Machine manual

en-23122.503-A

Rotary flow regulating

valve with
electropneumatic actuator

Code Word

Order Number

POLYSIUS Order Code (POC)

Machine manual Contents
Rotary flow regulating valve with electropneumatic actuator

Contents

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

2 Safety...................................................................................................... 2-1
3 Components and mode of functioning.................................................3-1
3.1 Components............................................................................................. 3-1
3.2 Mode of functioning..................................................................................3-8
4 Transport and assembly........................................................................4-1
4.1 Transport and storage instructions...........................................................4-1
4.2 Assembly.................................................................................................. 4-1
5 Lubrication..............................................................................................5-1
6 Preparation for the test run...................................................................6-1
6.1 Checks prior to the test run......................................................................6-1
6.2 Setting and adjustment.............................................................................6-2
6.3 Test run.................................................................................................... 6-3
7 Maintenance...........................................................................................7-1
7.1 Inspection.................................................................................................7-1
7.2 Servicing.................................................................................................. 7-1
7.3 Trouble shooting.......................................................................................7-2
7.4 Repair....................................................................................................... 7-3
8 Spare parts............................................................................................. 8-1
9 Appendix.................................................................................................9-1
9.1 Technical drawings...................................................................................9-1
9.2 Subsuppliers' documentation...................................................................9-1

en-23122.503-A
Machine manual Technical data
Rotary flow regulating valve with electropneumatic actuator 1

1 Technical data

NOTE
Information concerning the electrical equipment is contained in
the separate electrical documentation or in the subsuppliers'
documentation.

Information on the intended use

Material conveyed...............................................................................
Bulk density........................................................................................
Grain size.............................................................................................
Permissible conveyed material temperature.....................................
Permissible conveyed material moisture content.............................

Control air to be provided

Pressure........................................................min. 3.5 bar, max. 7 bar
Quality............................................................acc. to DIN ISO 8573-1
Solid impurities......................................max. particle size 5 µm
...............................................max. density of particles 5 mg/m3
Water content.............................max. pressure dew point +3 °C
Total oil content.............................max. concentration 5 mg/m3
Average total consumption..........................approx. litres per hour

Basic data
Year of manufacture............................................................................
Construction size................................................................................
Position of the actuator......................................................................
Dimensions..........................................................................................
Total weight.........................................................................................

Actuator
Type.....................................................................................................
Machine manual Safety
Rotary flow regulating valve with electropneumatic actuator 1

2 Safety

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

Use
 The rotary flow regulating valve may only be used for the flow
regulation of dry, powdery to fine-grained bulk materials.
 Be sure to comply with the instructions concerning the
intended use in the section Technical data.
 Any use other than the intended use is forbidden. POLYSIUS AG
is not responsible for damage resulting from any use other
than the intended use. All other use is at the owner’s own risk.
 The intended use also includes observance of the instructions
in the machine manual and compliance with the maintenance
instructions.

Transport and assembly

 All transportation instructions in this machine manual refer
exclusively to transportation of the machine at the plant site.
 Only use suitable hoisting and lifting equipment which is in
serviceable order and has a sufficient load bearing capacity.
 Never work under a suspended load.
Operation
 Any safety checks before or during operation depend on the
relevant national regulations. The plant management is
responsible for the performance and recording of such checks.
 If changes in the machine or its operating behaviour relevant
to safety occur, shut down the machine immediately.
Safety Machine manual
2 Rotary flow regulating valve with electropneumatic actuator

Maintenance

 Ensure that all machines and motors whose operation might

endanger persons or equipment are switched off and
safeguarded against restarting for the entire duration of the
maintenance work.
 When performing any work on the installed rotary flow
regulating valve, close the shutoff device before or above the
rotary flow regulating valve.
 Ensure that all rotating parts of the machine have come to a
standstill before you remove protection devices or open flaps.
 Keep the machine free of oily and combustible substances and
materials. Never use gasoline or other easily inflammable
substances for cleaning the machine.
 Make sure that the pneumatic pipes are relieved of pressure
before disconnecting them.
 Switch off the power supply to the electrical components
before commencing any maintenance work.
 Melting of polyester fabric causes hydrogen cyanide vapours.
 There is mortal danger.
 Extract the hydrogen cyanide vapours directly above the point
of work.
 After all maintenance work, check that there are no leaks in
connecting points and connections.
 Strictly observe the welding instructions when performing any
welding work.
 If you carry out electrical welding on any part of the machine,
never conduct the welding current through plain or antifriction
bearings, other movable connections or measuring equipment.
Always directly connect the welding current return lead to the
part being welded.
 Remount all protection devices and properly close all
inspection and service covers when maintenance work has
been finished.
Machine manual Components and mode of functioning
Rotary flow regulating valve with electropneumatic actuator 1

3 Components and mode of functioning

The rotary flow regulating valve is a flow-regulation device for

powdery to fine-grained bulk materials and is used in pneumatic
conveying pipes.
Usually, a hand-operated repair slide valve is arranged upstream
of the rotary flow regulating valve.

