Machine manual

en-PH.DFP.001.B

Distributing flap, motor actuated

Code word

Order number

POLYSIUS Order Code (POC)

Machine manual Contents
Distributing flap, motor actuated

Contents

1 Safety 1-1
2 Technical data 2-1
2.1 Actuator 2-1
3 Components and mode of functioning 3-1
3.1 Components 3-1
3.2 Mode of functioning3-4
4 Transport and assembly 4-1
4.1 Transport and storage instructions 4-1
4.2 Assembly 4-1
4.3 Installing the refractory lining 4-2
4.4 Installing the actuator 4-7
5 Lubrication 5-1
6 Commissioning 6-1
6.1 Checks prior to the test run 6-1
7 Maintenance 7-1
7.1 Safety instructions 7-1
7.2 Inspection 7-2
7.3 Servicing 7-2
7.4 Repair 7-3
7.4.1 Dismounting the flap vane plate 7-3
7.5 Trouble shooting 7-7
8 Spare parts8-1
8.1 Suggestions for enquiries and orders of spare parts 8-1
8.2 Spare parts8-1
9 Appendix 9-1
9.1 Technical drawings 9-1
9.2 Subsuppliers' documentation 9-1

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Machine manual Safety
Distributing flap, motor actuated 1

1 Safety
IMPORTANT
Be sure to comply with the general safety instructions in the supplement
Important notes on the documentation.
Use

● The distributing flap is a discharge device for separating and diverting a flow
of material. It is intended to be installed in a meal chute inside the preheater.
Be sure to comply with the specification of the intended use in section
Technical data.
● Any use other than the intended use is forbidden. POLYSIUS AG is not
responsible for damage resulting from any use other than the intended use. All
other use is at the owner's own risk.
● The intended use also includes observance of the instructions in the machine
manual and compliance with the maintenance instructions.
Transport and assembly
● All transportation instructions in this machine manual refer exclusively to
transportation of the machine at the plant site.
● Only use suitable hoisting gear and load-carrying equipment which is in
serviceable order, has been checked 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 plant management is responsible for the performance and
recording of such checks.
● If changes in the machine or its operating behaviour occur that are relevant to
safety, shut it down immediately.
Maintenance
● Make absolutely sure that all machines and motors whose operation might
endanger persons or equipment are switched off and safeguarded against
restarting for the entire duration of the maintenance work.
● Before performing any work on the machine, make absolutely sure that there
is no danger of suffering burns when touching the machine. Before opening
any inspection and service covers make absolutely sure that there is no hot
material left inside the machine.
● Depressurise the storage vessels of the air blast units and let the residual
pressure escape via a vent piping before opening the doors and poke holes.
● Then de-energise the air blast units and safeguard them against unintentional
restarting.

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Safety Machine manual
2 Distributing flap, motor actuated

● Doors and sealing covers may only be opened by specially authorised and
trained personnel on the express orders of the plant manager! The doors and
sealing covers are designed such that they can be secured by padlocks.
● Be careful when opening doors and maintenance openings, even after longer
cooling down periods. There is still a danger of suffering burns from hot
material spurting out.
● In the case of a power failure in the plant, overpressure can occur in the entire
plant. Only open doors or poke holes after any overpressure has been
completely eliminated.
● When the machine is being cleaned through poke holes, there is a risk of hot
material spurting out because of a blockage. There is mortal danger! Use very
long blasting lances, wear appropriate protective clothing and keep
emergency escape routes clear.
● Only use the specially provided cleaning devices for eliminating incrustations
and blockages of the machine.
● Disconnect the power supply of all electrical components before beginning
any maintenance work.
● Only use 24 volt lamps to illuminate the interior of the machine.
● Observe the welding instructions when performing any welding work.
● When performing electric welding work on any part of the machine, never
conduct the welding current through sliding or antifriction bearings, other
moving connecting elements or measuring devices. Always directly connect
the welding current return lead to the part to be welded.
● After all maintenance work has been completed, check that there are no leaks
in joints and connections.
● Remount all protection devices when the maintenance work has been
finished.
● Make absolutely sure that no persons are inside the plant component,
properly close the inspection and service covers.
● Make absolutely sure that all signs are complete and distinctly legible. Mount
new signs if necessary.

en-PH.DFP.001.B
Machine manual Technical data
Distributing flap, motor actuated 1

2 Technical data
IMPORTANT
Refer to the separate electrical documentation or to the subsuppliers'
documentation for information on the electrical equipment.

