rotary valves acl

AL-BL Rotary valves

DMN-Westinghouse

Operation instruction + Maintenance Safety instructions

AL-BL-AML Size : 100-150-175-200-250-300-350-400-450-500 (incl. BL 175/200 BL 200/250 BL 250/300 BL 300/350)

Standard

HT execution up to 250°C

HT execution up to 600°C

OS-GOS size: 400-450-500

Standard

GL Size: 150-175-200-250-300-350

Standard

Customer :

Purchase order no. :

DMN-Westinghouse order no. :

Type :

Serial no. :

DMN-Westinghouse AL-BL Rotary Valves

Code: AL-E.B.01.1 02-2001 2

General

- For the promotion of the life span and correct functioning of DMN-Westinghouse valves we advise you to respect these operation instructions and to carry out maintenance work accordingly.

- Should there be any problems, please contact our technical sales depart-ment.

Copyright

Copyright © DMN-Westinghouse. All rights reserved. All information including drawings shown in this manual are covered by copyright. No part of this manual may be reproduced or published in any form or in any way, electronically, by print, photoprint, microfilm or any other means without prior written permission from DMN-Westinghouse.


Code: AL-E.B.01.1 02-2001 3

Contents Page

1. Safety instructions Rotary valves 5 1.1 General safety instructions 5 1.2 Symbols 5 1.3 Responsibilities of management and maintenance personnel 5 1.4 Applying the safety instructions when installing a valve 6 1.5 Applying the safety instructions when the valve is in operation 6 1.6 Applying the safety instructions during maintenance and repair 6

2. Installing the valve in the system 7 2.1. Drive 7 2.2. Mounting the valve in the system 8

3. Operation instructions 3.1 AL-BL Standard execution 10

3.1.1 General 11 3.1.2 Technical specifications standard 11 3.1.3 Construction

3.1.3.1 General assembly and parts list AL-BL 12 3.1.3.2 Shaft sealing standard 13

3.1.4 Dismantling, assembling and adjusting instructions 15 3.1.4.1 Dismantling standard execution 15 3.1.4.2 Reassembling standard execution 16 3.1.4.3 Axial/radial adjustment of rotor and blades 17

3.2 AL-BL HT execution up to 250°C 20

3.3 AL HT execution up to 600°C 22 3.3.1 General 23 3.3.2 Technical specifications HT 23 3.3.3 Construction

3.3.3.1 General assembly and parts list AL-HT up to 600 C 24 3.3.3.2 Shaft sealing standard see 3.1.3.2 13


3.4 OS-GOS Standard execution 30 3.4.1 General 31 3.4.2 Technical specifications 31 3.4.3 Construction

3.4.3.1 General assembly and parts list OS-GOS 32 3.4.3.2 Shaft sealing executions see 3.1.3.2 13

3.4.4 Dismantling, assembling and adjusting instructions 33 Standard execution see 3.1.4 15


Code: AL-E.B.01.1 02-2001 4

Contents Page

3.5 GL Standard execution 34 3.5.1 General 35 3.5.2 Technical specifications 35 3.5.3 Construction

3.5.3.1 General assembly and parts list GL 36 3.5.3.2 Shaft sealing executions see 3.1.3.2 13


3.6 Dismantling and assembling standard drive 38 3.6.1 Chain drive 38 3.6.2 Direct drive 39

3.7 Accessories ( If fitted ) 40 Safety switch 40 Pulsating air execution 41 Pressure regulator 42 Zero speed indication 43 Inlet restrictor / Drop out box / Air vent box 44

4. Maintenance 45 4.1. General 45 4.2. Maintenance every 3 months or after 2,500 operating hours 45 4.3. Maintenance every 12 months or after 10,000 operating hours 45 4.4. Maintenance motor / gearbox 45 4.5. Cleaners 45 4.6. Lubricants 46

5. Malfunctioning 46 5.1. Probable cause 46

APPENDIX Declaration by the manufacturer Technical specifications drive SEW


Code: AL-E.B.01.1 02-2001 5

1. Safety instructions Rotary valves

1.1 General safety instructions

The safety instructions as described below should be followed by the user when:

- installing the valve; - maintaining and repairing the valve.

The safety instructions should be read carefully both by management and maintenance personnel before carrying out the above operations.

Failure to follow these safety instructions, may result in one or more of the following:

- the safety of the maintenance personnel could be endangered; - the valve may not function correctly; - the system which contains the valve may be damaged.

Modifications and alterations to the product is not permitted other than by DMN-Westinghouse trained personnel, to ensure safe operation.

1.2 Symbols

Remark.

Attention. Failure to follow these instructions, may result in damaging or breaking the valve.

Warning. Personal danger.

1.3 Responsibilities of the management and maintenance personnel

The management must take care that:

- the maintenance personnel maintains the safety instructions, as described in this document;

- all available means which are necessary for working according to the safety instructions are present;

- the maintenance personnel possess the necessary skills.

Maintenance personnel should follow these safety instructions when carrying out installation, repair and maintenance.


Code: AL-E.B.01.1 02-2001 6

1.4 Applying the safety instructions when installing a valve

After removing the packaging material it is possible to reach the inlet and outlet of the valve. During this operation do not turn the rotor by hand.

