Operating instructions

Transcription

1 Operating instructions Airlock MPSN-MS (-Ex) Original operating instructions

2 Table of contents 1 Important information Scope of validity Applicable documents Contact Address Feedback regarding this manual Personnel qualifications Mechanics Electrician Welders Presentation conventions Explanation of warnings Safety Intended use Technical condition ATEX labeling Personnel qualifications Safety devices Safety markings Safe working environment Slipping and tripping hazards Technical data Ambient conditions Performance characteristics Maximum permissible torque Rotor volume Operating temperature Airborne noise emission Measured values Weights and volumes Transport weights not including drive Transport weights including drive Volumes packaged in seaworthy manner Dimensions Pneumatic system Options Description Identification Type plate Type code ATEX designation for use in Ex zone ATEX designation without approval for use in potentially explosive zones Table of contents

3 4.2 Overview Mode of operation EMERGENCY STOP Protection devices Safety symbols Transport Packaging symbols Checking delivery Temporary storage Lifting instructions Installation Preparing installation location Series arrangement Connecting the utilities Electrical systems Commissioning Checking commissioning Checking the rotor Conformity Checking EC conformity Operation Starting and stopping Starting Stopping Checks during operation Trouble-shooting Faults Maintenance Cleaning Lubrication Lubrication schedule Bearing Maintenance Maintenance schedule Maintaining airlock Maintenance and repair Replace speed sensor Removing speed sensor Installing speed sensor Replacing bearing and shaft seal Removing bearing and shaft seal Fitting bearing and shaft seal Replacing rotor Decommissioning Dismantle Disposal Table of contents 3

4 Disposal of operating materials Disposing of machine Table of contents

5 1 Important information 1.1 Scope of validity Type MPSN-25/15-MS MPSN-25/23-MS MPSN-28/30-MS MPSN-25/15-MS-Ex MPSN-25/23-MS-Ex MPSN-28/30-MS-Ex 1.2 Applicable documents Designation Gearmotor Frequency converter Speed monitoring Spare parts catalog Identification number Refer to the manufacturer's documentation. Refer to the manufacturer's documentation. Refer to the manufacturer's documentation. MPSN-8230-x Contact If you have any questions, please contact the relevant branch of the manufacturer. Keep the instructions to hand Address Customer Service Grain Processing CH-9240 Uzwil, Schweiz Feedback regarding this manual Requests and suggestions relevant to this manual 1.4 Personnel qualifications Mechanics Individuals who work on mechanical equipment must be technically trained or have attended and passed the manufacturer's training. Chapter 1 Important information 5

6 1.4.2 Electrician Individuals who work on electrical equipment must be technically trained or have attended and passed the manufacturer's training Welders Personnel who weld on the equipment must have specialized training. 1.5 Presentation conventions Explanation of warnings DANGER Type and source of danger The danger will result in death or severe injuries. Precautionary measures to mitigate the danger. WARNING Type and source of danger The danger can result in death or severe injury. Precautionary measures to mitigate the danger. CAUTION Type and source of danger The danger can result in injuries. Precautionary measures to mitigate the danger. NOTICE Type and source of danger The danger can cause material damage. Precautionary measures to prevent material damage 6 Chapter 1 Important information

7 2 Safety 2.1 Intended use The airlock is designed for powdery to granular, free-flowing bulk materials in accordance with the requirements list. It is used to feed pneumatic intake and pressurized conveyance lines, for volumetric metering and for discharge from filters and other containers. Use the machine only as intended. Only operate the machine in accordance with the instructions in these operating instructions. 2.2 Technical condition If the machine is in poor technical condition, safety, proper operation and availability are compromised. Operate the machine only when it is in faultless technical condition. Comply with the maintenance schedule. Use only genuine replacement parts as listed in the spare parts catalog. If the performance characteristics of the machine change, check the machine for malfunctions. Correct malfunctions immediately. The machine must not be modified or altered without approval from the manufacturer. 2.3 ATEX labeling The ATEX designation indicates the conditions under which the machine may be used in a potentially explosive zone or connected to a potentially explosive zone. Note the type plate. 2.4 Personnel qualifications Unqualified personnel cannot recognize risks and are thus exposed to greater danger. Allow only technically qualified personnel to perform the activities described in these operating instructions. Ensure that personnel comply with local laws and regulations for safe and hazard-conscious work. Define and communicate work responsibilities. Only give keys and passwords to appointed staff. Chapter 2 Safety 7

