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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

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 excluding
certain warranties with respect to the company's equipment. Except as otherwise expressly provided by
Coperion 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 J ersey 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 operating
instructions?
Note the project or order number You will find these on the machine
or 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 executed
step-by-step.
This symbol identifies a general safety note.
If an error or ommission is found, please contact:
documentation@coperionktron.com
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.
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 ............................................................................................................6
1.1.2 Ground icon ...........................................................................................................................6
1.1.3 No hands icon ........................................................................................................................6
1.1.4 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 ...............................................................................................11
2.4.1 Safety devices .....................................................................................................................11
2.4.2 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 ..................................................................................................14
4.4.2 Gear lubrictation ..................................................................................................................14
4.5 Vented shear protector installation ......................................................................................15
4.5.1 Adjusting Seal Flap to fit Rotor ............................................................................................15
4.5.2 Ensuring Proper Fit / Checking Clearances ........................................................................15
4.5.3 Final Installation ...................................................................................................................15
4.6 Non-vented shear protector installation ...............................................................................16
4.7 AerolockTM and accessories installation ............................................................................16
4.8 Electrical connection ............................................................................................................18
Page 4 Docu-No.: 1190034611-EN Rev. 1.0.0
4.8.1 Motor connection .................................................................................................................18
4.8.2 Chain Adjustment ................................................................................................................19
4.8.3 Variable Speed Drive Settings .............................................................................................19
4.8.4 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 ...............................................28
8.9 Disassembly ........................................................................................................................28
8.9.1 T3 or Air purge sealsl ..........................................................................................................29
8.9.2 Drive-end seal & bearing removal .......................................................................................31
8.10 AerolockTM Reassembly .....................................................................................................32
8.10.1 Seal & End Plate Assembly .................................................................................................33
8.10.2 Bearing installation ..............................................................................................................36
8.10.3 Checking for proper clearances ...........................................................................................37
8.11 BT AerolockTM Puller Tool ..................................................................................................38
8.12 BT AerolockTM Driver Tool Kitsl. ........................................................................................39
9 Troubleshooting ................................................................................................................ 40
9.1 Troubleshooting table ..........................................................................................................40
Docu-No.: 1090034611-EN Rev. 1.0.0 Page 5
Safety notes 1
Safety symbols definitions 1.1
1 Safety notes
1.1 Safety symbols definitions
Installation, commissioning and programming of the specified
equipment should only be undertaken by qualified personnel.
DANGER indicates an extremely hazardous situation which, if not
avoided, 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 hazardous
situation which, if not avoided, could lead to light bodily injuries.
CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
The safety alert symbol is used to alert to the potential personal
injury hazards. Obey all safety messages that follow this symbol to
avoid possible injury or death.
Page 6 Docu-No.: 1090034611-EN Rev. 1.0.0
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.
Docu-No.: 1090034611-EN Rev. 1.0.0 Page 7
Safety notes 1
Responsibilities of the owner 1.2
1.2 Responsibilities of the owner
1.3 Proper use
1.4 Organizational measures
Ensure that only qualified and trained personnel work with the
equipment.
Establish personnel responsibilities for operation and
maintenance.
Ensure that the personnel has read and understood the operating
instructions to all installation components, particularly this chapter
"Safety notes".
The plant owner must replace damaged or missing components
immediately.
The operator has to avoid the entry of foreign substances (metal
parts, stones) reaching the equipment by appropriate methods.
The plant owner is responsible for compliance with legally
prescribed accident prevention and safety regulations.
Only operate the equipment in accordance with the specified
technical data.
Danger of explosion! Never use the equipment to process
explosive gas or air gas mix. Danger of explosion!
When processing dangerous materials, also comply with the
safety 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 the
manufacturer.
Never convey materials which may cause a chemical reaction with
the materials of the rotary valve.
Eliminate ignition sources, avoid spills and continually clean the
working 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 with
generally prescribed safety regulations governing accident
prevention and environmental safety.
Page 8 Docu-No.: 1090034611-EN Rev. 1.0.0
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 the
responsible member of the staff.
Always keep safety in mind while working.
When operating any valve to check its action, be careful not to
have hands near any open ports.
Before opening or disassembling any part of the equipment always
switch off the main power and air supply.
Operating the equipment without safety devices:
is dangerous for the health and life of the operator or third
persons
can damage the equipment or other material
Never alter the mechanical safety devices or the electrical control
system for the safety devices. Increased risk of accident.
Only operate the equipment if all safety devices are installed and
fully functional.
