MANUAL - Löderup

Instruction and Troubleshooting Manual for
Hurricanes and ReCyclone® Systems
in Boiler Applications
(includes Control Board Operation Manual)
November 2009
Introduction
This short manual intends to give the user of Hurricanes and ReCyclone®
Systems the most relevant information on its use and in troubleshooting. Fig.1
shows for illustrative purposes a typical ReCyclone® System comprising four
Hurricanes and one recirculator, but very different systems may exist.
Hurricanes
Recirculator
From boiler
To stack/id fan
Recirculation blower
Fig. 1 – Typical ReCyclone® System
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1. Hurricanes (stand alone)
Reverse-flow gas cyclones should be placed on the vertical. There are no

special precautions that should be taken with Hurricanes, except for detecting
abnormalities such as plugging and erosion.
ACS offers on all its systems differential pressure transducers that measure
pressure drop across the Hurricanes. Pressure drop may go from 0.8 to 2.5
kPa in stand-alone Hurricane systems, depending on the application.
Abnormalities such as plugging (usually due to condensation) or erosion,
are easily detected by a significant drop in the normal operating range of
pressure drop. The nominal (design) pressure drop varies with each
application, and is registered at the end of this manual.
It is important to avoid condensation in cyclones. The occurrence of
condensation, usually due to wrong operation of the boiler/cyclone system or
to some unforeseen situation (vis. a ruptured water pipe in a vapor-tube
boiler) cools the bottom part of the cone without any apparent cyclone exterior
surface deterioration. This cooled surface is a good indication of condensation
inside the cyclone.
Condensation should be immediately treated, since emissions may
increase well beyond legal limits. Condensation can be removed by cleaning
the cyclones from the bottom side with some long metal rod. Complete
removal of condensate material can be enforced by turning on the exhaust
blower for at least 15 min with the cyclones disconnected from the dust
hopper or discharge valve, whatever the case. However, care should be
exercised because emissions may drastically increase to a highly visible
plume during this period.
To minimize condensation, outdoor systems should be thermally insulated,
and the boilers should always be first turned off from fuel, letting the exhaust
blower (and recirculator blower, when it exists) run for at least an extra 30 min
(weekend shutdowns). Difficult situations may require heat tracing.
ACS offers its Hurricanes with strong resistant steels, reinforced cyclone
rooftops and outside cement (densit-type) filled double cones, whenever
suspicions arise that the fly ash has a large silica content (wood and cork
waste boilers, for example) or that other abrasive materials are present. For
extreme situations, ACS offers interior-lined Hurricanes for maximum erosion
protection.
Erosion shows up in holes or cracks that are at first very small (almost
invisible) but that quickly enlarge with operation time. These holes are usually
located near the cone bottom, on solder points or near the rear part of the
cylindrical top. Erosion usually results in a hiss-like functioning of the
cyclones, that is clearly audible, and obviously needs physical repair of the
damage.
Regular checking of flanged connections should ensure that no air is
getting inside the cyclones other than the boiler excess air. Again, this is
easily detected by a hiss-like sound.
ACS offers on its hoppers dust level detectors, so that the system stops if
this level is reached. This prevents hopper overfilling and complete cyclone
plugging, which obviously should be avoided at all costs. An audible alarm
detects any stoppage of the rotary valves, whenever they exist.
ACS may offer a pressure (draft) transducer to control the exhaust fan to
provide an adequate depression in the boiler furnace. The correct draft must
be provided by the boiler supplier. On belt-driven exhaust and recirculation
fans, induced rotation detectors monitor belt failure if the impeller stops.
2. Hurricanes within ReCyclone® Systems
Hurricanes within ReCyclone® Systems should be treated exactly as

stand-alone Hurricanes, except to what concerns the nominal design pressure
drop. Again, this value varies with applications, whether the ReCyclone®
system is mechanical or electrostatic, and is registered for this particular
application at the end of this manual.
2a. Mechanical ReCyclone® Systems

