Buhler MAYV Series User manual
Operating instructions Rotary distributor
MAYV (-Ex)
Original operating instructions
MAYV-20150-2-1808-en-US
Table of contents
1 Important information 4
1.1 Availability of the instructions ....................................................................... 4
1.2 Scope of validity ............................................................................................ 4
1.3 Applicable documents ................................................................................... 4
1.4 Contact .......................................................................................................... 4
1.4.1 Feedback regarding these instructions ......................................... 4
1.5 Personnel qualification .................................................................................. 4
1.5.1 Mechanics ...................................................................................... 4
1.5.2 Electricians .................................................................................... 5
1.5.3 Welders .......................................................................................... 5
1.5.4 Bühler service personnel .............................................................. 5
1.5.5 Owner's service personnel ............................................................ 5
1.6 Presentation conventions .............................................................................. 5
1.6.1 Explanation of warning messages ................................................ 5
2 Safety 6
2.1 Intended use ................................................................................................. 6
2.1.1 ATEX marking (Ex II 3D) .............................................................. 6
2.2 Technical condition ........................................................................................ 6
2.3 Personnel qualification .................................................................................. 7
2.4 Securing against unexpected startup ........................................................... 7
2.5 Protective devices ......................................................................................... 7
2.6 Safety signs ................................................................................................... 7
2.7 Safe work environment ................................................................................. 7
2.7.1 Slipping and tripping hazards ....................................................... 7
2.7.2 Aspiration ....................................................................................... 7
2.8 Fire protection ............................................................................................... 8
3 Technical data 9
3.1 Environmental conditions .............................................................................. 9
3.2 Features ........................................................................................................ 9
3.3 Operating supplies ........................................................................................ 9
3.3.1 Gear oil .......................................................................................... 9
3.4 Acoustic emission ......................................................................................... 10
3.4.1 Measured values ........................................................................... 10
3.5 Weights .......................................................................................................... 10
3.6 Dimensions .................................................................................................... 10
3.7 Electrical specifications ................................................................................. 11
3.7.1 Gearmotor ...................................................................................... 11
4 Description 12
4.1 Identification .................................................................................................. 12
4.1.1 Nameplate ..................................................................................... 12
4.1.2 Type code ...................................................................................... 13
4.1.3 Explanation of ATEX marking ....................................................... 13
4.2 Overview ........................................................................................................ 14
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Table of contents
4.3 Operating principle ........................................................................................ 14
4.4 EMERGENCY STOP .................................................................................... 14
4.5 Safety signs ................................................................................................... 15
5 Transportation 16
5.1 Safety ............................................................................................................ 16
5.1.1 Suspended load ............................................................................ 16
5.2 Packaging symbols ....................................................................................... 16
5.3 Checking delivery .......................................................................................... 16
5.4 Intermediate storage ..................................................................................... 16
5.5 Lifting instructions ......................................................................................... 17
6 Assembly 18
6.1 Installation ..................................................................................................... 18
6.2 Installing product connections ...................................................................... 18
6.3 Connecting supply units ................................................................................ 18
6.3.1 Connecting the electrical installation ............................................ 18
7 Commissioning 19
7.1 To be checked before commissioning .......................................................... 19
7.2 Inspection of EC conformity ......................................................................... 19
8 Operation 20
8.1 Starting and stopping the machine .............................................................. 20
8.1.1 Starting .......................................................................................... 20
8.1.2 Starting machine after EMERGENCY STOP ............................... 20
8.1.3 Stopping ......................................................................................... 20
9 Fault elimination 21
9.1 Faults ............................................................................................................. 21
10 Maintenance 22
10.1 Cleaning ........................................................................................................ 22
10.1.1 Cleaning schedule ......................................................................... 22
10.2 Lubrication ..................................................................................................... 22
10.2.1 Lubrication schedule ..................................................................... 22
11 Decommissioning 23
11.1 Disassembly .................................................................................................. 23
11.2 Disposal ......................................................................................................... 23
11.2.1 Disposing of operating supplies .................................................... 23
11.2.2 Disposing of the machine ............................................................. 23
Bühler AG
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Table of contents 3
1 Important information
1.1 Availability of the instructions
These instructions constitute part of the product.