8 2.5 Safety devices If safety devices are not functioning effectively, people are at risk. Before operating the machine, ensure that all safety devices are functioning effectively. 2.6 Safety markings If safety markings are not noticeable, people are at risk. Replace unreadable safety markings. Do not remove or cover safety markings. 2.7 Safe working environment Slipping and tripping hazards Slippery surfaces and tripping hazards may result in serious accidents. Keep aisles, handles, steps, ladders, platforms and handrails free of grease, oil and other types of dirt. Do not use the machine as a climbing aid or storage area. Use only the steps and platforms provided. Wear anti-slip safety shoes. 8 Chapter 2 Safety

9 3 Technical data 3.1 Ambient conditions Description Value Unit Temperature range C Relative humidity < 90 % 3.2 Performance characteristics Maximum permissible torque Description MPSN-25/15 MPSN-25/23 MPSN-28/30 Value Unit 415 Nm 415 Nm 425 Nm Rotor volume Fig. 3.1 Description Value Unit MPSN-25/ dm 3 MPSN-25/ dm 3 MPSN-28/ dm 3 Chapter 3 Technical data 9

10 3.3 Operating temperature Description Value Unit For low-temperature bulk material Up to 60 C ΔTmax (between ambient temperature and bulk material temperature) 20 C 3.4 Airborne noise emission Measured values The measured values do not take room effects into account. Description Equivalent workplace emission level L p Value Unit 70 db (A) 3.5 Weights and volumes Transport weights not including drive Description MPSN-25/15 MPSN-25/23 MPSN-28/30 Value Unit 50 kg 65 kg 85 kg Transport weights including drive Description MPSN-25/15 MPSN-25/23 MPSN-28/30 Value Unit 85 kg 100 kg 115 kg Volumes packaged in seaworthy manner Description Value Unit MPSN-25/ m 3 MPSN-25/ m 3 MPSN-28/ m 3 10 Chapter 3 Technical data

11 3.6 Dimensions F B A H I L M N O ø 35h6 E D D C max. Q P J K max. Q Fig. 3.2 MPSN 25/15 25/23 28/30 A 320 * 410 * 490 B C D E F H I J K L M N O P 8 M10 8 D D 13.5 Q max * Standard shaft, other shafts are optional. Chapter 3 Technical data 11

12 3.7 Pneumatic system Description Maximum pressure in continuous operation Maximum upper pressure limit Value Unit 0.6 bar 0.8 bar 3.8 Options NORD or SEW gearmotor NORD or SEW spur gearmotor NORD or SEW bevel gearmotor Frequency converter MOVIMOT Frequency converter TRIO SK200E Speed monitoring Airlock table with intermediate shafts, couplings and covers Sight glass Transition piece for airlock outlet Feed nozzle Distribution box 12 Chapter 3 Technical data

13 4 Description 4.1 Identification Type plate (1) Model: Serial No.: Manufactured: * (2) (3) (4) (6) Fig. 4.1 (5) Type plate (1) Manufacturer (4) Year of manufacture (2) Place of manufacture (5) Machine number (3) Machine type (6) ATEX labeling Position Fig. 4.2 Airlock with drive Type code MPSN-25/23-MS-Ex MPSN Machine code 25, 28 Rotor diameter in cm 15, 23, 30 Rotor length in cm MS Mild steel version Ex Approval for potentially explosive zone Chapter 4 Description 13