Do not alter, remove or paint the type specification plates of the valve, drive unit or fitted switches.

1.5 Applying the safety instructions when the valve is in operation

Only operate the valve when it is fitted with the protective safety parts supplied by DMN-Westinghouse. These are:

- mechanical protection i.e. chain guard and end cover plates (104); - electro-mechanical protection i.e. safety switches (if fitted).

While the valve is in operation no maintenance or repair work must be carried out.

1.6 Applying the safety instructions during maintenance and repair work

When product qualities necessitate supplementary safety instructions and wearing protective clothes, it is obligatory to follow the local safety instructions.

Before maintenance and repair work is carried out:

- electrical supply to the valve motor must be isolated. - air pressure to shaft seals must be isolated;

After the maintenance and repair work has been carried out, all safety parts removed during the work should be re-assembled and their operation should be checked.


Code: AL-E.B.01.1 02-2001 7

2 Installing the valve in the system

Turning the rotor is prohibited. Danger to fingers and hands.

2.1 Drive

- Before starting the valve, check the oil level in the gear box. It should be filled with the correct amount and type of oil according to the instructions (see 4.4). Fit the breather cap on the gear box and check that the venting nipple is clean.

- Check the rotating direction of the valve rotor. It should rotate clockwise seen from the drive end (see direction of the arrow).

Fig. 2.1 Rotating direction of rotor.

- Electrical specifications for connection must correspond to the information stated on name plate of drive.

- Follow instructions of drive supplier (connection diagram is in junction box)

If delivery excludes drive

- On one side of the valve holes have been tapped for fitting the motor base plate (see drawing for dimensions).

- To fasten the chain guard, three holes have been tapped in the bearing housing of the valve (see drawing for dimensions).

The sprockets should be fitted on the rotor shaft as close as possible to the bearing housing. The sprockets should not be hammered on to the shafts. The sprockets on the shafts of the valve and the gear box should always be perfectly aligned.

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Code: AL-E.B.01.1 02-2001 8

524

10mm

Fig. 2.2 Tighten chain.

Tightening drive chain - Tighten chain by adjusting nuts (524) to give 10 mm slack at chain. - Grease chain.

2.2 Mounting the valve in the system

When installing the valve make sure it is not unevenly loaded by external forces or vibrations.

- If it is a blowing seal, the conveying pipe line to be connected to the blowing seal should ideally have the same diameter as the connections on the seal.

- If there is some difference between the inner diameters of the blowing channel and the conveying line, the transition from one diameter to the other should be as smooth as possible.

- If the valve is fitted with air vents, the area of the venting pipe should be equal to the total area of both vent connections.

Remove all packing material and preservatives. Check for any transport damages.

Installation procedure

Please respect safety instructions.

- Install the valve stress free

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Code: AL-E.B.01.1 02-2001 9

- Connect conveying pipes stress free - Connect air vent pipework - Connect air purge supply and adjust pressure regulator - Fasten gland packing (see 3.1.3.2) - Connect motor - Check rotating direction (see fig. 2.1)

Shaft sealing with air purge. When using an air purge gland oil-free dry air must be used. The diameter of the air pipe supply should be equal to or larger than the connection on the valve. The pressure of this purging air should be 0.5 bar higher than the pressure in the valve. The air pressure must be applied before product enters the valve and before conveying pressures are applied. The air supply must always be present when there is product in the valve, and especially after conveying ceases.

DMN-Westinghouse valves have been manufactured with great care. To reduce air leakage’s, internal running clearances are kept extremely small during manufacture and assembly of the valve.

- do not use heavy or rough tools; - avoid damages like scratches and burrs; - clean all parts thoroughly.

In case of repair work to the valve, please follow safety instructions of chapter 1.

- Turn off the electrical supply, lock the switch and/or remove the fuses; - If necessary, disengage the chain to ensure that the rotor does not turn.

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Code: AL-E.B.01.1 02-2001 10

3.1 Operation instructions AL-BL-AML 3.1.1 General 11 3.1.2 Technical specifications 11 3.1.3 Construction

3.1.3.1 General assembly and parts list AL-BL 12 3.1.3.2 Shaft sealing standard 13


3.2 Al-BL HT execution up to 250 C 20


Code: AL-E.B.01.1 02-2001 11

3.1.1 General

The type AL and BL rotary airlocks are designed for the metering and pneumatic transport of products in powder form.

The limits stated in the technical specification 3.1.2 should not be exceeded. The user is responsible for any defects and/or risks or damages resulting from improper use.

3.1.2 Technical specifications

Standard execution:

Operating pressure permitted : -0,5 to +2 bar Temperature permitted : -10 C to +150 C

AL and BL valves explosion proof execution Most of the AL and BL valves are explosion proof up to 10 Bar pressure. They have been certified by the DMT (DMT-Gesellschaft für Forschung und Prüfung GmbH) after thorough testing pressure shock resistance and flame proofness. Tests are done according to VDI 2263.

Materials:

housing & end covers Cast iron GG25 Din 1691/0.6025 Size 100-350 Cast iron GGG40 Din 1691/0.7040 Size 400-500 Stainless steel AISI 316 Din 17445/1.4408 Cast aluminium LM25TF7 Din 1725/2.3716

Rotor Steel St.37 Stainless steel AISI 316

Capacity: Rotor with 9 adjustable blades.