ReCyclone® systems comprise one or more Hurricanes (collectors),
upstream of one or more cylindrical recirculators (concentrators). Since the
particles that escape the Hurricanes are those that enter the recirculators,
they will be much finer and much less concentrated than at the entrance of
the cyclone collectors. Thus, erosion and condensation problems in the
recirculators are inherently minimized.
Mechanical ReCyclones® usually operate with pressure drops that may
go up to 1.2 - 1.8 kPa in the cyclones, and to 1.8-2.8 kPa in the overall
system. Again, ACS offers on all its systems one differential pressure
transducer that measures this overall pressure drop.
It is important to realize that the exhaust and recirculation fans operate
one against the other, so the exhaust fan must be able to cope with the
compression provided by the recirculation fan. To address this matter, ACS
offers controlled frequency drivers where the exhaust fan is controlled by
the desired furnace draft and the recirculation fan is set at some pre-
specified operating point to achieve adequate recirculation.
Since the exhaust fan is stronger than the recirculation fan, the
recirculation fan must start with a faster slope than the exhaust fan if both
fans start simultaneously. This is usually set-up during the commissioning
period.
2b. Electrostatic ReCyclone® Systems
Electrostatic ReCyclone® systems differ from mechanical ones since the
recirculators are electrified with a central high voltage (HV) discharge wire,
connected to a HV source. It is imperative that a proper ground be
provided so that all equipment (Hurricanes, recirculators and piping)
is adequately grounded. This ground must be the same of the HV
power supply, and is of the responsibility of the client.
Electrostatic ReCyclones® usually operate with pressure drops that may
go up to 0.6-1.5 kPa in the cyclones, and to 1.0-2.0 kPa in the overall
system.
ACS offers control boards for remotely controlling the HV source, with an
emergency shutdown push-button, with automatic re-arming for a pre-
specified number of times before complete HV shutdown of the entire
system, in case of irrecoverable electrode failure or short-circuit.
Due to the capacitive nature of the output voltage multiplier, after
HV shutdown there must be a safety period (minimum 5 min) before
operators consider the equipment discharged, or otherwise, all HV
points should be ground discharged by a suitable metallic grip with
insulated handle.
Opening the recirculators’ access doors is absolutely forbidden
with HV enabled (there are no exterior interlocks). Fortunately, this
will only be needed if there is electrode failure. In boiler applications,
due to the high temperature of the flue gases, this danger will never
occur, as the system must be shutdown to be first cooled.
HV should never be turned on without at least some gas flow
through the system, to prevent ion buildup.
HV levels are similar to those operating in ESPs (60-80 kV) but power
(and thus current) is about 1/10th. For example, a boiler with 50000m3/h
flue gases at 300ºC requires less than 4kW of HV power.
 
DESIGN CONDITIONS 
 
3
• Normal flowrate (Nm /h)        3650 
3
• Approximate Effective flowrate (m /h)    6700 
• Temperature (ºC)         180 
• Maximum pressure drop (mm H20)     150 (approx.) 
3
• Inlet concentration at 6% O2 (mg/m )    up to 1500 
COMPONENTS
• 6 Hurricane cyclones with Ø600mm in abrasion‐resistant 2mm thick Docol Steel with 440 
Brinel hardness. Hurricanes are provided with galvanized half‐cones 1.5mm thick for 
refractory cement operating in parallel and disposed in one single battery with discharge 
hopper.  
• 6 electrostatic recirculators with Ø600mm in 2mm Carbon Steel operating in parallel and 
disposed in one single battery. They are provided with electrodes, ceramic HV insulators and 
polypropylene boxes for high voltage (HV) insulation protection from the surrounding 
environment and all appropriate connecting items. 
• Support structure for hurricanes and recirculators with only one layer of primer and paint,
taken into account that system will operate in an enclosed building.  
• Ducts between Hurricane cyclones, electrostatic recirculators and discharge hoppers.  
• 1 Spellman® High voltage transformer (up to 80 kV).  
• Command and monitoring board including the control and command of the high voltage, 
exhaust and recirculation fans, as well as rotary discharge valve with all required protections. 
The system includes a PLC automat with CPU, a communications modem remote control, 
frequency drivers for exhaust and recirculation fans and a touch‐screen with 5.7’.  
The proposed system allows the control and monitoring of the HV generator 
through the console installed on the outside of the door casing. The casing is 
designed to accommodate all remaining control and protection material of the  
unit. The casing is fitted with a 7.5 kW frequency converter for exhaust fan and a 
4kW frequency converter for the recirculation fan with protections.  
In addition to the material described above, this supply includes a depression sensor 
to be installed in the boiler in order to automatically adjust the exhaust fan speed.  
• 2 pressure transducers. 
• 2 Pneumatic vibrators to dislodge dust collected in concentrator walls and in the cyclones’ 
hopper. 
• 1 vibrating level detector for hopper overfilling control. 
• 2 rotation detectors for fans (id and recirculation) 
  
