1190034611 en 1.0.0 BT Aerolock Rotary Valve

8/11/2019 1190034611 en 1.0.0 BT Aerolock Rotary Valve

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Read this document prior to op-erating the device.

This document contains all safe-ty and warning notes.

Original operating instructions

1190034611-EN Rev. 1.0.0

OPERATING AND MAINTENANCE INSTRUCTIONS

BT Aerolock Rotary Valve


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Doc. No.: 1190034611-EN

Date: 2014/Feb/11

Original: 1190034611-EN

Coperion K-Tron assumes no responsibility for damages resulting from misuse of any equipment or neg-ligence on the part of operating personnel. Further, you may kindly refer to the purchase order, confirma-tion or other document that contains the express Coperion K-Tron warranty disclaimer limiting or excludingcertain warranties with respect to the company's equipment. Except as otherwise expressly provided byCoperion K-Tron in any such document, COPERION K-TRON MAKES NO WARRANTY OF MER-CHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, NOR ANY OTHER WARRANTY, EX-PRESS OR IMPLIED, WITH RESPECT TO THE EQUIPMENT.

Service

If you need assistance, please call your local service centre or

Coperion K-TRON Schweiz GmbH Tel. 0041 (0) 62 / 885 71 71

Lenzhardweg 43/45 Fax 0041 (0) 62 / 885 71 80

CH-5702 Niederlenz

Coperion K-Tron Pitman, Inc. Tel. 001 (0) 856 / 589 0500

590 Woodbury Glassboro Road Fax 001 (0) 856 / 589 81 13

Sewell, New Jersey 08080 USA

Coperion K-TRON Salina Tel. 001 (0) 785 / 825 16 11

606 N. Front St. Fax 001 (0) 785 / 825 8759

Salina, KS 67402-0017

Web: www.coperionktron.com

Before you call...

Do you have alarm displays? Are you able to eliminate the causes?

Have you modified part of the system, product or operating mode?

Have you tried to remedy the fault in accordance with the operatinginstructions?

Note the project or order number You will find these on the machineor in the system manual.

Example: 0403214

Using the manual:

This arrow identifies an individual action.

1. Numbers identify a sequence of actions which have to be executedstep-by-step.

This symbol identifies a general safety note.

If an error or ommission is found, please contact:[email protected]

Reference to another manual.

Important information.

This symbol indicates that tools are required for the following task.

Specifies where information or a situation must be checked.
http://www.coperionktron.com/mailto:[email protected]:[email protected]://www.coperionktron.com/


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Docu-No.: 1190034611-EN Rev. 1.0.0 Page 3

Table of Contents

1 Safety notes .........................................................................................................................5

1.1 Safety symbols definitions ..................................................................................................... 5

1.1.1 Electrical hazard icon ............................................................................................................61.1.2 Ground icon ...........................................................................................................................61.1.3 No hands icon ........................................................................................................................61.1.4 Power icon ............................................................................................................................. 6

1.2 Responsibilities of the owner ................................................................................................. 7

1.3 Proper use .............................................................................................................................7

1.4 Organizational measures ....................................................................................................... 7

1.5 Safety-conscious work ........................................................................................................... 8

1.6 Safety devices .......................................................................................................................8

1.7 High voltage ...........................................................................................................................8

1.8 Additional equipment ............................................................................................................. 9

1.9 Customer service and repairs ................................................................................................ 9

1.10 Shut-down procedure ............................................................................................................9

2 Application .........................................................................................................................10

2.1 Design .................................................................................................................................10

2.2 Construction Overview ........................................................................................................ 10

2.3 Options ................................................................................................................................10

2.4 Safety devices and warnings ...............................................................................................112.4.1 Safety devices .....................................................................................................................112.4.2 Warnings .............................................................................................................................11

3 Technical data .................................................................................................................... 12

3.1 Model sizes ..........................................................................................................................12

4 Installation ..........................................................................................................................13

4.1 Unpacking ............................................................................................................................13

4.2 Transport .............................................................................................................................13

4.3 Storage (Over 4 Months) .....................................................................................................14

4.4 AerolockTM mounting ..........................................................................................................14

4.4.1 Chain Power Transmission .................................................................................................. 144.4.2 Gear lubrictation ..................................................................................................................14

4.5 Vented shear protector installation ......................................................................................154.5.1 Adjusting Seal Flap to fit Rotor ............................................................................................154.5.2 Ensuring Proper Fit / Checking Clearances ........................................................................154.5.3 Final Installation ...................................................................................................................15

4.6 Non-vented shear protector installation ...............................................................................16

4.7 AerolockTM and accessories installation ............................................................................16

4.8 Electrical connection ............................................................................................................18


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Page 4 Docu-No.: 1190034611-EN Rev. 1.0.0

4.8.1 Motor connection ................................................................................................................. 184.8.2 Chain Adjustment ................................................................................................................194.8.3 Variable Speed Drive Settings .............................................................................................194.8.4 Mechanical variable Speed ................................................................................................. 20

4.9 Compressed air connections ...............................................................................................21

5 Start-up ...............................................................................................................................22

5.1 Start-up checklist .................................................................................................................22

6 Operation ............................................................................................................................23

6.1 Notes on operation ..............................................................................................................23

6.2 Switchin on/off .....................................................................................................................23

7 Cleaning .............................................................................................................................24

7.1 Switching off the installation ................................................................................................ 24

7.2 Notes on cleaning ................................................................................................................24

8 Maintenance .......................................................................................................................25

8.1 Maintenance intervals ..........................................................................................................25

8.2 Disengage Power Transmission ..........................................................................................26

8.3 Motor Bearing lubrication .....................................................................................................26

8.4 Oil lubrication .......................................................................................................................26

8.5 Gear reducer Lubrication .....................................................................................................27

8.6 Roller Chain Maintenance ...................................................................................................27

8.7 AerolockTM Motor bearing lubrication ................................................................................. 27

8.8 Filter, regulator and gauge maintenance for air purge seals ...............................................288.9 Disassembly ........................................................................................................................288.9.1 T3 or Air purge sealsl ..........................................................................................................298.9.2 Drive-end seal & bearing removal .......................................................................................31

8.10 AerolockTM Reassembly .....................................................................................................328.10.1 Seal & End Plate Assembly .................................................................................................338.10.2 Bearing installation ..............................................................................................................368.10.3 Checking for proper clearances ...........................................................................................37

8.11 BT AerolockTM Puller Tool .................................................................................................. 38

8.12 BT AerolockTM Driver Tool Kitsl. ........................................................................................ 39

9 Troubleshooting ................................................................................................................409.1 Troubleshooting table ..........................................................................................................40


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Safety notes 1

Safety symbols definitions 1.1

1 Safety notes

1.1 Safety symbols def in it ions

Installation, commissioning and programming of the specified

equipment should only be undertaken by qualified personnel.

