Machine manual

en-23122.202-A

Maintenance slide
gate manually
operated

Code Word

Order Number

POLYSIUS Order Code (POC)

Machine manual Contents
Maintenance slide gate manually operated

Contents

1 Technical data......................................................................................... 1-1

2 Safety...................................................................................................... 2-1
3 Components and mode of functioning.................................................3-1
3.1 Components............................................................................................. 3-1
3.2 Mode of functioning..................................................................................3-5
4 Transport and assembly........................................................................4-1
4.1 Transport and storage instructions...........................................................4-1
4.2 Assembly.................................................................................................. 4-1
5 Lubrication..............................................................................................5-1
6 Preparation for the test run...................................................................6-1
6.1 Checks prior to the test run......................................................................6-1
6.2 Setting and adjustment.............................................................................6-1
7 Maintenance...........................................................................................7-1
7.1 Inspection.................................................................................................7-1
7.2 Servicing.................................................................................................. 7-1
7.3 Trouble shooting.......................................................................................7-2
7.4 Repair....................................................................................................... 7-2
8 Spare parts............................................................................................. 8-1
9 Appendix.................................................................................................9-1
9.1 Technical drawings...................................................................................9-1

en-23122.202-A
Machine manual Technical data
Maintenance slide gate manually operated 1

1 Technical data

NOTE
Information concerning the electrical equipment is contained in
the separate electrical documentation or in the subsuppliers'
documentation.

Information on the intended use

Bulk material.......................................................................................
Bulk density........................................................................................
Grain size.............................................................................................
Permissible conveyed material moisture content.............................
Permissible conveyed material temperature.....................................
Permissible ambient temperature......................................................

Basic data
Year of manufacture............................................................................
Series/Type..........................................................................................
Frame size...........................................................................................
Type of actuation....................................................................manual
Diameter of hand-wheel......................................................................
Dimensions..........................................................................................
Total weight.........................................................................................
Machine manual Safety
Maintenance slide gate manually operated 1

2 Safety

NOTE
Be sure to comply with the general safety instructions in the
supplement Important notes on the documentation.

Use
 The maintenance slide gate may only be used in systems
handling dry, powdery to fine-grained or gritty bulk materials.
 Be sure to comply with the instructions concerning the
intended use in the section Technical data.
 Any use other than the intended use is forbidden. POLYSIUS AG
is not responsible for damage resulting from any use other
than the intended use. All other use is at the owner’s own risk.
 The intended use also includes observance of the instructions
in the machine manual and compliance with the maintenance
instructions.

Transport and assembly

 All transportation instructions in this machine manual refer
exclusively to transportation of the machine at the plant site.
 Only use suitable hoisting and lifting equipment which is in
serviceable order and has a sufficient load bearing capacity.
 Never work under a suspended load.
Operation
 Any safety checks before or during operation depend on the
relevant national regulations. The plant management is
responsible for the performance and recording of such checks.
 If changes in the machine or its operating behaviour relevant
to safety occur, shut down the machine immediately.
Safety Machine manual
2 Maintenance slide gate manually operated

Maintenance

 Ensure that all machines and motors whose operation might

endanger persons or equipment are switched off and
safeguarded against restarting for the entire duration of the
maintenance work.
 Before dismounting the maintenance slide gate, make
absolutely sure that the systems arranged above it are
completely emptied.
 Keep the machine free of oily and combustible substances and
materials. Never use gasoline or other easily inflammable
substances for cleaning the machine.
 Before performing work on the installed maintenance slide
gate, make absolutely sure that the area of the frame where
the valve moves during opening is safeguarded, so that there is
no danger of being crushed or caught in the machine.
 Strictly observe the welding instructions when performing any
welding work.
 If you carry out electrical welding on any part of the machine,
never conduct the welding current through plain or antifriction
bearings, other movable connections or measuring equipment.
Always directly connect the welding current return lead to the
part being welded.
 Remount all protection devices and properly close all
inspection and service covers when maintenance work has
been finished.
Machine manual Components and mode of functioning
Maintenance slide gate manually operated 1

3 Components and mode of functioning

The aerated maintenance slide gate serves as a shutoff device in

silos or containers. The maintenance slide gate is used when the
flow of material has to be interrupted to allow maintenance work
to be carried out.
The slide plate is actuated manually by means of a hand-wheel.

3.1 Components

NOTE
Some details of the drawings in this manual may not be identical
with the drawings supplied under the contract.

