07.01 Operating Manual

OPERATING AND MAINTENANCE MANUAL
CEMENT FEEDING SYSTEM

Rev. 2016-10-13
HAVER & BOECKER

Flow Control Gate Operating and Maintenance Manual
©Copyright Reserved
Contents
Contents
Chapter Description
1 Information
2 Safety
3 Machine Description
4 Transport
5 Assembly And Installation
6 Commissioning
7 Troubleshooting and Repairs
8 Maintenance
9 Spare Parts / Wear Parts List
10 Ordering Spare Parts

Contents
CONTENTS
1. Information
1.1 Manufacturer and originator of the machine

1.2 Identification
1.3 Liability and warranty
1.4 Notes on the operating manual
1.4.1 Safety symbols in the manual
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
4.1 Safety instructions

4.2 Transport to the building site
4.3 Transport on the building site
4.4 Storage/ long-term storage

Contents
5. Assembly and installation

5.2 Preparatory work
5.3 General installation instructions
5.4 Assembly
5.4.1 Assembly instructions
6. Commissioning

6.2 General instructions
6.2.1 Safe operating conditions
6.2.2 Safety precautions to be taken before start-up
6.3 Start- up
7. Troubleshooting and Repairs

7.2 Lateral dismounting of the dosing roller
7.3 Replacing the roller gasket
8. Service and maintenance

8.2 Warning instructions before maintenance and repair work
8.3 General
8.3.1 Maintenance table – vertical flow-control gate
8.4 Maintenance and repair log
9. Spare parts/ wear parts list
9.1 Flow Control Gate

9.2 Cement Feeding System

Information
Manufacturer and originator of the machine
1 Information
1.1 Manufacturer of the machine
Manufacturer of the machine is:
HAVER & BOECKER OHG
Carl-Haver-Platz 3
59302 Oelde, Germany
Phone: +49 2522 30-0

E-mail: haver@haverboecker.com
Internet: www.haverboecker.com
The copyright to this operating manual is held by HAVER & BOECKER

(HB here after).
This operating manual contains information which may not be duplicated,

distributed or used for purposes of competition without authorization or
passed on to third parties, either in part or in full.
This also applies analogously to the data processing programs employed

and the associated program descriptions.
In the event of the extension or exchange of existing programs, the

purchaser obligates himself to destroy the preceding versions, any
copies thereof and the exchanged documentation, insofar as no other
regulation exists.

Information
Identification
1.2 Identification
1
2
Item Designation
1 Order number
2 Year of manufacture
3 Type

Information
Notes on the operating manual
1.3 Liability and warranty
HAVER & BOECKER accepts no liability for:
 unauthorized technical and structural modifications (drive conditions,

power, speed, software);
 improper installation, commissioning, maintenance and repair;
 inadequate monitoring of machine parts that are subject to wear;
 improperly executed repairs;
 damage resulting from disregard of the operating manual, from the

use of spare parts other than those mentioned and of accessories
not authorised by the manufacturer;
 injuries to personnel or material damage to the machine as a

consequence of illegible or missing warning and instruction signs;
 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;
 damage caused by foreign bodies in the material to be conveyed;
 Disregard of the technical design data, in particular the safety

instructions in this printed document and the general safety
regulations of HB, releases HB from all warranties and liability for
damages.

Information
Liability and warranty
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.

Information
1.4 Notes on the operating manual
 This operating manual contains important instructions concerning

installation, commissioning, maintenance and accident prevention,
which you should be aware of in order to avoid mistakes and in
particular omissions that could have serious consequences. This
operating manual is therefore to be read completely before the
installation or initial commissioning by all persons who are entrusted
with the installation, operation, maintenance or repair of the machine,
and the instructions it contains are to be followed.
 The safe and trouble-free operation of the machine is only possible if

the contents of the operating manual are understood and observed
in their entirety by all of the persons mentioned above. This
particularly applies to the chapter on safety.
 The operating manual is part of the machine. Make sure that a copy
of the operating manual is always available at the machine.
 In the case of a structural modification, which must be approved in

each case in writing by HB, the operating manual must be
supplemented with regard to these modifications, including the safety
instructions.
 In order to ensure a safe working environment in which the machine

can work without trouble, make sure that the equipment is used for
its intended purpose in accordance with this manual and refer to the
technical specification (in the confirmation of order), see chapter 2.2
“Intended purpose of use”.
 If the machine should be sold, then all documentation belonging to

the machine is to be handed over with it, in particular including this
operating and maintenance manual as well as the general safety
instructions.
 Follow the recognized rules for occupational safety and accident

prevention.
 Follow the operating manuals and safety instructions in the supplier’s

documentation.