DANGER indicates an extremely hazardous situation which, if notavoided, could lead to heavy bodily injury or to death.

WARNING indicates a potentially hazardous situation which, if not

avoided, could lead to heavy bodily injury or to death.

CAUTION with safety alert indicates a potentially hazardoussituation which, if not avoided, could lead to light bodily injuries.

CAUTION indicates a potentially hazardous situation which, if notavoided, may result in property damage.

The safety alert symbol is used to alert to the potential personalinjury hazards. Obey all safety messages that follow this symbol toavoid possible injury or death.


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1 Safety notes

1.1 Safety symbols definitions

1.1.1 Electrical hazard icon

1.1.2 Ground icon

1.1.3 No hands icon

1.1.4 Power icon

This sign indicates an electrical hazard.

This sign indicates that a ground/PE connection is required.

Do not place hands or other body parts into moving parts or machine.

Power off and disconnect air supply before working on the equipment.


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Safety notes 1

Responsibilities of the owner 1.2

1.2 Responsibil it ies of the owner

1.3 Proper use

1.4 Organizat ional measures

Ensure that only qualified and trained personnel work with theequipment.

Establish personnel responsibilities for operation and

maintenance.

Ensure that the personnel has read and understood the operatinginstructions to all installation components, particularly this chapter"Safety notes".

The plant owner must replace damaged or missing componentsimmediately.

The operator has to avoid the entry of foreign substances (metalparts, stones) reaching the equipment by appropriate methods.

The plant owner is responsible for compliance with legallyprescribed accident prevention and safety regulations.

Only operate the equipment in accordance with the specifiedtechnical data.

Danger of explosion! Never use the equipment to processexplosive gas or air gas mix. Danger of explosion!

When processing dangerous materials, also comply with thesafety notes which govern the handling of such materials.

Any modifications and changes on safety devices are prohibited.

Do not use the equipment in a manner not intended by themanufacturer.

Never convey materials which may cause a chemical reaction withthe materials of the rotary valve.

Eliminate ignition sources, avoid spills and continually clean theworking area.

Always keep the operating instructions near the equipment, within

easy reach. Ensure that they are always complete and legible.

Observe the safety notes for the connected equipment.

In addition to the operating instructions, always comply withgenerally prescribed safety regulations governing accidentprevention and environmental safety.


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1 Safety notes

1.5 Safety-conscious work

1.5 Safety-conscious work

1.6 Safety devices

1.7 High voltage

Read the operating instructions, in particular these safety notes,and follow these instructions.

Ensure that only authorized personnel enter the working and

danger area of the equipment.

Any changes (including changes in the operational behavior)which affect safety must be reported immediately to theresponsible member of the staff.

Always keep safety in mind while working.

When operating any valve to check its action, be careful not tohave hands near any open ports.

Before opening or disassembling any part of the equipment alwaysswitch off the main power and air supply.

Operating the equipment without safety devices:

is dangerous for the health and life of the operator or thirdpersons

can damage the equipment or other material

Never alter the mechanical safety devices or the electrical controlsystem for the safety devices. Increased risk of accident.

Only operate the equipment if all safety devices are installed andfully functional.

Check that all safety devices operate properly every day.

Never open or remove covers or hoods while the equipment is inoperation.

Never operate the equipment when the housing is open.

Do not modify the electrical safety devices, for example fuses.Increased risk of accident.

Only use the specified fuse types when replacing fuses.

Replace damaged cable joints and connections immediately.

Only qualified electricians may work on the electrical equipment.

Protect electrical parts of the equipment against humidity.


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Safety notes 1

Additional equipment 1.8

1.8 Additional equipment

1.9 Customer service and repairs

1.10 Shut-down procedure

Modifications to the equipment are prohibited.

The operator is responsible for complying with all safetyregulations related to inter operation with any additional

equipment.

Have repairs to the equipment carried out by

by the responsible Premier / Coperion K-Tron (Switzerland) LLCcustomer service.

or

by specialized personnel trained by Premier / Coperion K-Tron(Switzerland) LLC.

Customer service address is found on the Project manual.

Only use original Premier / Coperion K-Tron (Switzerland) LLC parts.

The operator is responsible for the proper removal and disposal ofthe rotary valve from service.


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2 Application

2.1 Design

2 Application

The Blow-Through (BT) Aerolock configuration enhances rotorcleanout and makes installation in tight quarters possible. It is used insticky material applications to prevent material build-up in the rotorpockets.

2.1 Design

The BT is designed for heavy-duty industrial service in applications of

up to 0.8 bar [12 PSI] pressure differential. Eight blades maintain a

minimum twoblade labyrinth seal to minimize air leakage. The rotors

are equipped with relieved tips for materials that form skins or thin

sheets on end plates and housing, or non-relieved tips for cereal

products. The BT utilizes two tapered roller bearings on both the

thrust and drive sides.

2.2 Construction Overview

Round or square inlet/outlet flange patterns

Cast iron housing and end plates only (coatings available)

Carbon steel steel rotors

Outboard bearings

2.3 Options

Coatings: Tungsten, Nedox, Chrome, Nickel and other cartingsavailable

Rotor configurations: Standard flat or relieved tips or Open-ended.

