MPSN - 66543 1 en 0310
MPSN - 66543 1 en 0310
MPSN - 66543 1 en 0310
Operating instructions
Preface
These operating instructions document the rotary airlock for milling installations
MPSN.
The operating instructions have to be handed over to those persons who are
responsible for the operation and the supervision of these machines.
These operating instructions contain the information required for the user regarding
installation, operation and maintenance.
Description of activities that do not require any special knowledge have been omit-
ted.
Repair instructions that exceed the normal maintenance work are not provided.
The machine meets all acknowledged safety regulations. However, improper use
can involve physical danger for the user. Highest priority, therefore, has been given
to safety.
The corresponding safety instructions are marked as follows:
Danger!
Risk of injury to persons.
Caution!
Warning of material damage.
Note:
Important information or instructions.
Important information
• Procedures upon receipt
Inspect the equipment visually in accordance with the delivery contract as soon
as it has been received.
• Storage
Equipment that is not installed immediately must be stored protected against
weather and other influences.
• Installation
The assembly and installation of the machine and machine equipment must
only be carried out by observing all installation instructions supplied.
• Design versions
If different designs are described in the documentation provided, only the infor-
mation concerning the version supplied will apply. We reserve the right to make
modifications due to technical progress up to the time of delivery.
• Duty of instruction
Commissioning and maintenance must only be done by trained specialists. Prior
to the initial start-up the operating personnel must familiarize themselves with
the documentation provided.
Table of contents
1 Safety ........................................................................................................ 1-1
1.1 Protection of persons.................................................................................................. 1-1
1.2 Connecting to the electrical mains.............................................................................. 1-1
1.3 Safety concept ............................................................................................................ 1-1
1.4 Explosion protection ................................................................................................... 1-1
6 Operation...................................................................................................6-1
6.1 Troubleshooting...........................................................................................................6-1
6.2 Operation and servicing the frequency inverter ..........................................................6-1
7 Maintenance..............................................................................................7-1
7.1 Maintenance schedule................................................................................................7-1
7.2 Lubrication ..................................................................................................................7-2
7.3 Checks and maintenance works .................................................................................7-2
7.3.1 Drive motor cooling.........................................................................................7-2
7.3.2 Removing the shaft speed monitor.................................................................7-2
7.3.3 Removing the housing cover ..........................................................................7-3
7.3.4 Sealing the airlock ..........................................................................................7-4
7.3.5 Removing the rotor .........................................................................................7-5
7.4 Inspection and maintenance of the frequency inverter ...............................................7-5
7.5 Disposal ......................................................................................................................7-5
8 After-sales service....................................................................................8-1
8.1 Stockkeeping of spare parts .......................................................................................8-1
8.2 Address.......................................................................................................................8-1
8.3 Recommended spare parts ........................................................................................8-3
8.3.1 MPSN-25/15 ...................................................................................................8-3
8.3.2 MPSN-25/23 ...................... ............................................................................8-3
1 Safety
1.1 Protection of persons
• Safety covers must always be installed and locked. Open or removed safety
covers are danger spots for crushing and cutting injuries.
• Always keep safety devices in good working condition. Safety devices must not
be bridged over or put out of operation.
• Maintenance work at the rotary airlock for milling installations must only take
place with the installation at standstill. It is absolutely essential that the installa-
tion is switched off without exception and that the switch is locked!
Danger!
Do not reach into the airlock! Do not turn the rotor manually!
2 Description
2.1 Designated use
Due to its open rotor construction, the rotary airlock for milling installations is partic-
ularly suitable for use with powdery to fine-grained products. It is used for feeding in
pneumatic suction and pressure conveyor systems especially of the pneumatic mill
stock conveying system, as well as volumetric dosing and discharge from filters,
cyclones, silos, tanks and similar apparatus. A differential pressure of up to ± 0,5
bar and machine constructions for temperatures of up to 80 °C are possible.
Explosion hazard!
In potentially explosive zones the rotary airlock must only be operated with
the corresponding authorization.
2.2 Identification
2.2.1 Nameplate
Note:
Do not remove or cover up the nameplate.
The data marked with «"» are embossed into the nameplate according to the
machine specifications.