Information
1.4.1 Safety symbols in the operating manual
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
This symbol indicates a possibly dangerous situation.

Disregarding these instructions can lead to slight injuries or damage to
property.
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.

Safety
Safety instructions
2. Safety
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:
 The responsibility for the operation of the machine must be clearly

defined and specified.
 Operators must be competent, instructed and assigned!
 No improper repairs or modifications may be made to the machine, if
these are not approved by HB. In the event of problems, the
responsible person at HB must be contacted.
 Wear personal protective equipment, such as: helmet, gloves, safety

footwear with rubber soles, ear protection, goggles and close-fitting
clothing.
 Familiarize yourself with the safety, operating and monitoring

elements of the machine before switching it on.
 Use the machine only in accordance with the intended purpose of
use.
 Take the machine out of operation immediately in the event of a
malfunction!
 Do not remove or manipulate safety devices before or during
operation, as otherwise there is a danger of injury! For the same
reason, never bridge motor protection switches or EMERGENCY
STOP switches!

Safety
Intended purpose of use
 Follow the instructions by the manufacturers of vendor parts and their

general safety regulations.
 The specified inspection and maintenance intervals for all
components and wearing parts are to be adhered to.
 Shut off the air lines before working on the machine. Vent the valves
and air lines. It must be ensured during work that the lines remain
unpressurised and are secured against being put into operation again.
 Before starting work on the machine, close the upstream
maintenance gate and secure it against unintentional opening.
 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.
 Secure the load on means of transport according to applicable

regulations. Do not walk or stand under suspended loads. Use only
approved and tested lifting gear and hoisting equipment. Pay attention to
the intended attachment points and the center of gravity of the load.
2.2 Dangers due to electricity!

 Never operate the machine with electrical connections that are defective
or not ready for use, as otherwise there is a danger of injury.
 Work on the electrical equipment is to be carried out only by a qualified
electrician in accordance with the respectively valid national electro-
technical rules.
 Disconnect the power supply before working on the machine, so that the
functional unit cannot be switched on!
 Check the electrical system regularly for damage; danger due to loose
connections, defective and singed cables is to be eliminated immediately.
 Always keep the control cabinet locked. Only authorised personnel with
the appropriate training who have been instructed on safety are to be
allowed access.
 A second person must always be present when working on live parts.
 The machine is to be switched off immediately in the event of a
malfunction in the power supply.
 Defective electrical supply cables pose a danger due to electricity.
 The inspection and maintenance intervals specified by the
manufacturers of the electrical components are to be adhered to.

Safety
Safety instructions
2.3 Intended purpose of use

The Flow-control gate is intended for shutting off the discharge of silos
and for the controlled discharge of dry, pulverized bulk materials (such as
cement, lime, gypsum and fly ash).
Before using other materials, consult the responsible person at IBAU
HAMBURG or HAVER & BOECKER.
Conversions or modifications to the machine are only permissible after
written consultation with the manufacturer and only with its permission.
Any other use or use extending beyond that is inappropriate use. The
manufacturer is not liable for damage resulting from inappropriate use.
The operating company bears the risk alone.
Foreseeable misuse:
The Flow-control gate is not protected against pressure surges and may
in particular not be used for the conveying of inflammable dusts.

Safety
2.4 Machine safety

2.4.1 Safety and monitoring devices on the machine
Fig. 2 Safety and monitoring devices on the machine
Item Designation
Switchbox
1
Solenoid valve
2
Electro-pneumatic positioner controller
3

Safety
Machine safety
CAUTION
Follow the safety instructions in the operating manuals in the

supplier’s documentation!
All safety devices

 must be in perfect working order at all times
 are to be checked individually for functional reliability by technical
personnel on a regular basis
 may not be rendered entirely or partly ineffective
 may be only removed if the machine is not in operation
In the case of defective safety devices
 DO NOT put the machine into operation.

