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Operating manual Specification sheet

SMD Cellular wheel sluiceSMD FRDERTECHNIK GmbH Robert-Bosch-Str. 7 D-42477 Radevormwald, Germany Tel.: 0049 (0)2195-931910 Fax.: 0049 (0)2195-931909 E-Mail: [email protected] Internet: www.smd-foerdertechnik.de

Specification sheet*) General : SMD identification no. : KM08/3344-0101 Type : ZRS 630x630x800 with bush Year of construction : 2008 Net weight (kg) : 873 Dimensions W x H x L (mm) : 750 x 800 x 2240 Operating data : Conveyed material : cement raw meal Density (t/m) : 0,8 Grain size (mm) : dry and trickling Temperature of material (C) : max. 100 Humidity (%) : dry Exist. Conveying capacity (t/h) : 120 Exist. Conveying capacity (m/h) : 150 Theor. Conveying capacity (m/h) : 258 ( in case of fill factor 100% ) Fill factor (%) : 58 Technical data and usage to the intended purpose: Type of drive : Gear motor Drive description (brand/type) : SEW Eurodrive / RF97 DVE100L4, mounting position M1 Rated power of motor (kW) : 3,0 Output speed of gear unit (min-1) : 22 Voltage (V AC) : 220-240/380-415 Frequency (Hz) : 50 Amount of oil at changing (litre) : 5,1 Gear oil (type/recommendation) : Synthetic oil DIN 51502 CLP PG ISO VG220 /

Shell Tivela S220 Coupling (brand/type) : HFB / EK 250 A Speed monitoring (brand/type) : ifm electronics / DI0001 Housing: Design : welded construction Material of housing : S235JR Material of wear bush : HARDOX 400 Cellular wheel : Design : closed Nominal diameter (mm) : 630 Quantity of cells : 8 Material of cells : S235JR Shaft proctection sleeve : existing Bearing : Roller bearing Shaft sealing : Gland sealing Matrial of sealing strips : HARDOX 400 *) This specification sheet is provided for each purchase and is an applicable and valid part of the operating

manual. This specification sheet lies above the operating manual.

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Operating manual Specification sheet

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Operating manual

SMD Cellular wheel sluice

SMD FRDERTECHNIK GmbH Robert-Bosch-Str. 7

D-42477 Radevormwald, Germany

E-Mail: [email protected] Internet: www.smd-foerdertechnik.de

Tel.: 0049 (0)2195-931910 Fax.: 0049 (0)2195-931909

Date : 07.12.2007

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Operating manual Table of content

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Operating manual Table of content

Table of content

1 General 5

1.1 Introduction ........................................................................................... 5 1.2 Description ............................................................................................ 5 1.3 EC Declaration of conformity ............................................................... 5 1.4 Copyright............................................................................................... 5

2 Validity, warranty, liability 6

2.1 Validity of the operating manual........................................................... 6 2.2 Other valid document ............................................................................ 6 2.3 Field of application and usage to the intended purpose ........................ 6 2.4 Warranty and liability............................................................................ 7 2.5 Operational preconditions ..................................................................... 7

3 Safety 8

3.1 Symbols, warning signs and terminilogy .............................................. 8 3.2 Basic safety instructions........................................................................ 9 3.3 Special instructions ............................................................................... 9 3.4 Organisational measures ....................................................................... 9 3.5 Protective equipment........................................................................... 10 3.6 Informal safety measures .................................................................... 10 3.7 Training personnel............................................................................... 10 3.8 Cellular wheel sluice control............................................................... 10 3.9 Safety measures during normal operation........................................... 10 3.10 Risks from electrical energy................................................................ 10 3.11 Escape of hazardous gases, vapours and dusts.................................... 11 3.12 Maintenance, servicing and repairs..................................................... 11 3.13 Structural changes to the cellular wheel sluice ................................... 11 3.14 Cleaning the Sluice and disposal of wastes......................................... 11 3.15 Noise from the cellular wheel sluice ................................................... 12 3.16 Changing the location of the cellular wheel sluice ............................. 12

4 Transport and storage 13

4.1 Sensitivity............................................................................................ 13 4.2 Extent of delivery ................................................................................ 13 4.3 Intermediate storage ............................................................................ 13

5 Installation 14

5.1 General informations........................................................................... 14 5.2 Installation informations ..................................................................... 14 5.3 Installation of drive unit ...................................................................... 15 5.4 Installation of speed monitoring.......................................................... 15 5.5 Elektrical installation........................................................................... 16 5.6 Protection against contact by hot material conveying......................... 16 5.7 Tightening torques for boltings ........................................................... 16 5.8 Checks at the end of installation ......................................................... 17

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Operating manual Table of content 6 Commissioning 18

6.1 Notes.................................................................................................... 18 6.2 Visual check ........................................................................................ 18 6.3 Trial run without material ................................................................... 19 6.4 Trial run with material......................................................................... 19

7 Operation 20

7.1 Normal operation................................................................................. 20 7.2 What to do in the event of faults ......................................................... 20

7.2.1 Emergency stop .................................................................................. 20 7.2.2 Re-starting after a malfunction............................................................... 21 7.2.3 Troubleshooting.................................................................................. 21

7.3 Before a longer standstill period ......................................................... 22 7.4 After a longer standstill period............................................................ 22

8 Maintenance 23

8.1 Notes for routine maintenance and inspection .................................... 23 8.2 Routine maintenance ........................................................................... 23

8.2.1 Care.................................................................................................. 23 8.2.2 Routine maintenance and inspeciton list................................................... 24

8.3 Repairs................................................................................................. 24 8.3.1 Drive unit .......................................................................................... 25 8.3.2 Chain drive ........................................................................................ 25 8.3.3 Gland packing .................................................................................... 25 8.3.4 Replacing rubber sealing....................................................................... 25 8.3.5 Adjustment of the gap .......................................................................... 25 8.3.6 Disposal ............................................................................................ 25

8.4 Lubrication .......................................................................................... 26 8.4.1 Correct lubrication............................................................................... 26 8.4.2 Grease lubricant .................................................................................. 26 8.4.3 Mixing lubricating greases .................................................................... 26 8.4.4 Lubrication of the drive unit .................................................................. 26 8.4.5 Lubricant dispensers ............................................................................ 26 8.4.6 Rolling bearing ................................................................................... 26 8.4.7 Disposal ............................................................................................ 27 8.4.8 Lubrication instructions ........................................................................ 27 8.4.9 Lubrication chart................................................................................. 28 8.4.10 List of lubricating points....................................................................... 28

9 Spare parts stocking / Customer service 29

9.1 Spare parts stocking ............................................................................ 29 9.2 Spare parts sales / Customer service address ...................................... 29 9.3 List of spare parts / spare part drawing ............................................... 29

10 Layout drawing 31 11 Documentation of suppliers 33

11.1 Speed monitor ..................................................................................... 33 11.2 Drive motor ......................................................................................... 35 11.3 Coupling .............................................................................................. 37

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Operating manual 1 General

1 General

1.1 Introduction This information has been written with the intention that it be read, understood and all points herein observed by those persons responsible for the SMD cellular wheel sluice. The complete technical documentation should always be kept in the vicinity of the cellular wheel sluice. These operating instructions refer to particularly important details for working with the cellular wheel sluice. Errors on the cellular wheel sluice can only be avoided and a trouble-free operation guaranteed with an knowledge of these operating instructions. It is thus very important that the person responsible is in fact familiar with these operating instructions. We recommend that these operating instructions be read carefully before commissioning since we can accept no liability for damages and breakdowns which are due to a non-observance of these operating instructions. Should difficulties nevertheless arise, please contact our customer service or spare parts department which will be pleased to be of assistance (see operating instructions "Spare parts stocking/Customer service").

1.2 Description SMD cellular wheel sluices can be used for conveying, dosing and continuously discharging powdery and granular bulk materials with different physical properties. They are also suited for blocking under cyclones and filters. The sluices can be mounted to containers, under bins, product shafts or continuative conveyors. The cellular wheel sluices are composed of a housing, an internal cellular wheel and an external drive unit. SMD cellular wheel sluice are designed and manufactured according to the ordering requirements. The materials, the kind of drive and drive power depend on the respective usage.

1.3 EC Declaration of conformity The cellular wheel sluice which is described here and specified in the specification sheet (see chapter 2.2) has been produced by SMD FRDERTECHNIK GmbH in agreement with the valid EC machine directive. The declaration of conformity and manufacturer confirmation are separately filed in the quality documentation.