Specifications of the intended use

Feed material hot meal

Installation in meal chute

Basic data
Year of manufacture

Series/type

Construction size Ø

Quantity

Refractory lining thickness mm

Weight (with refractory lining) kg

2.1 Actuator

Type

Actuating torque Nm

Supply voltage V

Frequency Hz

Actuating time s

Setting angle °

en-PH.DFP.001.B
Machine manual Components and mode of functioning
Distributing flap, motor actuated 1

3 Components and mode of functioning

3.1 Components
IMPORTANT
Some details of the drawings in this manual may not be identical with the
contract-specific drawings.

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Components and mode of functioning Machine manual
2 Distributing flap, motor actuated

Fig. 1: Design of the distributing flap

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Machine manual Components and mode of functioning
Distributing flap, motor actuated 3

No. Name Description

1 Housing with refractory lining

2 Flap vane plate

3 Bearing assembly

4 Actuator

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Components and mode of functioning Machine manual
4 Distributing flap, motor actuated

3.2 Mode of functioning

The distributing flap is a discharge device for separating or diverting a flow of
material.
Depending on the position of the inside vane the flow of material is distributed in
a certain ratio to the two outlets or completely to one outlet.

en-PH.DFP.001.B
Machine manual Transport and assembly
Distributing flap, motor actuated 1

4 Transport and assembly

4.1 Transport and storage instructions
The distributing flap is delivered ready-assembled without refractory lining.
A hand lever for manual operation of the distributing flap is ready-installed. The
actuator is delivered separately.
Make absolutely sure that suitable lifting equipment is employed for lifting all the
components from the transport vehicle and transferring them to the storage area.
Upon arrival at the site, all parts must be inspected for transport damage and
placed on wooden beams with the provision of suitable protection against
moisture, soiling and damage. Never place the parts directly on the ground.
Store the material for the refractory lining in accordance with the subsuppliers'
instructions.

4.2 Assembly
Required personnel
To ensure correct performance of the work, only assign repair work to personnel
that have received special training for the tasks to be performed.
Required tools
It is a prerequisite for the correct performance of the work that all tools and
appliances are carefully selected.
No special tools are required.
Whether or not you need auxiliary equipment, such as scaffolds or auxiliary
mounting supports, depends on the conditions in your plant.

IMPORTANT
The fundamental safety instructions must be complied with. Also refer to the
section Safety.

 Install the distributing flap into the meal chute.

 Pre-install and adapt the distributing flap with the meal chute.
 Remove the distributing flap and the meal chute.
 Dismount the distributing flap from the meal chute.
 Install the refractory lining, see Transport and assembly, Installing the refractory
lining.
 Install the distributing flap into the meal chute.
 Install the distributing flap and the meal chute.
 Install the actuator, see Transport and assembly, Installing the actuator.

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Transport and assembly Machine manual
2 Distributing flap, motor actuated

4.3 Installing the refractory lining

 Dismount the distributing flap from the meal chute.
 Dismount the flap vane plate (2) from the housing (1).

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Transport and assembly Machine manual
4 Distributing flap, motor actuated

Fig. 2: Disassembly of the flap vane plate

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Machine manual Transport and assembly
Distributing flap, motor actuated 5

No. Name

1 Housing

1.1 Cover, large

1.2 Seal, large

1.3 Cover, small

1.4 Seal, small

2 Flap vane plate

2.1 Vane

2.2 Shaft

2.3 Sleeve with sealing disc (sealing sleeve)

2.4 Spring

2.5 Adjusting ring

2.6 Fastening sleeve

3 Bearing assembly

3.1 Pedestal bearing housing

3.2 Bearing (antifriction bearing)

6 Auxiliary assembly devices

6.1 Pipe

6.2 Hoisting gear

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Transport and assembly Machine manual
6 Distributing flap, motor actuated

 Loosen adjusting rings (2.5) of the springs (2.4) for the housing seal on
both sides.
 Dismount large and small covers (1.1, 1.3).
 Loosen screws and remove the cover with suitable hoisting gear.
 Bring flap vane plate (2) in approx. 28 degree position using lever and
secure against twisting.
 Remove the fastening bolts of the pedestal bearing housings (3.1) on both
sides.

