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Machine Manual

en-11091.011-F

Flap valve angular

Code Word

Order Number

POLYSIUS Order Code (POC)


Machine Manual Contents
Flap valve angular

Contents

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


2 Safety...................................................................................................... 2-1
3 Components and description of functioning.......................................3-1
3.1 Components............................................................................................. 3-1
3.2 Mode of functioning..................................................................................3-4
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 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.......................................................................................7-1
7.4 Repair....................................................................................................... 7-2
8 Spare parts............................................................................................. 8-1
9 Appendix.................................................................................................9-1
9.1 Technical drawings...................................................................................9-1
9.2 Subsuppliers’ documentation...................................................................9-1

en-11091.011-F
Machine Manual Technical data
Flap valve angular 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........................................................................................
Particle size.........................................................................................
Maximum moisture content................................................................
Maximum temperature.......................................................................

Basic data
Year of manufacture............................................................................
Construction size................................................................................
Installation height...............................................................................
Weight..................................................................................................
Machine Manual Safety
Flap valve angular 1

2 Safety

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

Use
 Be sure to comply with the information concerning the
intended use of the machine in the section Technical data.
 Any use of the machine other than for the specified purpose is
forbidden. POLYSIUS AG is not responsible for any damage
resulting from any other than the specified use of the machine.
All other use is at the operator’s own risk.
 The observance of these and the maintenance instructions is
part of the specified use.

Transport and assembly


 All transport instructions in this manual refer exclusively to the
transport of the machinery in the plant area.
 Use only 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 operator is responsible for
the performance and recording of such checks.
 If changes in the machine or its operating behaviour relevant
to safety occur, the machine must be immediately stopped.
Safety Machine Manual
2 Flap valve angular

Maintenance
 Ensure that all machines and motors whose operation might
endanger persons or equipment are switched off, isolated and
safeguarded against restarting for the entire duration of the
maintenance work.
 The outer levers with the sliding weights swing freely during
operation. Therefore, access to the flap valve is prohibited to
all non-operating personnel or persons not familiar with the
equipment.
 Before performing any work on the machine make sure that
there is no burning hazard.
 Keep the machine free of oily and explosive matters. Never use
benzine or other flammable substances for cleaning the
machine.
 De-energize the electrical parts before starting any
maintenance work.
 Strictly observe the welding instructions when performing any
welding work.
 If electrical welding is executed on any part within the
machine, the welding current must never be conducted through
sliding or anti-friction bearings, other moveable connections or
measuring equipment. Return lead welding current must
always be connected close to the point of welding and directly
connected to the part being welded.
 All safeguards have to be re-installed and all inspection flaps
and maintenance hatches must be properly closed when
maintenance work has been terminated.
Machine Manual Components and description of functioning
Flap valve angular 1

3 Components and description of functioning

The flap valves are used as air seals, simultaneously there is a


braking effect on the flow of material.
The feed material must be dry and free-flowing.

3.1 Components

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

The flap valve consists, among other things, of the following:


 the welded housing
 the flap blade made of steel
 the sliding weight
 the bearings
 the insert
Components and description of functioning Machine Manual
2 Flap valve angular

Items in the drawings

1 Housing
2 Flap blade
3 Sliding weight
4 Bearings
5 Insert
Machine Manual Components and description of functioning
Flap valve angular 3

Figure 1
Components and description of functioning Machine Manual
4 Flap valve angular

3.2 Mode of functioning

Flap valves are discharge devices for a varying mass flow with
simultaneous shutting-off of air.
The flap blade (2) is opened by the flow of material. The force of
the material flow and the weight of the sliding weight (3) keep the
flap in balance.
Machine Manual Transport and assembly
Flap valve angular 1

4 Transport and assembly

4.1 Transport and storage instructions

The flap valve is supplied in a fully-assembled condition.


The sliding weight (3) is tightly fastened so that the flap is not
knocked during transportation.
It must be observed 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 rain, contamination and
damage. The parts must not be stored directly on the ground.

4.2 Assembly

The ready-assembled flap valve is mounted into the system


according to the layout drawing. When bolting the flanges of the
flap valve to other units and chutes, care must be taken to ensure
that the flanges are not subjected to stresses.
Bolts, nuts, discs and seals are to be provided by the client. As
seals to be used we recommend asbestos-free IT plates
according to DIN 3754, approx. 3 mm thick.
The flap valve must be aligned in such a way that the shaft of the
flap is mounted horizontally. (See Figure 1 in section Components
and description of functioning.)
The sliding weight (3) must be positioned so that the flap blade
(2) lies on the internal stop and so that the force keeping it
closed can be overcome.