Control Board Operation Manual
1 – Control Board for Recyclone® System EH CEBM6700/RECY-ER-CP7200
1.1 – System Components

The objective of the system controller is to provide full control over the exhaust and
recirculator fans, and of the HV system. The system includes several alarms and
specifies typical actions for recovery from errors.
Fig 1 shows the general system configuration:
Fig.1 – Recyclone EH CEBM6700
The system to be controlled is composed by:
- Electrical board for protection and system command.
- ID Fan – this fan is responsible to exhaust the flue gases to the stack, and is
controlled by a frequency driver.
- Pressure Sensor refª. MF-P 0-1kPa, to monitor furnace draft (negative pressure).
- Rec Fan – recirculation fan to promote partial recirculation of flue gases and
particles to the collector Hurricanes, also controlled by a frequency driver.
- Indutive Sensors - ref. IFS205, for shaft movement detection in both i.d. and
recirculation fans.
- Rot. Valve – The rotary valve discharges the dust collected by the Hurricanes to
appropriate containers.
- Fork Vibrating Level Controller - ref. RRH – 302-0. This controller allows the
system to monitor ineffective particle discharge, to prevent hopper overfilling.
- Vibrating Cleaning System – The system has 2 solenoid valves that drive small
percussion vibrators, one for the Hurricanes discharge hopper and the other for the set
of electrostatic recirculators.
- HV Unit – Spellman ref. SL80N1200/LL20/230. The maximum voltage/current is

80kV / 15mA, giving a maximum rated power of 1200W. The absorbed power should
however be lower, due to corona supression. The HV source, coupled to the
recirculator geometrical configuration, generates a DC high frequency field, which is
responsible for particle charging.
3 – System functioning
The system may operate on purely mechanical recirculation, or on a mixed mode
(mechanical + electrostatic recirculation).
3.1 – Mechanical ReCyclone®

What to do before start-up:
1) Define the correct value for the furnace draft. This value must be supplied by
the boiler manufacturer;
2) Define the correct operating minimum and maximum frequencies for the
i.d.fan. As the frequency driver of the i.d. fan is controlled by the furnace nominal
draft set-point, this should be done to allow for some margin over the nominal 50 Hz
(i.e., 60 Hz), and to prevent going below the minimum to avoid motor overheating
(i.e., 25 Hz).
Fig.2 – Dedusting System
Fig. 2 represents the menu for parameter set-up associated with mechanical
ReCyclones®. To set-up the correct furnace draft (negative pressure), press ID Fan –
Parameters and introduce the required password (Anex). The operator will then have
access to the page where the correct furnace draft should be introduced, as follows:
Fig.3 – I.D. fan window panel
CV: Actual Value – measures the actual pressure

PV: Preset Value – sets the desired draft (negative pressure)
NOTE: obtaining the correct relation between the frequency range of the exhaust i.d.
fan and the required boiler set-up pressure must be locally done by trial and error, as
it also depends on furnace and flue gas temperature, and primary combustion air
flow-rate.
Since it is possible to change the pressure set-up online, the page (Fig.3) displays the
speed (frequency) of the i.d.fan and the corresponding current (A).
Following exactly the same procedure, it is possible to configure the speed

(frequency) of the recirculation fan, by pressing ID Fan – Parameters and introducing
the required password (Annex). Its maximum value should be 50Hz, and its correct
value (which should not be required to change below 25Hz) should be set-up during
the commissioning process.
Fig.4 – Recirculation fan window panel
CV: Actual Value – measures the actual frequency (Hz)