1.4 Copyright Copyright on these operating instructions remains with the firm of SMD FRDERTECHNIK GmbH. These operating instructions are for the operator and their personnel only. They contain information and instructions which may be neither wholly nor partly : - copied, - distributed or - otherwise propagated. Contraventions may entail criminal proceedings. We reserve the right to make technical changes to illustrations and data in these operating instructions which may become necessary to improve the cellular wheel sluice.

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Operating manual 2 Validity, warranty, liability

2 Validity, warranty, liability 2.1 Validity of the operating manual This operating manual are valid for SMD cellular wheel sluices with the following manufacturing variants (types): SMD cellular wheel sluice with free shaft end (drive provided by customer in aggreement with SMD FRDERTECHNIK

GmbH), with foot-mounted motor (-gear motor) and chain drive, with flange-mounted gear motor and coupling with latern, with flange-mounted gear motor and coupling without latern.

2.2 Other valid document The specification sheet provided for each order is an applicable and valid part of this documentation. This specification sheet lies above this operating manual. It contains following indicatings: SMD identification number of cellular wheel sluice.

This number specifies the ordering requirements, the design and particularly the field of application of the SMD cellular wheel sluice for which it is determined.

Type and description of cellular wheel sluice, year of construction, weight, operating data and the technical data of cellular wheel sluice

Other valid documents are the documents of suppliers, operating and maintenance instructions of the drive unit manufacturer for example.

2.3 Field of application and usage to the intended purpose The cellular wheel sluice has been manufactured exclusively for the field of application described in the ordering requirements and specification sheet. It is not permitted to use the SMD cellular wheel sluice for an application that does not comply with the design and operating conditions described in the specification sheet and ordering requirements. Any different use or use exceeding this field of operation shall not be deemed to be proper use. When it is used under changed operational conditions, permission for this changed application has to be obtained in writing from SMD FRDERTECHNIK GmbH. This cellular wheel sluice has exclusively been designed for the materials and material properties decribed in the ordering requirements and operating data. Any other materials and those with markedly different properties constitute an improper use of the cellular wheel sluice and must be avoided.

! Danger

Persons might get injured or killed if handling improper materials that constitute a fire or explosion risk or are prone to chemical reactions. Any different use or use exceeding this field of operation shall not be deemed to be proper use. SMD FRDERTECHNIK GmbH shall not be held liable for any damages arising from such improper use. SMD FRDERTECHNIK GmbH shall not be held liable in the event of improper use; any warranty shall expire immediately. The proper use of this cellular wheel sluice also content the proper compliance of all information from this operating manual and particularly the proper maintenance specification.

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Operating manual 2 Validity, warranty, liability

2.4 Warranty and liability All warranties and liabilities subject to our Standard Business Conditions ("Allgemeine Lieferungs- und Zahlungsbedingungen"). These have been handed over to the customer upon conclusion of the purchasing contract or earlier. No warranty and/or liability in the event of damages or injuries due to one or several of the following causes: Improper use of the cellular wheel sluice. Improper assembly, commissioning/starting, operation and maintenance of the cellular wheel

sluice. Operation despite defective safety equipment or improperly mounted or non-functional safety and

protection equipment. Disregard of instructions with respect to transport, storage, assembly, commissioning/starting,

operation, maintenance and set-up of the cellular wheel sluice. Unauthorized changes in the design and construction of the cellular wheel sluice. Unauthorized technical changes (e.g. drive condition, output and/or speed). Insufficient checking and inspection of components which are prone to wear. Improper repairs. Disastrous external events and force majeure. In principle, the first initial commissioning of the cellular whee sluice delivered by SMD FRDERTECHNIK GmbH may be procedured only by the company SMD FRDERTECHNIK GmbH, if this is not regulated differently by contract. All rights to claim under guarantee are dropped by nonobservance.

Attention !

SMD FRDERTECHNIK GmbH shall not be held liable for any damages arising from improper commissioning by other personal!

2.5 Operational preconditions Prevent product accumulation! Provide for a buffer space behind the cellular wheel sluice, continuative conveyors must have a higher conveying capacity. Facilitate maintenance! Install a slide valve in front of the inlet of cellular wheel sluice to make the maintenance sure and easier , a slide valve like SMD slide valve for example. Energy supply of drive unit! Connect the energy supply according to the details given in the specification sheet. Observe the regulations of the operator country.

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Operating manual 3 Safety

3 Safety

3.1 Symbols, warning signs and terminilogy The following terms and symbols will be used for warnings in the operating instructions:

! Danger

Danger: Danger notice, which if ignored can lead directly to serious injury or death.

! Warning

Warning: Danger notice, which if ignored can lead to serious injury or death. Caution: Danger notice or anger of uncertain handling which can lead to considerable injuries or

material damage. Warning of electrical voltage: Touching live parts can lead to immediate death. Doors and covers (e.g. cowls and

covers) bearing this sign may only be opened by "Experts and/or trained personnel" after the corresponding line voltage (feed, working or external) has been switched off beforehand.

Danger to operating safety of the system: Non-observance of these instructions affects the operating reliability and can lead to

system damage.

! Caution

Attention : The attention symbol identifies all safety instructions in this manual which refer to

regulations, guidelines or operating sequences which must be observed. Attention !

Non-observance of these instructions can lead to disturbances at the slide valve and in the surroundings.

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Operating manual 3 Safety 3.2 Basic safety instructions Pay attention to the information in the operating instructions: A basic precondition for the safe and trouble-free operation of this cellular wheel sluice is a

knowledge of the basic safety instructions and regulations. These operating instructions contain the most important information needed to operate the cellular

wheel sluice safely. These operating instructions, in particular the safety instructions, are to be observed by all persons

working at the cellular wheel sluice. In addition, the rules and regulations for the prevention of accidents applicable at the place of use

must also be observed. Operator's obligation: The operator promises to only let persons work at the cellular wheel sluice who re familiar with the basic regulations on job safety and accident prevention and have been trained

in the operation of the cellular wheel sluice, have read and understood the chapter Safety and warnings in these operating instructions and

have confirmed this through their signature. The safety-conscious working of the personnel will be checked at regular intervals. Personnel obligation: All persons commissioned to work on and with the cellular wheel sluice promise, before starting work, to observe the basis regulations on job safety and accident prevention, to read the chapter Safety and warnings in these operating instructions and confirm that they

have understood these through their signature. Risks associated with the cellular wheel sluice: This cellular wheel sluice has been designed and built according to the state of the art and in respect of the approved technical rules. Nevertheless, hazards to the life and limb of operators or third persons or damages to the cellular wheel sluice or other property cannot be excluded. This cellular wheel sluice shall be operated only: within the framework of proper use; in a safe condition; by personnel who are aware of the hazards and observe these instructions. Immediately clear all disturbances that might affect the safety of this cellular wheel sluice.

3.3 Special instructions We point out that the final manufacturer is obliged to equip the machine with the relevant

emergency-off devices! The final manufacturer must take protective measures against touching hot surfaces (EN 563)! Besides, the final manufacturer must earth the machine via an earthing cable which has to be

connected to the machine.

3.4 Organisational measures The necessary personal protective equipment is to be provided by the operator. All existing safety equipment is to be checked on a regular basis. The operating instructions must be supplemented by instructions including supervisory and

reporting obligations in order to take into account special on-the-job circumstances, e.g. with respect to labour organisation, job sequences, employed personnel, etc..

The personnel may not wear long hair open, loose clothing or jewellery including rings. Risk of injuries, e.g. these could get caught in or be drawn into the cellular wheel sluice.

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3.5 Protective equipment All protective equipment must be correctly installed and operational before the cellular wheel

sluice is started. Protective equipment may only be removed

- after the cellular wheel sluice comes to a standstill and - the cellular wheel sluice has been secured against restarting.

If part components have been delivered the protective equipment must be installed correctly by the operator.

3.6 Informal safety measures The operating maunal must always be kept at the place where the cellular wheel sluice is used. In addition to the operating instructions, the generally applicable and local regulations with respect

to accident prevention and environmental protection must be provided and observed. All safety signs and warnings on the cellular wheel sluice are to be kept in a legible condition. Publish the location and operation of fire extinguishers. Pay attention to the fire alarm and fire fighting facilities.

3.7 Training personnel Only trained and instructed personnel may work on and with the cellular wheel sluice. The responsibilities of the personnel must be clearly defined for the installation, commissioning,

operation, set-up, maintenance and repairs. Trainee personnel may only work on and with the cellular wheel sluice under the supervision of an

experienced person.

3.8 Cellular wheel sluice control Only trained personnel may operate the control system. Do not change any programs at the software.