Drives: Single speed or variable speed, right angle or parallel,Direct or indirect transmission, OSHA protective quarding

Seal configurations:

T3: Two quad ring Buna-N seals on a Teflon insert.

Lip: Type double spring loaded seal.

Air Purge: Compressed air defuser followed by standard seal

G5: Four quad rind Buna-N seals on a stainless steel insert.


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3 Technical data

3.1 Model sizes

3 Technical data

3.1 Model sizes

Specifications Limitations and notations

Manufacturer Premier Pneumatics

Designation Blow-Through Aerolock Rotary Valve

Model Sizes 98, 1110, 1312, 1514, 1716

Conformityor declaration by the manufacturer

Protection class of electrical

components

IP 65 Nema

allowable operating pressure 1.0 bar [15 PSI]

allowable differential pressure 1.0 bar [15 PSI]

allowable differential pressure

in a conveying system

0.8 bar [12 PSI]

Operating temperature range -10 to 121 C [14 to 250 F]

Noise level 70 dB (A)

Dimensions See dimensional drawing in the system project manual

Materials of construct ions: Cast iron or Stainless steel

Model size 98 1110 1312 1514 1716

Basic valve size mm [in] 203 [8] 254 [10] 305 [12] 356 [14] 406 [16]

Rotor end configuration Open Open Open Open Open

Displ. dm3/Rev [Ft3/Rev.] 6.8 [0.24] 13 [0.46] 22 [0.79] 35 [1.23] 52 [1.85]

Maximum allowabletorque in NM [lbs/in]

118[1.045]

249[2.200]

441[3.900]

441[3.900]

441[3.900]

Unit weight in kg [lb]

without drive

59

[129]

98

[216]

143

[316]

213

[469]

268

[590]

Unit weight in kg [lb]with drive

97[213]

141[311]

179[395]

270[595]

346[763]


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Installation 4

Unpacking 4.1

4 Installation

4.1 Unpacking

1. Remove the feeder carefully from the packaging.

2. Check whether the supplied goods are complete and check themfor transport damage.

3. Report any damage immediately to Coperion K-Tron (Switzerland)LLC.

4.2 Transport

Only have the rotary valve connected and commissioned by

authorized personnel.

Ambient condit ions

Only use explosion-proof feeders in hazardous areas.

Install the feeder only in surroundings conforming to the technicaldata (see Section 3) and in accordance with the safety notes (seeChapter 1).

Only have the rotary valve transported by authorized and qualifiedpersonnel.

Transport the rotary valve only with a hoisting equipment.

In order to avoid damage to the rotary valve, only use lifting strapswith sufficient lifting capacity for the hoisting equipment (for theweight of the rotary valve see section 3).

The lifting straps must be sufficiently long to avoid too much strainto the band.

1. Fix the lifting straps at the mounting supports as shown. Use theclamps to ensure that there is no slippage of the lifting straps.

Fig. 4.1 Transport


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4 Installation

4.3 Storage (Over 4 Months)

4.3 Storage (Over 4 Months)

For long term storage (over 4 months) desiccant strips or bags shouldbe placed in the internal cavity of the Aerolock.

The housing inlet and outlet flanges should be capped to prevent dust

and debris from accumulating in the Aerolock during storage.Bearings should be greased approximately every six months. At thistime it is also important to turn the rotor three full rotations to preventit from seizing in the Aerolock housing.

4.4 AerolockTMmounting

4.4.2 Gear lubrictat ion

4.4.1 Chain Power Transmission

Chain should be disconnected and found in a package stowed in theguard compartment.

Fig. 4.2 Chain drive

See the OEM gear reducer information for the proper grease selection

and lubricating instructions.


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Installation 4

Vented shear protector installation 4.5

4.5 Vented shear protector instal lat ion

4.5.1 Adjusting Seal Flap to fi t Rotor

1. Remove the long seal flap (B), the short shear protector flap (D),and all corresponding retainers from the shear protector.

2. Place the rotor in position with one blade is up and centered withinthe inlet.

3. Place the shear protector on the inlet, and secure it in place withsix bolts.

Fig. 4.3 Vented shear protector

4.5.2 Ensuring Proper Fit / Checking Clearances

1. The clearance between the rotor and the shear protector sideplates should be 1,59 mm [1/16] (Fig. 4.3).

2. If a clearance adjustment is needed, remove the shear protectorfrom the Aerolock and place it top-side down on a workingsurface. Loosen the screws and adjust both side plates (C) asneeded, being certain to adjust them evenly.

3. Reinstall the shear protector to the Aerolock, verifying that theclearance is correct. Remove the shear protector from the

Aerolock inlet, and reassemble flap (B) and flap (D) along withtheir retainers, and tighten the screws. Be certain that flap (B) is

installed on the same side as the vent tube (A) (see Fig. 4.3).

Fig. 4.4 Clearance

4.5.3 Final Instal lat ion

Install the shear protector to the Aerolock inlet, with the vent tubeoriented as shown in Fig. 4.5. It is critical that the rotor rotates from thelong flap to the short flap. Use bead sealant or a suitable caulking be-tween the flanges. Tighten the attachment bolts in equal stages so theshear protector will mate uniformly against the Aerolock.

Rotate the rotor by hand, to ensure that the short flap sweeps the rotortip. Adjust the flap if necessary. Continue with section 4.7.

Fig. 4.5 Mounting direction

1/16

1,59 mm


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4 Installation

4.6 Non-vented shear protector installation

4.6 Non-vented shear protector installation

4.7 AerolockTMand accessories installation

Install the Aerolock assembly and accessories. Use 1/4 thick neo-prene gaskets between all the connecting flanges. Tighten the att-tachement bolt in equal stages to ensure that the Aerolock flanges

mate uniformly against the gaskets

1. Place the Aerolock rotor in position with one blade up andcentered within the Aerolock inlet.

2. Install the shear protector to the Aerolock inlet, with the flap on

the correct side for the rotor rotation. Use bead sealant or asuitable caulking between the flanges. Tighten the attachmentbolts in equal stages so the shear protector will mate uniformlyagainst the Aerolock.

