Вы находитесь на странице: 1из 31

Umwelttechnik

seit 1912

- Original -
Operation manual
Rotary valve
Design ADG, Series 21

Size: ADG 1250 x 1250 - 21 VB LU


Year of manufacture: 2016

LOESCHE-Project: P12686 / BIM SON CS


LOESCHE-Code-No.: M20M05.010

________________________________________________________________________________________________
KREISEL GmbH & Co. KG  Mühlenstraße 38  D-02957 Krauschwitz  Telefon (035771) 98-0
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

Table of contents

1 Specifications ................................................................................. 3

2 Proper use ....................................................................................... 6

3 Safety information .......................................................................... 7


3.1 General instructions .....................................................................................7
3.2 Special instructions ......................................................................................8
3.3 Safety signs ..................................................................................................9

4 Constructional features ................................................................. 10


4.1 Design ..........................................................................................................0
4.2 Function ........................................................................................................10
4.3 Bearing / sealing ...........................................................................................12

5 Identification ................................................................................... 12

6 Transport and storage .................................................................... 13

7 Installation ....................................................................................... 14
7.1 How to install ................................................................................................14
7.2 General arrangement drawing .....................................................................16
7.3 Electrical connection ....................................................................................17

8 Start-up ............................................................................................ 18

9 Operation ......................................................................................... 19

10 Troubleshooting ............................................................................. 20

11 Maintenance and care .................................................................... 22


11.1 General .........................................................................................................22
11.2 Wearing bar readjustment ............................................................................22
11.3 Dismounting and mounting instructions (Repair) ........................................23
11.4 Inspections and maintenance ......................................................................26
11.5 Lubricating instructions ................................................................................27

12 Spare parts ...................................................................................... 28


12.1 Spare parts drawing .....................................................................................28
12.2 Spare parts list .............................................................................................29

13 Disposal ........................................................................................... 30

14 Documentation of vendor parts .................................................... 31

_______________________________________________________________________________ 2
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

1 Specifications
Customer: ....................................... LOESCHE GmbH Düsseldorf
Order No.: ....................................... 161344 Pos.10
Date of delivery: ............................. 2016-09-23
Type:............................................... ADG 1250x1250-21 VBLU - design right
Quantity: ......................................... 1 piece

Function: ......................................... mill feed


Material to be conveyed: ................ clinker, reject
Bulk density: ................................... 1.3 t/m3
Grain size: ...................................... max. 70 mm
Moisture: ......................................... ≤ 1 %
Wear behaviour: ............................. abrasive
Flowing properties: ......................... flowing requirement: no sticky
Product temperature: ..................... max. 120 °C
Ambient temperature: ..................... +10 to +40 °C
Differential pressure: ...................... 5 mbar
Pressure conditions on inlet side: .. atmospheric
on outlet side: . -5 mbar
Location: ......................................... above mill
Installation (indoor/outdoor): .......... no specified
Time of operating: .......................... 24 h/d

Existing conveying capacity: .......... 210 t/h (= 161.5 m3/h)


Designed for a conveying capacity of: . max. 335 t/h (= max. 257.6 m3/h)

Theoretical conveying capacity: ..... 573.7 m3/h


(at 100% fill factor and 8.2 r.p.m.)
Rotor capacity: ............................... 1166 dm3
Percentage fill:................................  28 % (max. 45 %)
Peripheral speed: ........................... 0.537 m/s

Weight (with motor): .......................  6730 kg


Weight (without motor): ..................  6200 kg

Material: .......................................... housing: carbon steel


with bolted wearing plates (composite
armour plate)
and product deflector in inlet area,
with wearing bush of hardened 42 CrMo4
(1.7225)
cellular wheel: HARDOX 400 / C 45
with side walls and 10 compartments
(rounded / heated version) ;
with wearing bars: C45E (1.1191)
on both sides hardened and grinded, may
be adjusted and replaced through inspection
opening in inlet area
wearing strips with cover strip for the
screw head incl. silicone seal

_______________________________________________________________________________ 3
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

Surface treatment: .......................... cleaning degree: SA 2.5


corrosion protection inside:
manufacturing
coating: Two-component epoxy resin-
zinc dust, grey, RAL 7001 dull
layer thickness 1x 40 µm
basic coating: Two-component epoxy resin-
(only outside) micaceous iron ore,
RAL 7001 dull, grey
layer thickness 2x 40 µm

total dry layer thickness:  120 µm


drive: as specified by manufacturer
OS 1

Rotary valve features

The rotary valve includes the following additional features:

- Housing with wearing bush.


- 150 dia. air inlet and outlet connections with connecting flanges in the side panels
of the housing for heating the cellular wheel.
- Lateral discs of rotor sealed by double labyrinth boxes
- 65 dia. air inlet openings in either cellular wheel side wall (intermediate
labyrinth) for sealing air introduction

- Shaft protective sleeves in the area of the adjustable and re-lubricating stuffing
box packing.