II ∗∗ EEx ∗ T ∗∗∗°C
Machine No.: ∗∗∗ Machine No.: ∗∗∗
Year of construction: ∗∗∗ Year of construction: ∗∗∗
Order No.: ∗∗∗ Order No.: ∗∗∗
Fig. 2.1
Fig. 2.2
Non-explosion-proof version Explosion-proof version
2.3 Structure
The rotary airlock for milling installations is exclusively meant for dosing and feeding
free-flowing bulk material in a pneumatic conveyor system. It can also be used to
separate two different pressurised containers.
The rotary airlock for milling installations (Fig. 2.3) consists of a housing (1) with an
inlet and an outlet, the rotor (2) complete with rotor and shaft (3) and the two hous-
ing covers (4). The rolling bearings (5), which are lifetime lubricated with food-safe
grease, are integrated in these covers. The integrated bearing seal protects the
bearing against dirt and leakages of grease. An additional seal (6) to protect the
bearing has been inserted into the front of the rotor.
1 6
5
2
Fig. 2.3
2.4 Operation
The bulk material that is poured into the inlet (A) is caught by the rotor (C) and deliv-
ered into the outlet (B).
In the application pneumatic in the mill stock conveying system, the airlock is con-
nected to the cyclone via the sight glass. On coast-down, connection to the spouting
is made via a reducing pipe. In other applications, such as cyclones and filters, the
airlock is often connected directly to the relevant element.
Integration into the conveyor line of a pneumatic suction or pressure system is also
possible with a feed nozzle.
Fig. 2.4
2.5 Design
The rotary airlock for milling installations is available as standard as follows:
Housing GG
Cover GG
Rotor GGG
Rotor shaft Steel
Inlet/outlet
MPSN-25/23
Inlet Outlet
MPSN-25/15 MPSN-25/15
Fig. 2.5
2.8 Options
• SEW parallel helical gear motor
• MOVIMOT® frequency inverter
• NORD parallel helical gear motor
• TRIO SK300E frequency inverter
• Shaft speed monitor
• Airlock table
• Sight glass
• Reducer pipe airlock inlet
• Feed nozzle
Note:
For information on:
– gear motor
– frequency inverter
– shaft speed monitor (inductive proximity sensor)
see separate documents of the respective suppliers.
Part number 823 022 6 823 023 4 823 024 2 823 025 0 823 026 9
Output power at Prated 1,1 kVA 1,4 kVA 1,8 kVA 2,2 kVA 2,8 kVA
Vin = 380…500 VAC
Connection voltages Vin 3 x 380 VAC / 400 VAC /415 VAC /460 VAC /500 VAC
Permitted range Vin = 380 VAC -10 %…500 VAC +10 %
Rated system current Isystem 1,3 AAC 1,6 AAC 1,9 AAC 2,4 AAC 3,5 AAC
(at Vin =400 VAC)
Output rated current Irated 1,6 AAC 2,0 AAC 2,5 AAC 3,2 AAC 4,0 AAC
3 Transport
The transport must only be handled by persons who are familiar with and trained for
this task.
Danger!
Never stand under suspended loads.
Caution!
The hoisting gear has to be checked for the required design and the permissible
load capacity. Only the specified attachment points may be used when lifting.
Note:
Generally the transport weights in the shipping papers apply and have to be
observed!
Generally the airlock is assembled on site with the airlock table and other airlocks
via couplings! With another scope of supply the assemblies are mounted according
to the prevailing circumstances.
4 Installation
4.1 Site conditions
Depending on use, the airlock is supplied as a single element or as a sealing and
discharge unit or installed on site on the airlock or sifter table. First the airlock tables
are to be installed in the correct position. The alignment of the feet (Fig. 4.1 and 4.2,
item 1) is especially important here, so that no stresses are transferred to the air-
locks to be installed. The horizontal position of the axes and longitudinal beams
(Fig. 4.1 and 4.2, item 2) must correspond to that of the air collection line.
Danger!
For safety reasons, service openings must be at least 850 mm away from the
airlock to avoid hands touching the rotor.
