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AL-BL Rotary valves DMN-Westinghouse

Operation instruction + Maintenance


Safety instructions AL-BL-AML
Standard HT execution up to 250C HT execution up to 600C Size : 100-150-175-200-250-300-350-400-450-500 (incl. BL 175/200 BL 200/250 BL 250/300 BL 300/350)

OS-GOS Standard

size: 400-450-500

GL
Standard

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

Customer Purchase order no.

: :

DMN-Westinghouse order no. : Type Serial no. : :

DMN-Westinghouse General -

AL-BL Rotary Valves

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 department.

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 2

02-2001

DMN-Westinghouse

AL-BL Rotary Valves Page 5 5 5 5 6 6 6 7 7 8

Contents
1. Safety instructions Rotary valves 1.1 General safety instructions 1.2 Symbols 1.3 Responsibilities of management and maintenance personnel 1.4 Applying the safety instructions when installing a valve 1.5 Applying the safety instructions when the valve is in operation 1.6 Applying the safety instructions during maintenance and repair 2. Installing the valve in the system 2.1. Drive 2.2. Mounting the valve in the system 3. Operation instructions 3.1 AL-BL Standard execution 3.1.1 General 3.1.2 Technical specifications standard 3.1.3 Construction 3.1.3.1 General assembly and parts list AL-BL 3.1.3.2 Shaft sealing standard 3.1.4 Dismantling, assembling and adjusting instructions 3.1.4.1 Dismantling standard execution 3.1.4.2 Reassembling standard execution 3.1.4.3 Axial/radial adjustment of rotor and blades 3.2 3.3 AL-BL HT execution up to 250C AL 3.3.1 3.3.2 3.3.3 HT execution up to 600C General Technical specifications HT Construction 3.3.3.1 General assembly and parts list AL-HT up to 600 C 3.3.3.2 Shaft sealing standard see 3.1.3.2 13 Dismantling, assembling and adjusting instructions 3.3.4.1 Dismantling standard execution 3.3.4.2 Reassembling standard execution 3.3.4.3 Axial/radial adjustment of rotor and blades

10 11 11 12 13 15 15 16 17 20 22 23 23 24 25 26 27 28 30 31 31 32 13 33 15

3.3.4

3.4

OS-GOS Standard execution 3.4.1 General 3.4.2 Technical specifications 3.4.3 Construction 3.4.3.1 General assembly and parts list OS-GOS 3.4.3.2 Shaft sealing executions see 3.1.3.2 3.4.4 Dismantling, assembling and adjusting instructions Standard execution see 3.1.4

Code: AL-E.B.01.1 3

02-2001

DMN-Westinghouse

AL-BL Rotary Valves Page

Contents
3.5 GL 3.5.1 3.5.2 3.5.3 Standard execution General Technical specifications Construction 3.5.3.1 General assembly and parts list GL 3.5.3.2 Shaft sealing executions see 3.1.3.2 Dismantling, assembling and adjusting instructions Standard execution see 3.1.4

34 35 35 36 13 37 15 38 38 39 40 40 41 42 43 44 45 45 45 45 45 45 46 46 46

3.5.4

3.6

Dismantling and assembling standard drive 3.6.1 Chain drive 3.6.2 Direct drive Accessories ( If fitted ) Safety switch Pulsating air execution Pressure regulator Zero speed indication Inlet restrictor / Drop out box / Air vent box

3.7

4. Maintenance 4.1. General 4.2. Maintenance every 3 months or after 2,500 operating hours 4.3. Maintenance every 12 months or after 10,000 operating hours 4.4. Maintenance motor / gearbox 4.5. Cleaners 4.6. Lubricants 5. Malfunctioning 5.1. Probable cause

APPENDIX Declaration by the manufacturer Technical specifications drive SEW

Code: AL-E.B.01.1 4

02-2001

DMN-Westinghouse

AL-BL Rotary Valves

1.
1.1

Safety instructions Rotary valves


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 5 02-2001

DMN-Westinghouse 1.4 Applying the safety instructions when installing a valve

AL-BL Rotary Valves

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 DMNWestinghouse. 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 6

02-2001

DMN-Westinghouse 2 Installing the valve in the system Turning the rotor is prohibited. Danger to fingers and hands.