 If a safety device fails during operation, stop the machine immediately
and only put it into operation again when the safety device is working.
2.4.2 Duties of the user
The user of the machine must ensure that:
 the intended use of the machine is possible at all times

 the technical design data are adhered to and the vertical flow-control
gate is used in accordance with its intended purpose of use
 the machine is always in perfect working order
 all safety and warning notices attached to the machine are legible and
have not been removed
 personnel are regularly informed about all necessary rules for
occupational safety and environmental protection
 all rules for occupational safety and environmental protection are
displayed and can be viewed at any time by personnel
 first-aid instructions are located near to the machine (available from the
responsible employer’s liability insurance association)
 personal protective equipment (PPE) is provided and also worn
(responsibility and monitoring)
 a regular examination of safety-conscious working of the personnel takes
place
 the workplace at the machine or in its direct vicinity is always kept clean
 safety and danger symbols are clean, intact and legible
 there is a duty to report malfunctions and damage

Safety
In addition, the following instructions are to be given:
 objects, over which somebody could trip, are to be removed immediately

 the floor is to be cleaned regularly
 all residues, on which somebody could slip, are to be removed
immediately
In addition to the information in the operating manual, the operator can
issue internal instructions (= operating instructions) that describe the
handling of the equipment in the special environment of its place of use.
2.4.3 Duties of the personnel

Before or during operation:
 Qualified and authorised personnel must read the contents of this

operating manual, in particular chapter 2 “Safety instructions”. Trainees
may only work on the machine under the supervision of a qualified and
authorised person.
 personal protective equipment is to be worn
 malfunctions of, and damage to the machine are to be reported to the
authorised technical personnel immediately
For transport, the assigned personnel must:
 be familiar with the safe use of the lifting equipment

 possess a suitable driving licence when fork-lift trucks are employed
 be qualified and authorised and have read the contents of this operating
manual, in particular chapter 2 “Safety instructions” and chapter 4
“Transport”
The connection of the machine
 to the compressed air supply may only be carried out by appropriately

trained and assigned persons
 to the electricity supply may only be carried out by appropriately trained
and assigned persons
2.4.4 Product data

► see chapter 3.5 “Actuators”

Safety
Machine safety
2.5 Behaviour in the event of danger, rescue of persons and first aid
WARNING
Stop the operation of the machine immediately in the case of danger.
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.
 If there is a danger of injured persons sustaining further injuries if they

remain where they are, bring the person(s) out of the direct danger zone
as quickly as possible whilst ensuring your own protection.
 Otherwise, leave the injured person(s) where they are.
 Administer first aid.
 Get assistance (colleagues, superiors, doctor or ambulance, fire brigade).
 Attend to the injured persons until help arrives.
2.6 Fire fighting

No special measures are necessary for firefighting.
The employment of CO2 fire extinguishers is recommended.
Follow the user’s factory regulations for fire protection and firefighting.

Machine description
3. Machine description
3.1 Structure
4 6 7
Fig.3 Vertical flow – control gate – structure
Item Designation
1 Housing
2 Roller
3 Shaft
4 Felt gasket
5 Handle
6 HHandle
Actuator (Euromatic)
7 Positioner 4 – 20mA (Buerkert)

Machine description
3.2 Description of function
The tasks/functions of the vertical flow-control gate are:
 the dustproof shutting off of silo discharges

 the infinite control of the flow of material from a silo into a
downstream unit ( e.g. a packing machine)
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 two functions mentioned above are realised by means of a simple

construction principle:
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.
In order to enable adaptation to different operating conditions, HAVER &

BOECKER offers a set of dosing rollers with differently shaped aperture cross-
sections. For all dosing rollers, the apertures are infinitely adjustable by rotating
the roller.
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 actual roller position is displayed in degrees on a scale on the housing of

the vertical flow-control gate. In addition, the roller position can be indicated by
means of a potentiometer or a rotary angle transducer (see section Fehler!
Verweisquelle konnte nicht gefunden werden.).
Flow Control Gate Operating Manual

Machine description
3.2.1 Roller aperture cross-sections

In order to optimally meet different operating conditions, dosing rollers with
differently shaped aperture cross-sections can be supplied:
Triangular aperture cross-section (‘A’)
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
Fig. 4 Roller aperture cross-sections – triangular aperture ‘A’
Linear control aperture (‘lin.’)
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
Fig. 5 Roller aperture cross-sections – linear control aperture ‘lin.’