3.1 Components

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

The rotary flow regulating valve essentially consists of:

 the housing with the flow regulating sector
 the sealing frame adjustable in the housing
 the aeration floor (porous fabric floor) in the outlet zone of the
rotary flow regulating valve
 the actuator with position controller and electrical position
indicator
Components and mode of functioning Machine manual
2 Rotary flow regulating valve with electropneumatic actuator

Items shown in the drawings

1 Housing
2 Flow-regulating sector
3 Sealing frame with seal
4 Shaft
5 Shaft
6 Bearing housing with bearing
7 Porous fabric floor
8 Holding strip
 Machine manual Components and mode of functioning
Rotary flow regulating valve with electropneumatic actuator 3

Figure 1
Components and mode of functioning Machine manual
4 Rotary flow regulating valve with electropneumatic actuator

Items shown in the drawings

1.2 Side cover with seal

2 Flow-regulating sector
3 Sealing frame with seal
3.1 Seal
3.2 Back retaining frame
3.3 Front retaining frame
6.1 Bearing housing
6.2 Ball bearing
6.3 O ring
10 Spacer bolt with locknut
11 Fixing bolt and set screw
 Machine manual Components and mode of functioning
Rotary flow regulating valve with electropneumatic actuator 5

Figure 2
Components and mode of functioning Machine manual
6 Rotary flow regulating valve with electropneumatic actuator

Items shown in the drawings

1 Housing
22 Actuator
23 Position controller with electrical position indicator
25 Bracket
 Machine manual Components and mode of functioning
Rotary flow regulating valve with electropneumatic actuator 7

Figure 3
Components and mode of functioning Machine manual
8 Rotary flow regulating valve with electropneumatic actuator

3.2 Mode of functioning

Just like a pneumatic trough conveyor, the rotary flow regulating

valve is divided by a porous fabric floor (7) into a conveyed
material throughput chamber and an aeration chamber, and works
with an adjustable flow regulating sector (2) arranged at right
angles to the flow direction of the material conveyed.
The through-opening of the cylindrical flow regulating sector is
designed so that the throughput rate will vary proportionately to
the aperture angle.
The highest accuracy of flow regulation is achieved with a
constant feed rate of material conveyed.
The shutoff sector (2) is connected without a coupling with the
actuator (22). (square)
Machine manual Transport and assembly
Rotary flow regulating valve with electropneumatic actuator 1

4 Transport and assembly

4.1 Transport and storage instructions

The rotary flow regulating valve including actuator is transported

in a ready-assembled condition. Make absolutely sure that
suitable lifting equipment is employed in removing the parts from
the transport vehicles and transferring them to the storage area.
The rotary flow regulating valve may only be lifted by the lifting
eyes provided for this purpose.
When they arrive at the site, all parts must be inspected for
transport damage and placed on wooden beams with the
provision of suitable protection against moisture, soiling and
damage. Never place the parts directly on the ground.
The sealing surfaces of the flow regulating sector (2) are coated
with a corrosion protecting lacquer.

4.2 Assembly

CAUTION
If you carry out electrical welding on any part of the machine,
never conduct the welding current through plain or antifriction
bearings, other moving connecting elements or measuring
equipment, in order to prevent damage to such parts.
Always directly connect the welding current return lead to the
part being welded.

Sequence of assembly

NOTE
Check that the flow regulating sector (2) moves freely and that
the porous fabric floor (7) is in a good condition. The porous fabric
floor must be dry and free of damage. Make absolutely sure that
there are no foreign bodies inside the rotary flow regulating valve.
To prevent accidents during installation, make absolutely sure
that movement of the shutoff sector is blocked.

 When bolting the flanges of the rotary flow regulating valve

onto other units and chutes, make absolutely sure that suitable,
Transport and assembly Machine manual
2 Rotary flow regulating valve with electropneumatic actuator

undamaged seals are used and that the flanges are not
subjected to stresses.
Machine manual Transport and assembly
Rotary flow regulating valve with electropneumatic actuator 3

 Connect the rotary flow regulating valve to the fluidisation air

pipe. The air for the fluidisation floor must be dry and clean so
that the porous fabric floor (7) remains capable of functioning.

