Machine Manual

en-23274.003-D

Coarse feed valve

Code word

Order number

POLYSIUS Order Code (POC)

Machine Manual Contents
Coarse feed valve

Contents

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

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

en-23274.003-D
Machine Manual Technical data
Coarse feed valve 1

1 Technical data

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

Information on the intended use

Feed material......................................................................................
Bulk density........................................................................................
Permissible particle size of the feed material.............................mm
Maximum moisture content................................................................

Basic data
Year of manufacture............................................................................
Series/type..........................................................................................
Construction size................................................................................
Diameter of the housing (internal)...............................................mm
Length of the valve (internal).......................................................mm
Overall height with base frame....................................................mm
Rotational speed of the vane rotor.............................................min-1
Maximally permissible filling ratio.............................................40 %
Total weight.....................................................................................kg

Heating with hot air yes/no

If you are heating the coarse feed valve with hot air, observe the
following indications.
Minimum velocity of the hot air in the valve vmin.....................18 m/s
Minimum hot air volume at vmin....................................................m3/h
Nominal width of the supply pipe.................................................mm
Minimum temperature of the hot air at the valve...................200 °C
Maximum permissible temperature of the hot air..................350 °C
2

Drive

Motor
Type.....................................................................................................
Design..................................................................................................
Output.............................................................................................kW
Rotational speed.........................................................................min-1
Voltage..............................................................................................V
Frequency........................................................................................Hz

Shaft-mounted gear unit

Type.....................................................................................................
Transmission.......................................................................................

Overload coupling
Type.....................................................................................................
Overload torque set when being delivered..................................Nm

Speed monitor
Type.....................................................................................................
Machine Manual Safety
Coarse feed valve 1

2 Safety

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

Use of the machinery

 The machine is exclusively intended for use as an air seal and
as a feeder for coarse-grained bulk materials.
Be sure to comply with the information concerning the
intended use of the machinery in the section Technical Data.
 Any use of the machinery other than for the specified purpose
is forbidden. POLYSIUS AG is not responsible for any damage
resulting from any other than the specified use of the machine.
All other use is at the operator’s own risk.
 The observance of these and the maintenance instructions is
part of the specified use.

Transport and assembly

 All transport instructions in this manual refer exclusively to the
transport of the machinery in the plant area.
 Use only suitable hoisting and lifting equipment, which is in
serviceable order and has a sufficient load bearing capacity.
 Never work under a suspended load.
Operation
 Any safety checks before or during operation depend on the
relevant national regulations. The operator is responsible for
the performance and recording of such checks.
 If changes in the machine or its operating behaviour relevant
to safety occur, the machine must be immediately stopped.
 Hearing protectors have to be worn in the roller mill building.
Safety Machine Manual
2 Coarse feed valve

Maintenance
 Be sure to also comply with the safety instructions in the
operating manual and in the machine manual for the roller mill
and in the subsupplier's documentation.
 Keep the machine free of oily and combustible substances and
materials. Never use gasoline or other easily inflammable
substances to clean the machine.
 You have to obtain the written permission of the plant manager
before you start with work on the machine, and you must shut
down the plant section in which the machine is installed.
 Make absolutely sure that all machines, motors and the
material flow whose operation might endanger persons or
equipment are switched off and safeguarded against restarting
for the entire duration of the maintenance work.
 Switch off the power supply to the electrical components
before beginning any maintenance work.
 Make absolutely sure that all parts of the machine have come
to a complete standstill before you remove any protection
devices or open any covers.
 The plant management must ensure that all moving parts are
protected against accidental contact.
 Before performing any work on the machine, make absolutely
sure that there is no danger of suffering burns when touching
the machine, and before opening any inspection and service
covers, make absolutely sure that there is no longer any hot
material inside the machines.
 Make absolutely sure that all piping is depressurised.
 Make absolutely sure that no hot gas can enter the machine or
the working area.
 When work is carried out on the machine, a large amount of
dust has to be expected, so make sure that dust protection
masks are worn.
 Only use 24 volt lamps to illuminate the interior of the
machine.
 For repair work to be carried out inside the plant sections you
have to install auxiliary platforms, if necessary. These auxiliary
platforms must be of stable design.
Machine Manual Safety
Coarse feed valve 3

