Formula Air RS-EXL User manual

RS-EXL – Ex rotary valve
Maintenance manual

1



Table of contents
1.Introduction.…………..…………………………………………………………………………………..……….…..2
2.Declarationofconformity…………………………....…………………………………………..……………..3
3.Typeofcertificate…………………………....………………………………………..…………………………...4
4.Usage&functionaldescription…………………………....………………..………………………………..6
5.Warning&Safetyinstructions…………………………....……………..………………….………………..8
6.Delivery/Mounting/Storage…………………………………………..………………………………………8
7.Mounting………………………………………………………………………..…………………………….………….9
8.Operation/Maintenance………………………………………………..……………………………………….9
9.Troubleshooting……………………………………………………………..………………………….…………….11
10.Spareparts……………………………………………………………………..………………………..…………….12
11.Disassemblyandrecycling….……………………………………………………………………………………13
12.Contacts…..…………….……….….……………………………………….……..……………………….…….…….14

2



1. INTRODUCTION


WearepleasedthatyouhavechosenanExrotaryvalvethathasbeenthoroughlytested,
andonlymaterialsandcomponentsfromrecognizedsuppliersareused.Inordertoobtain
optimaluseofthepropertiesoftheExrotaryvalveitispresumedthattheuserreadsthis
manualthoroughly.

AnExrotaryvalve(RS‐EXL)istypeapprovedfordustexplosionclassSt1.

AlwaysreadthismanualthoroughlybeforecommissioningofanExrotaryvalve.Pleasepay
specialattentiontothesectionconcerningmaintenance,ascorrectmaintenanceoftheEx
rotaryvalveisaprerequisitefortrouble‐freeoperation.Furthermore,itisaprerequisitethat
themanualiscompliedwithinordertokeepthewarrantyontheExrotaryvalve.

ThismanualmustbekeptthroughoutthelifeoftheExrotaryvalve.Inconnectionwith
reorderingofthemanual,theordernumberonthetypeplatemustbestated.
Youarewelcometocontactusforfurtherinformationandcomments.

Pleasenotethatmounting,operationandmaintenanceofanExrotaryvalveonlymustbe
carriedoutbyskilledpersonnel.




3



2. ECDECLARATIONOFCONFORMITY

Manufacturer: Moldow A/S
Jørge Hansens Vej 1
D K-6670 Holsted
Hereby states that EX rotary valve type:
RS-EXL
is in compliance with the following provisions:
EC directive on machinery 2006/42/EC of 17th May 2006 with specific reference
to exhibit I of the directive concerning important safety and health requirements in
connection with construction and manufacture of machines.
EMC-directive 2014/30/EU of 26th February 2014 on the harmonisation of the
laws of the Member States relating to electromagnetic compatibility.
ATEX-directive 2014/34/EU of 26th February 2014 on the harmonisation of the
laws of the Member States relating to equipment and protective systems intended
for use in potentially explosive atmospheres.
Furthermore declare that the following harmonized standards have been used:
EN ISO 12100:2011 General principles for design - Risk assessment and risk
reduction
EN 1127-1:2011 Explosive atmosphere – basic concepts and Methodology
EN 15089:2009 - Explosion isolation systems
EN 60204-1:2006 Electrical equipment of machines
The rotary valve is constructed in accordance to the ATEX-directive Group II
category 1 intended for use at zone 20 (II 1/- D).
The technical dossier is kept with notified body: FTZU
Director
Holsted, the 03-12-2014
EC declaration of conformity
K. Preben Hansen

4



3. TYPEOFCERTIFICATE
































5





































6




4. USAGE&FUNCTIONNALDESCRIPTION
AnEx‐rotaryvalveisconstructedforfollowinguse:
 Safetycomponentforisolationofexplosionsonaplant
 Non‐compressedunloadingofmaterials


TheExrotaryvalveisfunctionallybuiltupofthefollowingmainelements:
 Rotorcasing
 Rotor
 Driveset(motor,gearandcoupling)

4.1. Rotorcasing
Therotorcasingismadeofsheetsteel.Inletandoutletareprovidedwithflangeconnection.
Theendplatepositionedatthedrivesetcanbedismountedinawaythatprovidesaccessto
therotor.Therotorcasingisexternallycoatedwithprimerandfinishpaint.

4.2. Rotor
Therotorisbuiltupofarotorshaftmountedwith8setsofbladeretainersinhotgalvanized
plate.Sealingbladesindurablematerialaremountedinthebladeretainers.

4.3. Driveset
Therotorisdrivenbyanelectricmotor.Theconnectionbetweenrotorandelectricmotoris
establishedbycouplingandgear.