4.1.2 Setting up
When mounting the air locks, there must be sufficient space on the airlock shafts
and intermediate airlock shafts, so that the coupling (3) functions correctly. Fit the
shaft covers (4) after installing the terminal clamps (5). For the version with spur
gearing and coupling (Fig. 4.1), alignment must be made from the drive side. The
drive side is not flexible with regard to the arrangement on the airlock table. For the
version with quill gear (Fig. 4.2), flexibility is greater.
4 4
3 3
5 5
2 2
1 1
4.2 Installations
Note:
With the frequency inverter the direction of rotation is altered with the terminals
and
• Also make sure that the bulk material can discharge freely.
• When connected to a pneumatic suction or pressure conveying system, first
switch on the blower for the conveying air, and then turn on the airlock drive.
Water = category 1
Oil = category 2
5 Commissioning
Commissioning of the rotary airlock, trial run and settings may only be carried out by
suitably qualified and authorised personnel.
5. Service covers which are closer than 85 cm to the rotor of the airlock are fitted
with a prohibitive sign Access prohibited, risk of injury.
Danger!
For all checks which require the airlock to be at standstill for safety reasons,
always switch off the control and mains switch, withdraw the key, and
switch off and lock all master switches.
The airlock is remote-controlled. If acting carelessly, danger of accidents
may arise.
Danger!
The airlock must be equipped with an all-pole disconnecting and lockable
safety switch. Prior to checks, always switch off this safety switch, and
secure it with a padlock to make sure it is not switched on unintentionally.
Fig. 5.1
Note:
With incorrect installation, the housing can be distorted via the cyclone with the
pneumatic or air collection line. This can be the reason for the rotor scraping
against the housing. (The gap should be evenly distributed [left-right and top-bot-
tom].)
• Check whether all shaft covers (Fig. 4.1 and Fig. 4.2, ! 4-1, item 4) are correctly
fitted.
Danger!
Never start the machine without all protective covers.
• Make sure the product feed and discharge are there and are connected prop-
erly.
• Check the oil level in the gear motor.
• Check the operativeness of the emergency-off switch.
• Never carry out an initial start-up of the airlock without supervision on the site.
• Limit the duration of the trial run to 10 minutes.
• Should the conveying pressure vary strongly or be inhomogeneous (different
conveying routes), make sure that the setting of the safety valve assumes max.
conveying pressure and this is not higher than the max. airlock pressure!
• With pneumatic conveyors, check the correct functioning of the safety valve
(locks).
Note:
In case of problems or malfunctions during the trial run, check and eliminate them
(see Chapter 6.1, ! 6-1).
6 Operation
The machine may only be operated by specialist personnel trained and qualified for
this task.
Danger!
For all checks which require the machine to be at standstill for safety rea-
sons, always switch off the control and mains switch, withdraw the key, and
switch off and lock all master switches.
Operation can be started after a trouble-free trial run. Should malfunctions occur
during operation, observe chapter 6.1.
Check the elements regularly. By doing so, malfunctions can be discovered early in
time, and the necessary measures can be initiated.
6.1 Troubleshooting
Fault Cause Remedy
Throughput rate is too Bulk material supply is Check supply
low insufficient
Rotary speed is too low Increase speed
Dosing is insufficient Improve dosing,
or adjust dosing flap properly
Non-circular rotation Bearing is defect Check bearing and replace if
necessary
Rotor is blocked Foreign object is in the airlock Remove and repair the rotor
Temperatures are too high, Depending on the situation, either
or temperatures vary increase the play, or insulate or
heat the airlock
Airlock cannot be started Defect in the machine or plant See control system operating
control system instructions
Gear motor is not connected Connect gear motor correctly
Gear motor is overheated Let gear motor cool down, and elim-
inate the cause of the overheating
Gear motor is thermally Product friction is too high Clean the airlock
overloaded (possibly melted product)
Cool the product
If necessary, increase the airlock
play, and bevel the rotor blades
Bearing has overheated Check bearing and replace if
necessary
Product penetrates at the Seals are defect Replace seal and bearing
rotor shaft
Lubricant appears at the Shaft seal of the bearing is leaky Replace the seal
rotor shaft
7 Maintenance
Maintenance of the rotary airlock for milling installations may only be carried out by
suitably qualified and authorised personnel.
Danger!