AL-BL 150 175 200 250 300 350 400 450 500

AML 150 200 250 300 350 400

Ltr./Rev.

2,5 5,5 10,5 19 34 58 91 135 230

Capacity per revolution at 100% filling

Size AL 100 (0.8 Ltr./rev.) with round flanges PN6

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Code: AL-E.B.01.1 02-2001 12

3.1.3. Construction

3.1.3.1 General assembly and parts list type AL-BL

414

155

158

434

153

152

155

154

435

103

226

433

201

159

432

102

101

155

152

302225

224

413

412

159

201

226

158

102

415

101

222

221

202

151

104

105

431

422

223

421

222

105

221

202

151

104

411

223

401

436

423

Fig. 3.1.3.1 Execution AL-BL (AML).

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LUBRICATE BOLT


Code: AL-E.B.01.1 02-2001 13

414

412

413

401

415

411

101 Body 158 Name plate 302 Rotor blade 421 Gland follower 102 End cover 159 Arrow 303 Scraper blade 422 Lantern ring 103 Flange 304 Plastic rotor blade 423 Extension piece 104 Cover 201 Rotor 305 Clamp plate 431 Gland packing 105 Ball-bearing 202 Spacer ring 432 Coupling 151 Bolt 221 Safety ring 401 Gland follower 433 Stud 152 Bolt 222 Locknut 411 Gland packing 434 Nut 153 Nut 223 "O"-ring 412 Stud 435 Washer 154 Bolt 224 Headscrew 413 Nut 436 Cylinder bolt 155 Washer 225 Washer 414 Washer 156 Plug 226 Key 415 Plug

3.1.3.2 Rotor shaft sealing

Standard executions are : - shaft sealing with gland packing; - air purge with glandpacking; - air purge with lipseal.

3.1.3.2.1 Shaft sealing with gland packing

401 Gland follower 411 Gland packing 412 Stud 413 Nut 414 Washer 415 Plug

Fig. 3.1.3.2.1 Gland sealing.

Gland seals In case of gland seals by means of gland packing it is necessary before starting the system to fasten the gland in order to set the gland packing in such a way that it seals and the rotor will be able to run.

Adjustment of the gland packing seals should be made with the unit in stationary condition. The gland follower should be tightened up evenly and only to prevent leakage. The necessity of good gland maintain is very important to prevent contamination and also unnecessary wear.

If normal adjustment is insufficient to prevent leakage or overheating, the gland packing should be completely renewed. Replace the gland packing as follows:

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Code: AL-E.B.01.1 02-2001 14

421

436

423

434

435

433

431

422

432

435

434

433

421

422

431

432

- Withdraw gland follower (401) and pull these against the ball-bearing place. Remove the old gland packing using a suitable packing extractor tool.

Examine shaft journal for wear. Excessive wear or scoring in this area will reduce the effective life of the packing.

- Carefully fit the new packing and re-assemble the gland follower (401) which must be pulled up evenly by means of the gland nuts (413) but not beyond finger tightness at this stage. Insert packing rings one at the time with joints staggered 60 apart.

3.1.3.2.2 Shaft sealing with air purge and gland packing

421 Gland follower 422 Lantern ring 423 Extension piece 431 Gland packing 432 Coupling 433 Stud 434 Nut 435 Washer 436 Cylinder bolt

Fig. 3.1.3.2.2 Air purge glands.

For adjustment and replacement follow the instructions for shaft sealing with gland packing.(3.1.3.2.1)

3.1.3.2.3 Shaft sealing with air purge and lipseal

421 Gland follower 422 Lantern ring 431 Lipseal 432 Coupling 433 Stud 434 Nut 435 Washer

Fig. 3.1.3.2.3 Air purge glands. This seal cannot be adjusted. When carrying out a complete overhaul the air purge gland must be cleaned and checked for damage and if necessary replaced. All parts to


Code: AL-E.B.01.1 02-2001 15

be lightly greased prior to assembling the seals.

3.1.4 Dismantling, assembly and adjustment instructions for the valve





222

202

221

223

152

155

105

151

104

Fig. 3.1.4.1 Dismantling standard execution.

3.1.4.1 Dismantling standard execution Non-drive side - Remove the bolts (151) from the bearing cover (104) and remove cover. - Loosen the locking nut (222) remove the safety ring (221) and spacer ring (202). - Remove the end cover fixing bolts (152) fit two of these bolts in the tapped

jacking holes provided in the end cover (102) and remove, also remove the "O" ring (223) and retain.

Drive side - Dismantle the drive parts. - Loosen the locking nut (222) remove the safety ring (221) and spacer ring (202).


Code: AL-E.B.01.1 02-2001 16

- Remove the endcover fixing bolts (152), fit two of these bolts in the tapped jacking holes in the end cover (102) and remove, also remove the "O" ring (223) and retain. The rotor is removed by pulling it axially from the body.

Support the rotor to keep it in line with the bore otherwise damage may be caused to the rotor blades and/or bore of the body. Place the rotor on a wooden surface to prevent the rotor blades from being damaged.

- Remove the air purge glands (431) and gland packing (411).