IMPORTANT
Support the flap vane plate at both shaft ends before removing the complete
bearings.

 Loosen the screws for fastening the hand lever and remove the lever,
parallel key and shaft parts consisting of bearing assembly (3), fixing
sleeve (2.6), adjusting ring (2.5), spring (2.4) as well as sleeve with sealing
disc (2.3) from the shaft (2.2).
 Remove the shaft parts on the opposite side.
 Slip suitable pipes (6.1) as extension elements onto the shaft attachment of
the shaft (2.2) on both sides, guide the flap vane plate (2) half way through
the big orifice and set down.
 Hook the shaft (2.2) into suitable hoisting gear (6.2), pull it out of the
housing and set down onto a load-bearing wooden underlay.
 Line the housing (1) with refractory lining according to the subsuppliers'
instructions.
 Remount the flap vane plate (2) in reverse order.

IMPORTANT
Pre-tension the springs (2.4) using the adjusting ring (2.5) such that the sleeve
with sealing disc (2.3) properly seal the housing (1).

 Check the flap vane plate (2) for ease of movement.

IMPORTANT
The movability of the flap vane plate (2) must not be limited by the lining. The
gap between the housing lining and the flap vane plate (2) indicated in the
drawing must be complied with.

 Install the distributing flap into the meal chute.

IMPORTANT
Observe the correct installation position.
This is the only way to ensure a correct direction of flow and function of the
distributing flap.

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Machine manual Transport and assembly
Distributing flap, motor actuated 7

 Provide a poke hole in the meal chute above the distributing flap.

4.4 Installing the actuator

 Remove the bracket with hand lever.
 Mount the actuator (4) with the associated bracket.

en-PH.DFP.001.B
Machine manual Lubrication
Distributing flap, motor actuated 1

5 Lubrication
IMPORTANT
The POLYSIUS table of lubricants with the lubricant reference numbers is
contained in the supplement Important notes on the documentation. The
supplement is contained in this folder or at the beginning of the overall
documentation. Each lubricant has a unique reference number to which the
lubrication instructions in this section relate. The table gives a complete list of all
subsuppliers and products approved by POLYSIUS AG. It is the responsibility of
the lubricant supplier to select appropriate lubricants corresponding to the
lubricant reference numbers. POLYSIUS AG accepts no liability for the
correctness of this data. If you wish to use a lubricant that is not included in the
table of lubricants, you have to first obtain the express permission of POLYSIUS
AG. The supplement Important notes on the documentation also contains
general information about the lubrication.

WARNING
Contact with lubricants
Contact with lubricants can cause allergic reaction and skin irritation.
I. Wear personal protective equipment to prevent any contact.
II. Never inhale vapours. Always ensure that the workplace is sufficiently
aerated.
III. Avoid any skin contact. If skin contact has occurred, wash the skin
thoroughly.
IV. Avoid any contact with eyes. If eye contact has occurred, thoroughly
rinse the eyes with large amounts of water and consult a doctor if
necessary.
V. Do not swallow.
VI. Observe the manufacturer's safety data sheet.

NOTICE
Risk of damage when lubricating the flap vane plate bearings
Mill dust may get into the lubricant during operation and cause heavy
wear.
Never lubricate the flap vane plate bearings.

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Lubrication Machine manual
2 Distributing flap, motor actuated

Fig. 3: Lubrication chart

Lubrication points Quantity (l, kg) per Lubrication intervals (weeks)

lubrication point

No. Qty. Designation Lubricant Initial Topping up Topping up First Further

ref. no. filling change changes

1 1 Gear unit See the subsupplier's documentation

2 1 Motor See the subsupplier's documentation

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 contained in this folder or at the
beginning of the overall documentation.