The maintenance slide gate consists inter alia of:

 the slide gate frame
 the slide plate
 the stuffing box seal
 the slide plate actuator.
Components and mode of functioning Machine manual
2 Maintenance slide gate manually operated

Items shown in the drawing

1 Slide gate frame

2 Slide plate
3 Stuffing box seal
4 Slide plate actuator

Figure 1
 Machine manual Components and mode of functioning
Maintenance slide gate manually operated 3

Items shown in the drawing

1 Slide gate frame (upper part)

2 Slide plate
3 Stuffing box seal

4 Slide plate actuator

4.1 Spindle nut
4.2 Spindle

Figure 2
Components and mode of functioning Machine manual
4 Maintenance slide gate manually operated

Items shown in the drawings

2 Slide plate

3.1 Stuffing box (frame)

3.2 Stuffing box packing

4.1 Spindle nut

4.2 Spindle
4.3 Bush
4.4 Adjusting ring
4.5 Adjusting ring
4.6 Hand wheel
4.7 Fixing elements

Figure 3
Machine manual Components and mode of functioning
Maintenance slide gate manually operated 5

3.2 Mode of functioning

The maintenance slide gate has a horizontally movable slide plate

with a horizontally arranged spindle with hand wheel.
The slide plate (2) of the maintenance slide gate, which moves at
right angles to the flow direction of the bulk material, can go into
two end positions (OPEN/CLOSED). The flow of conveyed material
is either completely released or completely shut off.
A stuffing box seal (3) prevents bulk material from escaping
between the slide plate (2) and the upper part of the slide gate
frame (1).
Machine manual Transport and assembly
Maintenance slide gate manually operated 1

4 Transport and assembly

4.1 Transport and storage instructions

The maintenance slide gate is dispatched in a ready-assembled

condition.
Make absolutely sure that suitable lifting equipment is employed
in removing the parts from the transport vehicles and transferring
them to the storage area.
When they arrive at the site, all parts must be inspected for
transport damage and placed on wooden beams with the
provision of suitable protection against moisture, soiling and
damage. Never place the parts directly on the ground.
The slide plate (2) and the spindle (4.2) are provided with
corrosion proofing. If the machine is stored for a lengthy period of
time, you must apply a new protection coating if necessary.

4.2 Assembly

Make absolutely sure that the maintenance slide gate delivered

in a ready-assembled condition is installed in accordance with
the data in the general arrangement drawing.
When installing the maintenance slide gate, be sure to observe
the direction of conveyance. (See the following figure!)
Before performing work on the maintenance slide gate, make
absolutely sure that the area of the frame where the valve moves
during opening is safeguarded, so that there is no danger of being
crushed or caught in the machine.
When bolting the flanges of the maintenance slide gate onto
other units and chutes, make absolutely sure that suitable,
undamaged seals are used and that the flanges are not subjected
to stresses.

CAUTION
If you carry out electrical welding on any part of the machine,
never conduct the welding current through plain or antifriction
bearings, other moving connecting elements or measuring
equipment, in order to prevent damage to such parts.
Always directly connect the welding current return lead to the
part being welded.
Transport and assembly Machine manual
2 Maintenance slide gate manually operated

Figure 4

A = direction of conveyance
Machine manual Lubrication
Maintenance slide gate manually operated 1

5 Lubrication

NOTE
The POLYSIUS table of lubricants with the lubricant reference
numbers is contained in the supplement Important notes on the
documentation. The supplement is contained in this folder or at
the beginning of the overall documentation. Each lubricant has a
unique reference number to which the lubrication instructions in
this section relate. The table gives a complete list of all suppliers
and products approved by POLYSIUS AG.
It is the responsibility of the lubricant supplier to select
appropriate lubricants corresponding to the lubricant reference
numbers. POLYSIUS AG accepts no liability for the correctness of
these data.
If you wish to use a lubricant that is not included in the Table of
lubricants, you have to first obtain the express permission of
POLYSIUS AG.
The supplement Important notes on the documentation also
contains the generally valid Notes on lubrication.

CAUTION
Ensure that the environment is not polluted when lubricants are
stored, used and disposed of and carefully observe the relevant
national legislation for the protection of the environment when
handling lubricants.
Lubrication Machine manual
2 Maintenance slide gate manually operated

Lubrication chart

Figure 5

Lubrication points Quantity (ltr, kg) Lubrication intervals

per lubrication (weeks)
point
No. Qty. Designation Lubricant Initial Topping Topping First Further
ref. no. filling up up change changes

1 1 Spindle (4.2) 50 as as
required required
The lubricants of the respective manufacturers and the lubricant reference numbers are contained in
the Table of lubricants in the supplement Important notes on the documentation. The supplement is
contained in this folder or at the beginning of the overall documentation.
Machine manual Preparation for the test run
Maintenance slide gate manually operated 1

6 Preparation for the test run

NOTE
It is a prerequisite of our warranty that the first test run is carried
out in the presence of specialists from POLYSIUS AG and in
accordance with their instructions.

6.1 Checks prior to the test run

After completing the assembly work and prior to the first test run,
check all parts of the plant according to the list below. Take
particular care that all material remnants, tools and assembly
aids are removed.
 Have all bolts been properly tightened?
 Is the stuffing box seal (3) correctly adjusted?
 See 6.2 Setting and adjustment
 Have the connecting flanges been screwed on tightly?
 (Have the provided seals been fitted?)