14 4.1.3 ATEX designation for use in Ex zone 22 The ATEX designation indicates the conditions under which the machine may be used in a potentially explosive zone or connected to a potentially explosive zone. II */3D T=135 C Explanation of symbols: II ATEX symbol Device group */ Internal category: Does not have its own internal source of ignition /3 External category 3 D T Dust atmosphere Maximum expected surface temperature in C in normal operation at full load and at an ambient temperature of 40 C ATEX designation without approval for use in potentially explosive zones II */-D Explanation of symbols: ATEX symbol II Device group */ Internal category: Does not have its own internal source of ignition /- Not approved for use in potentially explosive zones D Dust atmosphere 4.2 Overview The airlock is intended for dosing and introducing free-flowing bulk materials to a pneumatic form of conveyance. The use of toxic conveyance gases is only permitted with restrictions. The airlock is not approved for hybrid mixtures. Special protective measures should be taken by the operator or customer (e.g. gas detectors, sealing gas) to ensure safe operation. The airlock must be operated in the vacuum range. 14 Chapter 4 Description

15 (1) (2) (3) (4) (5) (6) Fig. 4.3 (1) Housing (4) Axial seal (2) Rotor (5) Rotor shaft (3) Housing cover (6) Deep groove ball bearing 4.3 Mode of operation In the pneumatic grinder the airlock is connected to the centrifugal separator by the sight glass. At the outlet the airlock is connected to the piping by a transition piece. In other applications such as a centrifugal separator or filter, the airlock is often connected directly to the part in question. It can also be integrated together with a feed nozzle into the conveying line of an intake or pressurized conveyance system. Chapter 4 Description 15

16 (1) (2) (3) Fig. 4.4 The bulk material enters the airlock through the inlet (1). It is captured by the rotor (2) and guided to the outlet (3). 4.4 EMERGENCY STOP The EMERGENCY STOP button is integrated in the system control unit. The machine is stopped when the EMERGENCY STOP is triggered. Only trigger the EMERGENCY STOP to prevent imminent injury or damage to property. 4.5 Protection devices The airlock must be integrated in the system such that people cannot reach into the area near the rotor on either the inlet or outlet side. This is achieved using permanently screwed-down inlet and outlet channels. A lockable safety switch is present, and personnel have the matching padlock. 4.6 Safety symbols The "Move safety switch to 0 and lock" sign is affixed to the system. Service covers located less than 850 mm away from the rotor feature a Do not reach in prohibition sign. 16 Chapter 4 Description

17 Fig. 4.5 Airlock with drive Chapter 4 Description 17

18 5 Transport 5.1 Packaging symbols (1) (2) (3) (4) (5) Fig. 5.1 Packaging symbols (1) Top (4) Fragile (2) Protect against moisture (5) Attach here (3) Center of gravity Note packaging symbols. 5.2 Checking delivery Check for completeness of delivery according to the delivery note. Report any missing parts or transport damage. See page 5, chapter Contact. 5.3 Temporary storage Note packaging symbols. Leave the machine and machine parts in the original packaging until starting assembly work. Do not store the machine outdoors. Protect the machine from the effects of weather. Prevent temperature fluctuations. 18 Chapter 5 Transport

19 5.4 Lifting instructions The machine and its options are assembled on site. If a deviating scope of delivery is used, the modules are fitted depending on the options available. Fig. 5.2 Observe the transport weights in the shipping papers. Use only undamaged hoisting devices with a sufficient rating. Do not step or stand under suspended loads. 1. Screw eyebolts into flange. 2. Attach lifting straps to eyebolt. 3. If the airlock has a drive, place lifting straps around drive. 4. Transport the airlock. Chapter 5 Transport 19

20 6 Installation 6.1 Preparing installation location 850 mm 850 mm Fig. 6.1 WARNING Rotating rotor. Risk of extremities being drawn in, crushed or severed. Fit service openings at least 850 mm away from the rotor. Turn rotor with a piece of wood. When planning ensure sufficient space around the airlock for installation, maintenance and repair work. Position upstream and downstream machines where there is space. Cordon off the assembly area against unauthorized access. Secure the working area (e.g. prevent tripping hazards etc.). 20 Chapter 6 Installation