Machine description
Trapezoid aperture (‘max.’)
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
Fig. 6 Roller aperture cross-sections – trapezoid aperture ‘max.’

Machine description
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 digital position controller is microprocessor-controlled and is used particularly for

pneumatic actuators. The digital position controller can work both linearly, i.e. the
position controller produces an operating angle of 0-90° linear to the input signal of 4-
20 mA (basic setting), or it can also be easily adapted to a valve by means of the
proportional control characteristic which is selectable by pressing a button.
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.

Machine description
3.4 Electrical equipment

3.4.1 Rotary angle transducer
As an alternative to the potentiometer with transducer, a rotary angle transducer can
be supplied on request at an extra charge.
Technical data
Supply voltage: 20-30V DC

Output signal: 4-20 mA
Working resistance:  600 
Linearity:  0, 5%
Type: 2, 3 or 4-wire technology

Machine description
3.5 Technical data/ dimension sheet
Fig. 12 Dimension sheet – vertical flow-control gate, pneumatic with rotary

actuator (example with DR ACTUATOR with Positioner)

Transport
Transport on the building site
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.
Crushing/bruises due to falling down/slipping of the machine caused by

inadequate securing of the load and/or unsuitable lifting devices.
 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
Danger due to unsecured loads!

 Secure the load on means of transport according to applicable regulations.
Danger due to suspended loads!

 Do not walk or stand under suspended loads.
 Use only approved and tested lifting gear and hoisting equipment.
 Pay attention to the intended attachment points and the centre of gravity of the
load.
Note any unusual circumstances during operation and report them

immediately to your superior, in order to avoid personal injuries and
damage to the machine and/or the operational plants.

Transport
Transport to the building site
4.2 Transport to the building site
For transport, Flow-control gates must be protected against damage of all

kinds, such as rainwater, sea water, impact or breakage and must be
packed appropriately for the method of dispatch.
When carried overland, the Flow-control gate is transported to the
construction site on a pallet. When transported by sea, the Flow-control
gate is carried in a crate.
When transporting Flow-control gates with gear motors, the gearbox bleed
screw must be either secured to prevent oil spillage or else exchanged for
a plug screw. In the latter case, the bleed screw must be attached to the
gearbox so that the screw can be swapped back again later during
installation.

Transport
Transport on the building site
4.3 Transport on the building site
Cement Feeding System/ Flow-control gate, transport by paper box,

plastic pallet
1 1
Fig.13 Transport frame and attachment points on the vertical flow-control gate
Transport on the building site is to be carried out using suitable industrial

trucks or other suitable devices. The pallet provided by the factory is to
be used for unloading and transport on the building site to the place of
installation.
The follow-control gate must not under any circumstances be lifted by its
actuator (chain wheel or hand wheel).
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.

Transport
Storage/ long-term storage
4.4 Storage / long-term storage

The Flow-control gate must always be stored in a frost-free, roofed-over
place until assembly. The bare parts of the Flow-control gate must be
protected with preservation wax or oil.
The Flow-control gate must always be protected against external
influences such as rain water, snow, ice, impacts or breakage!

Assembly and installation
Safety regulations
5. Assembly and installation

WARNING
Crushing/bruising due to uncontrolled movements of parts caused by

unexpected starting or rotation of the machine.
 Assembly by technical personnel only.

 Connect the machine to the electricity and compressed air supplies only when
assembly is complete.
Crushing/bruising due to a loss of the stability caused by loose bolted
connections.
 Check that all bolts are securely fitted.

Falling on the floor, tripping and slipping due to components or tools lying
in the area of movement.
 Keep working areas and thoroughfares clear. Wear class S2 safety footwear.
DANGER
Danger due to unsecured loads!
 Secure the load on means of transport according to applicable regulations.
Danger due to suspended loads!
 Do not walk or stand under suspended loads.

 Use only approved and tested lifting gear and hoisting equipment.
 Pay attention to the intended attachment points and the centre of gravity of the
load.

immediately to your superior, in order to avoid personal injuries and damage
to the machine and/or the operational plants.