AL-BL Rotary Valves

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.

Code: AL-E.B.01.1 7

02-2001

DMN-Westinghouse
524

AL-BL Rotary Valves

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 02-2001 8

Code: AL-E.B.01.1

DMN-Westinghouse 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)

AL-BL Rotary Valves

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 leakages, 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.

Code: AL-E.B.01.1 9

02-2001

DMN-Westinghouse

AL-BL Rotary Valves

3.1
3.1.1 3.1.2 3.1.3

Operation instructions AL-BL-AML


General Technical specifications Construction 3.1.3.1 General assembly and parts list AL-BL 3.1.3.2 Shaft sealing standard Dismantling, assembling and adjusting instructions 3.1.4.1 Dismantling standard execution 3.1.4.2 Reassembling standard execution 3.4.4.3 Axial/radial adjustment of rotor and blades 11 11 12 13 15 15 16 17

3.1.4

3.2

Al-BL HT execution up to 250 C

20

Code: AL-E.B.01.1 10

02-2001

DMN-Westinghouse 3.1.1 General

AL-BL Rotary Valves

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 Temperature permitted : -0,5 to +2 bar : -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 fr Forschung und Prfung GmbH) after thorough testing pressure shock resistance and flame proofness. Tests are done according to VDI 2263. Materials: housing & end covers Cast iron Cast iron Stainless steel Cast aluminium Rotor Steel Stainless steel St.37 AISI 316 GG25 GGG40 AISI 316 LM25TF7 Din 1691/0.6025 Din 1691/0.7040 Din 17445/1.4408 Din 1725/2.3716 Size 100-350 Size 400-500

Capacity: AL-BL AML Ltr./Rev.

Rotor with 9 adjustable blades. 150 150 2,5 175 200 5,5 200 250 10,5 250 300 19 300 350 34 350 400 58 91 135 230 400 450 500

Capacity per revolution at 100% filling Size AL 100 (0.8 Ltr./rev.) with round flanges PN6

Code: AL-E.B.01.1 11

02-2001

DMN-Westinghouse

AL-BL Rotary Valves

3.1.3. 3.1.3.1
101 415 102

Construction General assembly and parts list type AL-BL


401 411 223

158 159 201 226 105 104 151

412 413 414

202 221 222

152 155

101 432 102

302

224 225

421 422 431 223

158 159 201 226 105 104 151

433 434 435 103 153 154 155 152 155

202 221 222 423 436

Fig. 3.1.3.1 Execution AL-BL (AML).

Code: AL-E.B.01.1 12

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DMN-Westinghouse
101 102 103 104 105 151 152 153 154 155 156 Body End cover Flange Cover Ball-bearing Bolt Bolt Nut Bolt Washer Plug 158 Name plate 159 Arrow 201 202 221 222 223 224 225 226 Rotor Spacer ring Safety ring Locknut "O"-ring Headscrew Washer Key 302 303 304 305 401 411 412 413 414 415 Rotor blade Scraper blade Plastic rotor blade Clamp plate Gland follower Gland packing Stud Nut Washer Plug

AL-BL Rotary Valves


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

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

415

401 411 412 413 414 415

Gland follower Gland packing Stud Nut Washer Plug

401 412 413 414 411

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

DMN-Westinghouse -

AL-BL Rotary Valves

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


432

421 422 423 431 432 433 434 435 436

Gland follower Lantern ring Extension piece Gland packing Coupling Stud Nut Washer Cylinder bolt

421 433 434 435 423 436 422 431

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

432

421 422 431 432 433 434 435

Gland follower Lantern ring Lipseal Coupling Stud Nut Washer

421 433 434 435 422 431

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 14 02-2001

DMN-Westinghouse be lightly greased prior to assembling the seals.