3.1.4.2 Re-assembly standard execution

After thoroughly cleaning, checking and renewing necessary parts the valve should be re-assembled as follows: - Check that the ball-bearings (105) are pressed in tight to the end cover (102). If

necessary, tap lightly on the outer bearing ring using a copper rod, to ensure that the bearing is seated properly.

- Air purge glands: reassemble the complete air purge gland in both end covers and secure by means of nuts (434).

- Gland packing: reassemble the gland follower (401) to the end covers without packing cord.

Clean the spigot edges of both end covers (102) carefully. To ensure the rotor position is concentric with the valve bore the endcover spigots are a light interference fit in the body. Before assembly the jack screws (152) have to be removed.

- Assemble the end cover to the non-drive side of the body and secure it using bolts (152).

- Assemble rotor blades finger tight to rotor with screws and washers. - Fit the rotor (the adjustable blade not yet adjusted) in the body and gently push

the rotor shaft through the sealing area at the non drive side end cover. Fit the "O"-ring (223) on the rotor shaft when the shaft is through the sealing area and then push the rotor further until the shaft end is positioned inside the ball-bearing.

- Fit the drive side endcover and make sure that the "O"-ring is fitted on the rotor shaft. Fit the spacer ring (202), retainer ring (221) and the locknut (222) at both ends of the rotor shaft.


Code: AL-E.B.01.1 02-2001 17

3.1.4.3 Rotor adjustment for standard execution

The standard executions have the following axial and radial clearances.

Body end covers

material

Rotor material Size valve Clearance axial and radial

Cast iron Mild Steel 150 up to 350 0,1 up to 0,15 mm

Cast iron Stainless steel 150 up to 350 0,1 up to 0,15 mm

Stainless steel Stainless steel 150 up to 250 0,1 up to 0,15 mm


Body end covers

material

Rotor material Size valve Clearance axial and radial

Cast iron Mild Steel 400 up to 500 0,15 up to 0,2 mm

Cast iron Stainless steel 400 up to 500 0,15 up to 0,2 mm


Special clearances are to be set with product temperatures of 50 C and higher, according to special instructions, depending on size and material of the valve. Product characteristics may influence the clearance. In case of any doubts please contact sales department.

Rotor with fixed blades

Rad.Ax.

226

201

Ax.

105

223

151

202

221

222

104

Fig. 3.1.4.3.1 Adjustment for axial clearance. The rotor must be adjusted in axial direction (at both sides) with a tolerance between


Code: AL-E.B.01.1 02-2001 18

the machined surfaces of the rotor.

- Push the rotor hard against the inside face of the end cover at the non-drive end.

- Measure the total end clearance. Equalise this clearance by placing a feeler gauge between the vane and the non-drive end cover.

- Tighten locknut until the gauge is just nipped in position. - Secure the locknut. - Now tighten the locknut at the drive end until the feeler gauge can be

removed. - Secure drive end locknut and check that both end clearances are

equal.

Rotor with adjustable blades Adjustment of axial rotor as described under rotor with fixed blades.

Axial/radial adjustment of the rotor blades: The tolerances for the axial adjustment of the rotor blades are the same as stated for the rotor. The radial clearance should normally be between 0.1-0.15 mm but it is preferable to try and achieve a smallest possible clearance (i.e. 0.1-0.12 mm). Feeler gauges or copper shims of the correct thickness should be used for adjusting clearances. They are placed between the loose rotor blades and the cylindrical wall of the body. (i.e. adjacent to the inlet opening and as close to the end covers as possible).

201

226

Rad.Ax. Ax.

223

304

305224

202

221

222

151

105

104

Fig. 3.1.4.3.2 Adjustment for axial and radial clearance rotor blades.

- Adjust axial/radial clearance and rotor blade using feeler gauges or copper shims of the correct thickness.

- Above described adjustment has to be executed with all blades.


Code: AL-E.B.01.1 02-2001 19

L R

0,05 0,050,05

Fig. 3.1.4.3.3 Adjustment scraper blades.

Adjustment of scraper blades: The axial clearance must be adjusted to a slightly closer tolerance (0.05-0.08 mm). Use again feeler gauges or copper shims of the correct thickness. The two scraper blades are set with the correct clearance at one side. Blade L on the left side, blade R is set on the right side with the correct clearance.

After adjustment of the blade feeler gauges or copper shims must be removed. Never let them remain in the valve.

Rotor with adjustable synthetic or flexible blades

- Average the axial clearance of the rotor blades. - Adjust radially with zero clearance. - Fasten clamp plate simultaneously.

Check the final adjustment by turning the rotor by hand. If larger valves of 300 and 350 size have flexible blades it may be necessary to rotate by lever action. If steel blades are used the rotor should turn noiselessly.

- Assemble cover. - Assemble gland (3.1.3.2). - Mount drive parts (3.6).

After assembly test run the valve.


Code: AL-E.B.01.1 02-2001 20

3.2 Al-BL HT execution up to 250 C

General assembly and parts list type Al-BL HT execution up to 250°C.

152

155

434

435

433

158

201

226

159

170

102

432

101 201303

302

225

224

221

222

202

105

104

151

172

171

431

422

421

423

436

413

152

155

414

412

201

226

159

158

170

102

415

101 201

172

221

222

202

104

151

105

171

401

411

Fig. 3.2.1 AL-BL HT execution up to 250°C.