3. Rotate the rotor, ensuring that the flap sweeps the rotor tip,adjusting the flap if necessary. Remove the attachment bolts.

Fig. 4.6 Mounting non-vented shear

protector

Do not install the Aerolock in a manner which leaves the inlet oroutlet opening exposed. An inlet / outlet guard is available fromPremier (see Fig. 4.7). It is a mandatory accessory if the inlet isexposed to personnel.

Do not use the Aerolock to support equipment other than thedrive assembly and line adapter. External loads on the inlet andoutlet flanges will cause undue compression or tension on thehousing.

When the Aerolock is located under a tank or hopper containing

large volumes of material, it is a good practice to install a maintenancegate above the Aerolock. The gate allows for temporary materialshut-off to perform maintenance.


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Installation 4

AerolockTM and accessories installation 4.7

Theread the ends of conveying line to be installed to the Aerolock.Use the correct pipe thread size as spezified on th dimension drawing.Threaded adapters can be used if necessary. install the conveyingline to the outlet ports at the bottom of the Aerolck, using tfelon tapeor a suitabel culking. Ensure that the connections re tight.

Fig. 4.7 Inlet / Outlet Guard


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4 Installation

4.8 Electrical connection

4.8 Electr ical connection

1. Connect the feeder in accordance with the electrical wiringdiagram.

2. Ground the feeder carefully. .

4.8.1 Motor connection

If the drive is an electronic variable-speed continue with chapter 4.8.3

Improper connection can cause danger to life through electric shock.

Only connected by qualified electricians.

Observe the local regulations.

Carefully follow all wiring and shielding procedures as indicated on theprovided wiring diagrams and operating instructions.

Connect the ground connection to a low-impedance equipotential

bonding (0.1 ).

Provide a lockable main switch to disconnect the main power supply.

Verify that the drive chain is still disconnected while performing to

avoid damage to the shear protector.

Counterclockwise rotation (when viewing from the drive shaft) iscritical.

1. Connect the appropriate power supply to the drive motor,referencing the motor nameplate and wiring diagram. Ensure thatthe motor is properly grounded. Continue wiht step 3.

2. If your drive is an electronic variable-speed drive, connect theappropriate power supply th the controller. A connection will alsobe required between the controller and the motor. See thecontroller wiring diagram for the proper connections, ensuringporper shaft rotation. Be certain that the motor is properlygrounded.

3. With the drive chain removed, jog the motor to ensure properratation. Be certain thtat the motor ventilation is not restricted.Then, disconnect the power suply.

Fig. 4.8 Motor


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Installation 4

Electrical connection 4.8

4.8.2 Chain Adjustment

4.8.3 Variable Speed Drive Settings

If the drive is not variable-speed drive, disregard this chapter.

1. Align the sprockets using a straight edge. Be certain that bothshaft keys are seated properly. Sprockets should be as close tothe back of the drive guard as possible without rubbing.

2. Reinstall the drive chain .

3. Adjust the nuts on the motor mount until the chain is snug, but nottoo tight. There should be slack (about 2% of the center distance)on the bottom side. A little slack is needed as it allows the chainlinks to take the best position on the sprocket teeth. Anovertightened chain will overload the shaft and bearings. Toomuch slack will cause the rollers to ride up on the teeth, causingwear on the sprocket.

4. Reinstall the drive guard cover.

5. After operationg the Aerolock for serveral hours, repeat steps 2-4

Fig. 4.9 Proper chain installation

Never operate the Aerolock wiht the drive cover removed.

Restore power from the drive.


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4 Installation

4.8 Electrical connection

4.8.4 Mechanical variable Speed

Do not turn control wheel wihle the motor is not operating see Fig. 4.10Doing so may cause damage to the unit.

1. Set the output speed by turning the control wheel located on theside of the motor.

2. Set the control wheel at 0 to achieve the slowest speed in thespecified speed range.

3. Each position after zero is approximately 10 percent faster, up to100 percent of maximum motor speed.

4. The dimension drawing specifies the speed range of the Aerolock

and the displacement in cubic feet/revolution. If a specific speed isrequiered, a tachometer reading can be taken from the Aerolocksshaft.

5. Set the output speed by turning the speed selector located in thecontroller (see Fig. 4.8).

6. Each position from 0 to 100 is a percent of the speed range of theAerolock, as specified on the dimension drawing.

Fig. 4.10 Electrical variabel speed


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5 Start-up

5.1 Start-up checklist

5 Start-up

5.1 Start-up checklist

1. Ensure the correct installation of the shear protector, as describedin Chapter 4. - 4.7Ensure that the clearance has been adjusted,as described in step 4.5.2, and that the long seal flap and shortshear protector flap have been installed properly.

2. All flange connections must be tight and mate uniformly againstthe gaskets.

3. Verify that the gear case has been filled with oil to the correct level.4. Check for proper electrical wiring to the motor as specified on the

motor nameplate.

5. To ensure correct shaft rotation and avoid shear protectordamage, make certain that the motor was jogged with the couplingseparated or chain removed, as described in section 4.8.2 andsection 4.8.3.

6. If the Aerolock has air purge seals, ensure that a filter, regulator,and gauge assembly has been installed to supply clean, dry,filtered, compressed air to the seals. The pressure should be setso the gauge will read 0.7 Bar [10 PSI] above the conveying

system's operating pressure (approximately 1.4 Bar [20 PSI] inmost systems). See section 4.9.

Only operate with all safety devices in place.

Verify that the Aerolock inlet and outlet openings are not

exposed to personnel. If so, install an inlet/outlet guard.


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7 Cleaning

7.1 Switching off the installation

7 Cleaning

7.1 Switching off the instal lat ion

7.2 Notes on cleaning

When carrying out maintenance work on the switched-off Aerolockthere is a danger of injury through unintentional switching-on.

Switch off the system before carrying out maintenance work on theconveying device and secure it against unintentional restarting(see chapter 7.1).