6.2 Setting and adjustment

Take care not to tighten the stuffing box (3.1) so far that the slide
plate (2) jams.
During this adjusting procedure, move the slide plate in order to
check the ease of movement.
Machine manual Maintenance
Maintenance slide gate manually operated 1

7 Maintenance

7.1 Inspection

No. Work to be performed Frequency Comments

1 General visual inspection for every 12

weeks
 cracks
 leakage
 damage
2 Check the slide plate (2) for ease of every 26 Never forcibly
movement weeks move the slide
plate
3 Check for tightness of the every 52
maintenance slide gate in position weeks
“CLOSED“

7.2 Servicing

No. Work to be performed Frequency Comments

1 Adjustment of the stuffing box seal as required see 6.2

(3)
Setting and
adjustment
Maintenance Machine manual
2 Maintenance slide gate manually operated

7.3 Trouble shooting

Fault Cause Elimination

The slide gate plate (2) The slide plate ( 2) is Loosen the stuffing box
is not moving easily or jamming in the stuffing seal and readjust it; see
is jamming box seal (3) 6.2 Setting and
adjustment
Material pile-up in the Feed material moist or Check feed material and
open maintenance slide not suitable conveyors
gate
Blockage by foreign Remove the foreign
bodies bodies
Material is escaping Stuffing box seal (3) Readjust the stuffing
leaky box seal or replace the
stuffing box packing
(3.2)

7.4 Repair

Before performing any repair work, switch off the power supply to
all electrical components.
Ensure absolute cleanliness at all times during repair work in
order to prevent dirt from entering the bearings, the drive units or
other sensitive parts of the machine or plant.

Removal of the maintenance slide gate from the overall system

 Support the units downstream of the maintenance slide gate
 (if necessary)
 Support or suspend the maintenance slide gate
 Undo the flange connections between the maintenance slide
gate and the neighbouring units or chutes
 Lift out or push out the maintenance slide gate
Machine manual Maintenance
Maintenance slide gate manually operated 3

Repairing the stuffing box seal (3)

If the slide plate (2) is stuck or stiff due to a lengthy stoppage,
you must never move it forcibly by operating the spindle (4.2).
In this case, you must loosen the stuffing box (3.1) by undoing its
four set screws. Then restore free movement of the slide plate by
moving it several times to-and-fro.
After eliminating the problem, retighten the set screws while
taking care that the stuffing box is not jamming the slide plate.
If the stuffing box packing (3.2) has to be changed, carry out the
following work:
 Open the maintenance slide gate
 Unscrew and remove the set screws of the stuffing box (3.1)
and open the stuffing box
 Change the stuffing box packing (3.2)
 Mount the stuffing box and slightly tighten the set screws

Changing the slide plate (2)

 Detach the stuffing box (3.1)
 Detach the adjusting ring (4.4)
 Withdraw the actuator (4) with slide plate (2) from the upper
part of the slide gate frame (1)
 Remove the spindle nut (4.1) from the slide plate
 Check and clean all parts before assembling them
 Assemble in reverse order
 Adjust the stuffing box seal (3) so that the slide plate can still
be moved.

Tools and auxiliary devices

No special tools are required for repair work on the machine.
However, you may need torque wrenches of a bigger size than
normal.
Whether or not you need auxiliary equipment, such as scaffolds
or hoists, depends on the conditions in your plant.

CAUTION
After you have completed the repair work you must check the
machine/plant again according to the section Preparation for test
run.
Machine manual Spare parts
Maintenance slide gate manually operated 1

8 Spare parts

Suggestions for enquiries and orders of spare parts

Dear Customer,
POLYSIUS AG want to make spare part enquiries and spare part order
placement as easy and efficient as possible. For this purpose we have prepared
a table containing all data required by our spare parts department to ensure
optimum processing in the most speedy and trouble-free manner.
Please copy the title page and the page with the table. Fill in the columns
Quantity and Unit. Please mark those parts which you require with a cross in the
column Order or Enquiry. Send the title page together with the table to the Spare
Parts Department of POLYSIUS AG.
If the table relates to more than one machine, please also inform us of the
POLYSIUS Order Code (POC) of the machine for which you require the spare
parts.
Spare parts Machine manual
2 Maintenance slide gate manually operated

Figure 6
Machine manual Spare parts
Maintenance slide gate manually operated 3

Code Word: Order-Number: POC:

Item Designation Quanti Unit Order Enquiry

ty

2 Slide plate 1 set

3.2 Stuffing box packing 1 piece

4 Slide plate actuator, 1 set

complete

4.1 Spindle nut 1 piece

4.2 Spindle 1 piece

4.3 Bush 1 set

4.4 Adjusting ring 1 piece

4.5 Adjusting ring 1 piece

4.6 Hand wheel 1 piece

4.7 Fixing elements 1 set

Machine manual Appendix
Maintenance slide gate manually operated 1

9 Appendix

9.1 Technical drawings

Designation Drawing No.

Assembly drawing