CAUTION
If electrical welding is carried out in any place of the machine,
welding current must never be conducted through plain bearings
and antifriction bearings, other moveable connections or
measuring equipment to prevent damage to such parts.
Return lead (of welding current) must always be directly
connected to the part being welded.
Machine Manual Lubrication
Flap valve angular 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 to be found in this folder or at
the beginning of the overall documentation. Each lubricant has a
clear reference number to which the lubrication instructions in
this section relate. The table gives a complete list of the
suppliers and products approved by POLYSIUS AG.
It is the responsibility of the lubricant supplier to select
appropriate lubricants corresponding to the reference numbers.
POLYSIUS AG is not responsible for the correctness of this data.
The use of a lubricant not explicitly stated in the table of
lubricants has to be previously approved by POLYSIUS AG.
The supplement Important notes on the documentation also
contains the generally valid Notes on lubrication.

Ensure that the lubricants are stored, used and disposed of in an


environmentally-friendly manner and observe your national
environmental legislation when handling lubricants.
Lubrication Machine Manual
2 Flap valve angular

Lubrication chart

Figure 2

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 2 Bearing 50 0.08 52 52

The different makes of lubricant corresponding to the lubricant reference numbers are shown in the
table of lubricants in the supplement Important notes on the documentation. The supplement is to be
found in this folder or at the beginning of the overall documentation.
Machine Manual Preparation for test run
Flap valve angular 1

6 Preparation for test run

6.1 Checks prior to the test run

After completion of 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.
 Are all bolts firmly tightened?
 Are the connecting flanges bolted air tight?
Have the seals intended for this purpose been inserted?
 Have the bearings (4) been firmly bolted onto the housing (1)?

6.2 Setting and adjustment

After mounting the opening and closing action of the flap blade
must be checked for smooth operation. The flap valve is then to
be observed under operating conditions and to be set by shifting
the sliding weights.
When closed, the flap blade must completely sit close on the
insert so that an air-sealing effect is reached.
Machine Manual Maintenance
Flap valve angular 1

7 Maintenance

7.1 Inspection

WARNING
The flap valve can be very hot.
You can burn yourself.
Wait until the flap valve has cooled down before you start any
repair work.

No. Work to be performed Frequency Comments


1 Functioning test of the flap for daily
smooth operation

7.2 Servicing

No. Work to be performed Frequency Comments


1 Cleaning the bearings (4) once per year

7.3 Trouble shooting

Fault Cause Elimination

Flap sticks Sliding weight (3) are Align sliding weight


not correctly aligned
Blockage in the housing Clear the blockage
(1)
Bearings (4) jammed Replace the bearings
Flap valve fails to close Cakings on the insert (5) Remove the cakings
Maintenance Machine Manual
2 Flap valve angular

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.

WARNING
The flap valve can be very hot.
You can burn yourself.
Wait until the flap valve has cooled down before you start any
repair work.

To allow removal of the flap blade, the flap valve must be


dismantled from the system.

CAUTION
After you have completed the repair work, you must check the
machine/ plant again according to the section Preparation for
the test run.

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.
The need for auxiliary equipment, such as scaffolds or hoists,
depends on the conditions in your plant.
Machine Manual Spare parts
Flap valve angular 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 Flap valve angular

Figure 3
Machine Manual Spare parts
Flap valve angular 3

Code word: Order no.: POC:

Item Designation Qty. Unit Order Enquiry

1 Housing with insert 1 piece

1.1 Sealing plate 1 piece

1.2 Plate with screwed 1 piece


connection

1.3 Sealing plate 1 piece

1.5 Sealing plate 1 piece

1.6 Plate with screwed 1 piece


connection

1.8 Sealing plate 1 piece

2 Flap blade with lever 1 piece

2.1 Bolts with keys and 1 set


washer

3 Sliding weight, complete, 1 piece


with lever

3.1 Lever 1 piece

3.2 Screwed connection 1 set

3.3 Sliding weight 1 piece

3.4 Set of tensioning 1 piece


elements

4 Bearing, complete 2 set

4.1 Flange 2 piece

4.2 Felt ring 2 piece

4.3 Self-aligning bearing 2 piece

4.4 Flange housing, 2 piece


complete

4.5 Screwed connection for 2 set


Spare parts Machine Manual
4 Flap valve angular

bearing arrangement

4.6 Shaft with 1 piece


parallel key and
threaded pin

6 Limit switch 1 set


(special equipment)
Machine Manual Appendix
Flap valve angular 1

9 Appendix

9.1 Technical drawings

NOTE
For drawing numbers, please refer to the table of contents of
this folder.

Designation Drawing no.

Flap valve

9.2 Subsuppliers’ documentation

Limit switch