- Rotation monitoring by an inductive sensor/ speed monitor


- Nozzle G ½” in the casing centre used for measuring the differential pressure
(empty side)

Conditions for optional equipment

sealing air connection DN 65 (1x each bearing plate)


required pressure: ................. 2500 Pa
required air flow rate: ............ 2x 725 m3/h (1x each bearing plate)

_______________________________________________________________________________ 4
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

Geared motor

 Motor to be supplied by rotary valve manufacturer


 Motor to be attached respectively provided by customer

Motor characteristics
Make: ........................................... SEW
Design: .........................................helical gear motor
Type: ............................................ RF147 DRN160 M6 /TF
Output: ......................................... 9.2 kW
Speed: ..........................................979 / 8.2 r.p.m.
Voltage / switching: ...................... 230 /400 V /
Rated current (to 230/400 V): ...... 27.5 / 15.8 A
Frequency: ................................... 50 Hz
cos : ........................................... 0.74
Relation IA / IN: ..............................8.2
Relation MA/ MN: ...........................2.7
Size: .............................................M1
Protective system: ........................ IP 55
Thermal class: .............................. F (155°C)
Motor efficiency class:.................. IE3
Motor protection: .......................... 6 temperature sensors (TF)
3 temperature sensors in thermal class B
as pre-alarms (130°C) and
3 temperature sensors in thermal class F
as cut-out (150°C) per winding

Inductive sensor / speed monitor


 sensor to be supplied by rotary valve manufacturer
 sensor to be attached
Make: ...........................................Turck
Type: ............................................DBI10U-M30-AP4X2
Rated operational voltage: ...........10 … 65 V DC
Output function: ............................3-wire, normally open, PNP
Degree of protection: ...................IP 67
with control proof (8 impulse/revolution) and housing for sensor

These specifications are based on a particular rotary valve design. The


safe operation can be guaranteed for this design only.

Modifications not properly done may result in damage on the rotary valve.
Note. The rotary valve is intended to be mounted in installations.
Observe the safety distances.

_______________________________________________________________________________ 5
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

2 Proper use

The rotary valve as designated above is exclusively intended for conveying


bulk goods in compliance with the performance data as specified under
Section 1.
For proper use, also follow the remaining chapters of this operation manu-
al, in particular the compliance with inspection and maintenance instruc-
tions.
Any other use going beyond this application is not permitted.

The risk for this is borne by the operator alone.

The throughput of foreign bodies of any type through the rotary valve sup-
plied is not in compliance with its intended purpose.
The user must decide upon precautions to reliably prevent foreign bodies
being passed through the rotary valve.

For the purpose of evaluating the complete machine and affix the CE label
on it, incomplete machines (rotary valve) to be incorporated in that machine
are only allowed to be operated by customers who are able to make a con-
formity evaluation as described in the machine guideline.

_______________________________________________________________________________ 6
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

3 Safety information

3.1 General instructions

This safety information should be particularly followed in addition to the product-


based operation manual. It is intended to protect persons and property from dam-
age and hazards resulting from improper use, wrong operation, inadequate or im-
proper maintenance or any other inappropriate treatment of the rotary valve.

At the time of delivery the rotary valve is in compliance with the applicable safety
requirements. The accident-prevention rules applicable at this time have been du-
ly taken into account during the manufacture of the rotary valve.

Any modification to the original state of the rotary valve is not permitted without
the prior consent of the manufacturer.
This also includes the exclusive use of original spare parts or purchased parts
manufactured according to drawing.
The operation manual and supplementary instructions (if any) must be within
easy reach of the operator.

Follow the time limits for recurrent tests / inspections as specified in the operation
manual.

_______________________________________________________________________________ 7
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

3.2 Special instructions

It is essential to the operator to make familiar with the content of the operation
manual prior to the installation, operation and servicing of the rotary valves.

The responsibilities for the installation, operation and servicing of the rotary
valves have to be unambiguously stipulated and complied with. There shall be no
unclear competences as far as safety is concerned.

The operator must observe the binding laws, regulations, rules and decrees ap-
plicable to the respective location.

For the purpose of evaluating the complete machine and affix the CE label on it,
incomplete machines (rotary valve) to be incorporated in that machine are only al-
lowed to be operated by customers who are able to make a conformity evaluation
as described in the machine guideline.

For transport and installation, follow the accident-prevention rules and the per-
missible loads for the means of transport and hoisting gear.

Prior to installation, remove the transport locks (cover plates).


Attention! The rotating cellular wheel is an accident hazard due to its shearing
effect!
For this reason, make sure to provide rotating parts with a protection.

The operator shall connect the machine to the earthing system via an earth cable.

Prior to taking the rotary valve into service, the operator has to make sure that
this equipment is properly used.

The operator is obliged to operate the rotary valve in proper condition only.