Check that all safety devices operate properly every day.
Never open or remove covers or hoods while the equipment is in
operation.
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.
Docu-No.: 1090034611-EN Rev. 1.0.0 Page 9
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 safety
regulations related to inter operation with any additional
equipment.
Have repairs to the equipment carried out by
by the responsible Premier / Coperion K-Tron (Switzerland) LLC
customer 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 of
the rotary valve from service.
Page 10 Docu-No.: 1090034611-EN Rev. 1.0.0
2 Application
2.1 Design
2 Application
The Blow-Through (BT) Aerolock configuration enhances rotor
cleanout and makes installation in tight quarters possible. It is used in
sticky material applications to prevent material build-up in the rotor
pockets.
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 cartings
available
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.
Docu-No.: 1090034611-EN Rev. 1.0.0 Page 11
Application 2
Safety devices and warnings 2.4
2.4 Safety devices and warnings
2.4.1 Safety devices
2.4.2 Warnings
Operate only with installed and operational safety devices.
Metal cover for coupling (3)
Guard cover for chain (6)
Connections at the inlet and outlet (5)
Confirm after installation that personnel are unable to access the
moving part such as the rotor and drive coupling.
Fig. 2.1 Safety devices and warning labels: direct drive
The warning is applied to the fol-
lowing positions at the Aerolock:
At the upper guard (Fig. 2.2/7)
At the upper guard cover
(Fig. 2.1/4)
At the upper guard cover
(Fig. 2.1/1)
At the Aerolock guard frame
(Fig. 2.1/1)
At the Aerolock guard frame
Fig. 2.2/8
At the Aerolock guard cover
Fig. 2.2/9
Fig. 2.2 Safety devices and warning labels: chain drive
Page 12 Docu-No.: 1090034611-EN Rev. 1.0.0
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
Conformity
or 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 constructions: 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. dm
3
/Rev [Ft
3
/Rev.]
6.8 [0.24] 13 [0.46] 22 [0.79] 35 [1.23] 52 [1.85]
Maximum allowable
torque 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]
Docu-No.: 1090034611-EN Rev. 1.0.0 Page 13
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 them
for 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 conditions
Only use explosion-proof feeders in hazardous areas.
Install the feeder only in surroundings conforming to the technical
data (see Section 3) and in accordance with the safety notes (see
Chapter 1).
Only have the rotary valve transported by authorized and qualified
personnel.
Transport the rotary valve only with a hoisting equipment.
In order to avoid damage to the rotary valve, only use lifting straps
with sufficient lifting capacity for the hoisting equipment (for the
weight of the rotary valve see section 3).
The lifting straps must be sufficiently long to avoid too much strain
to the band.
1. Fix the lifting straps at the mounting supports as shown. Use the
clamps to ensure that there is no slippage of the lifting straps.
Fig. 4.1 Transport
Page 14 Docu-No.: 1090034611-EN Rev. 1.0.0
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 should
be 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 this
time it is also important to turn the rotor three full rotations to prevent
it from seizing in the Aerolock housing.
4.4 Aerolock
TM
mounting
4.4.2 Gear lubrictation
4.4.1 Chain Power Transmission
Chain should be disconnected and found in a package stowed in the
guard compartment.
Fig. 4.2 Chain drive
See the OEM gear reducer information for the proper grease selection
and lubricating instructions.
Docu-No.: 1090034611-EN Rev. 1.0.0 Page 15
Installation 4
Vented shear protector installation 4.5
4.5 Vented shear protector installation
4.5.1 Adjusting Seal Flap to fit 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 within
the inlet.
3. Place the shear protector on the inlet, and secure it in place with
six 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 side
plates should be 1,59 mm [1/16] (Fig. 4.3).
2. If a clearance adjustment is needed, remove the shear protector
from the Aerolock and place it top-side down on a working
surface. Loosen the screws and adjust both side plates (C) as
needed, being certain to adjust them evenly.
3. Reinstall the shear protector to the Aerolock, verifying that the
clearance is correct. Remove the shear protector from the
Aerolock inlet, and reassemble flap (B) and flap (D) along with
their 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 Installation
Install the shear protector to the Aerolock inlet, with the vent tube
oriented as shown in Fig. 4.5. It is critical that the rotor rotates from the
long flap to the short flap. Use bead sealant or a suitable caulking be-
tween the flanges. Tighten the attachment bolts in equal stages so the
shear protector will mate uniformly against the Aerolock.