3.9 Safety measures during normal operation Only operate the cellular wheel sluice when all safety equipment has been installed and is

operational. Before switching the cellular wheel sluice on make sure that nobody can be endangered by the

cellular wheel sluice when it starts up. Check the cellular wheel sluice for externally visible damages and the operability of the safety

equipment at least once per shift. If necessary, stop the cellular wheel sluice immediately, secure against restarting and remedy the fault.

Do not perform any actions which could jeopardize safety. Extraction and ventilation equipment may not be switched off whilst the cellular wheel sluice is

running.

3.10 Risks from electrical energy Work on the power supply may only be carried out by qualified electricians and according to the

rules of electrical engineering. The cellular wheel sluice's electrical equipment should be checked regularly. Loose connections

and scorched cables should be remedied immediately. The switch cabinet must always be kept closed. Access only for authorized personnel with a key or

tool. If work has to be carried out on live parts a second person must be present to switch off the main

switch if and when necessary. The cellular wheel sluice / system must be stopped immediately in the event of faults in the

electrical power supply.

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3.11 Escape of hazardous gases, vapours and dusts Noxious gases, fumes and/or dusts may escape from open covers and hoods. Make sure that

sufficient ventilation and/or exhaustion is ensured. When handling dangerous materials take special safety measures, e.g. have eye-rinsing devices

available when handling caustic agents. Do not effect welding or grinding or other jobs involving fire without prior permission. There

might be fire or explosion or other hazards. When working in small rooms be sure to observe your local and national regulations.

3.12 Maintenance, servicing and repairs Take care that all required set-up, maintenance and servicing jobs are carried out in the required

intervals. Inform the operators before maintaining and servicing the cellular wheel sluice. Secure all components and equipment connected to the cellular wheel sluice against accidental re-

start. When maintaining, checking or repairing the cellular wheel sluice remove all electric supplies and

potentials and secure main switch against accidental operation. - Lock main switch and remove key. - Put up warning sign against re-start.

When handling big components use lifting and hoisting devices and secure carefully. Check screws and bolts for tight fit. After finishing maintenance jobs check safety equipment for good working order. When working high use safe ladders and working platforms. Never climb on cellular wheel sluice.

When working at great heights secure against falling down. Keep all grips, steps, hand rails, platforms, ladders, etc. free of dirt, snow and ice. Remove defective cellular wheel sluice components immediately. Use genuine SMD wearing and spare parts only.

Third-party products cannot guarantee to offer appropriate safety in design and construction.

3.13 Structural changes to the cellular wheel sluice No modifications, alterations or conversions may be carried out on the cellular wheel sluice

without the consent of the manufacturer. This also applies for welding work on load-carrying parts.

Any conversion work requires written confirmation from the firm of SMD FRDERTECHNIK GmbH.

Under no circumstances may modifications be made to the control system or the control software program modified!

3.14 Cleaning the Sluice and disposal of wastes All materials used must be handled and disposed of correctly, in particular

- during work on lubricating systems and equipment, - during cleaning with solvents.

Do not use any aggressive cleaning agents. Use fibre-less cleaning cloths. Before cleaning the cellular wheel sluice with water or steam (high-pressure cleaner) or other

cleaning agents, cover/seal all openings into which no water/steam/cleaning agent may penetrate for reasons of safety and/or function. Electric motors and switch cabinets are particularly endangered.

Make sure to remove all covers/seals after cleaning!

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3.15 Noise from the cellular wheel sluice A higher sound pressure level may arise depending on the local conditions and this can cause

impaired hearing. In this case the operating personnel must be protected with corresponding protective equipment or measures.

3.16 Changing the location of the cellular wheel sluice Use only lifting gear and load-suspension devices with a suitable load-carrying capacity during

loading and unloading. Appoint an experienced supervisor for the lifting procedure. Only raise the cellular wheel sluice properly according to the operating instructions (points of

attachment for load-suspension devices, etc.)! Do not stay or work under suspended loads. Use only a suitable transport vehicle with adequate load-carrying capacity. Secure the load safely. Use suitable points of attachment! Secure the cellular wheel sluice/system against accidental changes in position before or

immediately after completion of the loading work! Attach corresponding warning signs! Remove the transportation locking devices correctly before re-starting the cellular wheel sluice!

Parts which have had to be removed for transportation purposes must be carefully refitted and fastened before restarting.

Disconnect the cellular wheel sluice or system from all external energy supplies, even if only moving a short distance! Reconnect to the mains correctly before restarting the cellular wheel sluice!

Proceed in accordance with the operating instructions during restarting.

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Operating manual 4 Transport and storage

4 Transport and storage

4.1 Sensitivity The level of dismantling for the cellular wheel sluice depends on the transport conditions, the local circumstances and the lifting gear available. The cellular wheel sluice is delivered completely assembled, unless otherwise agreed. Take care when transporting the cellular wheel sluice so as to avoid damage through the effects of force or loading and unloading. The existing protective coating may not be destroyed. The SMD cellular wheel sluice must be transported by transport experts! Pay attention to chapter Safety as well as the local and general accident prevention regulations.

! Danger

The SMD cellular wheel sluice has to be slung carefully and professionally according to its type of construction! Transport the cellular-wheel sluice only by the provided transport eyes. The cellular wheel sluice mustnt never sling or lift at its drive or drive section!

! Caution

All suspension aids and lifting gear are to be fastened professionally and mustnt slip or become loose during transportation. Caution! Lifting equipment like chains, ropes, shackle, lifting crossbeam etc. are not part of SMDs scope of delivery.

4.2 Extent of delivery The extent of delivery must immediately be checked on receipt for completeness. Any damage incurred during transportation and/or missing parts must be reported immediately in writing to SMD FRDERTECHNIK GmbH.

4.3 Intermediate storage If the cellular wheel sluice are not assembled immediately they must be protected/stored carefully and correctly against all atmospheric influences. Protect all blank parts against corrosion with an oil film for example The cellular wheel sluice must be secure against accidental position changes.

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Operating manual 5 Installation

5 Installation

5.1 General informations When delivered to the construction site the parts of the cellular wheel sluice are to be lifted from the transport vehicle according to the transport instructions in chapter 4. Preconditions that have to be met by the customer for a successful installation are exactly aligned foundations, substructures and connecting flanges with respect to their angularity, flatness and dimensional accuracy. If these preconditions are not fulfilled great difficulties can arise during installation. In order to install and align the cellular wheel sluice it may be necessary to provide provisional bases (not included in the SMD extent of delivery).

! Danger

The complete installation of the cellular wheel sluice must be carried out by qualified installation experts! Supports or suspension are to be affixed safely and professionally. No persons may walk under the supported or suspensioned parts! Pay attention to the local safety regulations and chapter Safety of this operating instructions!

! Caution

Wear personal protective gear! Ensure adequate lighting during installation! All installations must always be carried out in such a way that no persons are put in danger! Check all delivered parts for any damage incurred during transport before any installation work.

5.2 Installation informations Mounting informations:

! Caution

Empty all containers and pipelines before starting the assembly. Danger of injury! Switch off the plant and secure against unintentional restarting. Inform the

control room and/or superior! Assemble the cellular wheel sluice in this way that no high forces are load the housing. Support cantilevered drive units. Choose the mounting position so that the bulk material enters the cellular wheel sluice vertically. Clean the flange surfaces, put on sealing (cellular rubber, silicone, neoprene etc.). Align the flanges plane-parallel and firmly tighten the connection screws crosswise. Checking: whether a set-up plan is available for the cellular wheel sluice, the condition of the ground and adjacent components, the dimensional accuracy of the connections, the free space required for assembly, maintenance, repair, the environment conditions (dust, climate etc.), the alignment of the cellular wheel sluice, the predefined distances to other parts of the plant, the possibilities of electrical installation, the accessibility of the inspection openings.

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Operating manual 5 Installation After completition of works the boltings should be checked and retightened if necessary. On completition of all installation work the "Checks the end of installation" must be carried out. The cellular wheel sluice may not be commissioned before these have been completed!

5.3 Installation of drive unit The drive unit of the SMD cellular wheel sluice consists of different variants depending on purchase order and ordering requirements. The following kinds are applicable: with free shaft end (drive provided by customer in arrangement with SMD FRDERTECHNIK

GmbH), with foot-mounted motor (-gear motor) and chain drive, with flange-mounted gear motor and coupling with latern, with flange-mounted gear motor and coupling without latern, For the assembly or dismantling descriptions of the individual drive components, please refer to the instructions given by the manufacturer, see chapter Documentation of suppliers. Check the oil level with gear motors and fill in or refill oil if necessary; pay attention to the

instructions of the gear manufacturer. Check the gear venting, remove or replace the plug, bolt the bleeder screw.