Table 1: Lubrication chart

en-PH.DFP.001.B
Machine manual Commissioning
Distributing flap, motor actuated 1

6 Commissioning
IMPORTANT
It is a prerequisite of our warranty that the first test run is carried out in the
presence of specialists from POLYSIUS AG and in accordance with their
instructions.

6.1 Checks prior to the test run

After completing the assembly work and prior to the first test run, check all parts
of the plant in accordance with the check list below. Make absolutely sure that all
material remnants, tools and auxiliary assembly devices have been removed.
● Has the refractory been installed in accordance with the subsupplier's
instructions?
● Have all bolts been properly tightened?
● Have all flange connections been bolted on tightly?
● Have the designated seals been fitted correctly?
● Has the actuator (4) been mounted and set correctly according to the
subsuppliers' instructions?
● Do the electrical data of the network match the data of the actuator?
● Has the distributing flap been checked for ease of movement (functioning)?
● Has the prescribed lubricant been supplied to all lubrication points?
● Have all platform openings been properly closed or safeguarded?
● Have all protection devices and warning signs been correctly mounted?

en-PH.DFP.001.B
Machine manual Maintenance
Distributing flap, motor actuated 1

7 Maintenance
7.1 Safety instructions
DANGER
Spurting out raw meal
When poke holes and inspection ports are opened, hot raw meal may
spurt out and cause life-threatening injuries.
I. Wear heat resistant protective clothing and visor.
II. Secure the working area against unauthorised access.
III. Keep emergency escape routes clear.
IV. Always stand to the side of any opening.
V. Use long blasting lances for removing incrustations of material.

CAUTION
Residual pressure
If the machine is equipped with automatic air blast units, air can escape
from the air blast units due to pressure after the electricity supply has
been switched off and cause severe injury.
I. Depressurise storage vessels of the air blast units.
II. Let the compressed air escape via a vent piping.
III. Open doors and poke holes.

WARNING
Hot surfaces
Components in contact with the material as well as bearings and motors
may heat up during operation. Skin contact with hot surfaces causes
severe burns.
Always wear heat resistant protective clothing and safety gloves when
working in the vicinity of hot surfaces.

IMPORTANT
After you have completed the repair work, you must check the machine/plant
again in accordance with the section Checks after assembly.

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Maintenance Machine manual
2 Distributing flap, motor actuated

7.2 Inspection
No. Work to be performed Frequency Note

1 Check for local thermal deformations Daily

2 Check the refractory lining Annually

3 Inspection work on the actuator (4) See

subsupplier's
information

7.3 Servicing
No. Work to be performed Frequency Note

1 Refurbish the refractory lining As required

2 Maintenance work on the actuator (4) See

subsupplier's
information

3 Move the flap vane plate (2) over the total control range, Daily
then move back to the initial position.

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Machine manual Maintenance
Distributing flap, motor actuated 3

7.4 Repair
If damage is found during the checks described in the sections Inspection and
Servicing, you must repair the damaged parts or replace them with new parts.

7.4.1 Dismounting the flap vane plate

Required personnel
To ensure correct performance of the work, only assign repair work to personnel
that have received special training for the tasks to be performed.
Required tools
It is a prerequisite for the correct performance of the work that all tools and
appliances are carefully selected.
No special tools are required. However, you may need torque wrenches of a
bigger size than normal and suitable hydraulic pumps.
Whether or not you need auxiliary equipment, such as scaffolds or auxiliary
supports, depends on the operating conditions in your plant.
General
The fundamental safety instructions must be complied with. Also refer to the
section Safety.
Switch off the power supply to all electrical components before beginning any
repair work.
Do not remove or open any covers or protection devices before all components
have come to a complete standstill.
Ensure absolute cleanliness at all times during the repair work in order to prevent
dirt from entering the bearings, the drives or other sensitive parts of the machine
or plant.
To dismount the flap vane plate (2), do not remove the distributing flap from the
meal chute.
 Remove the actuator (4) with associated bracket and mount the hand lever
(5) with associated bracket.
 Dismount the flap vane plate (2) from the housing (1).