►Retain the instructions and other applicable documents over the entire life-
time of the product and keep them at hand for reference.
►Pass on the instructions and other applicable documents to the next owner
or operator of the product.
1.2 Scope of validity
Type Designation
MAYV Rotary distributor with 4, 5, 6 or 8 outlets
Diameter of outlets: 120, 150
Diameter of inlets: 150, 200, 250
1.3 Applicable documents
The following documents are part of these instructions:
Designation Identification number
Spare parts catalog 20130-1
Circuit diagram Customer-specific
Gearmotor Refer to the documentation supplied by the manufacturer.
1.4 Contact
►If you have any questions, please contact the nearest branch of the Bühler
Group. See www.buhlergroup.com.
►Keep the instructions handy.
►Keep the machine number handy.
1.4.1 Feedback regarding these instructions
Send requests and suggestions relevant to these instructions to
1.5 Personnel qualification
1.5.1 Mechanics
Personnel who work on mechanical devices must be technically qualified or
have completed the training by the Bühler Group.
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Chapter 1 Important information
1.5.2 Electricians
Personnel who work on electrical devices must be technically qualified or have
completed the training by the Bühler Group.
1.5.3 Welders
Personnel who weld on the equipment must have specialized training.
1.5.4 Bühler service personnel
Manufacturer's personnel who execute the assembly and commissioning, as well
as complex service and maintenance tasks.
1.5.5 Owner's service personnel
Individuals who operate the machine must be technically trained or have attend-
ed and passed the manufacturer's training.
1.6 Presentation conventions
1.6.1 Explanation of warning messages
DANGER
Nature and source of the danger.
The danger will result in death or severe injuries.
►Measures to protect against the danger.
WARNING
Nature and source of the danger.
The danger may result in death or severe injury.
►Measures to protect against the danger.
CAUTION
Nature and source of the danger.
The danger may result in injuries.
►Measures to protect against the danger.
CAUTION
Nature and source of the danger.
The danger may result in property damage.
►Measures to protect against property damage.
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Chapter 1 Important information 5
2 Safety
2.1 Intended use
The rotary distributor is designed for the continuous distribution of a product
stream to 4 to 8 outlets. It is suitable only for free-flowing and dry, non-abrasive
products.
Any use that exceeds the contractually defined range of application is consid-
ered non-intended.
►Use the machine only as intended.
►Operate the machine only in accordance with these operating instructions.
2.1.1 ATEX marking (Ex II 3D)
When used as intended, the machine interior does not have any inherent poten-
tial ignition sources, even in the event of faults, which could cause an explosion.
The interior can be connected to any hazardous area.
No ignition sources may be fed into the machine.
An ATEX marking with a device category for the interior is therefore not re-
quired.
If the machine is identified on the nameplate as a 3D device, then it is approved
for operation in Zone 22.
►Connect the machine only to devices that have no ignition sources or to de-
vices in device categories 3, 2 or 1.
►Do not introduce any ignition sources into the machine.
►Refer to the nameplate.
2.2 Technical condition
If the machine is operated in poor technical condition, its safety, function and
availability are compromised.
►Operate the machine only when it is in perfect technical condition.
►Comply with the maintenance schedule.
►Only use original spare parts listed in the spare parts catalog.
►If the operating behavior of the machine changes, check the machine for
faults.
►Eliminate any faults immediately.
►The machine must not be modified or converted without approval from the
manufacturer.
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Chapter 2 Safety
2.3 Personnel qualification
Unqualified personnel cannot recognize risks and are thus exposed to greater
danger.
►Allow only technically qualified personnel to perform the activities described
in these operating instructions.
►Ensure that personnel comply with the local laws and regulations for safe
and hazard-conscious work.
►Define and communicate work responsibilities. Provide keys and passwords
to assigned staff only.
2.4 Securing against unexpected startup
If the machine starts up unexpectedly, individuals working on the machine could
be severely injured.
►Set the safety switch to <0> and lock it.
►Pull out the key and keep it with you.
2.5 Protective devices
People are at risk when protective devices are not functioning effectively.
►Before operating the machine, ensure that all protective devices are function-
ing effectively.