5.4 Installation of speed monitoring When the speed monitor is triggered the drive unit has to switch off basicly. The connecting cables of the proximity switch must sag by an appropriate amount. The pulses are evaluated with an evaluation unit (unless otherwise specified in the contract, the evaluation unit is not included in the SMD scope of supply). Proceed during installation: Set the switching gap X according to manufacturer information. Proceed the trial run according chapter Commissioning and possibly adjust the gap.

1 = Proximity switch ( Brand and type is specified in the specification sheet and Documentation of suppliers ) 2 = Housing 3 = Pulse disk X = Switching gap according to manufacturer information, see chapter Documentation of

suppliers.

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5.5 Elektrical installation Danger to life! The electrical connection of control lines and the lines to the power unit may only be carried out by qualified personnel according to the available wiring diagrams. Pay attention to its scheduled direction of rotation by the connection of the three-phase motor! Pay

attention to the rotation arrow on the housing! The proximity switch for speed monitoring is connected to the evaluation unit and adjusted

according to the manufacturer's instructions(if not even integrated in initiator). The evaluation unit should be mounted at a suitable place, protected against dirt and damage.

The effective power monitor for drive monitoring is adjusted according to manufacturer's instructions and should be mounted at a suitable place, protected against dirt and damage. (unless otherwise specified in the contract, the evaluation unit is not included in the SMD scope of supply!

If the drive unit is not integrated into an overall control system, install a motor protecting switch. Does the existing supply voltage comply with the value stipulated by the motor manufacturer

( data plate of motor )? Check the direction of rotation after connection(correct terminal-phase connections). Pay attention

to the rotation arrow on the housing! On completition of all installation work the "Checks the end of installation" must be carried out. The cellular wheel sluice may not be commissioned before these have been completed!

5.6 Protection against contact by hot material conveying Due to safety technical reasons a protection against contact and touching is to supply and install at site by others (no SMD supply!). This protection is necessary when the cellular wheel sluice surfaces are heated up due to hot material conveying.

5.7 Tightening torques for boltings

Tightening torques for electrically galvanised hexagon bolts in Nm (coefficient of friction = 0,125)

Normal thread Strenght class (metrical) 5.6 8.8 10.9 12.9

M6 4,3 9,9 14 16,5 M8 10,5 24 34 40

M10 21 48 67 81 M12 36 83 117 140 M16 88 200 285 340 M20 171 390 550 660 M24 295 675 960 1140 M30 590 1350 1900 2280

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5.8 Checks at the end of installation

! Warning

On completion of the electrical and mechanical installation the following checks should be carried out before commissioning: a) Foreign bodies :

Make sure that there are no foreign bodies (bolts, pieces of iron, etc.) in the cellular wheel sluice or valve line which could block the cellular wheel sluice.

b) Fastening screws:

All fastening screws must sit tight on completion of the installation work. All screws should be checked carefully after approx. 4 weeks of operation and tightened if necessary. The screws which fasten the gear are to be tightened with a torque wrench.

c) Speed monitoring:

The proximity switch for speed monitoring must be mounted, electrical connected and adjusted according to the manufacturer's instructions.

d) Effective power monitoring:

In case of existing, the effective power monitor for drive monitoring must be mounted, electrical connected and adjusted according to manufacturer's instructions.

e) Electrical connections/Motors:

Check that all connections are complete. Similarly check the direction of rotation of the motors. If the direction of rotation does not correspond to that specified on the data plate you should exchange the phases.

f) Safety devices:

All doors and inspection openings must be closed and tight fitting. The covers are safety devices and should also be installed.

g) Bearings:

All bearings must be lubricated with the lubricants specified in the chapter Lubrication. If lubricant dispenser are provided for lubrication these still must be activated at the commissioning according to the manufacturer's instructions and the hoses (if existing) must be filled up with lubricant, see chapter Lubrication and Documentation of suppliers.

h) Gear unit:

Check the oil level with gear motors and fill in or refill oil if necessary; pay attention to the instructions of the gear manufacturer. Check the gear venting, remove or replace the plug, bolt the bleeder screw.

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Operating manual 6 Commissioning

6 Commissioning

6.1 Notes In principle, we declare that the commissioning is forbid as long as until the cellular wheel sluice or plant, in which this cellular wheel sluice is installed or of which this cellular wheel sluice represents a component, corresponds as a whole to the regulations of guideline 89/392/EWG as well as to the corresponding, national right decree for the translation of the guideline into national right and the corresponding declaration of conformity is exhibited. In principle, the first initial commissioning of the cellular wheel sluice delivered by SMD FRDERTECHNIK GmbH may be procedured only by the company SMD FRDERTECHNIK GmbH, if this is not regulated differently by contract. All rights to claim under guarantee are dropped by nonobservance. SMD FRDERTECHNIK GmbH shall not be held liable for any damages arising from improper commissioning by other personal! For preparing of commissioning it is important that all checks have been carried out according to chapter Checks at the end of installationat the end of the installation work. Read chapter Safety before commissioning! Ensure adequate illumination during commissioning so that any disturbances or faults that may occur can be safely detected. Before commissioning the cellular wheel sluice and its electrical equipment must be checked by a qualified electrician in accordance with the regulations for installing electrical power installations with rated voltages of up to 1000 V (DIN VDE 0100, VBG 4). Commissioning is procedured in the following sequence: 1. Visual check 2. Trial run without material 3. Trial run with material

6.2 Visual check The visual check comprises those items listed under "Checks at the end of installation" in chapter Installation as well as a check for obvious defects. Check: the functioning of the electrical equipment. the safety. Only commission the cellular wheel sluice if all safety devices and safety-related monitoring devices are present and operational. it has been made sure that no foreign objects can get into the cellular wheel sluice during

commissioning without product. Therefore, previously verify at the cellular wheel sluice that this has been set up and connected as described, all electrical installations have been implemented, all foreign objects at, in and above the cellular wheel sluice (particularly in the filter element) have

been removed, all safety and monitoring devices are present and operational, nobody is in the dangerous area of the cellular wheel sluice, all inspection openings are secured or closed, all bearings and gears are provided with the required amount of oil and/or grease,

Page 18

Operating manual 6 Commissioning If lubricant dispenser are provided for lubrication these still must be activated at the commissioning according to the manufacturer's instructions and the hoses (if existing) must be filled up with lubricant, see chapter Lubrication and Documentation of suppliers. Remove all transport devices which might have been used on or in the cellular wheel sluice !

6.3 Trial run without material First proceed a non-load running, that means the cellular wheel sluice operates without any material and check the following: Check the following functions of cellular wheel sluice: Make sure that the direction of rotation of the motor and/or cellular wheel is correct!

Start the cellular wheel sluice without product first. The cellular wheel sluice can be damaged if it is started in the wrong direction.

If the cellular wheel sluice is installed as a component of complete plant check the operability of the electrical interlock.

Display of the speed monitoring and other monitoring devices if existing. Running noise. Ensure that all bearings run easily and smoothly, loud noises, sluggishness and excessive heating

are indications of an installation error or fault. Check the gap between side wall and cellular wheel. Check the gap at the sealing strips. If lubricant dispenser are provided for lubrication these still must be activated at the

commissioning according to the manufacturer's instructions.

6.4 Trial run with material After the checks at the end of installation have been repeated according to chapter Checks at the end of installation, if necessary, a trail run with material can then be carried out. Only commission the plant with the product when no faults occurred during the functional test

without product! For malfunctioning refer to the chapter Trouble shooting! Start the cellular wheel sluice without product first. Gradually load the cellular wheel sluice then

up to its maximum conveying capacity with the respective product. If existing, the presetting of effective power monitor and the overload point of the cellular wheel

sluice must be checked now. The setting of effective power monitor must be corrected to the real existing process value of the under load operating cellular wheel sluice. The overload detection of monitor must be setted and adjusted to the overload point of cellular wheel sluice to realize the overload monitoring. Note: Unless otherwise specified in the contract, the evaluation unit is not included in the SMD scope of supply!

Check after approximately eight operating hours under full load: the machine components for heating up, the glands for leakage (leaked product), all screw connections for a firm seat. For malfunctioning refer to the chapter Trouble shooting. The trial run is finished on completion of all of these checks.