AL-BL Rotary Valves

3.1.4

Dismantling, assembly and adjustment instructions for the valve

DMN-Westinghouse valves have been manufactured with great care. To reduce air leakages, 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.
155 152 105 223 104

151

202 221 222

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 15 02-2001

DMN-Westinghouse -

AL-BL Rotary Valves

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 ballbearing. 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 16

02-2001

DMN-Westinghouse 3.1.4.3 Rotor adjustment for standard execution

AL-BL Rotary Valves

The standard executions have the following axial and radial clearances. Body end covers material Cast iron Cast iron Stainless steel Stainless steel Rotor material Size valve Clearance axial and radial 0,1 up to 0,15 mm 0,1 up to 0,15 mm 0,1 up to 0,15 mm 0,15 up to 0,2 mm

Mild Steel Stainless steel Stainless steel Stainless steel

150 up to 350 150 up to 350 150 up to 250 300 up to 350

Body end covers material Cast iron Cast iron Stainless steel

Rotor material

Size valve

Clearance axial and radial 0,15 up to 0,2 mm 0,15 up to 0,2 mm 0,2 up to 0,25 mm

Mild Steel Stainless steel Stainless steel

400 up to 500 400 up to 500 400 up to 500

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
Ax.
Rad.

Ax.
223

105 104

201 226

151

202 221 222

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 17 02-2001

DMN-Westinghouse the machined surfaces of the rotor. -

AL-BL Rotary Valves

Push the rotor hard against the inside face of the end cover at the nondrive 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).
304 305 224

Ax.

Rad.

Ax.
223

105 104

201 226

151

202 221 222

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 18

02-2001

DMN-Westinghouse
0,05

AL-BL Rotary Valves


0,05
0,05

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 19

02-2001

DMN-Westinghouse

AL-BL Rotary Valves

3.2

Al-BL HT execution up to 250 C

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


101 415 102 158 170 159 201 226 105 171 172 104 151 201 401 411

412 413 414

202 221 222

152 155

101 432 102 158 170 159 201 226

201

302 303

224 225

423 436 421 422 431 105 171 172 104 151

433 434 435

202 221 222

152 155

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


101 102 104 105 Body End cover Cover 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 201 202 221 222 224 225 226 Rotor Spacer ring Safety ring Locknut Headscrew Washer Key 302 Rotor blade 303 Scraper blade 401 411 412 413 414 415 Gland Gland packing Stud Nut Washer Plug 421 Seal follower 422 Lantern ring 431 Gland packing 432 Coupling 433 Stud 434 Nut 435 Washer

Code: AL-E.B.01.1 20

02-2001

DMN-Westinghouse

AL-BL Rotary Valves

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/AMLinstruction 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 Klber HM 83-402 to the bearing grease nipples (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.

Code: AL-E.B.01.1 21

02-2001

DMN-Westinghouse

AL-BL Rotary Valves

3.3
3.3.1 3.3.2 3.3.3

Operation instructions AL-HT execution up to 600 C


General Technical specifications HT Construction 3.3.3.1 General assembly and parts list AL-HT execution up to 600 C 3.3.3.2 Shaft sealing standard see 3.1.3.2 13 Dismantling, assembling and adjusting instructions 3.3.4.1 Dismantling standard execution 3.3.4.2 Reassembling standard execution 3.3.4.3 Axial/radial adjustment of rotor and blades 23 23 24 25 26 27 28

3.3.4

Code: AL-E.B.01.1 22

02-2001

DMN-Westinghouse

AL-BL Rotary Valves

3.3
3.3.1

Operation instructions Al HT execution up to 600 C


General

The type AL-HT rotary airlocks are designed for the metering of products in powder form for temperature up to 600 C. The limits stated in the technical specification 3.3.2 should not be exceeded. The user is responsible for any defects and/or risks or damages resulting from improper use. 3.3.2 Technical specifications

AL-HT execution: Operating pressure permitted : -0.5 to +2 Bar No pressure difference over rotor Temperature permitted : Cast iron GG 25/ Mild steel St.St 316/ St.St 316 250 C to +400 C 250 C to +600 C

Materials: housing & end covers Cast iron Stainless steel Rotor Steel Stainless steel GG25 AISI 316 St.37 AISI 316 Din 1691/0.6025 Din 17445/1.4408

Capacity: AL-BL AML Ltr./Rev.