Preparatory work
5.2 Preparatory work

Before installing the flow control gate it must be checked whether all
parts are available on the building site in accordance with the
corresponding parts lists. If any parts are missing, also check the
shipping advices or packing lists. The plant diagrams provide further
information about possible missing parts.
If parts are missing, then the supplier of the flow control gate or the
responsible person at HB must be informed immediately.
To this end, please state the order number and the data on the type plate.
The place of installation of the flow control gate and the marking on the
component must correspond to the details on the plant drawing.
Minor transport damage to the flow control gate, such as, for example:
damage to the paintwork, is to be repaired on the building site. Damage
extending beyond this must be reported to the responsible person at HB.
If possible, photographs should be taken and sent to HB for the purposes
of evaluating the damage.

General instructions for the installation
5.3 General instructions for the installation

If all necessary parts are available and in perfect condition, check that all
conditions for the proper installation are fulfilled:
 Does the mounting situation comply with that on the installation
drawing?
 Does the mounting height comply with that on the installation drawing?
 Does the direction of material flow (see conveying direction arrow)
correspond to that of the flow control gate?

Assembly
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.
If necessary, heavy connecting elements must be relieved by supporting

or bracing structures. All bolts must be tightened crosswise. Maximum
tightening torque 4.0 da/Nm. This must be checked in any case after
completion of the assembly.
It is advisable to install a maintenance valve upstream of the vertical

flow-control gate so that maintenance work on the vertical flow-control
gate can be performed safely.

6 Commissioning
WARNING
Burns from hot machine parts due to high surface temperatures.
 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”
Falling on the floor, tripping and slipping due to components or tools

lying in the area of movement.
 Keep working areas and thoroughfares clear.
 Wear class S2 safety footwear.
Crushing/bruising due to a loss of the stability caused by loose bolted

connections.
 Check that all bolts are securely fitted.
Crushing/bruising due to uncontrolled movements of parts of the motor

actuated Flow-control gate.
 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
Take the machine out of operation immediately in the event of a malfunction!

Commissioning
6.2 General instructions

The vertical flow-control gate may only be started up – even for testing purposes
– if the openings for the material flow have been locked by means of fluid slides,
appropriate protective gratings or sheet metal covers!
 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.
6.2.1 Safe operating conditions

Dependency on other plant devices, if the planning of these is not
entirely our responsibility, cannot be known to us and must be
checked separately by the operating company.
Beyond that the following conditions for the regular operation of
the plant are to be fulfilled:
 a properly completed assembly;
 a successfully completed test run with all necessary adjustments;
 properly installed safety devices and electrical locking devices;
 instruction of the operating personnel on the proper operation of
the plant and the relevant safety regulations;
 Use of the machines for their intended purpose and their proper
maintenance.
6.2.2 Safety precautions to be taken before commissioning

Before each commissioning the operator must make sure that
 no persons or obstacles are in the danger area of the plant,
 the plant has no obvious defects and
 Signal and warning devices are in working order.
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
7. Troubleshooting and repair

WARNING
Damage to health due to touching or inhaling bulk material dust or due to

touching bulk material during troubleshooting on the machine.
The equipment must be emptied of all residues before working on it.
Wear protective gloves according to BS EN 388, respiratory protection

according to BS EN 140 and safety glasses with side protection according to BS
EN 166.
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.
Wear protective gloves according to BS EN 388.
Sign: “Warning: beware of hot surfaces”.
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.
Keep working areas and thoroughfares clear.
Wear class S2 safety footwear.

immediately to your superior, in order to avoid personal injuries and damage
to the machine and/or the operational plants.

Machine faults
7.2 Machine faults (table 10)
Fault Possible cause Remedy Skilled

person
Flow-control gate does not Mechanic

“CLOSE”
Material lumps, Briefly rotate the roller
foreign bodies completely into “open”
etc. in the dosing position and then
roller? completely into the
“closed” position. In
most cases the cause
of the trouble (material
lumps, foreign bodies)
will be released by this
action.
Material lumps, Carry out an inspection
foreign bodies of the area upstream of
etc. upstream of the roller and remedy
the dosing roller? the problem identified
(material lumps, foreign
bodies, etc.).
Flow-control gate with Hose connections Check the hose Mechanic

pneumatic actuator does leaking? connections for leaks
not maintain its position. by soaping.
Retighten or replace
Compressed air leaking compressed
connections leaking? air connections.
Flow-control gate with Pneumatic actuator The speed of the Mechatronic

pneumatic actuator does incorrectly adjusted? actuator is too high.
not drive to the correct Adjust the speed via the
position. throttle silencers.
Problems when Aeration fabric Check the aeration fabric Mechanic

discharging material impervious for permeability to air.
through the aerated (impermeable to air)? Replace aeration pad.
Flow-control gate.
Check the aeration fabric
Aeration fabric worn out? wear. Replace aeration
pad.