Page 19

Operating manual 7 Operation

7 Operation

7.1 Normal operation Normal operation is usually carried out automatically from the control desk. Ensure adequate illumination of the overall system during operation so as to ensure a safe handling of any faults that may arise. Pay attention to the instructions in chapter Maintenance! Only start the cellular wheel sluice if: all safety devices and safety-related monitoring devices are present and operational. nobody is in the dangerous area of the cellular wheel sluice, all inspection openings are secured or closed. Operating informations: The cellular wheel sluice may only be operated by the personnel having been instructed in this

respect. Check the cellular wheel sluice for externally visible damages and defects at least once per shift! Immediately inform the responsible person about any changes (also in the operating performance)

that have arisen! In case of malfunctioning, immediately switch off and secure the cellular wheel sluice in this state. Have any malfunctioning remedied at once! When switching on and off, pay attention to the control displays if available! Before switching on, make sure that nobody can be endangered by the starting cellular wheel

sluice! In normal operation the cellular wheel sluice is operated with other machines or parts of the plant

from a control room. The correct running of the cellular-wheel sluice can be monitored via the speed monitor. The current consumption also indicates any changes of the operating state. When starting the cellular wheel sluice, make sure that: the direction of rotation of the cellular wheel is correct, the plant on the discharge side starts first and then the product feed starts only afterwards. When switching off the cellular wheel sluice, make sure that: the product feed stops first, the cellular-wheel sluice runs empty and then the plant on the discharge side is switched off last.

7.2 What to do in the event of faults

! Warning

The local safety regulations apply in every case when operating the cellular wheel sluice irrespective of the information and instructions below. Make sure that the cellular wheel sluice is at a standstill as long as the trouble is remedied at the

cellular wheel sluice by the relevant personnel. Interlock electrically the cellular wheel sluice and ensure against unintentionally switching on, see chapter 7.2.1 Emergency stop.

Have the trouble only remedied by personnel qualified and instructed in trouble-shooting. Pay attention to any danger might arise from the trouble. Immediately stop the cellular wheel sluice if: abnormal operating noises can be heard, the cellular wheel sluice is overloaded. 7.2.1 Emergency stop

! Warning

We urgently recommend a lockable local switch which prevents an accidental starting of the cellular wheel sluice during repairs or faults. As for the rest, please refer to the pertinent accident prevention regulations of the respective employer's liability insurance associations.

Page 20

Operating manual 7 Operation 7.2.2 Re-starting after a malfunction Pay attention to the chapter Checks at the end of installation and chapter Commissioning! 7.2.3 Troubleshooting

Fault Cause Remedy Remedy by

Amount of discharged material is too little or no discharged material

ZRS stops

Amount of feeded material is too much, overfilling / blockage of ZRS

No discharge of material Blockage due to foreign

bodies. No material feeding No electrical voltage Jammed bearing Drive unit, motor or gear is

defective

Shut off the material feeding, discharge the ZRS, switch on downstream aggregates, restart the discharged ZRS with local control, adapt the feeded amount of material according to the throughput

Guarantee a free discharge flow of material

Remove any foreign bodies Check material feeding Check and restore electrical

connections/cables Check bearing, replace if

necessary See chapter

Documentation of suppliers

MP MP MP MP ET MP MP, ET

Abnormal noise development of ZRS

Motor, gear unit,

bearing or gland are heated

Foreign body/blockage in ZRS

Gap of sealing strips is too small

Incorrectly installed bearing, lubricant failure bearing defective

Drive unit, motor, gear, or coupling defective

Worn gland packing

See above remedy Aligne sealing strips ,

repalce if necessary Maintain the bearing See chapter

Documentation of supplier

Renew gland packing

MP MP MP MP, ET MP

No pulses from speed monitoring

Proximity switch is defective or adjusted incorrectly

ZRS stops Pulse disc defective ZRS is damaged Blockage due to foreign

bodies

Check gap, correct the switching gab

See above Renew pulse disc Check the scope of damage

and repair Remove any foreign bodies

ET MP MP MP MP

Material leakage, dust development

Leaky glands Flange sealing is defective Covers or inspection openings

are not tight or not closed

Tighten glands or renew packing

Renew sealing Close covers or inspection

opening, renew the sealing

MP MP MP

ZRS = Cellular wheel sluice ET = electricity specialist, MP = maintenance personnel

Page 21

Operating manual 7 Operation

7.3 Before a longer standstill period If the cellular wheel sluice is not used for a period of around 2 months pay attention to the following points: Sensitive parts such as electric motors, gears, bearings, etc. must be protected against moisture,

heat, dust and impacts, possibly preserve. Treat external parts according to the Documentation of suppliers. Secure cellular wheel sluice against accidental starting.

7.4 After a longer standstill period Remove protective coating against moisture, heat, dust and impacts of sensitive parts / Remove

preservative. Replace any safety parts that may have been removed. Carry out trial run without material.

Page 22

Operating manual 8 Maintenance

8 Maintenance 8.1 Notes for routine maintenance and inspection

! Warning

! Warning

! Warning

Pay attention to the operating instructions chapter Safety during maintenance and inspection work !

The set-up work and maintenance work (repairs and service work including cleaning) must be carried out when the cellular wheel sluice is at a standstill. A lockable local switch should prevent accidental restarting of the cellular wheel sluice. Procedure: 1. interrupting the energy supply 2. locking the main control devices 3. removing the key required for this 4. attaching a warning sign at the main switch. Malfunctions due to inadequate or incorrect maintenance can lead to very high repair costs and long downtimes for the cellular wheel sluice. Regular maintenance is thus indispensable.

The operational safety and service life of the cellular wheel sluice also depend, amongst others, on correct maintenance.

Ensure adequate illumination during maintenance and inspection work ! Maintenance and inspection work may only be carried out by qualified personnel. Do not use machine parts for climbing up ! Use the stepladders and working platforms intended for this purpose or other safe aids. Thoroughly fasten and secure the individual parts and bigger structural components to the lifting

devices for replacement. Only use suitable and technically perfect lifting devices and load suspension devices with

sufficient carrying capacity ! In case of electric welding, never conduct the welding current over sliding and roller bearings or

other moving connections or measuring devices in order to avoid damage to these parts! Always directly connect the return cable to the part to be welded ! Retighten all screw connections having been loosened for maintenance and repair work! After having finished maintenance and repair work, immediately mount all safety devices! Carry out all adjusting, maintenance and inspection activities including the replacement of parts or partial equipment prescribed in the operating instructions and keep to the schedule.

8.2 Routine maintenance 8.2.1 Care Avoid any dirt accumulation at the cellular wheel sluice! Clean the cellular wheel sluice and particularly all connections and screw connections from oil,

fuel or maintenance agents at the beginning of repair and maintenance work! Do not use any aggressive cleaning agents. Use lint-free cleaning rags! Before cleaning the cellular wheel sluice with water or steam jet (high-pressure cleaning) or other

cleaning agents, cover all openings in which no water/steam/cleaning agent may penetrate for safety and/or functional reasons!

Electro-motors, speed monitors and other monitoring and/or safety devices are particularly at risk! Remove the coverings completely after cleaning! Check all machine parts for damages after cleaning! Remedy all noticed defects at once!

Page 23

Operating manual 8 Maintenance 8.2.2 Routine maintenance and inspeciton list The maintenance contents the following items of the maintenance and inspection list:

Jobs to be executed ( if the component is existing ) daily every 3 months

yearly

Visual inspection of the cellular wheel sluice and current connection X Check the sealing strips and lateral disks for wear (for hazardous location use the check might be necessary daily) (X) X

Check the cellular wheel sluice for smoothness of running, replace bearings in case of trouble X

Check the chain tension and adjust if necessary X Check the star coupler (elastic intermediate pieces) for wear and replace if necessary X

Check the screw connections at the cellular-wheel sluice for firm seat and retighten if necessary X

Check the gland packing for tightness, retighten or replace rubber sealing if necessary X

Repalce the gland packing X Check the rubber sealing for tightness, retighten or replace rubber sealing if necessary X

Replace the rubber sealing X Disassemble and clean the cellular wheel sluice X Check the boundary disk for wear X Check the housing and/or wear bush for wear X

8.3 Repairs

! Warning

The repair of the cellular wheel sluice presupposes specialized knowledge and experience and only may be executed by repair specialist staff! Depending on the complexity of the cellular wheel sluice the specialist staff of SMD FRDERTECHNIK GmbH should be engaged for repairs. The SMD FRDERTECHNIK GmbH does not assume any liability for damages because of an improper repair by other staff! Pay attention to the safety instructions in these operating instructions! Use only original SMD spare parts for repairs. If screws or bolts become unusable after dismantling they must be replaced in the same quality (strength, material) and design. The cellular wheel sluice must be secured against accidental starting before any maintenance and repair work is started! Work on the electrical installation (connecting/disconnecting) or the electro-motor may only be carried out by a qualified electrician. Before starting to work on the cellular wheel sluice, inform the person responsible for safety! Danger to life! Connecting and disconnecting only by electrician! Danger of injury! Secure the SMD cellular wheel sluice against unintentional operation! Only dismount the inspection cover when the product feed shaft is empty! Never reach into the open SMD cellular wheel sluice, Danger of mutilation! In case any hot or harmful substances are conveyed, provide for suitable protection such as

protective clothing, safety glasses, gloves, breathing equipment. Provide for a collection container.

