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Machine manual

en-23261.004-B

Flat slide valve


with pneumatic
actuation

Code Word

Order Number

POLYSIUS Order Code (POC)


Machine manual Contents
Flat slide valve with pneumatic actuation

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..................................................................................3-6
4 Transport and assembly........................................................................4-1
4.1 Transport and storage requirements........................................................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....................................................................................................... 7-3
8 Spare parts............................................................................................. 8-1
9 Appendix.................................................................................................9-1
9.1 Technical drawings...................................................................................9-1
9.2 Subsuppliers' documentation...................................................................9-1

en-23261.004-B
Machine manual Technical data
Flat slide valve with pneumatic actuation 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


Conveyed material..............................................................................
Particle size.........................................................................................
Permissible temperature....................................................................
Permissible moisture content............................................................

Basic data
Year of manufacture............................................................................
Series/type..........................................................................................
Construction size................................................................................
Dimensions..........................................................................................
Total weight.........................................................................................
Wear protection........................................................................yes/no

Actuator

Actuating cylinder
Type.....................................................................................................
Control air pressure............................................................................
Control air quantity.............................................................................

Soleniod valve
Type.....................................................................................................
Frequency............................................................................................
Control voltage....................................................................................

Limit position switch


Type.....................................................................................................
2
Machine manual Safety
Flat slide valve with pneumatic actuation 1

2 Safety

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

Use
 The flat slide valve may only be used as a shut-off device for
dry, pulverulent or fine-grained bulk materials.
 Be sure to comply with the information concerning the
intended use of the machine in the section Technical data.
 Any use of the machinery 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 Flat slide valve with pneumatic actuation

Maintenance

 Ensure that for the entire duration of the maintenance work, all
machines and motors whose operation might endanger
persons or equipment are switched off, isolated and
safeguarded against restarting.
 Before performing any work on the machine, make sure that
there is no burning hazard when the machine is touched.
Ensure that there is no hot material inside the machine when
inspection flaps and maintenance hatches are opened.
 When work is to be performed on the installed flat slide valve,
the area of the frame in which the slide plate moves during
opening must be secured in such a way as to preclude any
danger of jamming or squeezing.
 Before dismantling the flat slide valve the systems arranged on
top of the flat slide valve must be completely emptied.
 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.
 Make sure that pneumatic lines are de-pressurized before they
are dismantled.
 Check the tightness of all connections and joints after 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 mode of functioning
Flat slide valve with pneumatic actuation 1

3 Components and mode of functioning

The flat slide valve is a shut-off device for pulverulent and fine-
grained bulk materials.

3.1 Components

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

The flat slide valve consists, amongst others, of the following


components:
 slide valve frame
 slide plate
 slide plate seal
 actuator for movement of the slide plate
 electrical position indicator for limit positions
Components and mode of functioning Machine manual
2 Flat slide valve with pneumatic actuation

Items in the drawings

1 Slide valve frame


1.1 Housing plate
2 Slide plate
3 Slide valve seal, conprising items 3.1 to 3.6
3.1 Stuffing box
3.2 Stuffing box packing
3.3 Set of springs
3.4 Screwed connection
3.5 Strip
3.6 sealing strip
4 Wear protection (special design)
5 Sealing
6 Pneumatic drive
7 Electrical position indicator
Machine manual Components and mode of functioning
Flat slide valve with pneumatic actuation 3

Figure 1
Components and mode of functioning Machine manual
4 Flat slide valve with pneumatic actuation

Items to the pneumatic drive (6)

6.1 Drive cylinder


6.2 Frok head
6.3 Clevis pin
6.4 Throttle valve
6.5 Solenoid valve
6.6 Shut-off valve
6.7 Conditioning unit
6.8 Pressure hose
Machine manual Components and mode of functioning
Flat slide valve with pneumatic actuation 5

Figure 2
Components and mode of functioning Machine manual
6 Flat slide valve with pneumatic actuation

3.2 Mode of functioning

The slide plate (2) of the flat slide valve which is moved at right
angles to the flow direction of the bulk material can assume
either of two limit positions (OPEN/CLOSED). The material flow is
either released entirely or shut off entirely.
The limit positions of the flat slide valve are monitored by limit
position switches.
Machine manual Transport and assembly
Flat slide valve with pneumatic actuation 1

4 Transport and assembly

4.1 Transport and storage requirements

The flat slide valve is transported in a ready-assembled condition.