Rotate the rotor by hand, to ensure that the short flap sweeps the rotor
tip. Adjust the flap if necessary. Continue with section 4.7.
Fig. 4.5 Mounting direction
1/16
1,59 mm
Page 16 Docu-No.: 1090034611-EN Rev. 1.0.0
4 Installation
4.6 Non-vented shear protector installation
4.6 Non-vented shear protector installation
4.7 Aerolock
TM
and 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 and
centered 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 a
suitable caulking between the flanges. Tighten the attachment
bolts in equal stages so the shear protector will mate uniformly
against 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 or
outlet opening exposed. An inlet / outlet guard is available from
Premier (see Fig. 4.7). It is a mandatory accessory if the inlet is
exposed to personnel.
Do not use the Aerolock to support equipment other than the
drive assembly and line adapter. External loads on the inlet and
outlet flanges will cause undue compression or tension on the
housing.
When the Aerolock is located under a tank or hopper containing
large volumes of material, it is a good practice to install a maintenance
gate above the Aerolock. The gate allows for temporary material
shut-off to perform maintenance.
Docu-No.: 1090034611-EN Rev. 1.0.0 Page 17
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 conveying
line to the outlet ports at the bottom of the Aerolck, using tfelon tape
or a suitabel culking. Ensure that the connections re tight.
Fig. 4.7 Inlet / Outlet Guard
Page 18 Docu-No.: 1090034611-EN Rev. 1.0.0
4 Installation
4.8 Electrical connection
4.8 Electrical connection
1. Connect the feeder in accordance with the electrical wiring
diagram.
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 the
provided 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) is
critical.
1. Connect the appropriate power supply to the drive motor,
referencing the motor nameplate and wiring diagram. Ensure that
the motor is properly grounded. Continue wiht step 3.
2. If your drive is an electronic variable-speed drive, connect the
appropriate power supply th the controller. A connection will also
be required between the controller and the motor. See the
controller wiring diagram for the proper connections, ensuring
porper shaft rotation. Be certain that the motor is properly
grounded.
3. With the drive chain removed, jog the motor to ensure proper
ratation. Be certain thtat the motor ventilation is not restricted.
Then, disconnect the power suply.
Fig. 4.8 Motor
Docu-No.: 1090034611-EN Rev. 1.0.0 Page 19
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 both
shaft keys are seated properly. Sprockets should be as close to
the 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 not
too tight. There should be slack (about 2% of the center distance)
on the bottom side. A little slack is needed as it allows the chain
links to take the best position on the sprocket teeth. An
overtightened chain will overload the shaft and bearings. Too
much slack will cause the rollers to ride up on the teeth, causing
wear 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.
Page 20 Docu-No.: 1090034611-EN Rev. 1.0.0
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. 4.10
Doing so may cause damage to the unit.
1. Set the output speed by turning the control wheel located on the
side of the motor.
2. Set the control wheel at 0 to achieve the slowest speed in the
specified speed range.
3. Each position after zero is approximately 10 percent faster, up to
100 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 is
requiered, a tachometer reading can be taken from the Aerolocks
shaft.
5. Set the output speed by turning the speed selector located in the
controller (see Fig. 4.8).
6. Each position from 0 to 100 is a percent of the speed range of the
Aerolock, as specified on the dimension drawing.
Fig. 4.10 Electrical variabel speed
Docu-No.: 1090034611-EN Rev. 1.0.0 Page 21
Installation 4
Compressed air connections 4.9
4.9 Compressed air connections
4. In some applications it is desirable to turn the purge air on only
when the Aerolock is running, using a solenoid valve. Make the
electrical connections to the solenoid valve, if applicable.
5. Turn the air supply on, and check for air leaks in the compressed
air line. Set the pressure so the gauge reads 0.69 Bar [10 PSI]
above the conveying system's operating pressure. If you dont
know the conveying system's pressure in advance, set the purge
air pressure to 1.38 Bar [20 PSI] and turn it down to the proper
level once the system is operating.
Disconnect air supply when disassembling the Aerolock.
To avoid seal damage, never operate an Aerolock equipped with air
purge seals unless the purge air is turned on.
1. If your Aerolock is equipped with air purge seals, a filter,
regulator, and gauge assembly is required to filter and regulate
compressed air into the seals. If your Aerolock does not include
air purge seals, disregard this section.
2. Connect a compressed air source of 170 - 284 liters/minute [6 - 10
SCFM] to the IN port on the filter/regulator (normally a 1/4 N.P.T.
connection). All air piping leading to the filter must be self
supporting.
