0 Bewertungen0% fanden dieses Dokument nützlich (0 Abstimmungen)
208 Ansichten46 Seiten
Coperion K-Tron assumes no responsibility for damages resulting from misuse of any equipment or negligence on the part of operating personnel. COPERION K-TRON MAKES no warranty of MERCHANTABILITY or FITNESS for a PARTICULAR PURPOSE, with respect to the EQUIPMENT.
Coperion K-Tron assumes no responsibility for damages resulting from misuse of any equipment or negligence on the part of operating personnel. COPERION K-TRON MAKES no warranty of MERCHANTABILITY or FITNESS for a PARTICULAR PURPOSE, with respect to the EQUIPMENT.
Coperion K-Tron assumes no responsibility for damages resulting from misuse of any equipment or negligence on the part of operating personnel. COPERION K-TRON MAKES no warranty of MERCHANTABILITY or FITNESS for a PARTICULAR PURPOSE, with respect to the EQUIPMENT.
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