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Maintenance Machine manual
4 Distributing flap, motor actuated

Fig. 4: Disassembly of the flap vane plate

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Machine manual Maintenance
Distributing flap, motor actuated 5

No. Name

1 Housing

1.1 Cover, large

1.2 Seal, large

1.3 Cover, small

1.4 Seal, small

2 Flap vane plate

2.1 Vane

2.2 Shaft

2.3 Sleeve with sealing disc (sealing sleeve)

2.4 Spring

2.5 Adjusting ring

2.6 Fastening sleeve

3 Bearing assembly

3.1 Pedestal bearing housing

3.2 Bearing (antifriction bearing)

6 Auxiliary assembly devices

6.1 Pipe

6.2 Hoisting gear

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Maintenance Machine manual
6 Distributing flap, motor actuated

 Loosen adjusting rings (2.5) of the springs (2.4) for the housing seal on
both sides.
 Dismount large and small covers (1.1, 1.3).
 Loosen screws and remove the cover with suitable hoisting gear.
 Bring flap vane plate (2) in approx. 28 degree position using lever and
secure against twisting.
 Remove the fastening bolts of the pedestal bearing housings (3.1) on both
sides.

IMPORTANT
Support the flap vane plate at both shaft ends before removing the complete
bearings.

 Loosen the screws for fastening the hand lever and remove the lever,
parallel key and shaft parts consisting of bearing assembly (3), fixing
sleeve (2.6), adjusting ring (2.5), spring (2.4) as well as sleeve with sealing
disc (2.3) from the shaft (2.2).
 Remove the shaft parts on the opposite side.
 Slip suitable pipes (6.1) as extension elements onto the shaft attachment of
the shaft (2.2) on both sides, guide the flap vane plate (2) half way through
the big orifice and set down.
 Hook the shaft (2.2) into suitable hoisting gear (6.2), pull it out of the
housing and set down onto a load-bearing wooden underlay.
 Remount the flap vane plate (2) in reverse order.

IMPORTANT
Pre-tension the springs using an adjusting ring such that the sleeve with sealing
disc properly seal the housing.

 Check the flap vane plate for ease of movement.

 Remove the hand lever (5) with associated bracket and mount the actuator
(4) with associated bracket.
IMPORTANT
After you have completed the repair work, you must check the machine/plant
again in accordance with section Checks prior to the test run.

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Machine manual Maintenance
Distributing flap, motor actuated 7

7.5 Trouble shooting

Malfunction Cause Elimination

Local thermal deformation on Refractory lining is faulty Replace the refractory lining
housing (1)

Difficult movement of the flap Coatings or tramp material in Eliminate coatings or tramp
vane plate (2) the housing (1) material through the poke hole

Flap vane plate (2) cannot be Actuator (4) is faulty Repair the actuator
moved
Bearings are faulty Replace the bearing

Coatings or tramp material in Eliminate coatings or tramp

the housing (1) material through the poke hole

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Machine manual Spare parts
Distributing flap, motor actuated 1

8 Spare parts
8.1 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 quickest and most trouble-free manner.
Please copy the title page and the page with the corresponding table. Complete
the columns for quantity and units. Mark the parts you require with a cross in the
column Order or in the column Enquiry. Send the title page and the table to the
POLYSIUS AG spare parts department.
If the table refers 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.

8.2 Spare parts

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Spare parts Machine manual
2 Distributing flap, motor actuated

Fig. 5: Design of the distributing flap

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Machine manual Spare parts
Distributing flap, motor actuated 3

No. Name Qty. Unit Order Enquiry

1.1 Cover, large 1 Pce

1.2 Seal, large 1 Pce

1.3 Cover, small 1 Pce

1.4 Seal, small 1 Pce

2 Flap vane plate 1 Pce

2.4 Spring 1 Pce

3.1 Pedestal bearing housing 2 Pce

3.2 Bearing (antifriction bearing) 2 Pce

4 Actuator 1 Pce

4.1 Motor 1 Pce

4.2 Gear unit 1 Pce

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Machine manual Appendix
Distributing flap, motor actuated 1

9 Appendix
9.1 Technical drawings

For drawing numbers, please refer to the table of contents of this folder.

Assembly drawing

9.2 Subsuppliers' documentation

Refractory lining

Actuator

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