Prior to start-up, make sure that all safety guards are in place.
Do not leave, loosen or remove any safety guards.

Cleansing holes in pipes etc. less than 1 m away from the rotary valve must not
be opened during the operation of the rotary valve.

Any mode of operation affecting the safety of the rotary valve must be avoided.

Any work on rotary valves such as repair and maintenance work shall be done
only when the machine is at standstill. For this purpose, also attach warning signs
to prevent an unauthorised starting of the machine.

Inadequate and improper repair and maintenance work is a safety risk so that on-
ly professional and qualified personnel shall be employed by the operator for this
work.

_______________________________________________________________________________ 8
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

3.3 Safety signs

Remember the following safety signs and follow the relevant instructions given in
the operation manual.

This sign is intended to alert you to all important safety information in


this operation manual referring to situations presenting a hazard to
the health and life of persons.
Follow these instructions carefully.
In addition to these instructions, the general safety and accident-
prevention rules effective in your country have to be adhered to.

The instructions, rules and regulations associated with this sign


should be followed in order to avoid hazards.

This sign identifies the hazard of a machine damage. Such signs


should be particularly followed to avoid damage or destruction to the
machine / installation.

This sign specifies that any work on electrical installations shall be


done by a skilled electrician only.

_______________________________________________________________________________ 9
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

4 Constructional features

4.1 Model

The model ADG rotary valve in non-wearing design is equipped with an inde-
pendent drive unit. It is of heavy welded steel construction and provided with a
flanged geared motor.
An elastic coupling transmits the power from the gear motor to the cellular wheel
shaft.
An inductive sensor / speed monitor is fitted for monitoring the speed of the
cellular wheel.

4.2 Function - Design

The rotary valve has a stationary housing in which a cellular wheel with ten
chambers is supported in a way that it can rotate.
In continuous or intermittent dust delivery mode the cellular wheel provides for the
sealing against the entry of secondary air at different pressure conditions above
or below the rotary valve.
The cellular wheel housing has a split inspection opening in the inlet area. To
protect the cellular wheel housing from excessive wear, the inlet area is lined with
fitted composite armour plates on three sides. The armour plate on one of the
longitudinal sides (incorporating the inspection opening) is of replaceable type.
The side opposite to the inspection opening is provided with a replaceable prod-
uct deflector. The baffle plate is made of composite armour plate.
The cellular wheel housing is protected by a hardened wearing bush in the cellu-
lar wheel area. On the side opposite to the motor this bush is connected to the
flange holds the housing side wall. If required the bush can be removed from the
housing by means of forcing screws.
The cellular wheel rotates at the same speed as the drive shaft of the flanged
geared motor. The direction of rotation is as indicated by the arrow on the hous-
ing cover. It should be toward the product deflector.
The vanes of the cellular wheel are fitted with wearing bars that can be readjusted
and replaced through the inspection openings.
Protective bars ensure that the heads of the wearing gib fastening screws are
protected from wearing.
The gap width between the housing and wearing bar is 0.90 - 1.10 mm in new
condition.
The cellular wheel is closed by side walls.
The side walls include labyrinth seals in conjunction with the bearing end plate
and bearing motor end plate while additional scrapers are mounted to the cellular
wheel side walls.
Four adjusting screws are found on the circumference of the housing side walls.
They allow the cellular wheel to be precisely centered in the housing.

_______________________________________________________________________________ 10
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

A DN 150 connection is incorporated in either housing side wall for heating the
cellular wheel with air. These connections are arranged to discharge directly into
the housing interior.
The side walls of the cellular wheel have openings within the labyrinth seals. This
concept allows that the process exhaust air available can be taken into (or forced
through) the rotating cellular wheel along the housing side walls for heating the
cellular wheel interior.
One sealing-air intake nozzle each (nozzle DN 65) is arranged at the top of the
two lateral casing walls (end plates).
Before putting the rotary valve into operation, these nozzles must be connected to
a pipe to be provided by the customer, and sealing air is to be admitted (for tech-
nical parameters see Item 1 of these Operation Manual).
The sealing air effectively prevents dusty air from streaming into the inner heating
space of the star feeder.
Operating the rotary valve without sealing air admission is not admissible!
It should be made sure, however, that the heating air streaming into the cellular
wheel is not excessively cooled down by the secondary air.
Dust that might reach the space between the cellular wheel side walls and the
bearing end plates may be escape again through slots at the housing bottom.
The differential pressure of the rotary valve is measured by a pressure gauge
arranged on the circumference of the wheel housing.
This measurement allows the degree of tightness of the rotary valve to be deter-
mined.

_______________________________________________________________________________ 11
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

4.3 Bearing / sealing

The cellular wheel is supported in bearing boxes arranged outside of the cellular
wheel housing. The bearings are of self-aligning roller type with clamping sleeve
and shaft seals according to DIN 3760.