Rotor with 9 adjustable blades. 150 150 2,5 175 200 5,5 200 250 10,5 250 300 19 300 350 34 350 400 58 91 135 230 400 450 500

Capacity per revolution at 100% filling

Code: AL-E.B.01.1 23

02-2001

DMN-Westinghouse 3.3.3 3.3.3.1 Construction

AL-BL Rotary Valves

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


201

101 415 102 158 159 201 226

401 411

227

104 202 203 221 222 151 156 105

106 108 160 412 413 414 152 155

201

101 432 102 158 159 201 226

302 303

224 225

421 422 431 151 163 227

104 202 221 222 170 171 105 423 436

106 108 160 433 434 435 152 155

Fig. 3.3.3.1 AL HT execution up to 600C. 101 102 104 105 108 127 151 152 155 156 158 159 160 Body End cover Cover Ball-bearing HT Bearing house Shaft protection Bolt Bolt Washer Washer Name plate Arrow Countersunksrew 201 202 203 221 222 224 226 227 301 Rotor Spacer ring Shim Safety ring Locknut Headsrew Key Retaining ring Rotor blade 401 411 412 413 414 415 421 422 431 432 433 434 435 436 Gland follower Gland packing Stud Nut Washer Plug Gland follower Lantern ring Gland Coupling Stud Nut Washer Cylinder bolt 02-2001 24

Code: AL-E.B.01.1

DMN-Westinghouse 3.3.3.2 Rotor shaft sealing Standard executions are : shaft sealing with gland packing; air purge with glandpacking;

AL-BL Rotary Valves

For adjustment and replacement follow the instructions for shaft sealing with gland packing. (3.1.3.2 Page 13.)
3.3.4 Dismantling, assembly and adjustment instructions for the valve DMN-Westinghouse valves have been manufactured with great care. To reduce air leakages, 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.

Code: AL-E.B.01.1 25

02-2001

DMN-Westinghouse 3.3.4.1 Dismantling standard execution


401 411

AL-BL Rotary Valves

227

104 202 203 221 222 151 156 105

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.
101 415 102 158 159 201 226

106 108 160 203

152 155

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 26 02-2001

DMN-Westinghouse -

AL-BL Rotary Valves

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 27

02-2001

DMN-Westinghouse 3.3.4.3 Rotor adjustment for standard execution

AL-BL Rotary Valves

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 28

02-2001

DMN-Westinghouse Rotor with adjustable blades

AL-BL Rotary Valves

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.
201 302 303 224 225

Ax.

Rad.

Ax.
151 163

201 226

104 202 221 222 170 171

106 108 160

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 29

02-2001

DMN-Westinghouse

AL-BL Rotary Valves

3.4
3.4.1 3.4.2 3.4.3

Operation instructions OS-GOS


General Technical specifications Construction 3.4.3.1 General assembly and parts list OS-GOS 3.4.3.2 Shaft sealing executions see 3.1.3.2 Dismantling, assembling and adjusting instructions Standard execution see 3.1.4 31 31 32 13 33 15

3.4.4

Code: AL-E.B.01.1 30

02-2001

DMN-Westinghouse 3.4.1 General

AL-BL Rotary Valves

The type OS and GOS rotary airlocks are designed for the metering and pneumatic transport of products in powder form. The limits stated in the technical specification 3.4.2 should not be exceeded. The user is responsible for any defects and/or risks or damages resulting from improper use.

3.4.2 Technical specifications Standard execution: Operating pressure permitted Temperature permitted Materials: housing & end covers Cast iron Stainless steel Rotor Steel Stainless steel St.37 AISI 316 GGG40 AISI 316 Din 1691/0.7040 Din 17445/1.4408 : -0,5 to +1,5 bar : -10 C to +150 C

Capacity: Rotor with 8 adjustable blades. Sizes Ltr./rev. 400 91 450 135 500 230

Capacity per revolution at 100% filling

Code: AL-E.B.01.1 31

02-2001

DMN-Westinghouse 3.4.3 Construction 3.4.3.1 General assembly and parts list type OS-GOS
101 301 224 225

AL-BL Rotary Valves

105 151 154

102

415 401 411

158 159

226 201

104 152 155

202 221 222 106 153 156 412 413 414

101

301 302

224 225

105 151 154

102

415 401 411

158 159 201 226 156 162 163 103 155 157 107 156 160 153 156

104 152 155

202 221 222 106 412 413 414

Fig. 3.4.3.1 OS-GOS standard execution.