Aggressive and toxic cleaning agents damage the equipment and rep-resent an increased accident risk.

Follow the safety regulations for dealing with cleaning agents.After use dispose properly of the cleaning agents.

Use only cleaning agents with 5.0


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Maintenance 8

Maintenance intervals 8.1

8 Maintenance

8.1 Maintenance intervals

Periodic cleaning is recommended.

When carrying out maintenance work on the switched-off rotary valve,there is a danger of injury through unintentional switching-on.

Switch off before carrying out maintenance work on the equipmentand secure it to prevent unintentional restarting (see section 7.1).

Only qualified and trained personnel may carry out maintenancework.

Only qualified electricians may work on the electrical equipment.

To avoid seal damage, never operate an equipped with air purgeseals unless the purge air is turned on.

Element Checkpoints Interval

Mechanics Eliminate dust accumulation morethan 5 mm [0.2 in] throughcleaning.

Check compressed air

Empty water-separator

Check Aerolock mechanical

connections for tightness. Check seal rings for damage

Check safety symbols at theequipment for legibility andcompleteness.

Weekly

Pneumatic (AirPurge option)

Check pressure regulator

Change filters

Monthly

As required

Electric Check ground wires and staticbonding.

Check all electrical connections

As required


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8 Maintenance

8.2 Disengage Power Transmission

8.2 Disengage Power Transmission

8.3 Motor Bear ing lubr ication

The motor end bearings are lubricated for life and require no re-lubri-cation.

8.4 Oil lubrication

If the drive utilizes a parallell-shaft, planetary gear reducer as shownin Fig. 4.9continue wiith Chapter 4.8

Switch off before carrying out maintenance work on the equipmentand secure it to prevent unintentional restarting (see section 7.1

The drive assembly is shipped without oil in the gear case.. Fill thegear case with an oil that is suitable for bronze worm gearing with mildEP additives, using the holes specified in Fig. 8.1andFig. 8.2Checkthe Lubrication Instruction Plate on the motor for the correct AGMA(American Gear Manufactures Association) Lubricant Number to ac-commodate the ambient temperature. Below are some examples ofoils suitable for the required AGMA specifications:

Fig. 8.1 Vertical configuration

OIL BRAND 7EP 8EP

Amoco Cylinder Oil 460 680

Mobil Super Cylinder Oil 600W Extra Hecla

Shell Omala 460 680

Texaco Vanguard 460 680

Most oil lubricated gear reducer are shipped without oil. Refer to in-struction manual with unit for specific type and grade of oil to be used,

change interval and level. If lubrication instruction specify synthetic oil,do not substitute.

Fig. 8.2 Horizontal configuration


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Maintenance 8

Gear reducer Lubrication 8.5

8.5 Gear reducer Lubr ication

If the drive utilizes a right-angle gear reducer continue with step 2.

1. See the OEM gear reducer information for the proper greaseselection and lubricating instructions for a parallel-shaft, planetary

gear reducer, continue with 8.6.2. Change the oil in the right-angle gear case after the firs week of

service and twice yearly thereafter. See oil lubrication - Installation8.4for the poroper oil selection and fill details.Keep the gear casefilled wiht the correct oil to the proper level.

8.6 Roller Chain Maintenance

The roller chain should be checked for proper alignment periodicallywith a straight edge. Check for the proper roller chain fit. The centerdistance may need to be adjusted after serveral weeks of operation.

The roller chain should e lubricated periodically wiht a high grade ofnon-detergent, petroleum-based oil.

8.7 AerolockTMMotor bearing lubrication

BT Aerolock have sealed-for-life ball bearings in the drive end. Theyare to be replaced when dirty or faulty. The tapered roller bearings inthe thrust end can be cleaned, lubricated, or replaced upon disassem-bly of the Aerolock. See section 8.9and 8.10.

Grease for Tapered Roller Bearing

(pack bearings with one of the following)

Universal Dyna-Plex 21C Moly EP 500+2

Mobile grease Special

Texaco Molytex EP2


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8 Maintenance

8.8 Filter, regulator and gauge maintenance for air purge seals

8.8 Filter, regulator and gauge maintenance for

air purge seals

Check the gauge reading periodically to ensure that the air purgeseals are receiving air at a pressure of 0.69 Bar [10 PSI] above the

conveying system's operating pressure (approximately 1.38 Bar [20PSI] in most systems).

The air supply to the seals is interrupted during the cleaning or repair-ing of the filter in the filter, regulator, and gauge assembly. So it is im-

portant to perform this task while the AerolockTMis not running.

8.9 Disassembly

Keep fingers and hands out of the inlet and outlet areas of theAerolock while disassembling. Even though the unit has beenremoved from service ther is still the potential for the blades to turnwhen working on disassembling. As a safety precaution, place aboard 101.6mm wide x 304.8mm long x 50.8mm thick [4.0 wide x12.0 long x 2 thick].This will prevent the rotor from turning.

Remove the Aerolock from service, then remove its drive assembly.

Fig. 8.3 Remove Aerolock


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Maintenance 8

Disassembly 8.9

8.9.1 T3 or A ir purge sealsl

1. Loosen the three set screws on both teflon inserts with a 3/32 hexAllen wrench.These set screws can be reached through the top and bottom slotson each end plate as seen in Fig. 8.4.

The rotor will need to be turned to gain access to each screw.2. Turn the Aerolock housing upsid down.

Fig. 8.4 Loosen screws

3. Remove the bolts from the drive end plate.

4. Remove two opposite plastic caplugs from the drive end plate, andinsert two 3/8-16 bolts with at least 3 1/2 of threads.Tighten these bolts in sequence, one turn at a time, until the endplate draws away from the housing and is free of the rotor shaft.

5. Note the location and thickness of all shims for reference duringassembly.

6. Lift and slide the drive end plate off of the rotor shaft, taking carenot to damage the shaft.

Fig. 8.5 Tighten bolts

7. Remove the brown paper shim (if used) and all individual boltshims from the end plate and housing flanges.

8. Remove the hub cap from the thrust of the Aerolock.

9. Remove the machined lock nut from the thrust end of the shaft,placing a board in the rotor pocket th keep the rotor from turning.