101 Body 102 End cover 104 Cover 105 Spherical roller

bearing 151 Bolt 152 Bolt 155 Washer 156 Plug 158 Name plate 159 Arrow

170 Grease nipple 171 Nilos ring 172 Nilos ring

201 Rotor 202 Spacer ring 221 Safety ring 222 Locknut 224 Headscrew 225 Washer 226 Key

302 Rotor blade 303 Scraper blade

401 Gland 411 Gland packing

412 Stud 413 Nut 414 Washer 415 Plug

421 Seal follower 422 Lantern ring 431 Gland packing 432 Coupling 433 Stud 434 Nut 435 Washer


Code: AL-E.B.01.1 02-2001 21

Clearance depends of size valve and product temperature and valve material. See enclosed table of clearances for the right adjustment of the rotor.

To achieve rotor end clearance stated above a gasket is fitted between the body and end cover non-drive end.

For instructions to adjust the rotor and blades see chapter 3.1.4.3 of the AL/BL/AML-instruction manual.

Lubrication data The interval between overhauls will vary with the product being handled and should be based on total operating time. To a large degree the rate of wear for a particular application would be assembled by practical experience.

Maintenance apart from planned overhaul should be adequately covered by regular and frequent attention to the rotor shaft glands, bearings, reduction gear lubrication and adjustment and lubrication of the motor drive chain and chain sprockets.

Bearing of the rotor shaft (for product temperature up to max. 250 C)

The bearings fitted in the rotary valve are roller bearings (105).

Apply a few shots of Klüber HM 83-402 to the bearing grease nipple’s (170) using a gun before starting the valve and at any future opportunity when the valves are 'cool'.

Check bearing monthly and grease if necessary.

Do not apply to valves when hot as the carrier in the lubricant will 'FLASH OFF'.

Drive chain and sprockets Lubricate with ROCOL FOLIAC L621 monthly.

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Code: AL-E.B.01.1 02-2001 22

3.3 Operation instructions AL-HT execution up to 600 C

3.3.1 General 23 3.3.2 Technical specifications HT 23 3.3.3 Construction

3.3.3.1 General assembly and parts list AL-HT execution up to 600 C 24 3.3.3.2 Shaft sealing standard see 3.1.3.2 13



Code: AL-E.B.01.1 02-2001 23

3.3 Operation instructions Al HT execution up to 600 C

3.3.1 General

The type AL-HT rotary airlocks are designed for the metering of products in powder form for temperature up to 600 C.



AL-HT execution:

Operating pressure permitted : -0.5 to +2 Bar

No pressure difference over rotor

Temperature permitted : Cast iron GG 25/ Mild steel 250 C to +400 C St.St 316/ St.St 316 250 C to +600 C

Materials:

housing & end covers Cast iron GG25 Din 1691/0.6025 Stainless steel AISI 316 Din 17445/1.4408



AL-BL 150 175 200 250 300 350 400 450 500

AML 150 200 250 300 350 400

Ltr./Rev.

2,5 5,5 10,5 19 34 58 91 135 230



Code: AL-E.B.01.1 02-2001 24

3.3.3 Construction

3.3.3.1 General assembly and parts list type AL HT execution up to 600 C

155

102

433

435

152

434

108

160

106

201

226

158

159

152

432

155

101

414

412

413

160

108

106

303

302201

224

225

105

436

423

170

171

222

202

221

104

227

151

163

421

422

431

105

156

222

151

221

203

226

201

158

159

102

415

101201

104

202

227

411

401

Fig. 3.3.3.1 AL HT execution up to 600°C.

101 Body 201 Rotor 401 Gland follower 102 End cover 202 Spacer ring 411 Gland packing 104 Cover 203 Shim 412 Stud 105 Ball-bearing HT 221 Safety ring 413 Nut 108 Bearing house 222 Locknut 414 Washer 127 Shaft protection 224 Headsrew 415 Plug 151 Bolt 226 Key 152 Bolt 227 Retaining ring 421 Gland follower 155 Washer 422 Lantern ring 156 Washer 301 Rotor blade 431 Gland 158 Name plate 432 Coupling 159 Arrow 433 Stud 160 Countersunksrew 434 Nut

435 Washer 436 Cylinder bolt


Code: AL-E.B.01.1 02-2001 25


Standard executions are : - shaft sealing with gland packing; - air purge with glandpacking;

For adjustment and replacement follow the instructions for shaft sealing with gland packing. (3.1.3.2 Page 13.)







Code: AL-E.B.01.1 02-2001 26

3.3.4.1 Dismantling standard execution

105

151

156

222

202

221

203

104

227

411

401

Fig. 3.3.4.1.1 Dismantling non drive side. Non-drive side - Remove shaft guards. - Remove the bolts (151) from the bearing cover (104) and remove cover. - Loosen the locking nut (222) remove the safety ring (221) and spacer ring (202). - Remove the bearing housing assembly fixing bolts (160) fit two of these bolts in

the tapped jacking holes provided in the bearing housing (108) and remove. - Remove inner spacer, shim (203) and retain. - Remove the end cover fixing bolts (152) fit two of these bolts in the tapped

jacking holes provided in the end cover (102) and remove. - Remove retaining circlip (227) and press out bearing (105) from bearing

housing.