3. It is a good practice to install a pipe union approximately 6" from
the filter to allow for future maintenance of the Aerolock.
Fig. 4.11 Air connections
Page 22 Docu-No.: 1090034611-EN Rev. 1.0.0
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 described
in Chapter 4. - 4.7 Ensure that the clearance has been adjusted,
as described in step 4.5.2, and that the long seal flap and short
shear protector flap have been installed properly.
2. All flange connections must be tight and mate uniformly against
the 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 protector
damage, make certain that the motor was jogged with the coupling
separated or chain removed, as described in section 4.8.2 and
section 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 set
so the gauge will read 0.7 Bar [10 PSI] above the conveying
system's operating pressure (approximately 1.4 Bar [20 PSI] in
most 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.
Docu-No.: 1090034611-EN Rev. 1.0.0 Page 23
Operation 6
Notes on operation 6.1
6 Operation
6.1 Notes on operation
6.2 Switchin on/off
1. Before switching on ensure that the inlet is free of objects such as
screws, packaging rests, etc.
2. Switch on/off the Aerolock with the connected controls.
Only operate with a protective grating.
Verify that the inlet and outlet openings are not exposed to
personnel. If so, install an inlet/outlet guard.
Do not bring hair, clothing and tools into the feeder.
Aerolock equipped with air purge seals unless the purge air is
turned on.
Never use to process materials which may cause a chemical
reaction wiht the materials, for example feed materials containing
the following substance:
Acid
Iodine
Chromium
Bromium
When conveying dangerous materials observe the safety notes
applying for handling these materials.
Fore more information see controller operating and programming in-
structions.
Page 24 Docu-No.: 1090034611-EN Rev. 1.0.0
7 Cleaning
7.1 Switching off the installation
7 Cleaning
7.1 Switching off the installation
7.2 Notes on cleaning
When carrying out maintenance work on the switched-off Aerolock
there is a danger of injury through unintentional switching-on.
Switch off the system before carrying out maintenance work on the
conveying 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 <pH <8.5.
Clean with non-toxic cleaning agents and disinfectants.
Only use cleaning agents that not affect the used seal and filter
materials (silicone / PTFE / Teflon / polyester fabric not included).
Any residues of cleaning agent on parts with product contact are
not allowed.
Do not clean with high pressure cleaners, steam cleaner or
compressed air.
Do not remove product adhesion with force.
There must be no moisture on electrical components.
All parts must be dry cleaned before assembly.
1. Switch off the equipment at the main switch.
2. Secure the main switch with a lock.
3. Attach a danger sign to the main switch.
4. Turn off compressed air for all the pneumatic devices.
Empty the unit before cleaning.
Clean only with mild air stream.
In case of external soiling, clean with a damp cloth and use normal
industrial cleaners
Use vacuum cleaner or soft brush for cleaning.
Remove dust layers over 5 mm.
Docu-No.: 1090034611-EN Rev. 1.0.0 Page 25
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 equipment
and secure it to prevent unintentional restarting (see section 7.1).
Only qualified and trained personnel may carry out maintenance
work.
Only qualified electricians may work on the electrical equipment.
To avoid seal damage, never operate an equipped with air purge
seals unless the purge air is turned on.
Element Checkpoints Interval
Mechanics Eliminate dust accumulation more
than 5 mm [0.2 in] through
cleaning.
Check compressed air
Empty water-separator
Check Aerolock mechanical
connections for tightness.
Check seal rings for damage
Check safety symbols at the
equipment for legibility and
completeness.
Weekly
Pneumatic (Air
Purge option)
Check pressure regulator
Change filters
Monthly
As required
Electric Check ground wires and static
bonding.
Check all electrical connections
As required
Page 26 Docu-No.: 1090034611-EN Rev. 1.0.0
8 Maintenance
8.2 Disengage Power Transmission
8.2 Disengage Power Transmission
8.3 Motor Bearing lubrication
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 shown
in Fig. 4.9 continue wiith Chapter 4.8
Switch off before carrying out maintenance work on the equipment
and secure it to prevent unintentional restarting (see section 7.1
The drive assembly is shipped without oil in the gear case.. Fill the
gear case with an oil that is suitable for bronze worm gearing with mild
EP additives, using the holes specified in Fig. 8.1 and Fig. 8.2 Check
the 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 of
oils 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
Docu-No.: 1090034611-EN Rev. 1.0.0 Page 27
Maintenance 8
Gear reducer Lubrication 8.5
8.5 Gear reducer Lubrication
If the drive utilizes a right-angle gear reducer continue with step 2.