The cellular wheel shaft is sealed externally by adjustable and relubricatable stuff-
ing box packing. The sealing material used is synthetic yarn blend-PTFE-graphite
packing.
To avoid wear of the cellular wheel shaft in the area of the stuffing boxes, the
shaft was provided with replaceable hardened shaft protective sleeves at the
places carrying the stuffing boxes.

5 Identification

Identification plate

Rotary valve are identified by an identification plate provided in a well visible


place containing, among others, the following data for identification:

- Name of manufacturer
- Type
- Year of manufacture
- Consignment No.

Attention! Do not remove or render unreadable the identification


plate needed to identify the rotary valve !

_______________________________________________________________________________ 12
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

6 Transport and storage

After delivery, check the rotary valve and the accessories for completeness and
soundness using the package list/delivery list.

Any damage suffered in transit should be reported both to the carrier and the
manufacturer without delay.

In addition to this, we refer to our terms of sale and delivery.

Use the means of transport locally available when moving the rotary valve.

Follow the relevant accident-prevention rules.

When lifting and moving the rotary valve, use ropes of adequate load capacity
and/or a stacker truck.

Do not support and move the rotary valve by using the suspension
eye of the flanged geared motor.

It is essential to support the rope on the cellular wheel housing proper.

Care should be taken to ensure that the component parts are sup-
plied to the place of installation torsion-free and without deformation.

We are not liable for claims for compensation or under a warranty due to in-
adequate means of transport or improper lifting.

If the rotary valve is not installed immediately and/or taken into service, it shall be
stored in a dry room at temperatures between -5 °C and +35 °C ensuring that no
condensate can form.

In particular, when being stored for a longer period (over 6 months) supplemen-
tary protection and preservation measures should be taken.

In addition, it is recommended to observe the following instructions for putting into


operation after a two years’ storage time:
- Protection from rust film
Provide all metallic, bright-finished parts such as motor flange facing, motor
journal, coupling parts, shaft and cellular wheel ribs with a protective wax.
- Relieve the stuffing box (slightly loosen the gland), turn the rotor up2 to 3 time in
start operation, then retighten the gland evenly.
- Remove the old bearing grease (anti-friction bearing of rotary valve) abt. 3 years
- Replace the gear oil, the new gear oil could in addition be provided with a
respective additive for a long-term effect.

_______________________________________________________________________________ 13
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

7 Installation
The installation requires experience and technical knowledge.

We are not liable for damage due to improper installation.

When doing electric welding work, take care to ensure that the welding current
does never pass the bearings, other moveable connections or measuring sys-
tems in order to eliminate damage to these parts.

Prior to setting up the rotary valve or installing into an equipment, check:


- whether an erection plan is available;
- the floor or the adjacent area for its condition;
- the connection points for their accuracy to size;
- the site for the required clearance needed for installation, repair and mainte-
nance work;
- for the environmental conditions.

7.1 How to install

Install the rotary valve in proper condition only.

The rotary valve is preferably designed for horizontal mounting.

The arrows on the cellular wheel housing indicate the direction of conveying and
must point downwards.

Prior to installation, remove the safety covers on the inlet and outlet openings.
Attention! Make sure to provide rotating parts of the installation with protections.

Any damage caused to the preservation during installation should be repaired in


compliance with the corrosion protection data.

_______________________________________________________________________________ 14
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

Check on site using the erection plan:


- the alignment of the rotary valve;
- the given clearances to adjacent equipment parts;
- the possibility of electrical connection.

Take care to ensure that the rotary valve is installed in a torsion-free state.

A contraction without any transition on the outlet opening of the rotary valve
should be avoided (material to be conveyed can pile up).

Regelgewinde/ regular type screw thread

Abmessung/
Vorspannkraft/ pre load(kN) Anziehmoment/ aduction torque (Nm)
dimension