Fig. 8.6 Note location and thickness

of individual bolt shims


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8 Maintenance

8.9 Disassembly

10. Assemble the puller toll (see the diagram capter 8.11 forconstruction of this toll) to the thrust end palte hub.

11. Assemble the gear puller to the thrust end of the Aerolock, andpush the rotor shaft free of the end plate.

12. Slide the rotor out of the housing, taking care not to damage the

rotor blade edges or the machined housing bore.13. Remove the thrust end plate as described in steps 2 and 3. Be

certain to save the caution tag from the thrust end platereassembly.

14. Remove the brown paper shim or individual bolt shims from theend plate and housing flanges.

Fig. 8.7 Pullrt tool

15. Remove any washer shims from the thrust end of the rotor shaft.

Note the location and thickness of shims, for reference duringreassembly.

16. Position the end olates, machined sid up, on a work bnech usingwood block to provide space unterneath.

17. Remove the two tapered roller bearing from the drive end plate,using a tapered punch.This will also remove the other bearing cup.Drive down on top of the bearing grease seal, forcing both the sealand remaining cup from the end palte.

18. Remove the sealed ball bearing from the drive end plate using atapered punch see Fig. 8.9.

Fig. 8.8 Bench using


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Maintenance 8

Disassembly 8.9

8.9.2 Drive-end seal & bearing removal

Ai r T-3 Seals :

1. Remove the insert from the end plate, working them out using atapered punch (see Fig. 8.8andFig. 8.9)Using a sharp awe or pick, remove the two to four quad ring sealsfrom the seal cases.Remove the two seal cases from the end plate using a taperedpunch.

Ai r purge seals:

1. Remove the insert from the end plate, working them out using atapered punch (see Fig. 8.8and Fig. 8.9).Remove the seal from each end plate, and then the air purgediffuser.

Lip seals:

1. Using a tapered punch, remove the two seals from the end plate(see Fig. 8.8and Fig. 8.9).

Fig. 8.9 Seal


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8 Maintenance

8.10AerolockTM Reassembly

2. Clean all machined surfaces, such as the end plate faces, housingbore, rotor blades, and shaft with steel wool to remove all materialbuildup.Remove any burrs from the rotor shaft and from the mating flangesof the end plate and housing.

3. If the thrust-end bearing are to be reused, palce them in a suitablecontainer with clean, cold petroleum solvent or kerosene, andallow the bearing to soak, preferably overnight. Turn the bearingsslowly, working with a brush to dislodge chips or solid particles.

After cleaning, they should be spun in light oil in order to removethe solvent completely. If the drive-end bearing is dirty, damaged,or worn, it should be replaced.

8.10 AerolockTMReassembly

Reassembling the Aerolock requires special drivers to install thebearings, seals, and teflon inserts.Driver tool kits that contain all the necessary drivers can be purchaseddirectly from Coperion K-Tron (Switzerland) LLC Premier.

Improper installation of the seals and bearings can lead to prematurewear and reduction in Aerolock efficiency and performance. Using thespecial driver tools during reassembly can increase the lifespan ofbearings and seals as well as keep the Aerolock performing at an op-timal level.

See the diagram in section 8.11for ordering the BT Aerolock drivertool kits.

If the Thrust-end bearings are to be reused, be certain that they are

properly cleaned, as described above in step 5 of the Seal & Thrust-end plate removal see section 8.10).

If the bearings and seals are damaged or worn, they should be re-placed. Replacement bearings and seals are available in an Replace-ment Parts Kit from Premier.


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Maintenance 8

AerolockTM Reassembly 8.10

8.10.1 Seal & End Plate Assembly

1. Place both end plates, machined side down, on a flat, cleansurface, as shown in Fig. 8.10.Take care not to damage the machined surfaces.

Fig. 8.10 Assemble seals

2. T-3 Seals:

Using the seal driver tool, install one seal case into each end plate,against the shoulder.

For T-3 seals, install a second seal case against the first.

Turn over both end plates, and insert the quad ring seals into thecases.

Be sure the quad ring seals seat evenly and are not twisted in theseal cases.

If they do not seat evenly, remove the seals and check for foreignmaterial in the cases.

Fig. 8.11 Seal


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8 Maintenance


Ai r purge seals:

Using the seal driver tool, install an air purge diffuser into each endplate, against the shoulder (see Fig. 8.11andFig. 8.12). Install theseal against the diffuser. The diffuser needs to be installed with thesmooth open end toward the rotor shaft.

Lip seals:

Using the seal driver tool, install one lip seal into each end plate,against the shoulder (see Fig. 8.11). Drive the second seal againstthe first seal.

3. Carefully slide the rotor into the housing, taking care not todamage the rotor blade edges or the machined housing bore.Ensure that the drive mounting lugs (1) are on the left whenlooking at the keyway end (2) of the rotor shaft.

4. Apply Alumilstic or another suitable caulking to the end plateflanges.

Fig. 8.12 Seal installation

5. Install the thrust end plate (noted by the tapped holes in the hub)over the threaded end of the rotor shaft.

6. Install the drive end plate over the keyway end of the rotor. Alignthe bolt holes with those in the housing.

7. Insert the bolts through the end plates and tighten in sequence,one turn at a time.

Install new shims of the same color as those removed duringdisassembly (see Fig. 8.16for shim location).If a brown paper shim was removed from the housing (or you areuncertain what color shims were removed), a clearance readingwill be taken in step 8 and individual shims can then be installed.

Fig. 8.13 Bolt shims


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Maintenance 8

AerolockTM Reassembly 8.10

T-3, G5, or air purge seals

Al l seals

8. Check the inserts for scratches or grooves on the internal bore andexternal sealing surfaces, replacing if necessary.

Position the set screws in such a manner as to prevent

interference with the rotor shaft and end plate bore duringinstallation

9. Position the expansion tool on one end of the rotor shaft, againstthe shoulder.If Aerolock is equipped with G5 seals, before proceeding slide aTeflon o-ring over the expansion tool, on to the shaft until it isseated in the tapered groove in the end plate.Slide an insert onto the expansion tool. Using the seal driver tool,drive the insert in the end plate as shown.Install an insert onto the other end of the shaft in the same manner.

