is 
dangerous  and  may  damage  equipment.  Inspect  the  lifting  bail  to  be  sure  it  is  not  damaged.  Replace 
immediately if the bail is weakened in any way. 

 

Do not allow people under the pump or nozzle assembly while it is being lifted. 

 

Pump and nozzle components can be heavy.  Proper methods of lifting must be employed to  avoid physical 
injury and/or equipment damage. Steel toed shoes should be worn at all times. 

 

Do  not  allow  liquid  to  be  trapped  in  pump  or  piping  between  two  closed  valves.  Always  drain  or  vent  the 
piping/pump  between  two  closed  valves.  Failure  to  vent  or  drain  could  allow  dangerous  pressures  to  build 
causing rupture damage resulting in injury, death, and equipment damage. 

Summary of Contents for ROTAMIX SYSTEM

Page 1: ...STALLATION OPERATION MAINTENANCE INSTRUCTIONS VAUGHAN CO INC 364 Monte Elma Road Montesano WA 98563 Phone 1 360 249 4042 Fax 1 360 249 6155 Toll Free Phone US only 1 888 249 CHOP 2467 Web Site www chopperpumps com Company E mail info chopperpumps com ...

Page 2: ...Form V372 Rev 12 10 18 ECN4334 This manual is for all Vaughan Rotamix Systems NOTE The pump for your Rotamix System will require an additional IO M manual ...

Page 3: ... A Receipt Inspection B Storage Considerations C Installation I Vaughan Foambuster II Roof Mounted Nozzles III System Venting D Nozzle Aiming Instructions 4 STARTUP INSTRUCTIONS Page 7 5 NORMAL OPERATION Page 12 A Digester Mixing B Sludge Tank Mixing C Blend Tank Mixing 7 SHUTDOWN INSTRUCTIONS Page 13 8 MAINTENANCE Page 13 A Routine Maintenance B Corrective Maintenance 9 TROUBLESHOOTING Page 14 10...

Page 4: ...of low voltage poor ventilation overloaded lines etc These motors can restart automatically as the motor cools down DO NOT work on the pump or motor without first disconnecting and locking out the power supply Enter tanks or pits with extreme caution and only after an instrument check of the pit tank has been completed to verify the absence of dangerous gases and the presence of safe levels of oxy...

Page 5: ...wn from the pump as a projectile All pumps must be run with suction and discharge piping in place or blind flanges installed on suction and discharge connections Blind flanges should be vented to avoid pressure build up Note that cast rotating parts could break if metal to metal contact occurs while the pump is running dry Shut pump off when adjusting fittings to avoid being sprayed with pumpage P...

Page 6: ... the crating is damaged look for cracked fittings and clamps or damaged paint report damage to your carrier Vaughan Co can also work with you to provide replacement fittings as needed B STORAGE CONSIDERATIONS The epoxy paint on the nozzle assembly is susceptible to damage from prolonged UV exposure If nozzle assemblies are to be stored for more than two weeks prior to installation they must be eit...

Page 7: ...ming particularly in activated sludge plants The Foambuster nozzle must be mounted above liquid level Only a few inches of distance is enough to allow the Foambuster to work Also the Foambuster needs about 4 ft of headroom above the height of the nozzle to allow the spray to cover as much of the tank surface as possible The Foambuster works best with a fixed cover Finally the Foambuster is designe...

Page 8: ...st approach b You can use a solenoid controlled valve 2 is best controlled by a timer in your control panel which would open this valve prior to each startup of the pump Based on experimentation you can determine how long it takes to vent the gas from the system to completely fill the pump casing before the pump starts You can then set the timer to this setting Again run the piping either to a dra...

Page 9: ...egree mark on the protractor See your Nozzle Layout drawing for the proper angles to set your nozzles Moving the lower nozzle will tend to move the protractor also Be sure to recheck the zero point before tightening the lower nozzle clamp STEP 4 To aim the upper nozzle tie the plumb bob string to the bolt on the nozzle clamp as shown Make sure that it hangs from the the center of the nozzle Loosen...

Page 10: ...o mixing at allSee the pump IO M Manual for pump startup and operating instructions Vaughan Co requires the Startup Certification Checklist pages with the job specific Vaughan Rotamix tank drawing marked up with nozzle locations nozzle angles nozzle elevations and confirmation of all bolt torques to be sent to Vaughan Engineering If the job specific tank drawing is not available please contact Vau...

Page 11: ...rmation of all bolt torques to be sent to Vaughan Engineering All verified dimensions should be indicated by a circle or check mark on that dimension Rotamix Drawing No _____________________________ Is drawing attached Yes ____ No ____ Is drawing marked up to show each verified nozzle location Yes ____ No ____ Is drawing marked up to show each verified nozzle angle Yes ____ No ____ SYSTEM DATA Tan...

Page 12: ..._____ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ___________________...

Page 13: ...f maintaining continuous mixing during foaming or RVE events is that pockets of feed sludge are continuously mixed with the rest of the digestate spreading out gas generation over a maximum time period to minimize sudden bursts of liberated gas By maintaining continuous mixing at lower speeds the gas generation and therefore the foam generation is kept more under control Reduced energy mixing for ...

Page 14: ...working order and that the nozzles are still properly aimed Whenever you check the nozzle system inspect the nozzle opening to make sure that the glass coating is still intact If the glass coating and ductile iron metal is worn away replace the nozzle For polyurethane nozzles measure the discharge diameter to make sure that it is no more than 15 larger than it was when new For example a new 2 00 d...

Page 15: ...ump speed For example if 100 speed is at 60 Hz on your VFD do not run the VFD at less than 45 Hz Too slow of a speed reduces pump and system pressure and can result in nozzle plugging 2 Troubleshooting the nozzles A Historically about of 1 of Rotamix systems experience a plugged nozzle so while blockage can occur it s not a common problem Nozzle blockage may show up as reduced mixing within your d...

Page 16: ...sentatives is required and can head off problems with installation of incorrect nozzle size D A worn nozzle may show up as increased mixing within your digester or storage tank Other symptoms of a worn nozzle could be higher than normal mixing pump electric motor power requirements higher amps and lower pump discharge pressure compared to your recorded readings at startup You may also hear pump ca...

Page 17: ... VSR and this means that more gases of decomposition methane and carbon dioxide are generated We want high VSR for better digestion and we want more gas for cogeneration of electricity However generating too much gas in a digester over too little time can lead to foaming RVE issues and possible digester overflows Digester overflow means bad odors a big cleanup and complaints from residential neigh...

Page 18: ... start If foaming occurs after startup of the mixing system and a Foambuster has not been installed with the system the recovery costs for installing a Foambuster are much higher D Poor mixing can result if the viscosity of the mixed sludge is too high This situation can occur when mixing very thick TWAS thickened waste activated sludge Once TWAS gets up to the range of 6 7 solids mixing may be di...

Page 19: ...le parts are repaired or replaced by anyone other than Vaughan Co or its duly authorized representatives Vaughan Co assumes no liability for consequential damages of any kind and the purchaser by acceptance of delivery assumes all liability for the consequences of the use or misuse of Vaughan Co products by the purchaser its employees or others Vaughan Co will not be held responsible for travel ex...

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