Festigkeits-
4.6 5.6 8.8 10.9 12.9 4.6 5.6 8.8 10.9 12.9
klasse

M 4x0,70 1,29 1,71 3,9 5,7 6,7 1,02 1,37 3,0 4,4 5,1

M 5x0,80 2,1 2,79 6,4 9,3 10,9 2,0 2,7 5,9 8,7 10

M 6x1,00 2,96 3,94 9,0 13,2 15,4 3,5 4,6 10,0 15,0 18,0

M 8x1,25 5,42 7,23 16,5 24,2 28,5 8,4 11,0 25,0 36,0 43,0

M 10x1,50 8,64 11,5 26,0 38,5 45,0 17,0 22,0 49,0 72,0 84,0

M 12x1,75 12,6 16,8 38,5 56,0 66,0 29,0 39,0 85,0 125,0 145,0

M 14x2,00 17,3 23,1 53,0 77,0 90,0 46,0 62,0 135,0 200,0 235,0

M 16x2,00 23,8 31,7 72,0 106,0 124,0 71,0 95,0 210,0 310,0 365,0

M 18x2,50 28,9 38,6 91,0 129,0 151,0 97,0 130,0 300,0 430,0 500,0

M 20x2,50 37,2 49,6 117,0 166,0 194,0 138,0 184,0 425,0 610,0 710,0

M 22x2,50 46,5 62,0 146,0 208,0 243,0 186,0 250,0 580,0 830,0 970,0

M 24x3,00 53,6 71,4 168,0 239,0 280,0 235,0 315,0 730,0 1050,0 1220,0

M 27x3,00 70,6 94,1 221,0 315,0 370,0 350,0 470,0 1100,0 1550,0 1800,0

M 30x3,50 85,7 114,5 270,0 385,0 450,0 475,0 635,0 1450,0 2100,0 2450,0

M 33x3,50 107,0 142,5 335,0 480,0 560,0 645,0 865,0 2000,0 2800,0 3400,0

M 36x4,00 125,5 167,5 395,0 560,0 680,0 1080,0 1440,0 2600,0 3700,0 4300,0

M 39x4,00 151,0 201,0 475,0 670,0 790,0 1330,0 1780,0 3400,0 4800,0 5600,0

_______________________________________________________________________________ 15
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

7.3 Electrical connection

CAUTION
Risk of electric shock

The electrical connection to the rotary valve shall only be made by an electrician.

The drive motor is assembled at the manufacturer’s works.

Follow the EMV Rules.

The mains supply and the switching and the monitoring devices shall be suffi-
ciently dimensioned with respect to type of starting and peak value of current and
subjected to a test by the operator.

For installation, follow in particular:


- the data in the motor manufacturer operation manuals;
- the respective data on the identification plate;
- the data in the circuit diagram contained in the terminal box; and
- make sure that all connections and protective conductors are tightly bolted.

When connecting the motor, make certain to choose the specified direction
of rotation.

It is essential that the rotational direction of the cellular wheel shaft matches the
arrow on the machine.

To protect the motor from overloads, it must be provided with an appropri-


ate protection device.

To prevent the electrostatic charging of the rotary valve during the operation of
the plant it will be necessary to provide a conductive connection with adjacent
components (structural steel work) using an earthing cable to be connected to
flanges of the rotary valve.
Rotary valve must be earthed, i.e. the leakage resistance must be less
than 106  against earth.

Prior to start-up, the rotary valve with its entire electrical equipment shall be test-
ed by an electrician in compliance with the regulations.

_______________________________________________________________________________ 17
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

8 Start-up
The start-up requires experience and technical knowledge.

We are not liable for damage due to an improper start-up.

All bearings and gearboxes have been provided by the manufacturer with the
specified amount of oil and grease and need not be opened and refilled for start-
up.

Attention !
Gear units of the “extended storage” type have a higher oil level in some
cases (synthetic oil).
Correct the oil level before start-up according to the specifications of the
manufacturer.

Prior to start-up, make a functional test of the rotary valve.

The rotary valve shall be started only after:


- all safety devices and the required monitoring equipment have been
installed and are operational.

Prior to start-up, check therefore the rotary valve whether:


- it has been installed and connected as specified;
- all electrical installations have been completed;
- all foreign matter has been removed from the rotary valve; and
- all safety and monitoring equipment is in place and operational;
- no person is staying in the danger area of the rotary valve;
- all inspection holes are secured and closed.

Dry functional test (without material)

In doing so, check the following functions:


- the rotational direction of the geared motor or the cellular wheel shaft must
match the arrow marked on the plate;
- the monitoring equipment display (if any);
- the running noise.

Wet functional test

Make certain the geared motor and the cellular wheel shaft are running in the
proper direction.

After about 8 operating hours under full load, check the rotary valve for:
- heated machine parts;
- any bulk material penetrating the rotary shaft seals;
- the tight seat of the bolted connections.

If problems occur, follow Section 10 “Troubleshooting“ of the operation manual.

_______________________________________________________________________________ 18
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

9 Operation

The rotary valve may be operated by trained personnel only.

The machine may only be in operated if:


- all safety devices and the monitoring equipment are in place and operational;
- no person is staying in the danger area of the rotary valve;
- all inspection holes are secured and closed.

Check the rotary valve at least once per shift for external damage and defects.
Any changes occurred should be immediately reported to those responsible.

In case of malfunctions, stop the rotary valve without delay and lock it. Eliminate
the problem promptly.

Make sure that the material to be conveyed can freely flow below the rotary valve,
otherwise the material might build up inside. This could result in the premature
wear or destruction of the machine.

Under normal operation, the rotary valve is controlled from a control station to-
gether with other machines and equipment parts.

When starting the rotary valve make sure that:


- first all downstream transport components have been properly connected;
- the rotary valve is then connected (without bulk material);
- the direction of rotation is correct;
- the upstream components are connected step by step.
(Product back-up must be prevented during the starting process.)