Fig. 8.14 Teflon insert (t-3 Seals)

10. Slide the rotor against one of the end plates, and check theclearance between the other end plate and the rotor.Check to see whether or not it equals the total clearance of bothends as specified on the Aerolock Clearence Sheet section.

11. If a clearance increase is required, pull each end plate away fromthe housing, as described in section 8.9steps 3 and 4, and insertshims at each bolt equal to half the required clearance increase.The thickness of each shim is specified by color, as follows:

Red 0.05 mm [0.002 inch]Green 0.08 mm [0.003 inch]Blue 0.13 mm [0.005 inch]Brown 0.25 mm [0.010 inch]

Fig. 8.15 Check clearance


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8 Maintenance


8.10.2 Bearing installation

3. Using a thrust-end bearing driver tool, install a bearing cup ontothe thrust end of the shaft. Drive the bearing cup until it is seated.

4. Pack the tapered roller bearing with one of the following:

Universal Dyna-Plex 21C Moly EP 500 +2

MobilgreaseSpecial

Texaco Molytex EP2.

5. Install the bearings onto the thrust-end of the shaft and into thebearing cup.

6. Tap the remaining bearing cup into the end plate, using thebearing driver tool.

7. Using the drive-end bearing driver tool, install the sealed ballbearing onto the drive end of the shaft.Drive until the bearing is properly seated in the end plate.

After the necessary shimming is complete, retighten the end plate as-sembly bolts.

Fig. 8.16 Bolt shims

1. Using the grease seal driver tool and the expansion tool, install thebearing grease seal onto the thrust end of the shaft.Drive the seal until it is seated, as shown.

2. Install new washer shims (the same color or with the samenotches as those removed during disassembly) against thebearing bore shoulder.Note:If the brass shim is replacing a colored aluminum shim, usethe color thickness guidelines listed under step 8 to determine thethickness of the brass shim (listed below) to be installed:

Brass shim with 0 notches 0.05 mm [0.002 inch]Brass shim with 1 notch 0.08 mm [0.003 inch]Brass shim with 2 notches 0.13 mm [0.005 inch]

Fig. 8.17 Bearing grease seal install


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8 Maintenance

8.11BT AerolockTM Puller Tool

8.11 BT AerolockTMPuller Tool

The puller tools is required to remove the rotor from the housing andthrust end plate during disassembly Refernece the following drawingto construct this tool.

12. Using the measurement from step 4, add the preload shim orshims that will allow for a tolerance between .0015 and .002inches.The thickness of each shim is specified by color as follows:

Red 0.05 mm [0.002 inch]Green 0.08 mm [0.003 inch]Blue 0.13 mm [0.005 inch]Brown 0.25 mm [0.010 inch]

13. Place the shim or shims on the hubcap. Align the hub and shimswith the end plate.

Fig. 8.18 Position micrometer

14. Install the hubcap and tighten the screws.

T3 or Air purge Seals

Ensure that the teflon inserts are still seated against the end plates,using a brake adjusting tool through the bottom end plate slots, andtighten the three set screws on both teflon insert, using a 3/32 hex al-len wrench. The rotor will require roating to gain access to each screw.

Al l seals

Reassemble the drive assembly to the Aerolock. See the spare partsDrawing for reassembly.

Fig. 8.19 Placing shim(s) on the

hubcap

Aerolock Size A B C D

76 & 98 4 1/2 2 1/4 1 1/16 2

1110 & 1312 6 3 1 5/16 2 1/2

1514 & 1716 6 3 1 3/8 2 3/4


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Maintenance 8

BT AerolockTM Driver Tool Kitsl. 8.12

8.12 BT AerolockTMDriver Tool Kitsl.

Each Driver Kit includes:

(1) Seal driver tool for installing T-3 seals, T-3 inserts, air purgediffusers, air purge seals, and lip seals

(1) Expansion tool for installing T-3 inserts and grease seal

(1) Bearing driver tool for installing drive-end bearings

(1) Bearing driver tool for installing thrust-end bearings and greaseseal.

Improper installation of the seals and bearings can lead to prematurewear and reduction in Aerolock efficiency and performance. Using thespecial driver tools during reassembly can increase the lifespan of

bearings and seals as well as keep the Aerolock performing at an op-timal level

To simplify ordering, the driver tools have been arranged in kits. Onlyone kit needs to be purchased for each size group listed below, as thedriver tool kits can be reused.

For example, if you are using (2) 98 BT Aerolocks and (1) 1110 BTAerolock, (1) driver tool kit for the BT 98 Aerolock and (1) driver toolkit for BT 1110 Aerolock should be purchased.

If you have not already purchased the appropriate driver tool kit for theAerolock you have in service, contact the Premier Parts Depart-ment. Replacement tools can also be purchased individually through

our parts department.

Fig. 8.20 driver tool size

Individual driver tool part numbers*

BT AerolockSize

Driver tool kitpart number

Seals Expansion tool Drive-End bear-ings

Thrust-EndBearings/

Grease seal

98 5501-170 3701-98 3701-104 3701-99 3701.118

1012 5501-173 3701-100 3701-105 3701-101 3701-119

1110 5501-171 3701-100 3701-105 3701.101 3701.119

1312 5501-171 3701-100 3701-105 3701.101 3701.119

1514 5501-172 3701-102 3701-106 3701-103 3701-120

1716 5501-172 3701-102 3701-106 3701-103 3701-120

*The part number is engraved on each tool for ease of identification

(2) 7/16DI

HOLES

D DIA

C Typ

B Typ C Typ

A SQ


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9 Troubleshooting

9.1 Troubleshooting table

9 Troubleshooting


Eliminating faults in a rotary valve which is running can cause seriousaccidents.