! Caution

Before working on the cellular wheel sluice, make sure that the above product container is emergency blocked!

Empty and switch off the plant before starting extensive work on the SMD cellular wheel sluice! Prevent the product from running by closing any stop valves or other suitable means!

Page 24

Operating manual 8 Maintenance 8.3.1 Drive unit For the assembly or dismantling descriptions of the drive elements like couplings, please refer to the instructions given by the manufacturer, see chapter Documentation of suppliers. 8.3.2 Chain drive If the cellular wheel sluice is driven by chain drive, then the following instrcuctions have to be taken into account for change the chain: Always disconnect the motor before replacing the chain. In order to replace the chain, remove the protection box, loosen the adjusting screws at the

pivoting motor base, release the chain. Open the chain joint and remove the chain. Put on a new chain with the same chain pitch and dimensions, and lock the chain with a new chain

joint. Tensioning the chain by adjusting the tensioning screws of the pivoting motor base. Caution! Damage to material! Do not over-tension the chain. This will increase wear of the chain

and the chain wheels. The bearings at the cellular wheel sluice and the gear will be unnecessarily strained. Check the alignment of the chain wheels with a ruler, fix the tensioning screws with a lock nut.

8.3.3 Gland packing If the cellular wheel sluice is equipped with gland packings, then the following instrcuctions have to be taken into account: Loosen the clamping frame and push it backwards. Remove the gland packing. Clean the seat of packing from the packing remains. Insert a new set of sealing rings, generously stagger the joints of the rings. Clean the clamping frame and put it on the packing, evenly tighten the screws. Retighten if necessary after commissioning. 8.3.4 Replacing rubber sealing If the cellular wheel sluice is equipped with rubber sealings, then the following instrcuctions have to be taken into account:

Outer side: Inner sideDismount drive unit and speed monitoring. Dismount drive unit and speed monitoring. Remove adjusting ring of the rubber sealing. Dismount the bearings incl. their housing

from the side wall. Replace rubber sealing. Replace rubber sealing Mount in a reverse way. Mount in a reverse way

8.3.5 Adjustment of the gap Loose the screws and adjust the sealing strip. The gap or clearance between the housing / wear bush and the sealing strips should be 1 - 2mm. 8.3.6 Disposal Carry out the disposal and disassembly of the cellular wheel sluice according to the relevant statutory regulations in force. Discharge the cellular wheel sluice completely, remove dirt accumulations and disassemble the cellular wheel sluice into its structural components. If possible, dispose of all machine parts separately based on their material, for example metal parts as steel scrap non-ferrous metal at the metal recycling plant plastics and compounds at the plastics recycling plant Collect waste oils, greases and other harmful substances in suitable containers and have them disposed of professionally according to the statutory regulations.

Page 25

Operating manual 8 Maintenance 8.4 Lubrication Correct lubrication at all times is a basic precondition for a trouble-free operation and long service life of the cellular wheel sluice. The following instructions describe all points of lubrication, lubricating intervals, lubricants and the type of lubrication. 8.4.1 Correct lubrication The rolling bearings must have an adequate supply of grease. They are filled with grease by SMD FRDERTECHNIK GmbH according to the specified amount for initial filling which is declared by bearing manufacturer. At the same time the grease filling serves as corrosion protection for the bearings. 8.4.2 Grease lubricant The used and approved grease lubricants can be gathered from the enclosed list of lubricating points. The list of lubricating points indicates the essential grease characteristic values. 8.4.3 Mixing lubricating greases Lubricating greases with different soap bases, in particular lithium and soda soap greases, may not be mixed together. Drop point, milling stability and working temperature of such mixtures normally drop considerably. Thus, if a different type of grease has to be used at one point the bearing should be cleaned beforehand to avoid damage to the bearing. 8.4.4 Lubrication of the drive unit All motors and gears are provided with the appropriate amount of lubricant as standard. The used and approved oil lubricants can be gathered from the enclosed list of lubricating points. We refer to the special details and instruction from manufacturer for the roller bearings inside the gears like shaft bearing and electrical motors, see the chapter Documentation of suppliers. 8.4.5 Lubricant dispensers If lubricant dispenser are provided for lubrication these still must be activated at the commissioning according to the manufacturer's instructions. The dispensing time is described in lubrication list and the dispensing quantity per day must be adjusted at the lubricant dispensers according to the manufacturer`s instructions, see chapter Documentation of suppliers. Before connecting the lubricant dispensers with the hose, the hoses have to filled up with lubricant if this have not done in workshop and the hoses are existing. The lubricant filled up in hose must be identical with the lubricant of dispensers, see chapter 8.4.3. 8.4.6 Rolling bearing All greased bearings are filled with grease by SMD FRDERTECHNIK GmbH according to the specified amount for initial filling which is declared by bearing manufacturer. The bearings should be cleaned and refilled every year. Rolling bearings should be washed out with petroleum spirit, benzene or trichlorethylene, dried and filled with suitable grease. Pay attention to the following points: a) Treatment instructions for rolling bearings The correct choice of bearings, careful storage, professional installation and correct maintenance are a precondition for the trouble-free running of rolling bearings. b) Installation Pay attention to chapter 8.3 when installing roller bearings. Before installation the bearings should be stored in a dry room to prevent damage from rust. The relative atmospheric humidity in the storeroom with small temperature fluctuations may not exceed 55%. Only remove from the original packaging shortly before installation. Protect against dust, sand, file dust and moisture. Do not lay on workbenches or the floor when open. Wash out dirty bearings in pure petroleum and then re-grease. Do not blow through with compressed air. The bearings doe not have to be washed out before installation sine only small amounts of the anticorrosive stick to the bearing. Clean all mounting parts thoroughly. Check the seats on the shaft and in the housing for dimensional accuracy. Provide suitable tools. When installing a bearing with a tapered bore make sure that the radial gap is not excessively reduced. Nuts and bolts which secure bearing rings must always be secured.

Page 26

Operating manual 8 Maintenance c) Commissioning Lubricate the bearings with the specified amount declared by bearing manufacturer during installation if possible, though at the latest before the trial run. During commissioning make sure that the bearing runs smoothly and quietly. Loud noises, sluggishness and excessive heating are indications of an installation error or fault (inadequate lubrication, internal tension, dirt, foreign body, etc.). Impurities cause uneven running. In such cases remove the bearing immediately; wash out dirty bearings, fill with new lubricant or remedy the installation error. Damaged bearings should be returned to the manufacturer with a description of the problem. They may not be washed out beforehand. d) Relubricating From time to time the lubricant has to be checked for his quality and has to be replaced if necessary. Bearings must be relubricated if service life of the used grease is lower than the expected emperic service life. The relubricating should always be procedured as long as a reliable lubrication is still ensured by the available grease. For normally stressed bearings which do not run with very high rotational speeds, are not exposed to strong external heating or pollution the service life of the used grease will be increased. Please contact the rolling bearing manufacturer should you require lubricants for the rolling bearings, and quote the bearing size, temperature, speed and other operating conditions. e) Removal The practical sequence for removal should be determined beforehand on the basis of drawings. Do not hit bearings. 8.4.7 Disposal The lubricants originating from the gear and the bearings or stuffing box packing are special refuse. At any rate, they have to be disposed of according to the local statutory regulations in force! 8.4.8 Lubrication instructions A. General The purpose of these lubrication instructions is to provide documents which offer detailed and specific information on the lubrication of every slide valve. B. Extent The slide valves which require any type of lubrication are shown here. All points of lubrication including subordinate ones are listed. C. Lubrication chart All lubricating points or their exact position details are shown on the enclosed lubrication chart. The lubricating points are marked with a reference line and positioned with a serial number from 1 to n. Identical points of lubrication may be summarised under one number. D. List of lubricating points The approved lubricants and the type of lubrication are specified in the list of lubricating points. Others as the listed lubricants may not be used.