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

General requirements
The following assembly instructions do not detail the individual
steps for assembling the unit, but rather give an overview on the
work to be performed.
Changes in the planning of the plant during the processing of the
contract may lead to deviations from these assembly
instructions.
Careful selection of the used tools and appliances and the
personnel is important for the correct execution of the assembly
work.

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.

The flat slide valve which is delivered in a ready-assembled


condition is mounted in accordance with the information in the
layout drawing.
When bolt-connecting the flanges of the flat slide valve with other
units and chutes, care must be taken to ensure that suitable,
undamaged seals are used and that the flanges are not subjected
to unacceptable stresses.
Transport and assembly Machine manual
2 Flat slide valve with pneumatic actuation

The actuator and the electrical position indicator (7) can then be
connected, provided the electrical values of the mains
correspond to the data on the rating plate.
Machine manual Lubrication
Flat slide valve with pneumatic actuation 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 chart

Lubrication points Quantity (ltr/kg) Lubrication intervals


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

1 1 Conditioning unit 3 as as
required required

The different makes of lubricant corresponding to the lubricant reference num-bers are shown in the
Lubrication Machine manual
2 Flat slide valve with pneumatic actuation

table of lubricants in the supplement Important notes on the documentation at the beginning of the
overall documentation.
Machine manual Preparation for the test run
Flat slide valve with pneumatic actuation 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 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 the bolts firmly tightened?
 Have the connection flanges been bolted up tightly? (Have the
seals intended for this purpose been inserted?)
 Are the actuator and the available monitoring facilities
connected according to the circuit diagram?
 Do the electrical values of the mains correspond to the data of
the electrical equipment?
 Does the slide plate (2) in „OPEN” position give free the entire
passage cross section?
 Does the control panel display agree with the slide plate
position?

6.2 Setting and adjustment

If the slide plate in „OPEN” position does not give free the entire
cross section, it will be necessary to readjust the pneumatic
drive (6).
 Interrupt voltage supply and air supply;
 Vent of actuating-cylinder piston spaces;
 Dismantle of housing plate (1.1);
 Remove bolt (6.3) and loosen fork head (6.2);
 Set the fork head (6.2) in such a way as to free the entire
passage cross section with the slide plate;
 Insert and secure the bolt;
Preparation for the test run Machine manual
2 Flat slide valve with pneumatic actuation

 Mount the housing plate;


 Connect the air supply unit.
Upon completion of this setting operation, the slide plate (2) is to
be moved in both directions to verify ease of movement.
The electrical position indicator (7) is to be adjusted such that
the limit positions „OPEN” and „CLOSED” are reached.
Machine manual Maintenance
Flat slide valve with pneumatic actuation 1

7 Maintenance

7.1 Inspection

No. Work to be performed Frequency Remarks

1 General visual check for cracks, every 12


leakages and damage weeks
2 Checking of slide plate (2) for ease of every 12 never move the
movement weeks slide plate by
force
3 Checking of flat slide valve for every 26
tightness in „CLOSED” position weeks
4 Inspection work on the pneumatic every 26 according to
drive (6) and on the electrical weeks manufacturer’s
position indicator (7) instructions
5 Checking of slide plate (2) for wear every 12 in either slide
weeks valve position:
„OPEN” and
„CLOSED”

7.2 Servicing

No. Work to be performed Frequency Remarks

1 Replace slide plate (2) as required


2 Maintenance work on the pneumatic according to
drive (6) and on the electrical manufacturer’s
position indicator (7) instructions
3 Clean or replace dirt protection filter as required
in pneumatic pipe upstream the flat
slide valve
Maintenance Machine manual
2 Flat slide valve with pneumatic actuation