Repair
7.3 Repair
7.3.1 Safety regulations
WARNING
Before beginning work, be sure to close the upstream maintenance

gate and secure the actuator of the Flow-control gate to prevent it
from being switched on accidentally.
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.
7.3.2 Lateral dismounting of the dosing roller
4
2
1
3
5/ 6
Fig. 14 Lateral dismounting of the dosing roller

Repair
Fig. 15 Felt gasket
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.
The parts are re-installed in the reverse order.

Repair
7.4 Replacing the roller gasket
Fig. 16 replacing the felt gasket
1. Remove the dosing roller (see section 9.2).
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).
4. Screw the bottom deflector (Fig. 16 / item 2) on loosely.
5. Pre-assemble the top deflector (Fig. 16 / item 1) with two long screws
approx. M10 x 80.
6. Turn the felt gasket over.
7. Apply the adhesive to the housing and the felt and let them air for approx.
5-10 minutes.
8. Fix the gasket in place with a plastic hammer.

9. Tighten the deflectors and replace the auxiliary screws on the top
deflector.
Assemble the roller and attachments.

Maintenance
Safety regulations
8. Maintenance
WARNING
Damage to health due to touching or inhaling bulk material dust and/or

due to touching bulk material during maintenance of the machine.
 The equipment must be emptied of all residues before working on it.

 Wear protective gloves according to BS EN 388, respiratory protection
according to BS EN 140 and safety glasses with side protection according
to BS EN 166.
 Obtain and pay attention to safety data sheets for the bulk material!
Falling on the floor, tripping and slipping due to components lying in the
area of movement.
 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”
Crushing/bruising due to uncontrolled movements of parts of the motor

actuated Flow-control gate.
 Maintain a safe distance between the driving rods, and the lever.
 The hand guard must always be fitted during operation.

CAUTION
Take the machine out of operation immediately in the event of a malfunction.

Maintenance
Warning instructions before maintenance and repair work
8.2 Warning instructions before maintenance and repair work

 Switch the machine off
 Secure the machine against being switched on again
 Attach a warning sign in a clearly visible place
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.
If you need assistance with maintenance or repair, please contact the

responsible person at HAVER & BOECKER.

Maintenance
General
8.3.1 Maintenance table 9
No. Description Interval Action Skilled person
Basic unit – vertical flow- control gate

1 Roller gasket Every 12 months Visual inspection / assessment Mechanic
of the gasket; replacement if
necessary,
2 Dosing roller Every 12 months Visual inspection / assessment Mechanic

of the roller; replacement if
necessary,
3 Basic unit (housing Every 12 months Clean the device, e.g. remove Mechanic
and roller) material deposits or adhering
foreign bodies
4 Aeration pad ** Every 12 months Visual inspection for wear; Mechanic

replacement if necessary,

Maintenance
Maintenance and repair log
8.4 Maintenance and repair log
It is recommended that you keep a machine logbook. In this you can

record the maintenance or repair work that has been carried out, who
carried it out and when. A machine logbook can be helpful if error
diagnosis should be necessary.

Spare parts/ wear list
List
9. Spare parts / wear parts List

9.1 Basic device size 300
Drawing no.: 22D30A00206
Fig. 1 Flow- control gate, basic type

List
Item Spare part Quantity Wear part Order no.
2 Roller A / max 1 22D030C07101
4 1 Roller gasket 22D030A02589
7 2 Wear protection liner 22D030D10722
8 2 Bushing 22D000E02590
9 Shaft 1 22D030D00031
11 2 Felt ring 22D000E03144
20 4 Shaft sealing ring 22D000X00425
21 O-ring seal 2 22D000X03011