Page 27

Operating manual 8 Maintenance

Page 28

8.4.9 Lubrication chart The approved lubricants and the type of lubrication are specified in the list of lubricating points. Others as the listed lubricants may not be used. Example of a cellular wheel sluice

1 = Gear of drive 2 = Flange bearing 8.4.10 List of lubricating points

Lubricating point

Lubrication interval Lubricant

Item 1 Gear of drive

The special instruction of the gear motor manufacturer are to be considered! See Documentation of suppliers! Oil level check after the first day, afterwards monthly. Oil change after 10.000h operation and/or 2 years

Gear oil: see specification sheet Amount of oil: see specification sheet Recommendated product: see specification sheet

Item 2 Flange bearing

A relubrication of the bearing is usually unnecessary, if the loads and rotation speed are

moderately no vibration are existed the operation temperature is not

exceeded In the case, that the bearings are exposed to extremely moisture

or stronger contamination have to take up high loads run longer with high numbers of

revolutions and/or run over the operation temperature

the bearings are to be relubricated to use the full bearing life and to prevent damages

Bearing grease according to DIN 51825 - KP2K-20 with the NLGI-classification 2 acc. to DIN 51818 Amount of lubricant for flange bearing: To relubricate the flange bearings the grease has to be slowly pressed in by rotating bearing, until fresh grease is emerged out of the seal. Excessive pressure is to be avoided, because otherwise the seal can be damaged! Recommended product: ESSO Beacon EP2

Operating manual 9 Spare parts stocking / Customer service

9 Spare parts stocking / Customer service

9.1 Spare parts stocking A stock of most important spare and wearing parts at the place of installation is an important precondition for the constant function and readiness for operation of the cellular wheel sluice. Please refer to the spare parts list when ordering spare parts. The spare parts drawings listed in the spare parts list serve for your further information. We can only assume a warranty for original spare parts supplied by us! Attention ! We would like to expressly emphasize that original spare parts and accessories which are not supplied by us have not been check and approved by us either. The installation and/or use of such products may thus under certain circumstances have a negative effect on the structural features of the SMD cellular wheel sluice and thus impair the active/passive safety. Any liability and warranty on the part of SMD FRDERTECHNIK GmbH for damages caused by the use of non-original spare parts and accessories is excluded. Please note that special manufacturing and delivery specifications often exist for own and external parts and that we always offer you spare parts according to the state-of-the-art and in line with the latest statutory regulations.

9.2 Spare parts sales / Customer service address Our address for spare parts sales / customer service: SMD FRDERTECHNIK GmbH Abteilung Ersatzteilvertrieb / Kundendienst Robert-Bosch-Str. 7 D-42477 Radevormwald, Germany E-Mail: [email protected] Internet: www.smd-foerdertechnik.de Tel. 0049 (0)2195-931910 Fax. 0049 (0)2195-931909

9.3 List of spare parts / spare part drawing

Page 29

Operating manual 9 Spare parts stocking / Customer service

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Page 30

Gebr. Pfeiffer AG Maschine / Machine:

Hasanoglan Ersatzteil- Zeichnungs-Nr.: / Drawing No.: 65-00-00-00-0017-ET

KM07/3344-0101

KKS-Nr.KKS-No.TAG-No.

Teile-Nr./Pos.-Nr.part-no./item

Zchn.Nr./Ident-Nr.drawing-no/identif.-no.

Verschleiteilwear part

"W"

Ersatzteilspare part

"S"

Lieferzeit(in Wochen)delivery time (in weeks)

Stckzahleingebautnumber of items installed

Stckzahl angebotennumber of items offered

Einzelpreis(EUR)

piece price

Gesamtpreis(EUR)

total price

Bemerkungremarks

1 65-05-00-00-0001 W 1Innenbuchse / Inner bush** 1 65-50-00-10-0001 W 1Stopfbuchsenpackung / packing for gland 8x8 ; 0,95 m 2 65-40-00-00-0001/3 W 2Flanschlager / flange bearing UCFC 216 3 65-15-00-00-0001/9 W 1Drehzahlwchter / speed monitor IFM DI0001 4 65-25-00-00-0001/4 S 1Getriebemotor / gear motor RF97 DVE100L4 5 65-05-00-00-0001/6 S 1Brechleiste Rotor / crushing rail of rotor 6 65-10-00-10-0003 W 8Kupplung / Coupling HFB EK 250A 7 65-05-00-00-0001/7 S 1elastisches Packet fr Kupplung / Flexible Coupling Elements 8 S 1Zellenradrotor / Cellular Rotor 9 65-10-00-00-0004 S 1

**nurinVerbindungmitPos.1/onlyinconjunctionwithitem1

17.08.2007 0 AlbertsAussteller / Editor:Datum / Date: Revision / Revision:

Gehuse / housing

Bezeichnung, Einsatzort bzw. Verwendung, Fabrikat, Typdescription, location, implementation, product, typ

Ersatz- und VerschleiteillisteLIST OF SPARE AND WEAR PARTS

Kunde / Client:

SMD Nr. / SMD No.:

Projekt / Project:

Zellenradschleusen 630x630x800 mit Buchse/cellular wheel sluice 630x630x800 with inner bush

Seite / Page 1 von / of 1 65-00-00-00-0017-ET_Zellenradschleuse 630 x 630 x 800 geschr mit Buchse und Wellenschutzrohr.xls

Operating manual

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Operating manual 10 Layout drawing

10 Layout drawing

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Operating manual 10 Layout drawing

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Operating manual

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Operating manual 11 Documentation of suppliers

11 Documentation of suppliers

11.1 Speed monitor

Page 33


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Page 34

Evaluation systems, power supplies

DI0001Compact speed monitor M30DIA2010-ZROA/5-300 I/MIN

Cable

Sensing range 10mm [f]flush mountable

Application simple evaluation of rotating and linear movement with regard tounderspeed; blocking

Electrical design AC/DCOutput normally openSetting range [pulses/min.] 5...300

Nominal voltage [V] 20...250 AC/DCCurrent rating (continuous) [mA] 350 AC (...50 C) / 250 AC (...80 C) / 100 DCCurrent rating (peak) [mA] 2200Minimum load current [mA] > 6Voltage drop [V] < 6.5Leakage current [mA] < 1.5Damping frequency (max.)[pulses/min] 1500Correction factors mild steel = 1 / stainless steel approx. 0.7 / brass approx. 0.5 / Al approx. 0.4 /

Cu approx. 0.3Reverse polarity/overloadprotection Hysteresis [% / Sr] 10Short-circuit protection

Start-up delay [s] 12Switching function output is switched during the start-up delay and if (f actual) is greater than (fpreset)Adjustment of the switch point multiturn potentiometerOperating temperature [C]

-25...80Protection IP 67Housing material brass special coated; PBT (Pocan)Function displaySwitching status LED greenConnection PVC cable / 2 m; 2 x 0.5 mmWiring

Core coloursBN brownBU blue

ifm electronic gmbh Teichstrae 4 45127 Essen We reserve the right to make technical alterations without prior notice. GB DI0001 23.01.2006

Operating manual

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Grne LED:

MontageanleitungInstallation Instructions

Notice de Montage

Compact Speed Monitor

DIA

Contrleur de vitessede rotation compact

Bestimmungsgeme VerwendungDer Drehzahlwchter Compact erfat berhrungslos, ob eine Mindest-Drehzahl eingehalten wird, und meldet die Unterschreitung durch einSchaltsignal.Nennschaltabstand (Sn) 10mm; Solldrehzahl einstellbar, siehe Typ-aufkleber.

MontageBefestigen Sie das Gert mit Hilfeeiner Montagehalterung. SichernSie es mit den mitgelieferten Mut-tern gegen Loslsen.Bndig einbaubar.

Fr optimale Funktion sollten folgende Mae eingehalten werden:

Elektrischer AnschluSchalten Sie die Anlage spannungsfrei. Schlieen Sie das Gertnach den Angaben auf dem Typenschild an.

Justierung

Halten Sie die zu berwachende Drehzahl in der Anlage konstant. Diegelbe LED mu blinken (Bedmpfungsimpulse werden erfat). Nach derAnlaufberbrckungszeit* (A siehe Typaufkleber) kann mit demAbgleich nach A oder B begonnen werden:

A BGrne LED leuchtet Grne LED leuchtet nicht

Poti nach rechts drehen, bis die LEDverlischt.

Poti langsam nach links drehen, bisdie LED aufleuchtet.

Poti langsam wieder nach linksdrehen, bis die LED aufleuchtet.

Auslieferungszustand: Poti in Rechtsanschlag.