155

152

106

160

203

108

226

159

201

158

415

102

101

Fig. 3.3.4.1.2 Dismantling drive side. Drive side - Remove shaft guards. - Dismantle the drive parts. - Loosen the locking nut (222) remove the safety ring (221) and spacer ring (202). - Remove the bearing housing assembly fixing bolts (160) fit two of these bolts in

the tapped jacking holes provided in the bearing housing (108) and remove.


Code: AL-E.B.01.1 02-2001 27

- Remove inner spacer, shim (203) and retain. - Remove the endcover fixing bolts (152), fit two of these bolts in the tapped

jacking holes in the end cover (102) and remove. - Remove retaining circlip (227) and press out bearing (105) from bearing

housing. - The rotor is removed by pulling it axially from the body.

Support the rotor to keep it in line with the bore otherwise damage may be caused to the rotor blades and/or bore of the body. Place the rotor on a wooden surface to prevent the rotor blades from being damaged.

- Remove the shaft seal.

3.3.4.2 Re-assembly standard execution

After thoroughly cleaning, checking and renewing necessary parts the valve should be re-assembled as follows:

It has been stressed by 'SKF' that no grease is to be used in the assembly or operation of the bearings.

- Gland packing: re-assemble the lantern ring (422) and the gland follower (421) to the end covers without packing cord.

- Bearing house assembly: Press the high temperature bearing into the housing and ensure it is tight to housing shoulder, re-fit circlip (227)

Clean the spigot edges of both end covers (102) carefully. To ensure the rotor position is concentric with the valve bore the endcover spigots are a light interference fit in the body. Before assembly the jack screws (152) have to be removed.

- Assemble the end cover to the non-drive side of the body and secure it using bolts (152).

- Fit the rotor in the body and gently push the rotor shaft through the sealing area at the non drive side end cover.

- Fit the drive side endcover. - Fit the inner spacer ring (202) to rotor shaft, press in bearing house

assembly to end cover and secure. - Loosely fit outer spacer ring (202), retainer ring (221) and the locknut

(222) at both ends of the rotor shaft.


Code: AL-E.B.01.1 02-2001 28

3.3.4.3 Rotor adjustment for standard execution

Special clearances are to be set with high product temperatures, according to special instructions. Product characteristics may influence the clearance. In case of any doubts please contact sales department.

Prior to the delivery the axial position of the rotor is set at the right clearance. This means that differences in clearance between the rotor and the end cover on both drive side and non-drive side have been equated as far as possible. Nevertheless, should it be necessary to readjust the axial position of the rotor, proceed as follows:

Shim thickness clarification Rotate rotor freely in the valve bore.

FEELER GAUGE

SHIM

Fig. 3.3.4.3.1 Shim thickness clarification.

The special bearings will locate themselves centrally in their recesses when this has been achieved check the clearances between inner spacer and the rotor shaft shoulder at both ends of the rotor.

- Loosen the locking nut (222) remove the safety ring (221) and spacer ring (202). - Remove the bearing housing assembly fixing bolts (160) fit two of these bolts in

the tapped jacking holes provided in the bearing housing (108) and remove. - Remove inner spacer ring, place required shim onto the rotor shaft

followed by the inner spacer ring. Press bearing housing assembly and secure.

- Fit spacer ring, retainer ring (221) and the locknut (222), tighten locknut and secure.

- Check that both end clearances are equal.


Code: AL-E.B.01.1 02-2001 29

Rotor with adjustable blades

Axial/radial adjustment of the rotor blades: The tolerances for the adjustment of the rotor blades depends on the

product temperature. The special settings for the valve you will find on the datasheet.

In case of any doubt please contact sales department.

106

108

160

226

201

170

171

Ax.

201225303

Rad.

Ax.

302 224

221

202

222

104

163

151

Fig. 3.3.4.3.2 Adjustment for axial and radial clearance rotor blades.

- Adjust axial/radial clearance and rotor blade using feeler gauges or copper shims of the correct thickness.

- Above described adjustment has to be executed with all blades.

After adjustment of the blade feeler gauges or copper shims must be removed. Never let them remain in the valve.

Check the final adjustment by turning the rotor by hand. If steel blades are used the rotor should turn noiselessly.

- Assemble bearing cover. - Assemble gland (3.1.3.2). - Assemble shaft guard. - Mount drive parts (3.6).

After assembly test run the valve.


Code: AL-E.B.01.1 02-2001 30

3.4 Operation instructions OS-GOS

3.4.1 General 31 3.4.2 Technical specifications 31 3.4.3 Construction

3.4.3.1 General assembly and parts list OS-GOS 32 3.4.3.2 Shaft sealing executions see 3.1.3.2 13



Code: AL-E.B.01.1 02-2001 31

3.4.1 General

The type OS and GOS rotary airlocks are designed for the metering and pneumatic transport of products in powder form.