PV: Preset Value – sets the desired frequency (Hz)
If we follow the menu on the parameter control window, Fig.2, it is possible to access
the Timer´s panel, Fig.5, that allows to define:
- Timer Hopper/ Recirculators Vibrator – time interval (on/off) for the solenoid
valves used for discharge hopper and recirculator walls cleaning. This must be
experimented for each particular application, since it will highly depend on particle
size and mechanical properties of the flue gas dust.
- Timer Hopper Discharge Failure – time after which the system completely halts,
if the level controller is active for that time interval. This prevents complete hopper
overfilling and disastrous consequences on overfilling the Hurricanes.
Fig.5 – Timer’s window panel
After all the above parameters have been introduced, press start, Fig.2, for the run
command.
3.2 – Electrostatic ReCyclone®
The HV generator can only be set-up after the Mechanical ReCyclone has been set-up
(see 3.1 above). Fig.6 shows the window panel for the HV generator:
Fig.6 – HV generator window panel
The first step is to power-on the generator, by pressing Power, Fig.6. Next, the
operator should define the required HV tension and allowable maximum current, by
pressing High Voltage – Parameters, followed by the Access password (Annex). The
maximum current should be that allowed by the HV source.
Fig.7 – Parameterization window for voltage level and maximum current
CV: Actual Value – actual voltage (kV) and current (mA) levels
PV: Preset Value – presets for applied voltage level (kV) and maximum current (mA)
For the Spellman SL80N1200/LL20/230A, high voltage can go up to 80KV, and is

current limited to 15mA. Fig.7 identifies the window where this parameterization is
performed. Normally, it will not be necessary to operate at maximum voltage, but this
depends on corona supression, which in turn depends on particles’ characteristics and
concentration.
After parameterization, it is possible to activate the HV source, by pressing HV ON,

Fig.6. Pressing HV OFF deactivates the HV generator.
3.3 – Emergency Shutdown

The emergency button completely deactivates the HV source, requiring re-arming for
further HV output.
4 – Monitoring
There are 2 general window panels, that allow the user to monitor the entire system.
Fig.8 – Monitoring window panel #1
In this window panel the operator can check the state of functioning of the various
components of the system, where GREEN is OK and RED is ERROR. By pressing
the inferior left arrow, we arrive at the second monitoring window, Fig.9.
Fig.9 – Monitoring window panel #2
This last monitoring panel allows the visualization of all values for HV tension and
current, i.d. / recirculation fans speeds and currents, and boiler actual depression,
5 – Malfunctioning (ERRORS)
The system communicates any malfunctioning with the operator, in an automatic way,
through dedicated window panels. These describe the type of error, where it occurred,
and gives tips on corrective measures.
There is a dedicated registry panel where all current system errors are given and
identified, as well as other error situations that have been already solved, Fig10.
Fig.10 – Malfunctioning Hystory
By selecting the appropriate line error, we access the corresponding description. I tis
necessary to view the corresponding panel, follow instructions and Reset to clear the
error, Fig.11.
Example:
This particular case is the shutdown of the magneto-thermal rotary valve switch, to
avoid overheating followed by motor failure. Following the instructions below, after
verifying that there is no problem with the motor, one should re-arm QM1 in the main
electrical board (Q.E.) and afterwards press Reset.
Fig.11 – Example of error window panel
Returning now to the Malfunction History (Fig. 10), we can check not only the error
timing but also if it has already been corrected (blue checkbox at left of error line) or
not (red checkbox at left of error line).
Fig.12 – Recyclone EH CEBM6700
Table I shows the supported malfunctions as well as the main corrective measures
applicable.
Tab. I – Supported malfunctions and corrective measures
Error Description and corrective action(s)
Power – U1/U2 - Protection switch (relay) shutdown of frequency drivers of both i.d. and
recirculation fans:
- Check motors of i.d. and recirculation fans

- Re-arm QF1 and/or QF2, inside Q.E.
- Press Reset
Alarm HV Unit - Malfunctioning of HV unit:
- Check correct electric feed to unit.