Flame cutting, grinding or welding work

● Strictly observe the welding instructions when performing any welding work.
● When electric arc welding or cutting are being performed, you must ensure
that personnel cannot come into contact with electrically conductive
components. Use insulating underlays for this purpose.
● Never situate the source of the welding current in a confined space where
walls have conductive properties.
● If you carry out electric welding on any part of the machine, never conduct the
welding current through plain or antifriction bearings, other moving connecting
elements or measuring devices. Always directly connect the welding current
return lead to the part being welded.
● In particular, never carry out any electrical or autogenous welding and flame-
cutting work on the grinding table, the grinding track, the roller tyres and the
tie rods, as these points may become starting points of cracks. Never connect
earthing cables to these components either.
Conclusion of maintenance work
● After having finished all maintenance work, check all joints and connections
for leaks.
● Remount all protection devices when maintenance work has been finished.
Make absolutely sure that no persons are inside the plant component before
you properly close the inspection and service covers.
 Check that all signs are complete and distinctly legible. Mount
new signs if necessary.
Machine Manual Components and mode of functioning
Coarse feed valve 1

3 Components and mode of functioning

The coarse feed valve with heating apparatus is suitable for

coarse-grained feed material.
 utilization as an air shut-off device.
 flow-regulated feeding of coarse-grained bulk materials.
The coarse feed valve minimizes the inleakage of air into grinding
systems operated at negative pressure. The coarse feed valve is
mainly employed for the proportioned feeding of coarse-grained
bulk materials into roller mills. By heating the coarse feed valve
with hot air it is possible to prevent sticky feed materials from
building up cakings.
Components and mode of functioning Machine Manual
2 Coarse feed valve

3.1 Components

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

Items in the drawings

1.0 Housing
1.1 Cleaning flaps (for 800 x 800 size and larger)
1.3 Impact table
1.4 Scraper flap
1.5 Expansion chamber
1.6 Cover for cleaning port
2.0 Side cover with bearing bracket
2.1 Connecting flange for the hot-air heater
2.2 Stuffing box
2.4 Fixed bearing housing
2.9 Floating bearing housing
3.0 Vane rotor
3.1 Sealing strips
4.0 Speed monitor
5.0 Shaft-mounted gear unit
5.1 Motor support
5.2 Counter-torque support
5.3 Overload clutch
5.4 Guard
5.5 Motor
6.0 Base frame
Machine Manual Components and mode of functioning
Coarse feed valve 3

Figure 1
Components and mode of functioning Machine Manual
4 Coarse feed valve

Items in the drawings

2.0 Side cover with bearing bracket
2.2 Stuffing box
2.3 Packing cord
2.4 Fixed bearing housing
2.5 Self-aligning roller bearing
2.6 Clamping sleeve
2.7 Fixed ring
2.8 Seal for fixed bearing housing
2.9 Floating bearing housing
2.10 Self-aligning roller bearing
2.11 Clamping sleeve
2.13 Seal for floating bearing housing
3.0 Vane rotor
3.1 Sealing strips
4.0 Speed monitor
Machine Manual Components and mode of functioning
Coarse feed valve 5

Figure 2
Components and mode of functioning Machine Manual
6 Coarse feed valve

3.2 Mode of functioning

The coarse feed valve minimizes the inleakage of air into grinding
systems operated at negative pressure. The coarse feed valve is
mainly employed for the proportioned feeding of coarse-grained
bulk materials into roller mills. By heating the coarse feed valve
with hot air it is possible to prevent sticky feed materials from
building up cakings. Please observe the instructions in the
Technical data section.

Figure 3

The figure shows a cross section of the coarse feed valve. The
feed material is fed onto the impact table (1.3). The impact
energy is thus not directly transmitted to the vane rotor. From the
impact table the feed material is fed into the individual cells.
The scraper flap (1.4) prevents coarse grains from becoming
jammed between the housing inlet edge and the sealing strips
(3.1). If coarse grains nevertheless pass the scraper flap, the
expansion chamber (1.5) prevents them from becoming jammed
between the housing wall and the sealing strips.

CAUTION
Never feed iron particles or other foreign matter into the coarse
feed valve!
Machine Manual Components and mode of functioning
Coarse feed valve 7

In this respect observe the indications given in the Section

Technical data.
Machine Manual Transport and assembly
Coarse feed valve 1

4 Transport and assembly

4.1 Transport and storage requirements

The machine is transported in single parts or in sub-assemblies.