Standard execution:

Operating pressure permitted : -0,5 to +1,5 bar Temperature permitted : -10 C to +150 C

Materials:

housing & end covers Cast iron GGG40 Din 1691/0.7040 Stainless steel AISI 316 Din 17445/1.4408



Sizes 400 450 500

Ltr./rev. 91 135 230



Code: AL-E.B.01.1 02-2001 32

3.4.3 Construction 3.4.3.1 General assembly and parts list type OS-GOS

153

156

201

226

158

159

102

101225

301224

151

154

105

413

414

412

106

152

221

222

202

155

104

411

401

415

153

156

160

156

157

107

155

103

163

162

156

226

159

201

158

102

101302

301

225

224

154

151

105

106

413

414

412

221

222

202

411

104

155

152

401

415

Fig. 3.4.3.1 OS-GOS standard execution.

101 Body 158 Name plate 301 Rotor blade


Code: AL-E.B.01.1 02-2001 33

102 End cover 159 Arrow 103 Flange 160 Cylinder bolt 401 Gland follower 104 Cover 162 Bolt 411 Gland packing 105 Vent/inpection 163 Nut 412 Stud

plate 413 Nut 106 Ball-bearing 201 Rotor 414 Washer 151 Bolt 202 Spacer ring 415 Plug 152 Bolt 221 Safety ring 153 Bolt 222 Locknut 154 Washer 223 "O"-ring 155 Washer 224 Bolt 156 Washer 225 Washer 157 Bolt 226 Key


Standard executions are : - shaft sealing with gland packing; - air purge with glandpacking; - air purge with lipseal.

For adjustment and replacement follow the instructions for shaft sealing . (3.1.3.2 Page 13.)






Standard execution For further instructions use operation instructions Chapter 3.1.4.1 – 3.1.4.2 – 3.1.4.3


Code: AL-E.B.01.1 02-2001 34

3.5 Operation instructions GL

3.5.1 General 35 3.5.2 Technical specifications 35 3.5.3 Construction

3.5.3.1 General assembly and parts list GL 36 3.5.3.2 Shaft sealing executions see 3.1.3.2 13



Code: AL-E.B.01.1 02-2001 35

3.5.1 General DMN-Westinghouse GL valves are specially designed for gravity feeding and pneumati-cally conveying granular products. The configuration of the body and rotor has been developed specifically to minimise degradation whilst retaining the best possible pocket filling efficiency.



Standard execution:

Operating pressure permitted : -0,5 to +1,5 bar Temperature permitted : -10 C to +150 C

Materials:

housing & end covers Stainless steel AISI 316 Din 17445/1.4408 Cast aluminium LM25TF7 Din 1725/2.3716

Rotor Stainless steel AISI 316

Capacity: End-disc rotor with 10 blades.

Sizes 150 200 250 300 350

Ltr./rev. 5 10 17,5 32 79



Code: AL-E.B.01.1 02-2001 36

3.5.3 Construction 3.5.3.1 General assembly and parts list type GL

414

130

154

153

131

155

152

153

154

131

132

156

222

102

412

413

226

159

158

415

101

151

221

202

104

105

223

201

401

411

Fig. 3.5.3.1 GL standard execution.

101 Body 156 Plug 401 Gland follower 102 End cover 158 Name plate 411 Gland packing 104 Cover 159 Arrow 412 Stud 105 Ball-bearing 413 Nut 130 Vent adapter 201 Rotor 414 Washer 131 Gasket 202 Spacer ring 415 Plug 132 Vent plate 221 Safety ring 151 Bolt 222 Locknut 152 Bolt 223 "O"-ring 153 Bolt 226 Key 154 Washer 155 Washer


Code: AL-E.B.01.1 02-2001 37


Standard executions are : - shaft sealing with gland packing;

For adjustment and replacement follow the instructions for shaft sealing . (3.1.3.2 Page 13.)






Standard execution For further instructions use operation instructions Chapter 3.1.4.1 – 3.1.4.2 – 3.1.4.3


Code: AL-E.B.01.1 02-2001 38

3.6 Dismantling and assembly standard drive

3.6.1 Chain drive

504

522

506

524

523

503

528

529

521

507

520

505

522

530

527

501

526

525

502

Fig. 3.6.1 Chain drive.

Drive Type B6

501 Drive 506 Chain wheel 522 Adjusting screw 527 Bolt 502 Support plate 507 Chain 523 Stud 528 Washer 503 Plate 524 Nut 529 Bolt 504 Chain guard 520 Chain joint 525 Bolt 530 Washer 505 Chain wheel 521 Half a link 526 Washer

Dismantling - Remove chain guard - Dismantle chain - Remove chain of chain wheel - Loosen adjusting screw of chain wheel - Remove chain wheels

Assembly - Fit chain wheels on shaft - Align chain wheels and secure - Mount chain - Tighten chain (see fig. 2.2) - Refit chain guard 3.6.2 Direct drive


Code: AL-E.B.01.1 02-2001 39

504501

507

505

509

506

508

502

Fig. 3.6.2.1 Direct drive. Drive type B5

501 Drive 506 Cylinder bolt 502 Connecting piece 507 Washer 504 Coupling 508 Washer 505 Bolt 509 Cap

Dismantling - Dismantle drive - Remove connecting piece - Remove coupling

Assembly - Mount and secure coupling parts - Mount connecting piece on end cover - Mount drive on connecting piece

524

522

501

521

502

Fig. 3.6.2.2 Direct drive.