2.6 Safety signs
If safety signs are not noticeable, people are at risk.
►Replace safety signs which are not noticeable.
►Do not remove or cover safety signs.
2.7 Safe work environment
2.7.1 Slipping and tripping hazards
Slippery surfaces and tripping hazards may result in serious accidents.
►Keep aisles, handles, steps, ladders, platforms and guard rails free of
grease, oil and other contamination.
►Do not use the machine as a climbing aid or storage area. Use only the
steps and platforms provided.
►Wear non-slip safety footwear.
2.7.2 Aspiration
Gases and dusts are harmful to health and can result in dangerous situations
during operation of the machine.
►Leave aspiration equipment activated during operation of the machine and
do not remove.
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Chapter 2 Safety 7
2.8 Fire protection
During operation, an excessively high product temperature or flammable parti-
cles can cause a fire.
►Ensure that personnel know the fire prevention measures.
►Prepare a water connection for extinguishing fires.
►Keep a fire extinguisher near the machine.
►Hang up fire prevention measures where they are clearly visible.
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Bühler AG
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Chapter 2 Safety
3 Technical data
3.1 Environmental conditions
Designation Value Unit
Temperature range +5 … +40 °C
Relative humidity 30 … 95 %
3.2 Features
Capacity
Designation Value Unit
Inlet ø150 40 m3/h
Inlet ø200 84 m3/h
Inlet ø250 141 m3/h
Conveying capacity for flour (0.5 t/m3)
Designation Value Unit
Inlet ø150 20 t/h
Inlet ø200 40 t/h
Inlet ø250 60 t/h
Conveying capacity for wheat (0.75 t/m3)
Designation Value Unit
Inlet ø150 30 t/h
Inlet ø200 60 t/h
Inlet ø250 100 t/h
3.3 Operating supplies
3.3.1 Gear oil
Refer to the documentation supplied by the manufacturer:
■Getriebebau NORD
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Chapter 3 Technical data 9
3.4 Acoustic emission
3.4.1 Measured values
The measured values do not take ambient effects into account.
Designation Value Unit
Equivalent workplace-related emission value LpA ≤70 dB (A)
3.5 Weights
Designation Value Unit
Unpackaged without supports 95 kg
Unpackaged with supports 120 kg
3.6 Dimensions
40
A
670
50
580225
D
50
800
819
ø600
B
35°
210
C
ø590
Fig. 3.1
A 150 / 200 / 250
B 4 outlets 5 outlets 6 outlets 8 outlets
90 ° 72 ° 60 ° 45 °
C 120 / 150
D According to purchase order
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Bühler AG
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Chapter 3 Technical data
3.7 Electrical specifications
3.7.1 Gearmotor
Designation Value Unit
Brand Nord
Power consumption 0.37 kW
Degree of protection IP55
Speed 29 rpm
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Chapter 3 Technical data 11
4 Description
4.1 Identification
4.1.1 Nameplate
Model:
SerialNo.: Manufactured:
*
(5)(5)(6)
(2)
(3)
(4)
(1)
Fig. 4.1 Nameplate
(1) Manufacturer (4) Year of manufacture
(2) Address of the manufacturer (5) Machine number
(3) Machine type (6) ATEX marking
Position of the nameplate
Fig. 4.2
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Bühler AG
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Chapter 4 Description
4.1.2 Type code
MAYV-15-2-6-Ex
MAYV Machine code
15 Inlet diameter 150
2 Discharge diameter 120
6 Number of outlets
Ex Approval for potentially explosive atmosphere
4.1.3 Explanation of ATEX marking
II 3D T125°C
Marking Meaning
ATEX symbol
II Equipment group
…/3 External category 3
D Dust atmosphere
T Maximum surface temperature in °C to be expected in nor-
mal operation at full load and at a maximum ambient tem-
perature of +40 °C
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Chapter 4 Description 13
4.2 Overview
(3)
(5)
(4)
(6)
(2)
(7)
(8)
(1)
Fig. 4.3
(1) Housing jacket (5) Base plate
(2) Rotary cylinder (6) Gearmotor
(3) Hopper (7) Inlet
(4) Drive shaft (8) Lid
4.3 Operating principle
The product stream is distributed uniformly through a rotary cylinder rotating at
29 rpm to the hoppers and thus to the outlets. Because the housing is tight, it
requires no additional aspiration connection.