It must be observed that suitable lifting equipment is employed in
removing the parts from the transport vehicles and transferring
them to the storage area.
When they arrive at the site, all parts must be inspected for
transport damage and placed on wooden beams with the
provision of suitable protection against rain, contamination and
damage. The parts must not be stored directly on the ground.
Motors, couplings, gear units, measurement and control
equipment must be stored in buildings which are well aerated and
must be protected against moisture.
If you intend to store the coarse feed valve at site for a longer
period of time, please observe the following instructions:
 Protect the bright machine parts by applying a preserving
agent.
 For the long-term storage of the gear unit and the motors
observe the instructions given by the respective subsupplier.

4.2 Assembly

General requirements
The following assembly instructions do not detail the individual
steps for assembling the unit, but rather give an overview on the
work to be performed.
Changes in the planning of the plant during the processing of the
contract may lead to deviations from these assembly
instructions.
Careful selection of the used tools and appliances and the
personnel is important for the correct execution of the assembly
work.

CAUTION
If you carry out electric welding on any part of the machine, never
conduct the welding current through plain or antifriction bearings,
other moving connecting elements or measuring devices, in order
to prevent damage to these parts.
Transport and assembly Machine Manual
2 Coarse feed valve

Always directly connect the welding current return lead to the

part being welded.
Never carry out any electrical or autogenous welding and flame-
cutting work on the grinding table, the grinding track, the roller
tyres and the tie rods, as these points may become starting
points of cracks.
Never connect earthing cables to these components either.
Machine Manual Transport and assembly
Coarse feed valve 3

Assembly sequence:
If the coarse feed valve has been stored at site for a longer
period of time, it is important that you observe the following
instructions before and during its installation:
 Carefully remove any preserving agent.
 Check the stuffing box packings and replace them, if required.
 Replace the bearing grease (see also Section Lubrication).
 Turn the vane rotor several times by hand in the defined
direction (arrow on the housing).
 Install the coarse feed valve in such a way that the feed
material is fed onto the impact table (1.3).
The maximum permissible height of fall for the material is
approx. 2000 mm. If this height of fall is exceeded, the rate of
fall has to be reduced by suitable measures, e.g. by installing
baffle plates in the feed chute.
 The inlet and outlet flange must be arranged in horizontal
position.
 Seal the inlet and the outlet flange against the respective
connecting flange.

Figure 4
Transport and assembly Machine Manual
4 Coarse feed valve

Heating with hot air

 Screw the hot air duct onto the connecting flanges (2.1) with
inserted seals.

Figure 5

Installation of the drive

 The drive has to be mounted onto the shaft of the vane rotor
(3.0) according to the instructions of the manufacturer.
 Mount the counter-torque support (5.2) between the shaft-
mounted gear unit (5.0) and the base frame (6.0).
 Check of the sense of the motor’s rotation; The sense of
rotation of the vane rotor must correspond to the arrow on the
housing. The vane rotor must never be rotated against the
specified sense of rotation.
 Only then you may establish connection with the overload
clutch!
Machine Manual Lubrication
Coarse feed valve 1

5 Lubrication

NOTE
The POLYSIUS table of lubricants with the lubricant reference
numbers is contained in the supplement Important notes on the
documentation. Each lubricant has a clear reference number to
which the lubrication instructions in this section relate. The
table gives a complete list of the suppliers and products
permitted by POLYSIUS AG.
It is the responsibility of the lubricant supplier to select
appropriate lubricants corresponding to the reference numbers.
POLYSIUS AG is not responsible for the correctness of this data.
The use of a lubricant not explicitly stated in the table of
lubricants has to be previously approved by POLYSIUS AG.
The supplement Important notes on the documentation also
contains the generally valid Notes on lubrication.

Ensure that the lubricants are stored, used and disposed of in an

environmentally-friendly manner and observe your national
environmental legislation when handling lubricants.
Lubrication Machine Manual
2 Coarse feed valve

Lubrication chart

Figure 6

Lubrication points Quantity (ltr/kg) Lubrication intervals

per lubrication (weeks)
point
No. Qty. Designation Lubricant Initial Topping Topping First Further
up change changes
ref. no. filling up
[1]
1 2 Bearing 52 52
[2]
2 1 Gear unit

3 1 Motor according to manufacturer’s instructions

The different makes of lubricant corresponding to the lubricant reference numbers are shown in the
table of lubricants in the supplement Important Notes on the Documentation. The supplement is to be
found in this folder or at the beginning of the overall documentation.