1. See the OEM gear reducer information for the proper grease
selection 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 - Installation
8.4 for the poroper oil selection and fill details.Keep the gear case
filled wiht the correct oil to the proper level.
8.6 Roller Chain Maintenance
The roller chain should be checked for proper alignment periodically
with a straight edge. Check for the proper roller chain fit. The center
distance may need to be adjusted after serveral weeks of operation.
The roller chain should e lubricated periodically wiht a high grade of
non-detergent, petroleum-based oil.
8.7 Aerolock
TM
Motor bearing lubrication
BT Aerolock have sealed-for-life ball bearings in the drive end. They
are to be replaced when dirty or faulty. The tapered roller bearings in
the thrust end can be cleaned, lubricated, or replaced upon disassem-
bly of the Aerolock. See section 8.9 and 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
Page 28 Docu-No.: 1090034611-EN Rev. 1.0.0
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 purge
seals are receiving air at a pressure of 0.69 Bar [10 PSI] above the
conveying system's operating pressure (approximately 1.38 Bar [20
PSI] 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 Aerolock
TM
is not running.
8.9 Disassembly
Keep fingers and hands out of the inlet and outlet areas of the
Aerolock while disassembling. Even though the unit has been
removed from service ther is still the potential for the blades to turn
when working on disassembling. As a safety precaution, place a
board 101.6mm wide x 304.8mm long x 50.8mm thick [4.0 wide x
12.0 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
Docu-No.: 1090034611-EN Rev. 1.0.0 Page 29
Maintenance 8
Disassembly 8.9
8.9.1 T3 or Air purge sealsl
1. Loosen the three set screws on both teflon inserts with a 3/32 hex
Allen wrench.
These set screws can be reached through the top and bottom slots
on 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, and
insert 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 end
plate draws away from the housing and is free of the rotor shaft.
5. Note the location and thickness of all shims for reference during
assembly.
6. Lift and slide the drive end plate off of the rotor shaft, taking care
not to damage the shaft.
Fig. 8.5 Tighten bolts
7. Remove the brown paper shim (if used) and all individual bolt
shims 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
Page 30 Docu-No.: 1090034611-EN Rev. 1.0.0
8 Maintenance
8.9 Disassembly
10. Assemble the puller toll (see the diagram capter 8.11 for
construction of this toll) to the thrust end palte hub.
11. Assemble the gear puller to the thrust end of the Aerolock, and
push 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 plate
reassembly.
14. Remove the brown paper shim or individual bolt shims from the
end 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 during
reassembly.
16. Position the end olates, machined sid up, on a work bnech using
wood 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 seal
and remaining cup from the end palte.
18. Remove the sealed ball bearing from the drive end plate using a
tapered punch see Fig. 8.9.
Fig. 8.8 Bench using
Docu-No.: 1090034611-EN Rev. 1.0.0 Page 31
Maintenance 8
Disassembly 8.9
8.9.2 Drive-end seal & bearing removal
Air T-3 Seals:
1. Remove the insert from the end plate, working them out using a
tapered punch (see Fig. 8.8 and Fig. 8.9)
Using a sharp awe or pick, remove the two to four quad ring seals
from the seal cases.
Remove the two seal cases from the end plate using a tapered
punch.
Air purge seals:
1. Remove the insert from the end plate, working them out using a
tapered punch (see Fig. 8.8 and Fig. 8.9).
Remove the seal from each end plate, and then the air purge
diffuser.
Lip seals:
1. Using a tapered punch, remove the two seals from the end plate
(see Fig. 8.8 and Fig. 8.9).
Fig. 8.9 Seal
Page 32 Docu-No.: 1090034611-EN Rev. 1.0.0
8 Maintenance
8.10AerolockTM Reassembly
2. Clean all machined surfaces, such as the end plate faces, housing
bore, rotor blades, and shaft with steel wool to remove all material
buildup.
Remove any burrs from the rotor shaft and from the mating flanges
of the end plate and housing.
3. If the thrust-end bearing are to be reused, palce them in a suitable
container with clean, cold petroleum solvent or kerosene, and
allow the bearing to soak, preferably overnight. Turn the bearings
slowly, working with a brush to dislodge chips or solid particles.
After cleaning, they should be spun in light oil in order to remove
the solvent completely. If the drive-end bearing is dirty, damaged,
or worn, it should be replaced.