List
Electro-, pneumatic rotary actuator with positioner – size 300
Drawing no.: 22D030B00205
12
Fig. 3 Flow- control gate with rotary actuator and electro-, pneumatic
positioner
Item Spare part Quantity Wear part Order no.:
8 / 12 DR ACTUATOR with Positioner, 1 X04869
anti-clockwise closing (Euromatic)
9 Hand lever right / left 1 22D000C00114

List
Spare parts / wear parts List
Item no.: N7615
Pos. 0100
Pos. 0200
Pos. 0110/ 0111
Pos. 0201
Pos. 0300
HAVER Cement Feeding System

List
Item Spare part Quantity Order no.
0100 CONNECTING PIECE 1 200369754
0110 AERATION PAD 2 202715788
0111 GASKET RUBBER 2 N3132
0200 FLOW CONTROL GATE 300 1 N10378.HB
0201 GASKET RUBBER SQUARE #300 2 N1297
0300 INLET 1 200369761
HAVER Cement Feeding System

Ordering spare parts/ wear parts
10. Ordering spare parts/ wear parts

Please consult our spare parts department when ordering spares or
seeking information on offers/tenders.
Please give full details of the data on the type plate/label when ordering.
To HAVER & BOECKER spare part sales department
Tel. no.: +49 2522 30-0
Customer: Date:
Location: Machine No.:
Name/
ordering Item-No.:
person:
Telephone: Type:
Item Description Part No.: Quantity

Ordering spare parts/ wear parts
Notes

Contact information
10.3 Contact Information
HAVER & BOECKER

Carl-Haver-Platz 3
59302 Oelde, Germany
Telephone: +49 2522 30-0

Fax: +49 2522 30-403
10.4 Liability for defects (warranty for spare parts)
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.
HB accepts no liability and grants no warranty for the normal degradation

of wear parts.

Australia: France:
HAVER TRADING
HAVER AUSTRALIA HAVER FRANCE S.A.R.L. Ul. Kolejowa 3
35 Millrose Drive, ZA - 7, rue des Bauches Bielany Wroclawskie
Malaga, WA 6090 Australia 78260 ACHÈRES 55-040 Kobierzyce
Phone: +61 8 6240 6900 Phone: +33-1-39118080 Phone: 0048 71 7960204
Telefax: +61 8 9249 4030 Telefax: +33-1-39118089 Telefax: 0048 71 7960205
E-mail: info@haveraustralia.com.au E-mail: contact@haverfrance.fr E-mail: htr@haverboecker.com
Internet: haveraustralia.com.au Internet: www.haverfrance.fr Internet: www.havertrading.pl
Brazil: France: Russia:
HAVER & BOECKER NEWTEC BAG PALLETIZING HAVER & BOECKER, Russia
Latinoamericana Màqs. Ltda. 32 avenue de Suisse Gostinichny Proezd, 8,
Rod. Campinas à Monte Mor km 20 Z.I. Ile Napoléon - B.P. 256 bld.1, office 46
13190 MONTE MOR S.P. 68315 Illzach cedex 127106 MOSCOW
Phone: +55-19-3879-9101 Phone: +33 389 633750 Phone/Telefax: +7 495 783 34 48
Telefax: +55-19-3879-1410 Telefax: +33 389 618212 E-mail:
E-mail: haverhbl@haverbrasil.com.br E-mail: info@newtecbag.com haverboecker@haverrussia.ru
Internet: www.haverbrasil.com.br Internet: www.newtecbag.com Internet: www.haverrussia.ru
Chile: Spain:
Great Britain:
HAVER & BOECKER ANDINA Ltda HAVER & BOECKER IBERICA
Marchant Pereira 150 HAVER CONTINENTAL Ltd. Plaza Tetuán, 40 2a planta/oficina 37
of. 401-402, Providencia Invincible Road 08010 BARCELONA
CP 7510194 Santiago FARNBOROUGH, Phone: +34-93-247 61 90
Phone: +56 29 52 79 00 Hants Gu14 7QU Telefax: +34-93-247 61 91
E-mail: haverandina@haverandina.cl Phone: +44-1252 512122 E-mail: hbi@haverboecker.com
Internet: www.haverhaverandina.cl Telefax: +44-1252 549291 Internet: www.haver.es
E-mail: info@havercontinental.com
Internet: www.havercontinental.com
China: USA:
HAVER TECHNOLOGIES (Tianjin) India: HAVER FILLING SYSTEMS, INC.