7.3 Trouble shooting

Fault Cause Elimination

Slide plate (2) does not Pneumatic drive (6) check electric system or
move with-out current or compressed-air system
control air (system pressure)
Pneumatic drive (6) repair or replace the
defective
drive cylinder
Electrical position repair or replace the
indicator (7) defective electrical position
indicator
Slide plate (2) operates Slide plate stuck in the loosen stuffing box and
with difficulty or jams stuffing box readjust it; if necessary,
renew stuffing box
packing
Build-up of material in Material moist or check feed material and
the opened flat slide unsuitable conveyors
valve
Tramp material stuck remove tramp material
Leakage of feed Flange seal(s) defective repair flange seal(s)
material to the outside
Flat slide valve not Sealing strip (3.6) worn replace sealing strip
sealing tightly
Electrical position Adjust or repair
indicator (7) not electrical position
correctly adjusted or indicator
defective

If faults occur that are not described above, additional


information regarding causes and eliminations of faults can be
taken from the subsuppliers’ documentation.
Machine manual Maintenance
Flat slide valve with pneumatic actuation 3

7.4 Repair

Before performing any repair work, make sure all electrical


components are disconnected.
Ensure the utmost cleanliness at all times during the repair work
in order to guarantee that the bearings, the drive system, the
hydraulic system or other sensitive parts of the machine are kept
free of contamination.

The following work can be carried out with the flat slide valve in
installed position:
Repair or replacement of the electrical position indicator (7) or
soleniod valve (6.5).

Instructions for dismantling the flat slide valve from the complete plant
 interrupt the voltage supply,
 disconnect the air supply system,
 support the piping and units downstream of the flat slide valve
(as required),
 support or suspend the flat slide valve,
 loosen the flange connections of the flat slide valve,
 lift out or push out the flat slide valve.

Assembly instructions
All parts must first be checked and cleaned.
 Push the stuffing box (3.1) on to the slide plate (2), push the
slide plate into the slide plate frame (1).
 Front-side chamfering of the slide plate must be on the bottom
side!
 Install the stuffing box packing (3.2), mount the stuffing box
(3.1) and tighten it such that the slide plate (2) can still be
moved.
 Insert the slide valve seal; seal strips (3.6 must rest upon the
slide plate, when the flat slide valve is closed.
 Mount the pneumatic drive and connect it.
 Mount the electrical position indicator (7).
Maintenance Machine manual
4 Flat slide valve with pneumatic actuation

CAUTION
After you have completed the repair work, you must check the
machine/plant again according to the section Preparation for the
test run .
Machine manual Maintenance
Flat slide valve with pneumatic actuation 5

Tools and auxiliary devices


No special tools are required for repair work on the machine.
However, torque wrenches of a bigger size than normal may be
necessary.
The need for scaffolds or hoists depends on the conditions in your
plant.
Machine manual Spare parts
Flat slide valve with pneumatic actuation 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 Flat slide valve with pneumatic actuation

Figure 3
Machine manual Spare parts
Flat slide valve with pneumatic actuation 3

Code word: order-number: POC:

Item Designation Qty. Unit Order Enquiry

1 Slide valve frame 1 piece

1.1 Housing plate 1 piece

2 Slide plate 1 piece

3 Slide valve seal, 1 set

complete

3.1 Stuffing box 1 set

3.2 Stuffing box packing 1 set

3.3 Set of springs 1 set

3.4 Screwed connection 1 set

3.5 Strip 1 piece

3.6 Sealing strip 1 piece

4 Wear protection 1 set

(special design)

5 Sealing 1 set

7 Electrical position 1 set


indicator
Spare parts Machine manual
4 Flat slide valve with pneumatic actuation

Figure 4
Machine manual Spare parts
Flat slide valve with pneumatic actuation 5

Code word: order-number: POC:

Item Designation Qty. Unit Order Enquiry

6 Pneumaticen drive 1 set

6.1 Drive cylinder 1 piece

6.2 Fork head 1 piece

6.3 Clevis pin 1 piece

6.4 Throttle valve 2 piece

6.5 Solenoid valve 1 piece

6.6 Shut-off valve 1 piece

6.7 Conditioning unit 1 piece

6.8 Pressure hose 1 set


Machine manual Appendix
Flat slide valve with pneumatic actuation 1

9 Appendix

9.1 Technical drawings

Designation Drawing no.

Assembly drawing

9.2 Subsuppliers' documentation

Drive cylinder

Soleniod valve