8.10 Aerolock
TM
Reassembly
Reassembling the Aerolock requires special drivers to install the
bearings, seals, and teflon inserts.
Driver tool kits that contain all the necessary drivers can be purchased
directly from Coperion K-Tron (Switzerland) LLC Premier.
Improper installation of the seals and bearings can lead to premature
wear and reduction in Aerolock efficiency and performance. Using the
special driver tools during reassembly can increase the lifespan of
bearings and seals as well as keep the Aerolock performing at an op-
timal level.
See the diagram in section 8.11 for ordering the BT Aerolock driver
tool 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.
Docu-No.: 1090034611-EN Rev. 1.0.0 Page 33
Maintenance 8
AerolockTM Reassembly 8.10
8.10.1 Seal & End Plate Assembly
1. Place both end plates, machined side down, on a flat, clean
surface, 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 the
cases.
Be sure the quad ring seals seat evenly and are not twisted in the
seal cases.
If they do not seat evenly, remove the seals and check for foreign
material in the cases.
Fig. 8.11 Seal
Page 34 Docu-No.: 1090034611-EN Rev. 1.0.0
8 Maintenance
8.10AerolockTM Reassembly
Air purge seals:
Using the seal driver tool, install an air purge diffuser into each end
plate, against the shoulder (see Fig. 8.11 and Fig. 8.12). Install the
seal against the diffuser. The diffuser needs to be installed with the
smooth 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 against
the first seal.
3. Carefully slide the rotor into the housing, taking care not to
damage the rotor blade edges or the machined housing bore.
Ensure that the drive mounting lugs (1) are on the left when
looking at the keyway end (2) of the rotor shaft.
4. Apply Alumilstic or another suitable caulking to the end plate
flanges.
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. Align
the 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 during
disassembly (see Fig. 8.16 for shim location).
If a brown paper shim was removed from the housing (or you are
uncertain what color shims were removed), a clearance reading
will be taken in step 8 and individual shims can then be installed.
Fig. 8.13 Bolt shims
Docu-No.: 1090034611-EN Rev. 1.0.0 Page 35
Maintenance 8
AerolockTM Reassembly 8.10
T-3, G5, or air purge seals
All seals
8. Check the inserts for scratches or grooves on the internal bore and
external 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 during
installation
9. Position the expansion tool on one end of the rotor shaft, against
the shoulder.
If Aerolock is equipped with G5 seals, before proceeding slide a
Teflon o-ring over the expansion tool, on to the shaft until it is
seated 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 the
clearance between the other end plate and the rotor.
Check to see whether or not it equals the total clearance of both
ends as specified on the Aerolock Clearence Sheet section.
11. If a clearance increase is required, pull each end plate away from
the housing, as described in section 8.9 steps 3 and 4, and insert
shims 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
Page 36 Docu-No.: 1090034611-EN Rev. 1.0.0
8 Maintenance
8.10AerolockTM Reassembly
8.10.2 Bearing installation
3. Using a thrust-end bearing driver tool, install a bearing cup onto
the 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 the
bearing cup.
6. Tap the remaining bearing cup into the end plate, using the
bearing driver tool.
7. Using the drive-end bearing driver tool, install the sealed ball
bearing 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 the
bearing 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 same
notches as those removed during disassembly) against the
bearing bore shoulder.
Note: If the brass shim is replacing a colored aluminum shim, use
the color thickness guidelines listed under step 8 to determine the
thickness 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
Docu-No.: 1090034611-EN Rev. 1.0.0 Page 37
Maintenance 8
AerolockTM Reassembly 8.10
8. Position a board in the rotor pocket, as showing in Fig. 8.6.
Screw the machined lock nut onto the thrust-end of the shaft, and
tighten.
8.10.3 Checking for proper clearances
1. Check the clearance between the rotor and the thrust end plate.
This should equal the clearance specified Aerolock Clearence
Sheet 8.11.
If the clearance is correct, continue with step 8. If not, calculate the
adjustment needed and continue with step 2.
2. Remove the machined lock nut from the thrust end,
3. Disassemble the thrust-end plate from the housing,
4. Remove the tapered roller bearings and cups from the end plate.
5. Install the correct thickness of washer shims onto the shaft,
making the required clearance change (see step 5 to choose the
correct shim).
Install the thrust end plate and the bearings onto the shaft, as
described Aerolock reassembly.
6. Position a micrometer against the bearing cup and determine the
clearance between the bearing and the Aerolock end plate
7. Take a clearance reading at four points around the bearing cup
and end plate.
