07.01 Operating Manual
07.01 Operating Manual
07.01 Operating Manual
Contents
Chapter Description
1 Information
2 Safety
3 Machine Description
4 Transport
6 Commissioning
8 Maintenance
CONTENTS
1. Information
2. Safety instructions
2.1 General
2.2 Special safety instructions for the vertical flow- control gate
2.3 Intended purpose of use
2.4 Machine safety
2.4.1 Safety and monitoring devices on the machine
2.4.2 Duties of the user
2.4.3 Duties of the personnel
2.4.4 Product data
2.5 Behavior in the event of danger, rescue of persons and first aid
2.6 Fire fighting
3. Machine description
3.1 Structure
3.2 Description of function
3.2.1 Roller aperture cross-section
3.3 Actuators
3.3.1 Pneumatic actuator with positioner 4-20mA
3.4 Electrical equipment
3.4.1 Rotary angle transducer
3.5 Technical data/ dimension sheet
4. Transport
6. Commissioning
1 Information
1.1 Manufacturer of the machine
Manufacturer of the machine is:
Carl-Haver-Platz 3
59302 Oelde, Germany
1.2 Identification
1
2
Item Designation
1 Order number
2 Year of manufacture
3 Type
the installation or attachment and use of parts which are not original
HB parts or accessories; This may affect constructively specified
characteristics of the equipment under certain circumstances;
The data in this manual have been written with the greatest possible care by
HAVER & BOECKER for the safe handling of the product concerned and are
checked on a regular basis. The product-specific documentation current at the
time of handover was delivered with the product. However, such a product may
be modified in the course of continuing technical developments at HB and the
usability of such a product, in particular within the context of a complete operating
system, may change due to legal or official requirements, thus also requiring the
adaptation of the product-specific documentation. The customer is therefore
called upon each time before starting work or before putting the product back into
operation following a break in operation, or at least from time to time, to enquire
to HB about the latest level of knowledge in the form of updated product-specific
documentation, in order to determine whether its product is still current and, if
necessary, to purchase and install modification equipment, with regard to
individual technical or legal changes that have occurred, in consultation and
agreement with HB. If the customer continues to use the previously acquired
product without enquiring about the further technical development of this product
each time before putting it into operation, or at least from time to time, then it
does so on its own responsibility. HB cannot be held liable for damage caused in
particular by the product and the product-specific documentation delivered with it
no longer meeting current technical or legal requirements.
The operating manual is part of the machine. Make sure that a copy
of the operating manual is always available at the machine.
DANGER
This symbol indicates a direct danger to the life and the health of persons.
Disregarding these instructions leads to serious damage to health, extending
as far as life-threatening injuries.
WARNING
This symbol indicates a possible danger to the life and the health of persons.
Disregarding these instructions can lead to serious damage to health,
extending as far as life-threatening injuries.
CAUTION
NOTICE
This symbol gives important instructions for the proper handling of the
machine. Disregard of these instructions can lead to damage to the machine or
disruptions to its environment.
2. Safety
2.1 Safety instructions
Attention must be paid to the respectively valid legal regulations, in particular
the occupational health and safety regulations, as well as all regulations
contained in the product-specific documentation (e.g. operating and
maintenance manuals, general and product-specific safety instructions).
The work described below may only be carried out by personnel who are
familiar with the functions of the machine and its components and who have
been briefed on the safety instructions that need to be followed.
The machine complies with the European safety regulations. Nevertheless,
unavoidable residual technical risks can endanger persons and property. In
order to prevent this, operators must follow the following safety instructions:
Before working on the machine, disconnect the power supply and secure
the machine against being switched on again.
Use only suitable tools and bolts, nuts and screw connections that
conform to the respective standard and configuration.
Item Designation
Switchbox
1
Solenoid valve
2
Electro-pneumatic positioner controller
3
CAUTION
2.5 Behaviour in the event of danger, rescue of persons and first aid
WARNING
The factory regulations specified by the user for the rescue of persons are to be
adhered to. Those following procedures are recommendations and are not
binding.
Follow the user’s factory regulations for fire protection and firefighting.