Explanation of the numbers

[1]
Wash out the anti-friction bearing and provide it with a new grease filling.
[2]
Also observe the manufacturer’s instructions.
Machine Manual Preparation for test run
Coarse feed valve 1

6 Preparation for test run

6.1 Checks prior to the test run

After completion of the assembly work and prior to the first test
run, check all parts of the plant according to the list below. Take
particular care that all material remnants, tools and assembly
aids are removed.
 Is the feed material being fed onto the impact table?
 Have suitable measures been adopted to reduce the rate of the
feed material’s fall, if the material needs to be fed from a very
high level?
 Have all bolts and screws been firmly and properly tightened?
 Have the inlet and outlet flanges been tightly screwed up and
have the seals specified for that purpose been inserted?
 Is the sense of rotation of the vane rotor correct?
 Has the drive unit been correctly mounted and properly aligned
in accordance with the manufacturer’s instructions?
 Have the bearings and the gear unit been filled with the
lubricants specified in the Lubrication section?
 Have the cleaning port (1.6) and the cleaning flaps (1.1) [for 800
x 800 size and larger] been tightly closed?
 Does the overload clutch (5.3) respond at the specified torque
 (See section Technical data)?
 Have all guards and all warning signs been properly fixed?

6.2 Setting and adjustment

Overload clutch
The overload clutch (5.3) must respond at the specified torque
(see section Technical data). If this is not the case, adjust the
overload clutch according to the instructions of the manufacturer.

Heating with hot air

Whenever you heat the coarse feed valve with hot air, observe the
indications given in the section Technical data.
Machine Manual Maintenance
Coarse feed valve 1

7 Maintenance

7.1 Safety instructions

CAUTION
The noise level in the machine building can exceed 90 dB(A).
Your hearing could be harmed.
Wear hearing protectors.

DANGER
The machine is hot.
You could be seriously injured or killed.
I. Wear the prescribed protective clothing.
II. Wait until the mill has cooled down before starting the
maintenance work.

WARNING
There are rotating components at the machine.
You could suffer severe injuries.
Do not enter the areas cordoned off during operation of the
machine.

WARNING
Open doors can move suddenly and without warning.
You might be crushed.
Secure open doors against unintentional closing.

WARNING
Material can fall out.
You could suffer severe injuries.
Stay at an adequate distance.
Maintenance Machine Manual
2 Coarse feed valve

DANGER
There are hot gases in the machine.
You could be seriously injured or killed.
I. Make absolutely sure that there are no remaining hot gases in
the machine and that no hot gases can enter the working area.
II. Wear the prescribed protective clothing.
III. Wait until the machine has cooled down before starting the
maintenance work.

WARNING
Suspended loads
You could be seriously injured or killed.
Never work under a suspended load.

Note
After you have completed the maintenance work, you must check the
machine/plant again in accordance with the section Checks prior to the
test run.
Machine Manual Maintenance
Coarse feed valve 3

7.2 Inspection
No. Work to be performed Frequency Remarks
1 Check for tightness of once per day only the
 all flanged connections 800 x 800 and
 the stuffing boxes (2.2) larger size
 the cleaning port (1.6) models are
 the cleaning flap (1.1) equipped with
cleaning flaps
2 Check condition of guard (5.4) once per day

WARNING
The coarse feed valve can become very hot.
You run the risk of suffering severe burns or injuries.
Do not start any work at the coarse feed valve before all
rotating parts have come to a complete halt and before the
coarse feed valve has cooled down.
Your fingers are in danger to get crushed between the sealing
strip and housing.

No. Work to be performed Frequency Remarks

3 Check the sealing strips (3.1) for when the
wear
machine has
been stopped
4 Check for wear of when the
 the impact table (1.3) machine has
 the scraper flap (1.4) been stopped
5 Check the hot air ducts for cloggings when the
machine has
been stopped
6 Inspection work on the drive unit according to
manufacturer’s
instructions
Maintenance Machine Manual
4 Coarse feed valve

7.3 Servicing

No. Work to be performed Frequency Remarks

1 Retighten the stuffing boxes (2.2) of as required
the shaft passages; replace the
packing cord,
if necessary
2 Replacement of as required
 the impact table (1.3)
 the scraper flap (1.4)
 the sealing strips (3.1)
3 Maintenance work on the drive unit according to
manufacturer’s
instructions

7.4 Trouble shooting

WARNING
The coarse feed valve can become very hot.
You run the risk of suffering severe burns or injuries.
Do not start any work at the coarse feed valve before all
rotating parts have come to a complete halt and before the
coarse feed valve has cooled down.
Your fingers are in danger to get crushed between the sealing
strip and housing.