- Press Reset
QM1 – V.R. - Protection switch (relay) shutdown of rotary valve:
- Check motor of rotary valve

- Re-arm QM1, inside Q.E.
- Press Reset
Mov. ID Fan - I.D. fan motor malfunctioning. The impeller has stopped turning:
- Check motor/exhaust fan

- Press Reset
Mov. Rec Fan - Recirculation fan motor malfunctioning. The impeller has stopped turning:
- Check motor/exhaust fan

- Press Reset
U1- Rec Fan Error - Malfunctioning of frequency driver for recirculation fan:
- Identify the corresponding error on the driver manual

- Press Reset of U1
- Press Reset
U2- ID Fan Error - Malfunctioning of frequency driver for i.d.exhaust fan:
- Identify the corresponding error on the driver manual

- Press Reset of U2
- Press Reset
War. Cyc. Hopper - Dust level above safety height on dust hopper. The system continues to operate
(Warning) for a predetermined period, so this is only a warning (see below):
- Verify the discharge hopper

Av. Cyc. Hopper - After elapsing the time period allowed in Timer Hopper Discharge Failure, if
(Error) the controller stays active the Av. Cyc. Hopper (Error) message becomes active,
and the system is completely shutdown.
- Verify the discharge hopper
Note: In the event of malfunctioning of the HV source, the system keeps on

functioning as a mechanical ReCyclone®. This is a great advantage over electrostatic
precipitators, where malfunctioning of the HV sections is fatal, drastically reducing
collection efficiency and increasing emissions. For any case not solvable by console
correction, please contact Advanced Cyclone Systems.
Annex
The systems’ access password for parameterization is 1111. To change this password,
it is necessary to:
1º - Simultaneously press the upper right and lower left corners of the control board.
In this manner we open the access to the configuration (set-up) menu.
2º - Select Password – Level 1
3º - Introduce the old password followed by the new one.
4º - Select Write, to save changes.
R. Salcedo
CTO, Advanced Cyclone Systems

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Instruction and Troubleshooting Manual for

Hurricanes and ReCyclone® Systems

(includes Control Board Operation Manual)

Fig. 1 – Typical ReCyclone® System

Reverse-flow gas cyclones should be placed on the vertical. There are no

Hurricanes within ReCyclone® Systems should be treated exactly as

2a. Mechanical ReCyclone® Systems

1 – Control Board for Recyclone® System EH CEBM6700/RECY-ER-CP7200

1.1 – System Components

Fig 1 shows the general system configuration:

Fig.1 – Recyclone EH CEBM6700

The system to be controlled is composed by:

- Electrical board for protection and system command.

- HV Unit – Spellman ref. SL80N1200/LL20/230. The maximum voltage/current is

3.1 – Mechanical ReCyclone®

Fig.2 – Dedusting System

CV: Actual Value – measures the actual pressure

Following exactly the same procedure, it is possible to configure the speed

CV: Actual Value – measures the actual frequency (Hz)

3.2 – Electrostatic ReCyclone®

Fig.6 – HV generator window panel

Fig.7 – Parameterization window for voltage level and maximum current

For the Spellman SL80N1200/LL20/230A, high voltage can go up to 80KV, and is

After parameterization, it is possible to activate the HV source, by pressing HV ON,

3.3 – Emergency Shutdown

Fig.8 – Monitoring window panel #1

Fig.9 – Monitoring window panel #2

Fig.10 – Malfunctioning Hystory

Fig.11 – Example of error window panel

Fig.12 – Recyclone EH CEBM6700

- Check motors of i.d. and recirculation fans

- Check correct electric feed to unit.

- Check motor of rotary valve

- Check motor/exhaust fan

- Check motor/exhaust fan

- Identify the corresponding error on the driver manual

- Identify the corresponding error on the driver manual

- Verify the discharge hopper

- Verify the discharge hopper

Note: In the event of malfunctioning of the HV source, the system keeps on

2º - Select Password – Level 1

3º - Introduce the old password followed by the new one.

4º - Select Write, to save changes.

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