21 6.2 Series arrangement Airlock series on airlock table. (1) (2) (3) (5) (2) (3) (4) (4) Fig. 6.2 (1) Spur gear (4) Clamping bracket (2) Coupling (5) Shaft-mounted gear unit (3) Bearing cover Important Align axle horizontally and mount airlock in deenergized system. 1. Ensure there is sufficient space around airlocks and intermediate shafts. The coupling must function correctly. 2. Fit airlock. 3. Mount clamping bracket. 4. Mount bearing cover. 5. Where a spur gear is fitted, align and mount airlocks from drive side. 6. Where slip-on gear unit is fitted, align and mount airlocks from both sides. 6.3 Connecting the utilities Electrical systems Fit overload protection upstream of drive motor. This may take the form of a motor protection switch or a contactor with thermal overload trigger. Near the airlock, install a lockable safety switch which can be used to fully disconnect the drive motor from the electrical supply (provided by customer). This ensures that the drive is blocked in the event of maintenance and repair work. Check that the rotor is turning in the right direction. Chapter 6 Installation 21

22 To change the direction of rotation, swap the two phases in the terminal box. The direction of rotation is changed in the frequency converter by swapping the corresponding phases. Ensure that the bulk material is flowing freely. If connecting to an intake or pressurized conveyance system, first switch on the blower for the conveyance air and then the drive for the airlock. If available: Install speed monitoring device in plant control system. Earthing (1) (1) Fig. 6.3 Connect all earthing connections and check for electrostatic charging by the product being conveyed. Earthing in the piping is ensured by earthing the system. Ensure conductivity for screwed/bolted connections with contact washers or copper strands. Check: Inspect the screw unions. Resistance across butt joints may not exceed 10 ohms. If resistance exceeds 10 ohms, restore electrical conductivity. Safety switch Fit a lockable safety switch with a performance level (PL) c according to ISO near the machine. Note local specifications. 22 Chapter 6 Installation

23 7 Commissioning 7.1 Checking commissioning No. Check 1 There are no foreign objects in the machine. 2 Rotor is freely rotating. See page 23, chapter Checking the rotor. 3 All transport aids and assembly fixings have been removed. 4 Product feed and discharge are present and connected correctly. 5 Electrical connections and connection voltages correspond to specifications on sign. 6 All electrical terminal boxes and plug sockets are closed. 7 Machine is earthed. 8 Airlock is turning in correct direction. 9 All controls and warning systems are functional. 10 A lockable safety switch is present, and personnel have a matching padlock. 11 The EMERGENCY STOP button is working. 12 All screwed/bolted connections have been properly tightened. 13 The gearmotor is filled with lubricant. 14 All connections for the lines are leak tight. 15 A safety valve has been provided for pneumatic conveyance systems. The maximum pressure depends on the form of conveyance and must be observed. 16 Warning signs are fitted to the side of the housing Checking the rotor If incorrectly installed, the airlock housing may be distorted. 1. Remove fan cover. 2. Move the rotor by hand using the fan wheel on the motor. Rotor is turning freely and not rubbing against the housing. 3. Mount fan cover. Chapter 7 Commissioning 23

24 7.2 Conformity Checking EC conformity Operate the machine in the European Union only if EC conformity has been checked and confirmed using the following checklist. Checklist No. Check 1 The operator has been informed that the operating instructions must be accessible to the personnel at all times. 2 The operator is responsible for instructing the personnel. 3 Assembly and installation have been carried out in accordance with the operating instructions. 4 Machine has been connected and checked by an electrician. All connection sockets and boxes are properly closed. 5 Warnings and signs are attached so they are clearly visible. 6 A lockable safety switch has been fitted. Personnel are in possession of the padlock for this. 7 Components on the inlet and outlet side can only be removed with a tool. This prevents access to the machine's moving parts. 8 Inspection covers fitted on the system are at least 850 mm away from danger areas or fitted with a prohibition sign: 24 Chapter 7 Commissioning