When stopping the rotary valve, make certain that:


- the material supply is stopped first; and
- then the rotary valve is running idle;
- the equipment is switched off on the conveying side last.

_______________________________________________________________________________ 19
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

10 Troubleshooting

Avoid damage to the machine.

The rotary valve should be immediately stopped if:


- abnormal operating noise is heard;
- the rotary valve is under overload.

As long as the problem is corrected, the machine should be secured during the
standstill.

The problems should be eliminated by trained and instructed personnel only.


Remember that a defect can cause a danger.

Recall the following operating data of the rotary valve:


* Rotary valve may be in operation.
o Rotary valve shall be OFF and secured against turning ON again.

The problems shall be eliminated by the following personnel only:


M mechanic
E electrician

Problems when starting


or restarting after a longer standstill

Problem
Cause Remedy Operating Personnel
state

Machine does not start


Drive gets no power Check power supply o E
Drive defective Repair or replace the o E/M
drive
Bearing seized Replace the bearing o M
Foreign matter in the Remove the foreign o M
machine matter
Machine clogged Clean machine inside o M

Abnormal operating noise on the machine


Machine clogged Clean the machine inside o M
Foreign matter in the Remove the foreign o M
machine matter

_______________________________________________________________________________ 20
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

Problems during operation

Problem
Cause Remedy Operating Personnel
state

Abnormal operating noise


on the machine
Machine clogged Clean machine inside o M
Foreign matter in the Remove the foreign o M
machine matter

Machine or parts thereof


are getting hot
Motor is getting hot Check the motor according o E
to manufacturer’s data
Gearing is getting hot Check the gearing according o M
to manufacturer’s data
Bearings are getting hot Check the lubricant and refill o M
or replace the bearing if ne-
cessary
Stuffing box are getting Check and readjust or replace o M
hot (if necessary) the
stuffing box packing material

Machine does not convey any or insufficient material


Machine is at standstill Check the power supply and
re-connect if necessary o E
Repair or replace the defec- o E/M
tive drive
Replace the bearing seized o M
Remove obstruction/foreign o M
matter
Machine in operation Check the feeder o M
No material supply Bridge builds up above the o M
rotary valve
Insufficient material Rotary valve o M
supplied chambers clogged

_______________________________________________________________________________ 21
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

11 Maintenance and care

11.1 General

Maintenance work and inspections shall be carried out by qualified tech-


nical personnel only.

The maintenance and inspection intervals specified in this operation manual shall
be adhered to.

Prior to starting this work, the operators should be informed accordingly.

When doing repair and maintenance work on the rotary valve, make certain:
- to disconnect the main power supply and
- interlock against unauthorised restarting.

Close off a wide area around the place of maintenance if necessary.

Use appropriate and safe lifting gear and load suspension devices with sufficient
load capacity only when replacing component parts and larger assemblies.

Keep the rotary valve free of contamination.

When starting the repair and maintenance work, clean in particular connections
and screwed connections.

After cleaning, check the machine parts for damage and eliminate any defects
promptly.

Retighten any screwed connections that have been loosened during servicing.

On completing the maintenance work, replace all safety devices (protection de-
vices). After this is done, the machine may be restarted.

11.2 Wearing bar readjustable

The wearing bars of the cellular wheel are set with a gap of 0.90 - 1.10 mm. If this
gap is found to have increased it will be necessary to readjust the wearing bars.
Access for readjusting is possible through the inspection opening in the inlet area.

CAUTION: Take care to observe the safety instructions. Refer to section 3.

_______________________________________________________________________________ 22
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

11.3 Dismounting and mounting instructions (Repair)

- Loosen and remove all air connection lines


(mark this lines to facilitate the assembly work).

Optimum alternative:
Dismount the rotary valve as a whole unit from the plant

- Dismount the driving motor and keep in mind that


* the motor may be disconnected only by authorized skilled personnel and
* the coupling halves shall remain on the motor shaft
- Dismount the coupling guard, oiling tube and motor bracket
- Dismount the sensor casing and capstan handle

- On both sides, loosen the fastening screws M 24 of the casing side walls by un-
screwing the same only approx. 3 turns (but do not remove these bolts).
- Lower the cellular wheel together with the side walls to the casing bottom
(approx. 1mm) by evenly loosening the 4 lower adjusting screws M20
(i.c. 2 screws on each side wall).
- Detach the bearing covers on both sides and mark them because they are of
different design (loose bearing / fixed bearing).
- Loosen and remove the 2 adapter sleeve nuts and lock washers.
- Force away both bearing casings together with the antifriction bearing from the
bearing seat (2 forcing screws M 16 for each bearing), mark the loose bearing
and the fixed bearing.
- Sling one casing wall each to the crane and remove the loosened fastening
screws; force them out of the cellular wheel casing by means of 4 forcing
screws M 20 each.