 Connect the position controller (23) to the control air pipe.

 For the control air quality, see the section Technical data.
 Subsequently, you can connect the cables for the position
controller (23) and the electrical position indicator, provided
that the electrical data of the network correspond with the
data of the rating plates.
Machine manual Lubrication
Rotary flow regulating valve with electropneumatic actuator 1

5 Lubrication

NOTE
This machine/unit requires no lubrication.
Machine manual Preparation for the test run
Rotary flow regulating valve with electropneumatic actuator 1

6 Preparation for the test run

NOTE
It is a prerequisite of our warranty that the first test run is carried
out in the presence of specialists from POLYSIUS AG and in
accordance with their instructions.

6.1 Checks prior to the test run

After completing the assembly work and prior to the first test run,
check all parts of the plant according to the list below. Take
particular care that all material remnants, tools and assembly
aids are removed.
 Have all foreign bodies been removed from the interior of the
rotary flow regulating valve?
 Has the flow regulating sector (2) been checked for
rotatability?
 Has the porous fabric floor (7) been checked for proper
functioning?
 Have all bolts been properly tightened?
 Have the connecting flanges been screwed on tightly?
 (Have the provided seals been fitted?)
 Has the position controller (23) with the electrical position
indicator been connected according to the circuit diagram?
 Do the electrical data of the network correspond with the data
of the electrical equipment?
 Has the position controller been correctly connected to the
control air system?
 Is control air available in sufficient quality and quantity?
 See the section Technical data.
 Has the fluidisation air pipe been connected, and is dry, clean
air available?
Preparation for the test run Machine manual
2 Rotary flow regulating valve with electropneumatic actuator

6.2 Setting and adjustment

Adjusting the inlet frame and the inlet seal
If the rotary flow regulating valve is operating with difficulty or is
jammed, this fault can be caused by too narrow a gap between
the sealing frame (3) and the flow regulating sector (2).
The flow regulating segment is sealed by a needle felt seal (3.1)
that surrounds the total periphery of the flow regulating sector
(2).
If the pretensioned seal is set too close, the shaft torque may be
significantly increased.
Adjusting may also be necessary as a result of wear on the flow
regulating sector and on the seal (needle felt).

Figure 4
At several points of the sealing frame, distance bolts with
locknuts (10) are located, so that the sealing frame can be
located and fixed in relation to the flow regulating sector .

WARNING
The flow regulating sector can move unexpectedly.
Your hands may be crushed.
Disconnect the pneumatic supply line from the control air
network before starting the adjusting work.
Machine manual Preparation for the test run
Rotary flow regulating valve with electropneumatic actuator 3

Adjust the sealing frame so that the needle felt seal is always in
contact with the periphery of the flow regulating sector.
6.3 Test run

After concluding all the checking, setting and adjustment work,

you can carry out a test run of the rotary flow regulating valve.
During the test run, check the proper functioning of the actuator
and the electrical position indicator.
If any faults are found, the test run must be interrupted and
resumed after the faults have been eliminated.
After successful completion of the test run, the rotary flow
regulating valve is ready for operation.
Machine manual Maintenance
Rotary flow regulating valve with electropneumatic actuator 1

7 Maintenance

7.1 Inspection

No. Work to be performed Frequency Comments

1 General visual inspection for every 12

weeks
 cracks
 leakage
 damage
2 Check for soiling and damage every 26
weeks
 the porous fabric floor (7) and the air
space underneath
3 Check for damage and wear every 26
weeks
 the inside of the housing
 the flow regulating sector (2)
4 Check the clearance between every 26 the seal must be in
weeks contact with all
 flow regulating sector (2) and
points of the
 sealing frame (3) periphery
5 Inspection work on the actuator see manufacturer’s
(22) with the position controller documentation
and the electrical position
in the section
indicator
Appendix

7.2 Servicing

No. Work to be performed Frequency Comments

1 Readjust the clearance between every 26 Execution

weeks
 flow regulating sector (2) and according to 6.2
 seal of the sealing frame Setting and
adjustment
2 Maintenance work on the actuator see manufacturer’s
(22) with the position controller documentation
and the electrical position
in the section
indicator
Maintenance Machine manual
2 Rotary flow regulating valve with electropneumatic actuator

Appendix
Machine manual Maintenance
Rotary flow regulating valve with electropneumatic actuator 3