8. Divide the total of the readings (tcr) by four. Subtract .002 inches
from this average reading, and the result is the required shim
thickness
9. required shim thickness =(tcr / 4) - 0.002
10. The clearance of the thrust bearing preload must be between 0.04
mm and 0.05 mm / 0.0015 and 0.002 inches.
11. If the clearance is correct, continue with step 8. If it is not, continue
with step 5 to install preload shims.
Page 38 Docu-No.: 1090034611-EN Rev. 1.0.0
8 Maintenance
8.11BT AerolockTM Puller Tool
8.11 BT Aerolock
TM
Puller Tool
The puller tools is required to remove the rotor from the housing and
thrust end plate during disassembly Refernece the following drawing
to construct this tool.
12. Using the measurement from step 4, add the preload shim or
shims that will allow for a tolerance between .0015 and .002
inches.
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 shims
with 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, and
tighten 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.
All seals
Reassemble the drive assembly to the Aerolock. See the spare parts
Drawing 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
Docu-No.: 1090034611-EN Rev. 1.0.0 Page 39
Maintenance 8
BT AerolockTM Driver Tool Kitsl. 8.12
8.12 BT Aerolock
TM
Driver Tool Kitsl.
Each Driver Kit includes:
(1) Seal driver tool for installing T-3 seals, T-3 inserts, air purge
diffusers, 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 grease
seal.
Improper installation of the seals and bearings can lead to premature
wear and reduction in Aerolock efficiency and performance. Using the
special 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. Only
one kit needs to be purchased for each size group listed below, as the
driver tool kits can be reused.
For example, if you are using (2) 98 BT Aerolocks and (1) 1110 BT
Aerolock, (1) driver tool kit for the BT 98 Aerolock and (1) driver tool
kit for BT 1110 Aerolock should be purchased.
If you have not already purchased the appropriate driver tool kit for the
Aerolock 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 Aerolock
Size
Driver tool kit
part number
Seals Expansion tool Drive-End bear-
ings
Thrust-End
Bearings/
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) 7/16 DIA
HOLES
DDIA
C Typ
B Typ C Typ
A SQ
Page 40 Docu-No.: 1090034611-EN Rev. 1.0.0
9 Troubleshooting
9.1 Troubleshooting table
9 Troubleshooting
9.1 Troubleshooting table
Eliminating faults in a rotary valve which is running can cause serious
accidents.
Switch off the rotary valve before every intervention and secure it
against 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 the
connectet control device or host computer.
Document faults and call the local service center
(for customer service information, project manual).
Error Cause Remedy
Aerolock or motor
will not start.
No power source
Motor defect
Gear case defect
Rotor jammed
Check the power source for
sufficient power as specified on the
nameplate. Check the wiring
connections and the motor
protection devices; e.g., fuses,
circuit breakers, and overload
elements. Replace the fuses, if
blown, and reset the circuit
breakers or overload elements, if
tripped.
The motor may be burned out. If so,
it will need to be repaired or
replaced.
The gears in the gear case may
have seized up due to the lack of
oil. Replace the gears or the gear
case.
Check for a jammed rotor. If
jammed, the Aerolock may need
to be disassembled and cleaned.
The bearings or seals may need to
be replaced.
Table page 1 of 6
Docu-No.: 1090034611-EN Rev. 1.0.0 Page 41
Troubleshooting 9
Troubleshooting table 9.1
Unusual drive or
motor noise
Gear case oil level
Drive alignment wrong
Check the oil level in the gear case.
If it needs to be filled, see the OEM
gear reducer information for the
proper grease selection and
lubricating instructions.
Check for the proper alignment of
the drive components.
Unusual Aerolock
noise
Material build up Check the motors amp draw to
determine whether material buildup
on the rotor or housing is
overloading the motor. If the
buildup is excessive, clean the
rotor and housing.
Some materials are susceptible to
buildup and may cause a squealing
noise as the rotor turns. This will be
normal for some types of material
and should not be a cause for
concern.
Check for the correct direction of
rotation. A rotor with relieved tips
rotating in the wrong direction will
cause material buildup.
The rotor may be rubbing on the
housing. Check for external loads
on the inlet and outlet flanges. The
Aerolock is not to be used as a
support for loads other than the
drive assembly and line adapter.