- Using two separate hemp ropes, sling the shaft ends of the cellular wheel to the
crane and slightly lift the same (so that the cellular wheel is swinging in the
casing) and, by means of the crane, push it toward the shaft collar side of the
wearing bush as far as possible.
Then place down the cellular wheel and attach again the slinging means and
continue to push it (refer also to the schemes in which the steps of dismounting
work are shown).

Insert 4 forcing screws M20 in the flange of the wearing bush, tighten them
against the casing flange and pull the bush from the casing seat (approx. 30 mm).
By using the crane, lift the wearing bush out of the casing.

_______________________________________________________________________________ 23
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

For mounting, follow the preceding steps in reverse order.

- Lift the wearing bush into the casing and align it with reference to the casing’s inlet
and outlet cross section and the respective flange holes.
Apply a slight coat of grease to all sealing surfaces at the flange and the fitting sur-
faces of the bush.
- Insert 8 screws M 24 through the flange of the wearing bush into the casing flange
and tighten them crosswise by ¼ revolutions so that the bush is forced to its seat.
- Remove again the screws M 24.

- Using the crane, insert the cellular wheel into the casing (proceed in reverse order
as described for the dismounting work and refer to the drawings) and centrally align
it to the casing (by laterally measuring the distance between the casing flange and
the side wall of the cellular wheel) and place it down.

- Attach the tackles and slings each to the casing side walls and the crane and push
them over the shaft journal to the casing; insert the fastening screws M 24 and
tighten them crosswise. Then apply a slight coat of grease to the sealing surfaces of
the flange as well as to the hub of the stuffing box.

- Push the lubricating ring and the stuffing box gland onto the shaft so that they fit
loosely.
- Mount the bearing casing to the bearing end shield.
- Push the lubricated antifriction bearing with adapter sleeve, lock washer and adapter
sleeve nut onto the shaft journal and into the bearing casing (for arranging the loose
and fixed bearings, refer to the drawing).

- Loose bearing: Tighten the adapter sleeve nut and, doing so, check the bearing seat
in the bearing casing.
- Fixed bearing: Keep a distance of 238 mm between the shaft end and the bearing.
When the adapter sleeve nut is tightened, the original bearing clearance is reduced.
For this reason, when tightening the adapter sleeve nut, check the bearing clearance
level achieved after every half revolution and compare this level with the bearing
manufacturer’s specification (refer also to the table below).
After the bearing clearance level as specified has been achieved, secure the adapter
sleeve nut (by turning over a lug of the lock washer to the groove of the adapter
sleeve nut) to prevent it from being loosened subsequently.

Reduction of the bearing clearance in case of self-aligning bearings with conical bore
Nominal size Radial clearance Radial clearance
before the installation after the installation
for the clearance group C 3 for the clearance group C 3
115 mm dia. at least not more than at least
0.135 mm 0.17 mm 0.065 mm

_______________________________________________________________________________ 24
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

- Mount the bearing cover.


- Axially adjust the cellular wheel in the cellular wheel casing.
- Insert and tighten all adjusting screws as far as it will go (while forcing against the
casing side wall).
- Turn the casing by 90° (the inlet and outlet will be visible).
- Determine any differences in the gap between the casing and the cellular wheel and,
if necessary, compensate them by means of the adjusting screws (when checking
the gap, use the gap gauge).
- After the cellular wheel sits exactly in the casing, secure all tightened adjusting
screws by lock nuts.
- Firmly tighten the fastening screws M 24 in the casing side wall (by tightening them
crosswise).
- Insert the stuffing box packing ( 2 packing layers, lubricating ring, 2 packing layers).
- Tighten the stuffing box gland.
- Mount the lubricating nipple and oiling tube, lubricate the stuffing box packing.
- Mount the capstan handle and sensor casing.
- Mount the motor bracket and the coupling guard.
- Mount the driving motor and the electrical connection lines.
- Mount all air connection lines to the rotary valve.

_______________________________________________________________________________ 25
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

11.4 Inspections and maintenance

Attention! The details given in the following table refer to the preventive mainte-
nance and should be followed.

The maintenance work shall be carried out by qualified personnel only.

Check the rotary valve for external damage and defects once per shift.
Changes that have occurred should be reported without del-ay.

Note. In addition to the details given in the table, also follow the respective sec-
tions of the operation manuals for the parts supplied (motors etc.) and the section
“Troubleshooting“ of this operation manual.