501 Drive 522 Cylinder bolt 502 Connecting piece 524 Washer 521 Cylinder bolt


Code: AL-E.B.01.1 02-2001 40

3.7 Accessories

- Safety switch

511

542

543

540510

541

Fig. 3.7.1 Safety switch.

510 Safety switch 541 Cylinder bolt 511 Fastening plate 542 Bolt 540 Countersunkscrew 543 Nut

Technical information standard safety switch Type : Schmersal Type AZ15VR Rated insulation voltage : 500 VAC 26-60 Hz Rated operation current : 2A (220 VAC) Protection : IP 67

* Also available explosion proof Schmersal Type EexAZ16ZV


Code: AL-E.B.01.1 02-2001 41

- Pulsating air execution

720

719

700

721

7161

712

718

717

21

3

32

710

714

711

713

715

701

Fig. 3.7.2 Pulsating air injection.

700 Cam disc 715 Tube Ø8 701 Shim 716 Bolt 710 Solenoid 717` Washer 711 Coupling 1/8” 718 Nut 712 Coupling 1/4” 719 Bolt 713 T-coupling 720` Washer 714 Plug 1/8” 721` Cyl. Adjusting screw

Technical data Valve mechanical : Norgren type S/666 Connection : 1/4” Tube Ø8mm Operating pressure : 2 up to 10 Bar Operating temperature : -5°C up to +80°C Air consumption : 15-20 m3/H at 6 Bar

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Code: AL-E.B.01.1 02-2001 42

- Pressure regulator

42

1

0

2

5

6

5 3

1

3

4

6

Fig. 3.7.3 Pressure regulator.

1 Air filter / Pressure regulator 4 Solenoid 2 Pressure gauge 5 Ball valve G 1/4” 3 2/2 valve 6` T-coupling Ø10mm

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Code: AL-E.B.01.1 02-2001 43

610611

600

- Zero speed indication

202

221

222

612

600

611

610

614

613

Fig. 3.7.4 Drive side option 1. Fig. 3.7.5 Drive side option 2.

615

600

610

221

222

202

601

Fig. 3.7.6 Non drive side.

621

620

610

Fig. 3.7.7 Direct drive.

600 Impulssender 612 Bolt 620 Bolt 601 Fastening ring 613 Bolt 621 Nut 610 Proximity switch 614` Nut 611 Fastening clip 615 Cylinderscrew


Code: AL-E.B.01.1 02-2001 44

- Inlet restrictor Ventury adaptor Air vent box

X

Fig. 3.7.8 Inlet restrictor Drop out box Air vent box

Installation procedure

Please respect safety instructions.

- Check rotating direction. - Check clearance between rotor and inletrictor/vent box.

Clearance must be 1.5 x particle size. - Check Air flow direction drop out box.


Code: AL-E.B.01.1 02-2001 45

4. Maintenance

4.1 General

The interval between overhauls will vary with the product being handled and should be based on total operating time. To a large degree the rate of wear for a particular application would be ascertained by practical experience.

Maintenance apart from planned overhaul should be adequately covered by regular and frequent attention to the rotor shaft glands, reduction gear lubrication and adjustment and lubrication of the motor drive chain and chain sprockets.

It is recommended that the complete rotary valve is dismantled for cleaning, inspection and overhaul as necessary at regular intervals.

Please read safety instructions (chapter 1) before carrying out routine overhauls on valves.

4.2 Maintenance every 3 months or after 2,500 operating hours

- Check if valve turns smoothly. - Check adjustment and functioning purge air, if necessary re-adjust. - Check chain, tighten and grease (see 2.1).

4.3 General maintenance every 12 months or after 10,000 operating hours

- Remove valve from system and clean it completely. - Dismantle valve . - Check packing/lipseal for damages. - Check drive shaft for wear or damages. - Check rotor blades for wear or damages. Repair if possible, otherwise

replace. - Assemble the valve and adjust rotor/rotor blades. - Connect air coupling and adjust . - Check chain, tighten and grease.

4.4 Maintenance drive Please study operation instructions supplied.

4.5 Cleaners

Do not use cleaner with solvent. If using a cleaner with solvent is necessary, make sure that solvent can not reach bearing and sealing.

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Code: AL-E.B.01.1 02-2001 46

In case of high-pressure cleaning, pay attention to the ball-bearing. Damaging the sealing of the ball-bearing may cause dis-functioning of the bearing.

4.6 Lubricants

Lubricant Type Supplier Application

Bolt Copaslip Cassida

Molyslip Atlantic Ltd. Shell Nederland

General Food

Chain Alvania R Shell Nederland General

The bearings fitted in the rotary valve are dust-proof ball-bearings. These bearings are lubricated for life and does not require further maintenance.

5. Malfunction

5.1 Probable cause

Common disturbances and possible solutions are stated below. If you are not able to solve the problem, please contact our service department.

Problem Cause

Solution

- Low capacity - Insufficient product supply - Speed too low - Too much air leakage

- Check supply - Increase speed - Improve venting

Check blades (adjust/replace)

- Rotor is not turning - Broken chain - Rotor jammed - Working temperature too high - Malfunction drive

- Replace chain - Dismantle valve - Adjust rotor - Check drive

- Shaft sealing is leaking

- Gland packing worn-out - Lipseal damaged

- Tighten gland follower - Replace lipseal

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