R

B

E

C

AD

ABC

D

E

mindestens Durchmesserdes Drehzahlwchters

mindestens 2 x A

1/2 x Sn

LEDs

Ausgang durchgeschaltet(Istdrehzahl > Solldrehzahl)

Gelbe LED(optional bei 2-Leiter AC/DC):Sensor bedmpft

Mehrgang-potentiometer

Sollwert

Sach

nr.:

7010

92/0

2

03

/200

4

BetriebPrfen Sie, ob das Gert sicher funktioniert.Der Betrieb ist wartungsfrei. Fr einwandfreies Funktionieren ist zubeachten: Die aktive Flche und der Freiraum sollten von metallischen Ablage-

rungen und Fremdkrpern freigehalten werden; insbesondere beiMontage mit aktiver Flche nach oben.

Gerte mit hoher Nahfeldstrke (z. B. Sprechfunkgerte) nicht inunmittelbarer Nhe des Drehzahlwchters betreiben.

*) Die Anlaufberbrckung (A) unterdrckt eine Fehlermeldung, solange die Anlage anluftund die Nenndrehzahl noch nicht erreicht ist.Sie ist nach Anlegen der Betriebsspannung nur einmal wirksam. Wird der Antrieb hufigein- und ausgeschaltet, sollte die Spannungsversorgung von Antrieb und DIA gekoppeltwerden. Dadurch ist die Anlaufberbrckung bei jedem Anlaufen der Anlage wirksam.

DrehzahlwchterCompact

Function and featuresThe speed monitor compact detects without contact whether a mini-mum speed is reached and signals underspeed by means of a switchingsignal. Nominal sensing range (Sn) 10 mm. Preset speed adjustable, seetype label.

InstallationMounting by means of a mount-ing device. Secure by means of thenuts provided so that it cannotwork loose. Flush installation.

For optimum functioning the following dimensions should be adheredto:

Electrical connectionDisconnect power before connecting the speed monitor.Connect according to the indications on the type label.

Adjustment

Keep the speed to be monitored in the plant on a constant level. Theyellow LED must blink (damping pulses are detected). When thestart-up delay* (A see type label) has elapsed, the adjustmentaccording to A or B can be started:

A BGreen LEDis lit Green LED is not lit

Turn the pot clockwise until the LEDgoes off.

Turn the pot slowly anticlockwiseuntil the LED is lit.

Turn the pot slowly anticlockwiseuntil the LED is lit.

Unit delivered with pot in right stop position.

Emploi prescrit par les usagesLe contrleur de vitesse de rotation compact dtecte sans contact si unevitesse de rotation minimum est atteinte et signale la sous-vitesse parun signal de commutation. Portee nominale (Sn) 10mm. Valeur deconsigne rglable, voir ltiquette.

MontageMontage laide dune flasque defixation. Utiliser les crous fournisavec le DIA pour une fixationoptimale. Montage encastrpossible.

Afin de garantir un fonctionne-ment optimal, les dimensions suivantes devraient tre respectes:

Raccordement lectriqueMettre linstallation hors tension avant le raccordement du con-trleur de vitesse de rotation.Raccordement selon les indications de ltiquette.

Rglage

Lors du rglage maintenir stable la vitesse de rotation. La LED jaune doitclignoter (les impulsions transmises par les cames sont dtectes).Quand la temporisation de dmarrage est coule*(A voir ltiquette)le rglage selon A ou B peut tre commenc:

ALED verte est allume

Tourner le potentiomtre droitejusqu ce que la LED soit teinte.

Tourner le potentiomtre lentement gauche jusqu ce que la LED estallume.

Tourner le potentiomtre lentement gauche jusqu ce que la LED estallume.

Appareil livr rgl en bute droite.

B

E

C

AD

ABC

D

E

at least the diameter ofthe speed monitor

at least 2 x A

1/2 x Sn

LEDs

Green LED: output switched(actual speed > preset speed)

Yellow LED(optional for 2-wire AC / DC):sensor damped

B

E

C

AD

ABC

D

E

au moins le diamtre ducontrleur de vitesse derotation

au moins 2 x A

1/2 x Sn

LEDs

LED verte: sortie commute(vitesse de rotation actuelle >vitesse de rotationde consigne)

LED jaune(en option pour desappareils 2 fils AC / DC):came dtecte

OperationCheck the safe functioning of the speed monitor.The operation of the speed monitor is maintenance-free. For perfectfunctioning make sure that: the active face and the open space are kept free of metal deposits and

foreign bodies, particularly for installation with the active face facingupwards;

units with high field intensity (e.g. walkie-talkies) are not used at closerange to the speed monitor.

*) The start-up delay (A) suppresses an error signal as long as the machine is in the processof starting and has not yet reached its nominal speed.After application of the operating voltage the start-up delay is active only once. If the driveis often turned on and off, couple the supply voltage of the drive and the monitor. By doingso, the start-up delay is active every time the drive is turned on.

*) La temporisation de dmarrage (A) supprime les alas de fonctionnement quandlinstallation est en train de dmarrer et na pas encore atteint sa vitesse nominale.Aprs la mise sous tension la temporisation de dmarrage nest effective quune seule fois.Lorsque le moteur est souvent mis en marche et arrt, coupler la tension dalimentationdu moteur et du contleur. Ainsi la temporisation de dmarrage est effective chaque foisque le moteur est mis en marche.

FonctionnementVrifier le bon fonctionnement du contrleur de vitesse de rotation.Pour un bon fonctionnement il faut respecter les indications suivantes: La face active et lespace libre doivent tre dgags de toute prsence

de dpts et de corps trangers mtalliques, notamment en cas demontage avec la face active vers le haut.

Ne pas faire fonctionner des appareils champ de grande intensit(par exemple talkie-walkies) proximit immdiate du contrleur devitesse de rotation.

LED verte est teinteB

multiturnpotentiometerpreset value

potentiomtremultitour

valeur de consigne


11.2 Drive motor

Page 35


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Page 36

Gearmotors \ Industrial Gear Units \ Drive Electronics \ Drive Automation \ Services

Gear Units, R..7, F..7, K..7, S..7 Series, SPIROPLAN W

Operating Instructions

A6.B01

Edition 05/200411226811 / EN

SEW-EURODRIVE Driving the world

Contents

Operating Instructions Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN W 3

1 Important Notes................................................................................................. 42 Safety Notes ...................................................................................................... 63 Gear Unit Structure ........................................................................................... 9

3.1 Basic structure of helical gear units .......................................................... 93.2 Basicstructure of parallel shaft helical gear units.................................... 103.3 Basic structure of helical-bevel gear units .............................................. 113.4 Basic structure of helical-worm gear units .............................................. 123.5 Basic structure of SPIROPLAN gear units ............................................ 133.6 Nameplate, unit designation ................................................................... 14

4 Mechanical Installation................................................................................... 154.1 Required tools / aids ............................................................................... 154.2 Prerequisites for assembly...................................................................... 154.3 Installing the gear unit............................................................................. 164.4 Gear unit with solid shaft......................................................................... 194.5 Torque arms for mounted gear units....................................................... 214.6 Mounted gear unit with keyway or splined hollow shaft .......................... 234.7 Mounted gear units with shrink disc........................................................ 274.8 Mounted gear units with TorqLOC ........................................................ 304.9 AM adapter coupling ............................................................................... 364.10 AQ adapter coupling ............................................................................... 384.11 AD input shaft assembly ......................................................................... 40

5 Startup.............................................................................................................. 445.1 Startup of helical-worm and SPIROPLAN W gear units........................ 445.2 Startup of helical, parallel shaft helical and helical-bevel gear units....... 44

6 Inspection and Maintenance .......................................................................... 456.1 Inspection and maintenance intervals..................................................... 456.2 Lubricant change intervals ...................................................................... 456.3 Inspection and maintenance of the gear unit .......................................... 466.4 Inspection / maintenance of AM / AQA adapters .................................... 476.5 Inspection / maintenance of AD adapters ............................................... 47

7 Malfunctions .................................................................................................... 487.1 Gear unit malfunctions ............................................................................ 487.2 AM / AQA / AL adapter malfunctions ...................................................... 487.3 AD input shaft assembly malfunctions .................................................... 49

8 Mounting Positions......................................................................................... 508.1 General information on mounting positions ............................................ 508.2 Key to the mounting position sheets ....................................................... 518.3 Mounting positions for R helical gearmotors........................................... 528.4 Mounting positions of RX helical gearmotors.......................................... 558.5 Mounting positions for parallel shaft helical gearmotors ......................... 578.6 Mounting positions for helical-bevel gearmotors..................................... 608.7 Mounting positions for helical-worm gearmotors .................................... 658.8 Mounting positions for SPIROPLAN W gearmotors.............................. 71

9 Lubricants........................................................................................................ 749.1 Lubricant table ........................................................................................ 749.2 Lubricant fill quantities ......

Rotary Lock

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