Fault Cause Elimination

Vane rotor blocks and Foreign body in the Remove foreign body
overload clutch coarse feed valve
responds
maximum permissible check the feed of bulk
filling ratio exceeded
material

If faults occur that are not described above, additional

information regarding causes and eliminations of faults can be
taken from the subsuppliers’ documentation.
Machine Manual Maintenance
Coarse feed valve 5

7.5 Repair

Before performing any repair work, make sure all electrical

components are disconnected.
Ensure the utmost cleanliness at all times during the repair work
in order to guarantee that the bearings, the drive system or other
sensitive parts of the machine are kept free of contamination.
Do not remove or open any flaps or protective equipment before
all rotating parts have stopped and the hot air supply system is
switched off.
Jam the vane rotor against unintentional rotation.

Dismantling the vane rotor

 Disconnect the electric supply from the motor and the speed
monitor.

Figure 7

 Loosen the shaft safety device at the gear unit.

 Support the drive unit and remove the torque stay arm (5.2).
 Pull the drive unit with the motor support (5.1) off the shaft.
 Remove the speed monitor (4).
 Dismantle the bearing arrangement on the drive side (item 2.4
to 2.8).
 Remove the screws of the stuffing box (2.2) on the drive side.
 Unscrew on the non-located bearing side the hot air duct from
the connecting flange (2.1).
Maintenance Machine Manual
6 Coarse feed valve

 Undo the screwed connection of the side cover (2.0) on the non-
located bearing side.
Machine Manual Maintenance
Coarse feed valve 7

 Pull the vane rotor (3) with the side cover (2.0) and the floating
bearing out of the housing.

Figure 8

Readjustment or replacement of the sealing strips (3.1)

 Loosen the screws.
 Turn the sealing strips around by 180 _ and screw the sealing
strips again to the vane rotor.
 The diameter of vane rotor in the area of the sealing strips
must be smaller than the housing diameter by 4 mm.
 Subsequently retighten the screws.

Note
After you have completed the maintenance work, you must check the
machine/plant again in accordance with the section Checks prior to the
test run.

Tools and auxiliary devices

No special tools are required for repair work on the machine.
However, torque wrenches of a bigger size than normal may be
necessary.
The need for scaffolds or hoists depends on the conditions in your
plant.
Machine Manual Spare parts
Coarse feed valve 1

8 Spare parts

Suggestions for enquiries and orders of spare parts

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

Figure 9
Machine Manual Spare parts
Coarse feed valve 3

Code word: Order-No.: POC:

Item Designation Qty. Unit Order Enquiry

1.0 Housing 1 piece

with signs and warning

signs

1.1 Cleaning flaps 2 piece

1.4 Scraper flap 1 piece

1.4.1 Bearing bolt with flange 2 piece

1.6 Cover for cleaning port 1 piece

5.0 Shaft-mounted gear unit 1 piece

5.1 Motor support 1 piece

5.2 Counter-torque support 1 piece

5.3 Overload clutch 1 piece

5.3.1 Holding brake 1 piece

5.4 Guard 1 piece

5.5 Motor 1 piece

Spare parts Machine Manual
4 Coarse feed valve

Figure 10
Machine Manual Spare parts
Coarse feed valve 5

Code word: Order-No.: POC:

Item Designation Qty. Unit Order Enquiry

2.0 Side cover 2 piece

with bearing bracket

2.2 Stuffing box 2 piece

2.3 Packing cord 2 set

2.4 Fixed bearing housing 1 piece

2.5 Self-aligning roller 1 piece

bearing

2.6 Clamping sleeve 1 piece

2.7 Fixed ring 2 piece

2.8 Seal for fixed bearing 2 piece

housing

2.9 Floating bearing housing 1 piece

2.10 Self-aligning roller 1 piece

bearing

2.11 Clamping sleeve 1 piece

2.13 Seal for fixed bearing 2 piece

housing

3.0 Vane rotor 1 piece

3.1 Sealing strips 1 set

3.2 Screws for sealing strips 1 set

4.0 Speed monitor 1 piece

Machine Manual Appendix
Coarse feed valve 1

9 Appendix

9.1 Technical drawings

Designation Drawing no.

Assembly drawing

9.2 Subsuppliers’ documentation

Drive unit

Speed monitor