7.3 Trouble shooting

Fault Cause Elimination

Flow regulating Actuator (22) is not
sector (2) does not being supplied with
turn control air
Actuator (22) is faulty
Position controller (23)
is faulty
Electrical position
indicator is faulty
Flow regulating sector
(2) blocked by foreign
bodies
Flow regulating Too small a clearance Adjust the clearance;
sector (2) does not between flow regulating
see 6.2 Setting and
move easily or is sector (2) and seal of
adjustment
jamming the sealing frame
Blockage by foreign
bodies
Material pile-up in No fluidisation air
rotary flow
regulating valve
Porous fabric floor (7)
clogged up
Feed material moist or
not suitable
Material is Flange seal(s) faulty
escaping
Inadequate flow Flow regulating sector
regulation (2) is worn
Position controller (23)
is faulty
 Check and repair control air
network
 Check and repair position
controller (23)
Repair or replace the
actuator
 Replace position controller
 Check the control air quality; see
the section Technical data.
Replace and adjust electrical
position indicator
Remove the foreign bodies
Remove the foreign bodies
Check and, if necessary,
repair air generator and pipes
Replace porous fabric floor.
Check feed material and
conveyors
Replace flange seal(s)
Replace the flow regulating
sector
 Replace position controller
 Check the control air quality;
Maintenance Machine manual
4 Rotary flow regulating valve with electropneumatic actuator

If any faults occur which are not described above, consult the
additional information about faults, their causes and their
elimination in the subsuppliers’ documentation.
Machine manual Maintenance
Rotary flow regulating valve with electropneumatic actuator 5

7.4 Repair

Before performing any repair work, switch off the power supply to
all electrical components.
Ensure absolute cleanliness at all times during repair work in
order to prevent dirt from entering the bearings, the drive units or
other sensitive parts of the machine or plant.

WARNING
The flow regulating sector can move unexpectedly.
Your hands may be crushed.
Disconnect the pneumatic supply line from the control air
network before starting the repair work.

Removal of the rotary flow regulating valve from the overall system
 Close the shutoff device before or above the rotary flow
regulating valve.
 Shut off the control air supply.
 Disconnect the control air connections and close the openings
against ingress of dirt.
 Disconnect the position controller (23) and the electrical
position indicator.
 Support the unit following the rotary flow regulating valve.
 Support or suspend the rotary flow regulating valve.
 Undo the flange connections between the rotary flow
regulating valve and the neighbouring units or chutes.
 Lift out the rotary flow regulating valve.

For replacement of the parts mentioned below, the rotary flow

regulating valve has to be dismounted:
 Flow regulating sector (2)
 O ring (6.3); dismounting is recommended
 Ball bearing (6.2); dismounting is recommended
 Porous fabric floor (7) with holding strip (8) and bolts
Repair work on the installed rotary flow regulating valve
 Close the shutoff device before or above the rotary flow
regulating valve.
Maintenance Machine manual
6 Rotary flow regulating valve with electropneumatic actuator

 Shut off the control air supply.

 Disconnect the control air connections and close the openings
against ingress of dirt.
Machine manual Maintenance
Rotary flow regulating valve with electropneumatic actuator 7

The following work can be carried out on the installed rotary flow
regulating valve:
 Repair or replacement of the actuator;
 Repair or replacement of the position controller;
 Repair or replacement of the sealing frame (3);
 Repair or replacement of the seal (3.1);
Instructions for disassembling the unit
 Unscrew the bolts from the bracket (25) to the housing (1) and
dismount the complete actuator.
 Unscrew the side cover and unscrew the holding bolts of the
sealing frame.
 Turn the flow regulating sector in dismounting position for
dismounting the sealing frame
 Dismount the sealing frame.
 Unscrew and remove the anti-turning device of the inner rings
of the ball bearing.
 Unscrew and remove the fixing bolts of the ball bearing.
 Withdraw the ball bearing from the shaft.
 Dismount the O ring.
 Dismount the aeration floor by unscrewing the flange bolts.

Assembly instructions
Check and clean all parts.
 For installation of the aeration floor, seal the bottom side of the
polyester fabric by means of the prescribed sealing compound
(Dimaplast), clamp it between the upper flange and the housing
flange and bolt it down. Make the holes in the Polyester fabric
with a red-hot spike.