4.4 EMERGENCY STOP
The EMERGENCY STOP stops the machine in dangerous situations.
The EMERGENCY STOP button is integrated in the system control unit.
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Chapter 4 Description
4.5 Safety signs
Safety signs warn against dangers.
Fig. 4.4
Safety signs Meaning
Set the safety switches to “0” and lock them.
No reaching in.
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Chapter 4 Description 15
5 Transportation
5.1 Safety
5.1.1 Suspended load
Falling loads can cause serious injuries.
►Use only undamaged hoisting devices with a sufficient rating.
►Fasten loads in accordance with regulations.
►Do not step or stand under suspended loads.
►Ensure that there is no one in the danger zone.
5.2 Packaging symbols
(1) (2) (4)
(3) (5)
Fig. 5.1 Packaging symbols
(1) Top (4) Fragile
(2) Protect against moisture (5) Attach here
(3) Center of gravity
►Observe the packaging symbols.
5.3 Checking delivery
►Check the completeness of the delivery according to the shipping note.
►Report any missing parts or transportation damage. See page 4,
chapter “Contact”.
5.4 Intermediate storage
►Observe the packaging symbols.
►Leave the machine and machine parts in the original packaging until assem-
bly work begins.
►Do not store the machine outdoors.
►Protect the machine from the effects of weather.
►Avoid temperature fluctuations.
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Chapter 5 Transportation
5.5 Lifting instructions
Fig. 5.2
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Chapter 5 Transportation 17
6 Assembly
6.1 Installation
1. Bolt supports firmly to floor or ceiling.
2. Align the base plate horizontally with a spirit level.
6.2 Installing product connections
Connect gravity spouts to inlet and outlets. Take care to ensure that the connec-
tions are tight.
6.3 Connecting supply units
6.3.1 Connecting the electrical installation
Installation and inspection work on the electrical elements of the machine may
be carried out only by locally authorized specialists.
►Connect the machine in accordance with the circuit diagram.
Fitting the safety switch
►Fit a lockable safety switch near the machine that has a performance level
of (PL) “a” according to ISO 13849-1.
►Observe local regulations.
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Chapter 6 Assembly
7 Commissioning
7.1 To be checked before commissioning
No. Check ✓
1 All transport aids and assembly fixings have been removed.
2 The electrical installation has been carried out and checked by an
authorized, qualified electrician.
3 All electrical terminal boxes and sockets are closed.
4 The machine is grounded.
5 Direction of rotation of gearmotor is correct.
6 All bolted joints are tightened.
7 There are no foreign objects in the machine.
8 The gearmotor is filled with lubricant.
9 All piping connections are tight.
7.2 Inspection of EC conformity
Operate the machine in the European Union only if EC conformity has been
checked and confirmed using the following checklist.
No. Check ✓
1 The operating company has been informed that the operating in-
structions must be accessible to personnel at all times.
2 The operating company has been informed that it is responsible
for instruction of personnel.
3 Assembly and installation have been carried out in accordance
with the operating instructions.
4
5 The machine is grounded via the motor protection conductor or
the connection labeled with the symbol (equipotential bond-
ing). The paint coating has been removed in the area around the
ground connection.
6 The operating company has been informed that the items in the
operating instructions marked with the symbol MUST be ob-
served for compliance with the ATEX certification. The ATEX ap-
proval ceases to apply if such points are not observed.
7 A lockable safety switch is present, and personnel have a match-
ing lock.
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Chapter 7 Commissioning 19
8 Operation
8.1 Starting and stopping the machine
8.1.1 Starting
1. Start machine via the plant control system. Refer to the documentation for
the control.
2. Start product feed.
8.1.2 Starting machine after EMERGENCY STOP
1. Eliminate the cause of the fault.
2. Reset EMERGENCY STOP button.
3. Start the machine.
8.1.3 Stopping
1. Interrupt the product feed.
2. Discharge the machine completely.
3. Switch off the machine.
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Chapter 8 Operation
Table of contents