Error Cause Remedy
Table page 2 of 6
Page 42 Docu-No.: 1090034611-EN Rev. 1.0.0
9 Troubleshooting
9.1 Troubleshooting table
High motor
temperature
Bearings
Material build up
Wrong electrical overload elements
Motor ventilation
Gear case oil level
Check for proper operation of the
Aerolock bearings. See
troubleshooting table Aerolock
bearing malfunction or failure.
Check for excessive material
buildup in the rotor. See Error
unusual Aerolock noise
Verify that the electrical overload
elements are properly sized per the
full load amp specification on the
motor nameplate. Oversized
elements will not protect the motor
from overload.
Check for proper ventilation around
the motor. Material or dust buildup
on the exterior of the motor may
hamper ventilation.
Check the oil level in the gear case.
If it needs to be filled, see the OEM
gear reducer information for the
proper grease selection and
lubrication instructions.
Error Cause Remedy
Table page 3 of 6
Docu-No.: 1090034611-EN Rev. 1.0.0 Page 43
Troubleshooting 9
Troubleshooting table 9.1
Aerolock bearing
malfunction or failure
Bearing damaged
Lubrication from thrust-ends
Wear or dirt in the drive-end bearing
Check for wear, dirt or material in
the thrust-end bearings. Clean the
bearings, as instructed in section
8.10 step 5. If there is damage, the
bearings will need to be replaced.
Replacement bearings are
available in a Replacement Parts
Kit from Premier. If there is material
in the bearings, check the condition
of the seals. See troubleshooting
table Leaking seals.
Check for proper lubrication of the
thrust-end bearings. Lubricate as
instructed in section 8.10.2 step 3.
Be certain that the proper lubricant
is being used. Over lubrication of
the bearings may cause
overheating.
Check for wear, dirt, or material in
the drive-end bearing. If so, replace
the bearing, as it is a sealed-for-life
bearing. Replacement bearings are
available in a Replacement Parts
Kit from Premier.
Error Cause Remedy
Table page 4 of 6
Page 44 Docu-No.: 1090034611-EN Rev. 1.0.0
9 Troubleshooting
9.1 Troubleshooting table
Leaking seals Air purge seals
T-3 seals
Lip seals
Ensure that a filter, regulator, and
gauge assembly has been installed
to the Aerolock, along with the
compressed air supply. If the
Aerolock has been operated
without the air purge operating, the
seals are probably damaged and
need to be replaced. See section
8.9 and section 8.10. Replacement
seals are available in a
Replacement Parts Kit from
Premier.
Check for proper operation and
adjustment of the filter, regulator,
and gauge assembly. The
regulator should be set 0.69 Bar
[10 PSI] above the conveying
system's operating pressure. If the
regulator is set too low, material will
not be properly cleaned from the air
purge diffusers and will damage
the seals. The seals should be
replaced.
Disassemble the Aerolock, and
replace the seals. See section 8.9
and section 8.10. Replacement
seals are available in a
Replacement Parts Kit from
Premier.
Disassemble the Aerolock, and
replace the seals. See section 8.9
and section 8.10. Replacement
seals are available in a
Replacement Parts Kit from
Premier.
Air loss Seals damaged or wrong clearance Check for the correct rotor-to-
housing and rotor-to-end plate
clearance. If there is too much
clearance, air loss through the
clearances will result.
Check the condition of the seals.
See troubleshooting table Leaking
seals.
Error Cause Remedy
Table page 5 of 6
Docu-No.: 1090034611-EN Rev. 1.0.0 Page 45
Troubleshooting 9
Troubleshooting table 9.1
Material not flowing Material build up
Wear or dirt in the drive-end bearing
Material bridging
Wrong rotor speed
Check for material buildup in the
rotor pockets. Clean the
Aerolock rotor.
Check for the correct rotor-to-
housing and rotor-to-end plate
clearance. If there is too much
clearance, air loss through the
clearances may cause the material
to bridge above the Aerolock,
decreasing or stopping the material
flow.
Vented shear protectors are
designed to minimize the chances
for material bridging above the
Aerolock by venting the air
displaced from each pocket as it
fills, as well as any air leakage
through the clearances. A vented
shear protector may need to be
installed for your application.
If a vented shear protector is
installed, check the condition of the
long seal flap. If it is worn or
sheared off due to incorrect
installation or incorrect rotor
rotation, it will need to be replaced.
See section 4.5. Replacement seal
flaps are available from Premier.
Check for the correct Aerolock
RPM.
Error Cause Remedy
Table page 6 of 6
Page 46 Docu-No.: 1090034611-EN Rev. 1.0.0
9 Troubleshooting
9.1 Troubleshooting table

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