North Area of Wuqing Development P.O.Box 80937
Zone III, No.5 Quanhua Road, HAVER IBAU INDIA Pvt. Ltd. 460, Gees Mill Business Court
UDA New Tech Park, Survey No. 32/4/41 & 42 Khandiwada, CONYERS, GA 30013
Tianjin, People’s Republic of China Baroda Halol Road, Post Asoj, Phone: +1-770-760-1130
P.C.: 301700 Vadodara 391 510 Gujarat, India Telefax: +1-770-760-1181
Phone: +86 22 5898 3800 Phone: +91 2676 306-600 E-mail: sales@haverusa.com
Telefax: +86 22 5898 3801 Telefax: +91 2676 306-999 Internet: www.haverusa.com
E-mail: htt@havertechnologies.com E-mail: info@haveribauindia.com
Internet: www.havertechnologies.com Internet: www.haveribauindia.com
UAE:
HAVER MIDDLE EAST FZE

Amenity Centre 1, Mezzanine Floor,
Office No. 1, Al Jazeera Al Hamra
Ras Al Khaimah, UAE
Phone: +971 (0) 7 20 680 00
Telefax: +971 (0) 7 20 680 09
E-mail: hme@haverboecker.com
Internet: www.havermiddleeast.com
HAVER & BOECKER OHG

Carl-Haver-Platz 3 · 59302
OELDE · Germany
Phone: +49 2522 30-0
Telefax: +49 2522 30-403
E-mail: haver@haverboecker.com ... and representatives worldwide!
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OPERATING AND MAINTENANCE MANUAL

CEMENT FEEDING SYSTEM

HAVER & BOECKER

5 Assembly And Installation

7 Troubleshooting and Repairs

9 Spare Parts / Wear Parts List

10 Ordering Spare Parts

Flow Control Gate Operating and Maintenance Manual

1.1 Manufacturer and originator of the machine

4.1 Safety instructions

Flow Control Gate Operating and Maintenance Manual

5. Assembly and installation

5.1 Safety instructions

6.1 Safety instructions

7. Troubleshooting and Repairs

7.1 Safety instructions

8. Service and maintenance

8.1 Safety instructions

9. Spare parts/ wear parts list

9.1 Flow Control Gate

Flow Control Gate Operating and Maintenance Manual

HAVER & BOECKER OHG

Phone: +49 2522 30-0

The copyright to this operating manual is held by HAVER & BOECKER

This operating manual contains information which may not be duplicated,

This also applies analogously to the data processing programs employed

In the event of the extension or exchange of existing programs, the

Flow Control Gate Operating and Maintenance Manual

Flow Control Gate Operating and Maintenance Manual

1.3 Liability and warranty

HAVER & BOECKER accepts no liability for:

 unauthorized technical and structural modifications (drive conditions,

 improper installation, commissioning, maintenance and repair;

 inadequate monitoring of machine parts that are subject to wear;

 improperly executed repairs;

 damage resulting from disregard of the operating manual, from the

 injuries to personnel or material damage to the machine as a

 damage caused by foreign bodies in the material to be conveyed;

 Disregard of the technical design data, in particular the safety

Flow Control Gate Operating and Maintenance Manual

Flow Control Gate Operating and Maintenance Manual

1.4 Notes on the operating manual

 This operating manual contains important instructions concerning

 The safe and trouble-free operation of the machine is only possible if

 In the case of a structural modification, which must be approved in

 In order to ensure a safe working environment in which the machine

 If the machine should be sold, then all documentation belonging to

 Follow the recognized rules for occupational safety and accident

 Follow the operating manuals and safety instructions in the supplier’s

Flow Control Gate Operating and Maintenance Manual

1.4.1 Safety symbols in the operating manual

This symbol indicates a possibly dangerous situation.

Flow Control Gate Operating and Maintenance Manual

 The responsibility for the operation of the machine must be clearly

 Wear personal protective equipment, such as: helmet, gloves, safety

 Familiarize yourself with the safety, operating and monitoring

Flow Control Gate Operating and Maintenance Manual

 Follow the instructions by the manufacturers of vendor parts and their

 Secure the load on means of transport according to applicable

2.2 Dangers due to electricity!

Flow Control Gate Operating and Maintenance Manual

2.3 Intended purpose of use

Flow Control Gate Operating and Maintenance Manual