3. Machine description
3.1 Structure
4 6 7
Item Designation
1 Housing
2 Roller
3 Shaft
4 Felt gasket
5 Handle
6 HHandle
Actuator (Euromatic)
7 Positioner 4 – 20mA (Buerkert)
The vertical flow-control gate essentially consists of a cast housing (item 1), a
dosing roller (item 2) with shaft (item 3), a roller gasket (item 4), a handle (item
5), a pneumatic actuator (item 6) and a positioner (item 7).
The silo discharge can be completely opened or closed by rotating the dosing
roller by 90°. In addition to that, by rotating the dosing roller by a smaller angle,
the aperture can be changed such that the desired quantity of material flows out
of the silo.
The size of the dosing roller is determined by HAVER & BOECKER according to
the volumetric flow. The following sizes are used: 200, 300, 400 and 500.
The shape of the triangular cross-section suits almost all operating conditions
and its dosing accuracy is sufficient for most applications.
cross-section
Aperturecross-section
Aperture
Angle of rotation
This type of cross-section is used for feeding belt weighers or flow meters. The
aperture for the flow of material is linear in relation to the angle of rotation of the
dosing roller.
Aperture cross-section
Angle of rotation
This type of cross-section is used for high flow rates at a low silo admission
pressure while maintaining the selected vertical flow-control gate size. They are
used, for instance, as quick-action shut-off gates upstream of vertical flow-
control gates for control purposes.
Aperture cross-section
Angle of rotation
3.3 Actuators
3.3.1 Pneumatic actuator – rotary actuator with electro-pneumatic control device
The rotary actuator works according to the principle of rotary paddle pneumatics and
dispenses with lever arms, toothed racks and gears. This allows the pure torque to be
transferred, with no interfering lateral forces acting on the square drive.
The actuator is characterised by its compact and weight-saving design and requires
virtually no maintenance.
The exhaust units on the rotary actuator allow the optional manual operation of the
vertical flow-control gate. The hand lever is supplied separately and is attached to the
square drive on the rotary actuator.
The pneumatic rotary actuator is coupled with an electro-pneumatic control device
(position controller).
The digital position controller is attached directly to the corresponding rotary actuator
and in most cases requires no external piping. It serves the pneumatic actuation and
control of the position of the rotary actuator.
The digital position controller is operated via the 4-20 mA input signal.
The actuator position is set by applying a set-point signal (reference variable w). The
microprocessor-controlled control circuit compares this signal with the signal from an
angle sensor built into the controller (actual value x). Depending on the result of the
comparison, the control circuit drives the switching valves integrated in the controller,
which move the connected rotary actuator. This produces a linear relationship between
the actuator position and the set-point signal.
The digital position controller works without any drift within the range of 3.5-7 bar of
supply air. The direction of movement can be simply reversed internally without
additional parts. The pneumatic part is sealed off from the electrical part inside the
housing. The complete circuit is accommodated in a compact IP65 cast housing.
After a power failure the unit begins to regulate immediately without a reference run.
Technical data
4. Transport
4.1 Safety regulations
It is essential that you read chapter 2 “Safety”, before commencing work.
WARNING
Damage to health due to dust or bulk material residues in the machine after
use.
Clean the machine thoroughly before storage, before transport and after use.
Pay attention to the qualification of the personnel for the respective task.
Specify attachment points for lifting gears.
Pay attention to the load capacity of load handling attachments/hoisting
equipment.
Wear protective helmet and protective gloves according to BS EN 388 and
Step S2 safety footwear.
DANGER
1 1
Fig.13 Transport frame and attachment points on the vertical flow-control gate
NOTICE
Only the marked attachment points (1) shown in 0 may be used, as otherwise
damage to the vertical flow-control gate cannot be ruled out.
WARNING
Pay attention to the qualification of the personnel for the respective task.
Keep working areas and thoroughfares clear. Wear class S2 safety footwear.
DANGER
5.4 Assembly
5.4.1 Assembly instructions
Vertical flow-control gates have a cast housing, therefore their
connecting flanges must not be subjected to heavy loads. The equipment
must be installed free of stress using the original rubber seals.
WARNING
Allow the machine to cool down for one hour before working on it.
Wear protective gloves according to BS EN 388.
Sign on the machine: “Warning: beware of hot surfaces”
Pay attention to the qualification of the personnel for the respective task.
Keep working areas and thoroughfares clear.
Wear class S2 safety footwear.