When carrying out servicing, cleaning, or overhaul works, the rotary airlock
must always be at standstill (all airlock movements stopped).
The all-pole disconnecting and lockable main switch must be set to «0» and
be locked.
The drive motor of the rotary airlock must be equipped with an all-pole dis-
connecting and lockable safety switch. This switch must always be switched
off and locked with a padlock when carrying out maintenance, overhaul and
servicing works. Make sure the product feed and the conveying air feed are
cut off.
Note:
Always remove dust, dirt, or product deposits. Keeping the airlock clean and
observing the maintenance rates increases the operational safety of the airlock.
Normally, maintenance work at the rotary airlock for milling installations is confined
to checking the wear symptoms (seals). The airlocks of all sizes are equipped with
sealed ball bearings. These are lifetime lubricated and cannot be relubricated.
Replace bearing as necessary.
Note:
Also observe the separate manufacturer‘s maintenance and servicing instructions
for the gear motor.
Projecting electric cables may only be cleaned with damp cloths without solvents.
7.2 Lubrication
The bearings used in this airlock are lifetime lubricated with food-safe grease class
H1 in accordance with USDA. The built-in bearing seals prevent the grease leaking
and becoming contaminated.
If the grease is nevertheless used up, a new bearing is to be inserted!
3 4
1 2
Fig. 7.1
7
1 1
4 6
Fig. 7.2
Note:
Replace worn out or damaged parts. Wipe off and remove grease which has
leaked out of the bearing. If there is no longer sufficient grease in the bearing,
please order new bearing from Bühler replacement parts service!
Procedure:
1. If necessary, first disassemble the drive or the shaft speed monitor.
2. Remove the cover (3) (see Chapter 7.3.3, ! 7-3).
3. Remove old shaft seals (4) and bearings (5).
4. Clean the turned grooves of the defective shaft seal in the airlock and the
defective bearing in the housing cover as well as the shaft (1) and the airlock
(2).
5. Check surface of the shaft and cover and repair if necessary.
6. Insert new bearing and seals.
2
4
Fig. 7.3
Danger!
Prior to starting the dismantling, disconnect the drive motor from the mains
with the all-pole disconnecting safety switch. Switch off the product feed
and the rinsing air.
Procedure:
1. If necessary, first remove the drive or the shaft speed monitor.
2. Remove the cover (see Chapter 7.3.3, ! 7-3).
3. Pull the rotor out of the housing.
4. If necessary, separate shaft and rotor.
5. Assemble in reverse order.
Caution!
Make sure no foreign objects can enter the inside of the airlock while the rotor is
installed. Chips, screws, welding beads, etc. may cause sparks and thus lead to
dust explosions. Furthermore, check the width of the slit. The rotor must not
scrape when rotating!
7.5 Disposal
The rotary airlock and its components must be disposed of in accordance with
locally valid regulations.
Once the rotary airlock is definitively decommissioned all components must be
properly disposed of or recycled in the interests of environmental protection:
• Fluids (Diesel, motor and gearbox oil etc.)
• Hazardous waste (e.g. batteries, electronic parts)
• Separate plastic parts
• Pre-sort metal according to type
8 After-sales service
8.1 Stockkeeping of spare parts
Please use the following pages with the appropriate illustrations when ordering
spare parts.
Please note that special manufacturing and delivery specifications are frequently
applied to Bühler and non-Bühler parts and that the spare parts supplied by Bühler
will always conform to the latest technical state of development.
Ordering instructions
An order for spare parts must include the following information:
Note:
These order details are required in order to prevent incorrect deliveries.
In case of uncertainties, please enclose dimensioned sketch with description.
When placing an order for spare parts without part numbers, state subassembly
number and instead of the part number the item number on the parts list.
Motors or gears units:
Indicate the motor or gear unit number when making any inquiries or placing
orders for spare parts.
Abbreviations
V = Wear part
E = Replacement part
8.2 Address
Bühler AG
Ersatzteildienst Grain Processing
CH-9240 Uzwil, Switzerland
Fax +41 71 955 34 17
10
3
6
9
7
5
Fig. 8.1
8.3.1 MPSN-25/15
Drawing No.: MPSN-82001
8.3.2 MPSN-25/23
Drawing No.: MPSN-82000