25 8 Operation 8.1 Starting and stopping The machine is started and stopped using a superordinate system control unit. The EMERGENCY STOP button is integrated in the system control unit. The machine is stopped as soon as the EMERGENCY STOP button is triggered Starting 1. Ensure that the bulk material is flowing freely. 2. If connecting to an intake or pressurized conveyance system, first switch on the blower for the conveyance air and then the drive for the airlock. 3. Start airlock. 4. Supply product Stopping 1. Interrupt product feed. 2. Wait until airlock is free of product. 3. Stop airlock. 8.2 Checks during operation Regularly check the elements. This allows you to detect faults early on and initiate any actions required. Check bearing temperature. Check seal integrity (traces of conveyed product or air leaking). Chapter 8 Operation 25

26 9 Trouble-shooting 9.1 Faults Fault Cause Remedy Throughput too low. Insufficient bulk material feed. Check feed. Speed too low. Increase speed up to maximum of limit speed. Insufficient feeding. Improve feeding or adjust feeding flap. Product deposits on rotor. Clean rotor. Irregular running. Defective bearing. Check bearing and replace if necessary. Rotor blocked. Foreign objects in airlock. Remove and maintain rotor. Airlock not starting. Gearmotor thermally overloaded. Product leaking out at rotor shaft. Lubricant on rotor shaft. Oil on gearmotor. Temperatures or differences in temperature too high. Defect in machine or plant control system. Increase clearance. Insulate or heat airlock. See operating instructions for control system. Gearmotor not connected. Correctly connect gearmotor. Gearmotor overheating. Allow gearmotor to cool and rectify whatever is causing it to overheat. Excessive product friction. Occurs with melted product. Clean airlock. Cool product. Enlarge rotor and slope rotor blades. Bearing hot. Replace bearing. Rotor seal not tight. Remove and clean seal. If defective, replace seal. Bearing shaft seal not tight. Replace bearing. Bearing shaft seal not tight. Remove and clean seal. If defective, replace seal. Gear leaking. Replace seals in gearmotor. Ventilation positioned incorrectly. Correct position. Refer to the documentation supplied by the gearmotor manufacturer. 26 Chapter 9 Trouble-shooting

27 10 Maintenance CAUTION Conveyed product may be blown out when opening the airlock. Eye injuries. Only open or disassemble airlocks if the system is depressurized and the pressure system is protected against being switched on by locking the associated safety switch Cleaning The cleaning intervals depend on the product, location and climate and have to be determined by the user. Keep airlock clean. Remove dust, dirt or product deposits. Always clean dry with cloths, brush or vacuum cleaner. If dirty, clean the fan cover's intake apertures and the cooling fins on the electric motor. If changing product, clean rotor and other cavities Lubrication Lubrication schedule Interval Machine part Duration 500 h / once a month Measure Gearmotor : Check the oil level. Top up if necessary Bearing The bearings in the airlock have lifetime lubrication with lubricant of class NSF H1 as defined by the FDA. The bearing seals prevent grease from leaking out and becoming contaminated. When the grease is used up, replace bearing. Minimum lifetime of bearings: 30,000 hours. Chapter 10 Maintenance 27

28 10.3 Maintenance Maintenance schedule Interval Machine part Duration 120 h / once a week Frequency converter Measure : Refer to the manufacturer's documentation. Bearing seal : If product, air or grease is escaping at rotor shaft, check bearing seal for wear and replace if there are signs of wear Maintaining airlock (2) (1) (3) (4) (1) (5) (7) (6) Fig Dismantling airlock 1. Stop the machine. 2. Set safety switch to 0 and lock it. 3. Switch off product feed and rinse air/conveyance air. 4. If necessary, first remove the drive or speed monitoring. 5. Remove coupling halves and keys (1). 6. Release screws (2) from housing cover (3). 7. Remove housing cover from shaft (5) of rotor. 8. If necessary, loosen grub screw (7) to separate rotor and shaft. 9. Leave bearing on shaft or in cover. 10. Check and clean following parts. Remove axial groove rings, check for damage and clean grooves. Clean surface of shaft. Check and clean bearing, replace if necessary. Replace worn or damaged parts. If there is insufficient grease in bearing, replace bearing. 28 Chapter 10 Maintenance