DANGER
Melting of polyester fabric causes formation of hydrogen cyanide
vapours.
There is mortal danger.
Extract the hydrogen cyanide vapours directly above the point of
work.
Maintenance Machine manual
8 Rotary flow regulating valve with electropneumatic actuator

 Check for leaks in the flange connection using soap suds and
compressed air with approx. 0.1 bar.
 Fit the O ring on the shaft ends and slip on the ball bearings
and bolt them onto the housing.
 Screw in the anti-turning devices for the inner bearing rings
 Insert the sealing frame with new seal
 Adjust the seal, see next point Adjusting the sealing frame (3)
 When you have installed the seal, install the drive bracket and
then the drive unit and fix with the respective holding bolts. Put
the square of the shaft, without coupling, directly into the
intake opening of the drive unit.
Machine manual Maintenance
Rotary flow regulating valve with electropneumatic actuator 9

Adjusting the sealing frame (3)

 The sealing frame is so designed that the installed needle felt

seal (3.1) tightly surrounds the flow regulating sector when
being installed.
 The felt seal is able to adapt to the outside contour of the flow
regulating sector, particularly at the edges.
 The deformation is elastic.
 You must locate the sealing frame so that the seal is in contact
with the entire periphery of the flow regulating sector and the
elastic deformation of the seal is uniform over the entire
periphery.
 At the sealing frame and at the housing, there are several
distance bolts with locknuts (10) which you must use to
position the sealing frame and brace it in the housing.
 After carrying out the adjustment, screw on the two side covers
with seal (1.2).

1.2

Figure 5
Maintenance Machine manual
10 Rotary flow regulating valve with electropneumatic actuator

Consumables

Designation Manufacturer Comments

Adhesive Teroson GmbH, for sticking on the

flange seals
TEROKAL BE-WEISS Heidelberg
Dimaplast 30 x 2 mm Happich for sealing the bottom
side of the polyester
Item No. 531 2008
fabric

Tools and auxiliary devices

No special tools are required for repair work on the machine.
Whether or not you need auxiliary equipment, such as scaffolds
or hoists, depends on the conditions in your plant.

CAUTION
After you have completed the repair work, you must check the
machine/plant again according to the section Preparation for the
test run.
Machine manual Spare parts
Rotary flow regulating valve with electropneumatic actuator 1

8 Spare parts

Suggestions for enquiries and orders of spare parts

Dear Customer,
POLYSIUS AG want to make spare part enquiries and spare part order
placement as easy and efficient as possible. For this purpose we have prepared
a table containing all data required by our spare parts department to ensure
optimum processing in the most speedy and trouble-free manner.
Please copy the title page and the page with the table. Fill in the columns
Quantity and Unit. Please mark those parts which you require with a cross in the
column Order or Enquiry. Send the title page together with the table to the Spare
Parts Department of POLYSIUS AG.
If the table relates to more than one machine, please also inform us of the
POLYSIUS Order Code (POC) of the machine for which you require the spare
parts.
Spare parts Machine manual
2 Rotary flow regulating valve with electropneumatic actuator

Figure 6
Machine manual Spare parts
Rotary flow regulating valve with electropneumatic actuator 3

Code Word: Order Number: POC:

Item Designation Qty. Unit Order Enquiry

1 Housing 1 Piece

2 Flow regulating sector 1 Piece

3 Sealing frame with seal 1 set

4 Shaft 1 Piece

5 Shaft 1 Piece

6 Bearing housing with 1 set

bearing

7 Porous fabric floor 1 Piece

8 Holding strip 1 Piece

Spare parts Machine manual
4 Rotary flow regulating valve with electropneumatic actuator

6.3

6.2

6.1

3.2 3.3 1.2

Figure 7
Machine manual Spare parts
Rotary flow regulating valve with electropneumatic actuator 5

Code Word: Order Number: POC:

Item Designation Qty. Unit Order Enquiry

1.2 Side cover with seal 2 set

3.1 Seal (needle felt) 1 Piece

6.2 Ball bearing 2 Piece

6.3 O ring 2 Piece

10 Spacer bolt 1 set

with locknut

11 Fixing bolt and set screw 1 set

Spare parts Machine manual
6 Rotary flow regulating valve with electropneumatic actuator

Figure 8
Machine manual Spare parts
Rotary flow regulating valve with electropneumatic actuator 7

Code Word: Order Number: POC:

Item Designation Qty. Unit Order Enquiry

22 Actuator

23 Position controller with

electrical position see manufacturer’s documentation
indicator

25 Bracket
Machine manual Appendix
Rotary flow regulating valve with electropneumatic actuator 1

9 Appendix

9.1 Technical drawings

Designation Drawing No.

Assembly drawing

9.2 Subsuppliers' documentation

Electropneumatic actuator