101

Body

158

Name plate

301

Rotor blade 02-2001

Code: AL-E.B.01.1 32

DMN-Westinghouse 102 103 104 105 106 151 152 153 154 155 156 157 End cover Flange Cover Vent/inpection plate Ball-bearing Bolt Bolt Bolt Washer Washer Washer Bolt 159 160 162 163 201 202 221 222 223 224 225 226 Arrow Cylinder bolt Bolt Nut Rotor Spacer ring Safety ring Locknut "O"-ring Bolt Washer Key

AL-BL Rotary Valves

401 411 412 413 414 415

Gland follower Gland packing Stud Nut Washer Plug

3.4.3.2 Rotor shaft sealing 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.)

3.4.4

Dismantling, assembly and adjustment instructions for the valve

DMN-Westinghouse valves have been manufactured with great care. To reduce air leakages, 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.

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 33

02-2001

DMN-Westinghouse

AL-BL Rotary Valves

3.5
3.5.1 3.5.2 3.5.3

Operation instructions GL
General Technical specifications Construction 3.5.3.1 General assembly and parts list GL 3.5.3.2 Shaft sealing executions see 3.1.3.2 Dismantling, assembling and adjusting instructions Standard execution see 3.1.4 35 35 36 13 37 15

3.5.4

Code: AL-E.B.01.1 34

02-2001

DMN-Westinghouse

AL-BL Rotary Valves

3.5.1 General DMN-Westinghouse GL valves are specially designed for gravity feeding and pneumatically 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. The limits stated in the technical specification 3.5.2 should not be exceeded. The user is responsible for any defects and/or risks or damages resulting from improper use.

3.5.2 Technical specifications Standard execution: Operating pressure permitted Temperature permitted Materials: housing & end covers Stainless steel Cast aluminium Rotor Stainless steel AISI 316 AISI 316 LM25TF7 Din 17445/1.4408 Din 1725/2.3716 : -0,5 to +1,5 bar : -10 C to +150 C

Capacity: Sizes Ltr./rev.

End-disc rotor with 10 blades. 150 5 200 10 250 17,5 300 32 350 79

Capacity per revolution at 100% filling

Code: AL-E.B.01.1 35

02-2001

DMN-Westinghouse 3.5.3
101

AL-BL Rotary Valves

Construction 3.5.3.1 General assembly and parts list type GL


201

415 102

401 411 223

158 159 105 104 151 226

412 413 414

202 221 222

152 155

156

130 131

131 132 153 154

153 154

Fig. 3.5.3.1 GL standard execution. 101 102 104 105 130 131 132 151 152 153 154 155 Body End cover Cover Ball-bearing Vent adapter Gasket Vent plate Bolt Bolt Bolt Washer Washer 156 158 159 201 202 221 222 223 226 Plug Name plate Arrow Rotor Spacer ring Safety ring Locknut "O"-ring Key 401 411 412 413 414 415 Gland follower Gland packing Stud Nut Washer Plug

Code: AL-E.B.01.1 36

02-2001

DMN-Westinghouse 3.5.3.2 Rotor shaft sealing Standard executions are : shaft sealing with gland packing;

AL-BL Rotary Valves

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

3.5.4

Dismantling, assembly and adjustment instructions for the valve

DMN-Westinghouse valves have been manufactured with great care. To reduce air leakages, 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.

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 37

02-2001

DMN-Westinghouse 3.6 3.6.1 Dismantling and assembly standard drive Chain drive
504

AL-BL Rotary Valves

527 530

505 522

507 520 521 528 529 502 503 523 524 525 526

506 522

501

Fig. 3.6.1 Chain drive.