29 Assembling airlock 1. Assemble rotor and shaft with setscrew. Ensure that rotor is easy to turn by hand. Do not distort bearing. 2. Press housing cover onto rotor's shaft. 3. Install coupling halves and key. 4. Install drive and speed monitoring. 5. Check the rotor. See page 23, chapter Checking the rotor. Chapter 10 Maintenance 29

30 11 Maintenance and repair 11.1 Replace speed sensor Removing speed sensor 1. Stop the machine. 2. Set safety switch to 0 and lock it. 3. Switch off product feed and rinse air. 4. Separate electric plug (2) from sensor. (1) (2) 5. Remove 3 screws and lid (1). 6. Release counter nut (4). (3) (4) (5) 7. Remove nut (3) and speed sensor (5). 30 Chapter 11 Maintenance and repair

31 8. Perform the following work if necessary. (6) (7) Loosen screw (7) and remove housing (6). 9. Loosen setscrew (8) and remove contact tab (9) from shaft. (8) (9) Chapter 11 Maintenance and repair 31

32 Installing speed sensor 1. Slide contact tab (2) onto shaft. (1) (2) Do not tighten setscrew (1). 2. Secure housing (3) to machine with screw (4). (2) (3) (4) (2) 3. Center contact tab (2) in threaded hole. 4. Tighten setscrew (1) to contact tab. Contact tab is fixed. 32 Chapter 11 Maintenance and repair

33 5. Insert speed sensor (7). (5) (6) (7) 6. Use nut (5) to set distance between speed sensor and contact tab. Distance between speed sensor and contact tab: 1 5 mm 7. Tighten counter nut (6). 8. Ensure that contact tab cannot touch speed sensor. 9. Secure lid (8) to housing with 3 screws. (8) (9) 10. Connect electric plug (9) with sensor. Chapter 11 Maintenance and repair 33

34 11.2 Replacing bearing and shaft seal (1) (2) (3) (4) (5) Fig Removing bearing and shaft seal 1. Stop the machine. 2. Set safety switch to 0 and lock it. 3. Switch off product feed and rinse air. 4. If necessary, first remove the drive or speed monitoring. 5. Remove housing cover (1). Dismantle airlock. See page 28, chapter Dismantling airlock. 6. Remove shaft seal (5) and bearing (3). 7. Clean shaft seal groove on rotor. 8. Clean bearing groove in housing cover. 9. Clean shaft (4) and rotor (2). 10. Check surface of shaft and housing cover Fitting bearing and shaft seal 1. Insert new bearing and shaft seal. 2. Assemble airlock Replacing rotor WARNING Spark formation. Serious burns. Ensure that foreign bodies such as swarf, screws or welding beads do not enter the airlock. 1. Stop the machine. 2. Set safety switch to 0 and lock it. 3. Switch off product feed and rinse air. 4. Remove housing cover (1). Dismantle airlock: 5. Pull rotor out of the housing. 6. If necessary, separate rotor and shaft. 34 Chapter 11 Maintenance and repair

35 7. Insert new rotor. 8. Assemble airlock. See page 29, chapter Assembling airlock. 9. Check rotor. See page 23, chapter Checking the rotor. Chapter 11 Maintenance and repair 35

36 12 Decommissioning 12.1 Dismantle Once work with the machine is complete (inspection, removal or disposal), the machine is disassembled in reverse order to the assembly process. Before starting the disassembly process, the person who is responsible must obtain instructions from the manufacturer for safe disassembly. The machine may only be disassembled in accordance with all accident prevention measures and only by instructed personnel. This personnel must be familiar with the safety precautions Disposal Disposal of operating materials Remove operating materials completely from the machine and dispose of them properly in accordance with the local legal requirements Disposing of machine 1. Dismantle machine into its components. 2. Sort components according to materials and dispose of them in compliance with local applicable laws and regulations. 36 Chapter 12 Decommissioning

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38 CH-9240 Uzwil, Schweiz