Switch off the rotary valve before every intervention and secure itagainst unintentional restarting (see chapter 7.1).

Always switch off before carrying out repairs.

Check the equipment.

Please observe the error messages which are displayed on theconnectet control device or host computer.

Document faults and call the local service center(for customer service information, project manual).

Error Cause Remedy

Aerolock or motorwill not start.

No power source

Motor defect

Gear case defect

Rotor jammed

Check the power source forsufficient power as specified on thenameplate. Check the wiringconnections and the motorprotection devices; e.g., fuses,circuit breakers, and overloadelements. Replace the fuses, if

blown, and reset the circuitbreakers or overload elements, iftripped.

The motor may be burned out. If so,it will need to be repaired orreplaced.

The gears in the gear case mayhave seized up due to the lack ofoil. Replace the gears or the gearcase.

Check for a jammed rotor. If

jammed, the Aerolock may needto be disassembled and cleaned.The bearings or seals may need tobe replaced.

Table page 1 of 6


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Troubleshooting 9

Troubleshooting table 9.1

Unusual drive ormotor noise

Gear case oil level

Drive alignment wrong

Check the oil level in the gear case.If it needs to be filled, see the OEMgear reducer information for theproper grease selection andlubricating instructions.

Check for the proper alignment ofthe drive components.

Unusual Aerolocknoise

Material build up Check the motors amp draw todetermine whether material buildupon the rotor or housing isoverloading the motor. If thebuildup is excessive, clean therotor and housing.

Some materials are susceptible to

buildup and may cause a squealingnoise as the rotor turns. This will benormal for some types of materialand should not be a cause forconcern.

Check for the correct direction ofrotation. A rotor with relieved tipsrotating in the wrong direction willcause material buildup.

The rotor may be rubbing on thehousing. Check for external loads

on the inlet and outlet flanges. TheAerolock is not to be used as asupport for loads other than thedrive assembly and line adapter.

Error Cause Remedy

Table page 2 of 6


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9 Troubleshooting


High motortemperature

Bearings

Material build up

Wrong electrical overload elements

Motor ventilation

Gear case oil level

Check for proper operation of theAerolock bearings. Seetroubleshooting tableAerolockbearing malfunction or failure.

Check for excessive materialbuildup in the rotor. See Errorunusual Aerolock noise

Verify that the electrical overloadelements are properly sized per thefull load amp specification on themotor nameplate. Oversizedelements will not protect the motorfrom overload.

Check for proper ventilation around

the motor. Material or dust buildupon the exterior of the motor mayhamper ventilation.

Check the oil level in the gear case.If it needs to be filled, see the OEMgear reducer information for theproper grease selection andlubrication instructions.

Error Cause Remedy

Table page 3 of 6


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Troubleshooting 9


Aerolock bearingmalfunction or failure

Bearing damaged

Lubrication from thrust-ends

Wear or dirt in the drive-end bearing

Check for wear, dirt or material inthe thrust-end bearings. Clean thebearings, as instructed in section8.10step 5. If there is damage, thebearings will need to be replaced.Replacement bearings areavailable in a Replacement PartsKit from Premier. If there is materialin the bearings, check the conditionof the seals. See troubleshootingtable Leaking seals.

Check for proper lubrication of thethrust-end bearings. Lubricate asinstructed in section 8.10.2step 3.Be certain that the proper lubricant

is being used. Over lubrication ofthe bearings may causeoverheating.

Check for wear, dirt, or material inthe drive-end bearing. If so, replacethe bearing, as it is a sealed-for-lifebearing. Replacement bearings areavailable in a Replacement PartsKit from Premier.

Error Cause Remedy

Table page 4 of 6


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9 Troubleshooting


Leaking seals Air purge seals

T-3 seals

Lip seals

Ensure that a filter, regulator, andgauge assembly has been installedto the Aerolock, along with thecompressed air supply. If the

Aerolock has been operatedwithout the air purge operating, theseals are probably damaged andneed to be replaced. See section8.9and section 8.10. Replacementseals are available in aReplacement Parts Kit fromPremier.

Check for proper operation andadjustment of the filter, regulator,and gauge assembly. The

regulator should be set 0.69 Bar[10 PSI] above the conveyingsystem's operating pressure. If theregulator is set too low, material willnot be properly cleaned from the airpurge diffusers and will damagethe seals. The seals should bereplaced.

Disassemble the Aerolock, andreplace the seals. See section 8.9and section 8.10. Replacementseals are available in aReplacement Parts Kit fromPremier.

Disassemble the Aerolock, andreplace the seals. See section 8.9and section 8.10. Replacementseals are available in aReplacement Parts Kit fromPremier.

Air loss Seals damaged or wrong clearance Check for the correct rotor-to-housing and rotor-to-end plate

clearance. If there is too muchclearance, air loss through theclearances will result.

Check the condition of the seals.See troubleshooting table Leakingseals.

Error Cause Remedy

Table page 5 of 6


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Troubleshooting 9


Material not flowing Material build up

Wear or dirt in the drive-end bearing

Material bridging

Wrong rotor speed

Check for material buildup in therotor pockets. Clean the

Aerolock rotor.

Check for the correct rotor-to-housing and rotor-to-end plateclearance. If there is too muchclearance, air loss through theclearances may cause the materialto bridge above the Aerolock,decreasing or stopping the materialflow.

Vented shear protectors aredesigned to minimize the chancesfor material bridging above the

Aerolock by venting the air

displaced from each pocket as itfills, as well as any air leakagethrough the clearances. A ventedshear protector may need to beinstalled for your application.

If a vented shear protector isinstalled, check the condition of thelong seal flap. If it is worn orsheared off due to incorrectinstallation or incorrect rotorrotation, it will need to be replaced.

See section 4.5. Replacement sealflaps are available from Premier.

Check for the correct AerolockRPM.

Error Cause Remedy

Table page 6 of 6


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9 Troubleshooting


1190034611 en 1.0.0 BT Aerolock Rotary Valve

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Transcript of 1190034611 en 1.0.0 BT Aerolock Rotary Valve