Drive Type B6 501 502 503 504 505 Drive Support plate Plate Chain guard Chain wheel 506 Chain wheel 507 Chain 520 Chain joint 521 Half a link 522 523 524 525 526 Adjusting screw Stud Nut Bolt Washer 527 528 529 530 Bolt Washer Bolt 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 38 02-2001

DMN-Westinghouse
505 507 502 506 508

AL-BL Rotary Valves

501

504

509

Fig. 3.6.2.1 Direct drive. Drive type B5 501 502 504 505 Drive Connecting piece Coupling Bolt 506 507 508 509 Cylinder bolt Washer Washer 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
522 524

501 502 521

Fig. 3.6.2.2 Direct drive. 501 502 521 Drive Connecting piece Cylinder bolt 522 524 Cylinder bolt Washer

Code: AL-E.B.01.1 39

02-2001

DMN-Westinghouse

AL-BL Rotary Valves

3.7
-

Accessories
Safety switch

511

542 510 541 540 543

Fig. 3.7.1 Safety switch. 510 511 540 Safety switch Fastening plate Countersunkscrew 541 542 543 Cylinder bolt Bolt 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 40

02-2001

DMN-Westinghouse Pulsating air execution


713

AL-BL Rotary Valves

715 701

700 721

711 2 3 710 714 716 717 718

719 720

712

Fig. 3.7.2 Pulsating air injection. 700 701 710 711 712 713 714 Cam disc Shim Solenoid Coupling 1/8 Coupling 1/4 T-coupling Plug 1/8 715 716 717` 718 719 720` 721` Tube 8 Bolt Washer Nut Bolt Washer Cyl. Adjusting screw

Technical data Valve mechanical Connection Operating pressure Operating temperature Air consumption

: Norgren type S/666 : 1/4 Tube 8mm : 2 up to 10 Bar : -5C up to +80C : 15-20 m3/H at 6 Bar

Code: AL-E.B.01.1 41

02-2001

DMN-Westinghouse Pressure regulator


4 1

AL-BL Rotary Valves

5
2 1 0

3 4 5 6

Fig. 3.7.3 Pressure regulator.

1 2 3

Air filter / Pressure regulator Pressure gauge 2/2 valve

4 5 6`

Solenoid Ball valve G 1/4 T-coupling 10mm

Code: AL-E.B.01.1 42

02-2001

DMN-Westinghouse

AL-BL Rotary Valves

Zero speed indication


613 614

202 221 222

610 611

600

610

600 611

612

Fig. 3.7.4 Drive side option 1.


601 610

Fig. 3.7.5 Drive side option 2.

202 221 222

600

615

Fig. 3.7.6 Non drive side.


610 620 621

Fig. 3.7.7 Direct drive. 600 601 610 611 Impulssender Fastening ring Proximity switch Fastening clip 612 613 614` 615 Bolt Bolt Nut Cylinderscrew 620 621 Bolt Nut

Code: AL-E.B.01.1 43

02-2001

DMN-Westinghouse

AL-BL Rotary Valves

- Inlet restrictor

Ventury adaptor

Air vent box

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 44

02-2001

DMN-Westinghouse 4. 4.1 Maintenance General

AL-BL Rotary Valves

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.

Code: AL-E.B.01.1 45

02-2001

DMN-Westinghouse

AL-BL Rotary Valves

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

4.6

Lubricants Lubricant Bolt Chain Type Copaslip Cassida Alvania R Supplier Molyslip Atlantic Ltd. Shell Nederland Shell Nederland Application General Food 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. 5.1

Malfunction 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 - Low capacity

Cause - Insufficient product supply - Speed too low - Too much air leakage

Solution - Check supply - Increase speed - Improve venting Check blades (adjust/replace) - Replace chain - Dismantle valve - Adjust rotor - Check drive - Tighten gland follower - Replace lipseal

- Rotor is not turning

- Broken chain - Rotor jammed - Working temperature too high - Malfunction drive - Gland packing worn-out - Lipseal damaged

- Shaft sealing is leaking

Code: AL-E.B.01.1 46

02-2001

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