Machine part Person- Type of Operating Application class


nel mainte- state Maintenance interval
nance I II III
1. Drive motor M 4 8 b 6m 3m m
Cable supply E 5 s 6m 3m m
Cooling ribs M 7 b 6m 3m m

2. Gearbox M 1 2 s 6m 3m m
M 4 8 b 6m 3m m

3. Bearing M 1 s 6m 4m 2m
M 4 8 b 6m 4m 2m

4. Stuffing box M 2 s 3m 2m m
M 4 8 b 3m 2m m
Gland M 6 s 3m 2m m

5. Housing M 5 7 9 s 6m 3m m
wearing bush M 5 9 s 6m 3m m

6.Cellular wheel M 9 s 6m 3m m
build-up M 5 7 s 6m 3m m
wearing bars M 5 6 9 s 4m 2m m
width of port M 5 s 4m 2m m

7. Inductive M 1 s 4m 2m m
sensor E 3 s 4m 2m m

Explanation:
Personnel Type of mainte- Operating Application class Frequency
nance state
M Mechanic 1 Fastening b Operation I Occasional use m monthly
E Electrician 2 Leakage s Standstill with longer rest w weekly
3 Functional test periods
4 Noise II Regular use with
5 Inspection discontinuous
6 Readjustment operation
7 Cleaning III Regular use in
8 Temperature continuous
9 Wear operation

_______________________________________________________________________________ 26
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

11.5 Lubricating instructions

This work shall be done by instructed personnel only.

All lubricating jobs should be done only when the rotary valve is at a standstill.

In dealing with oil and grease, follow the safety regulations applicable to the
product.

Attention! Hazard of machine damage.

Do not mix up synthetic lubricants with each other and with mineral lubricants.

First clean the lubrication points from outside, then check the old lubricants for
their condition.

If lubricants have to be removed, collect them in appropriate reservoirs and dis-


pose them compatible with the environment in accordance with the applicable
regulations.

Use the proper grade and amount of lubricant.

Lubrication point Lubrication Lubricant Amount Remarks


interval
Geared motor abt. 3 000 h Check oil and oil
level

abt. 17 000 h synthetic oil 16.4 l Oil renewal as


or every 5 CLP HC 220 specified by motor
years manufacturer

Antifriction bearing abt. 16 000 h Mobiltemp 78 200 g / For grease re-


grease bearing newal: remove
grease, clean bear-
ing, refill grease.

abt. 8 000 h 90 g / For re-lubrication


bearing
Stuffing boxes abt. 4 000 h Mobiltemp 78 30 g / For re-lubrication
grease lubrication
point

_______________________________________________________________________________ 27
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

12.2 Spare parts list

Item Description Priority Pcs. Ident-No. / Remarks

1 Housing -right E 1 166375


1.1 Wearing bush V 1 170204
1.2 Product deflector V 1 200325
with composite armour plate
1.3 Composite armour plate V 2 200365
1.4 Composite armour plate V 2 200365
2 Cellular wheel -right V 1 169787
with side walls and 10 compartments
2.1 Wearing bars (two-parts) V 10 170154
2.2 Shaft protective sleeve 125 V 2 170700
3 Bearing bracket E 1 167670
at motor end
4 Bearing bracket E 1 168109
5 Engine bracket E 1 167120
6 Bearing housing E 2 168363
7 Bearing cap for solid bearing E 1 168221
8 Bearing cap for loose bearing E 1 168291
9 Casing for sensor and E 1 166522
control proof ( 8 imp.)
10 Gland E 2 169968
11 Elastic coupling E 1 138248

12 ---
13 Helical gear motor E 1 203726

14 ---
15 Inductive sensor/speed monitor E 1 156887
16 Self aligning roller bearing with V 2 152532
adapter sleeve 152646
17 ---
18 ---
19 Grease ring 145 E 2 155266
20 Shaft seals V 4 155229
21 Stuffing box packing V 8 132453-170 (145218)

E = spare part V = wearing part


When ordering spare parts, always specify order No., quantity desired and part name.

_______________________________________________________________________________ 29
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

13 Disposal

The disposal and disassembly of the rotary valve should be


effected out in compliance with the applicable laws and regulations.

Run the machine until it is completely empty, remove heavy contamination


and dismantle the machine in its assemblies.

Dispose of all machine parts separately with respect to kind of material,


e.g.:
- metal parts are scrapped,
- plastic and compound parts are recycled to plastics.

Collect waste oil, grease and other pollutants in appropriate reservoirs and
have them disposed of professionally in compliance with the applicable
regulations.

_______________________________________________________________________________ 30
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)
OPERATION MANUAL
ROTARY VALVE
Design ADG, Series 21
Umwelttechnik
seit 1912

14 Documentation of vendor parts

This machine includes the documentation from suppliers for certain ma-
chine parts.
These documentation attached should be kept together with the operation
manual and to be followed in connection with the operation manual.

The operation manual is supplemented by the following documentation:

For the Type Scope of Supplier


vendor part Documentation

Gear unit RF147 - Operating instructions SEW


- Parts list

Drive motor DRN160 M6 / TF - Operating instructions SEW


- Parts list
- Circuit diagram

Elastic coupling Flender N-EUPEX - Operating instructions Siemens


A 400

Inductive DBI10U-M30- - Technical data TURCK


Sensor/ AP4X2
Speed monitor

_______________________________________________________________________________ 31
September 2016 161344 Pos.10 (P12686/ BIM SON CS – M20M05.010)