Maintain a safe distance between the driving rods (Fig. 8, item 13), and
the lever.
The hand guard (Fig. 8, item 14) must always be fitted during operation.
CAUTION
Each vertical flow-control gate delivered has been subjected to a test run in
the factory.
The limit switches in the switchbox are already present.
6.3 Start-up
Carry out a signal check
Check direction of rotation (‘OPEN’ and ‘CLOSED’ position)
Check stop position in the case of a 5/3-way valve
Check the controller if the vertical flow-control gate is equipped with a position
controller.
If these functions are all in order the vertical flow-control gate can be operated
with material.
Troubleshooting and repair
Safety regulations
WARNING
Obtain and pay attention to safety data sheets for the bulk material.
Allow the machine to cool down to room temperature before working on it.
Falling on the floor, tripping and slipping due to components or tools lying
in the area of movement.
Pay attention to the qualification of the personnel for the respective task.
7.3 Repair
7.3.1 Safety regulations
WARNING
The dosing roller and the roller gasket can be removed from the side of
the Flow-control gate while it remains installed in the conveyor system.
4
2
1
3
5/ 6
Fig. 14 Lateral dismounting of the dosing roller
If the inspection of the dosing roller (Fig. 14 / item 2) or the roller gasket (Fig. 14
/ item 4) reveals that these parts have to be replaced, it is not necessary to
dismount the complete vertical flow-control gate.
CAUTION
Prior to starting work, the upstream maintenance gate must be closed
and the drive of the vertical flow-control gate must be secured against
being switched on unintentionally!
The dosing roller and the gasket can be dismounted laterally from the vertical flow-
control gate installed in the conveying system.
1. Remove the rotary actuator (Fig. 14 / item 1) and the handle (Fig. 14 / item 3).
2. Dismount the cover plates (Fig 14 / item 5+6).
3. You can now remove the dosing roller (Fig. 14 / item 2) from the housing.
2. Remove the old gasket (Fig. 16 / item 3) and clean the gasket seat with a
thinner or a similar product before installing the new gasket.
3. Insert the felt so that it is in the same position as previously. The dark
side of the felt is glued to the housing (Fig. 15).
5. Pre-assemble the top deflector (Fig. 16 / item 1) with two long screws
approx. M10 x 80.
7. Apply the adhesive to the housing and the felt and let them air for approx.
5-10 minutes.
8. Maintenance
8.1 Safety regulations
It is essential that you read chapter 2 “Safety”, before commencing work.
WARNING
Falling on the floor, tripping and slipping due to components lying in the
area of movement.
Pay attention to the qualification of the personnel for the respective task.
Keep working areas and thoroughfares clear.
Wear class S2 safety footwear.
Allow the machine to cool down for one hour before working on it.
Wear protective gloves according to BS EN 388.
Sign on the machine: “Warning: beware of hot surfaces”
CAUTION
8.3 General
The maintenance of the vertical flow-control gate depends on the respective
operating conditions. Under normal operating conditions the maintenance work
specified in Table 9: is to be carried out.
3 Basic unit (housing Every 12 months Clean the device, e.g. remove Mechanic
and roller) material deposits or adhering
foreign bodies
8 2 Bushing 22D000E02590
9 Shaft 1 22D030D00031
12
Fig. 3 Flow- control gate with rotary actuator and electro-, pneumatic
positioner
Pos. 0100
Pos. 0200
Pos. 0110/ 0111
Pos. 0201
Pos. 0300
E-mail: haver@haverboecker.com
Customer: Date:
Name/
ordering Item-No.:
person:
Telephone: Type:
Notes
IMPORTANT
HAVER & BOECKER (HB in brief hereafter) shall only take warranty for
original spares delivered directly by HB.
HB expressly points out that only original spare parts and original
accessories delivered by HB have been checked and released by HB.
The installation and/or use of spare parts in the machine procured from
other sources may deteriorate the predetermined design features of the
machine. This may affect the active and / or passive safety of the
machine.
HB does not accept liability or warranty for damage resulting from the
use of non-original spare parts and non-original accessories. In many
cases, specific manufacturing and delivery specifications are applicable
for in-house and externally procured parts. HB supplies spare parts that
meet state-of-the-art technological standards and the latest statutory
regulations.
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