4.4. Protectivesystem

7



Theexplosionresistantrotaryvalves(RS‐EXL)havebeentestedasexplosionblockingdevices
industexplosivehazardouscontainersand/orequipment(zone20internally)forflammable
dusttypes(Kstmax).Theexplosionpressureimpactstrengthandbreak‐throughresistanceof
theExrotaryvalveshavebeendemonstratedwithcoaldustuntilthemaximumreduced
explosionpressurepred,maxasflamebreak‐ throughorsparkbreak‐throughdidnottake
place.
Break‐throughandflamebreak‐throughresistanceinandagainstthetransportdirectionhave
beensecured.
Thesealinglistsmustensureimpermeabilitybetweenrotorandcasing.
Userhastoaddsuchequipmentthatupondetectionofanexplosiontherotaryvalvewillstop
automaticallyandinstantaneously.

4.5. Technicaldata
NetweightMax.110kg
RotatingspeedRS‐3Max.38rpm
RotatingspeedRS‐7,5/9Max.18rpm

4.6. Transport
Thetypeoftransport,time,packagingandtemperaturehastobetakenintoconsideration,
byselectingasafemethodoftransport.

4.7. Lifting
Incaseoflifting,useonlyapprovedliftingequipment.Donotstay
underoverhangingloads–DANGERZONE!!!
IMPORTANT:
Theliftingequipmentmustbeapprovedforthecurrentload.
Makesurethatliftingandloweringoccurasslowlyaspossible.Shock,vibrationandfallmay
causeimbalanceandinjury.

4.8. Failure
Anyelectricalfailuremustberectifiedbyauthorizedpersonnelonly.Anymechanicalfailure
mustberectifiedbyauthorizedpersonnelonly.

4.9. Cleaning
Thepowersupplytotheunitmustbedisconnectedsafelyandsecuredagainstreconnection
beforecleaning.






8



5. WARNING&SAFETYINSTRUCTIONS
WARNING‐WARNING‐WARNING!!!
THEPOWERSUPPLYTOTHEPLANTMUSTBEDISCONNECTED
PROPERLYANDSECUREDAGAINSTRECONNECTINGBEFOREANY
KINDOFMAINTENANCEMUSTBECOMMENCED!

TheExrotaryvalveisasafetycomponentforwhichreasonthiswarningsignisplacedonit:
Unintendedusemaycausesqueezing/crushingofhandsandfingers.
Rotatingshaft
Ifthemotorisconnectedelectrically,therotorwithrubberbladesmaybeabletorotate,and
thehandsmaygetsqueezed.Consequently,themotormustnotbeconnecteduntiltherotary
valvehasbeeninstalledunderthefilterandtheductforconveyingthewastehasbeen
installed.
Ifthemotoristobeinstalledinconnectionwithasilo,thecyclonemustbemountedonthe
rotaryvalveandthevalveboltedontothesilobeforeconnectingthemotor.

6. DELIVERY/MARKINGS/STORAGE

6.1. Delivery
Ondelivery,theExrotaryvalveisequippedwithmotorandgear,whichareselectedby
Moldow.

6.2. Marking
Therotaryvalveismarkedaccordingtocurrentrequirements.Thetypeplatestatesamong
otherstype,ordernumberandyearofmanufacture.





9



6.3. Storage
Untilmountingiscommenced,anExrotaryvalvemustbestoredunderconditionsthatprevent
rusting,corrosion,decompositionanddeformations,oranotherkindofstorage,whichcanlead
toriskofmalfunction.

7. MOUNTING

AnExrotaryvalvemustnotbestarteduntilithasbeenmechanicallyconnectedonboth
sides.
TheExrotaryvalvemustbesealedonbothsidesoftheholeseriesandboltedinthe
predrilledholeswithM8bolts.
Important:Alwayswearthesafetyequipmentrequired.

7.1. Electricalconnection
Electricalconnectionmustonlybecarriedoutbyacertifiedelectrician.
Inrelationtoelectricalconnection,therotatingdirection
oftherotaryvalvemustbechecked.Therotating
directionisindicatedbythearrowonthecoupling
housing.
Theelectricalconnectionmustbecarriedoutinaccordancewith
currentnationalregulation.

7.2. Electrostaticbond
ElectrostaticbondingofanExrotaryvalvemustbecarriedout
beforecommissioning

8. OPERATION/MAINTENANCE

IfthereisanydoubtwhetheranExrotaryvalveoranyimportantparts
hereofisintactuntilnextoverhaul,replacementmustalwaysbe
carriedout.

Important:Alwayswearthesafetyequipmentrequired.
Thenationalsafetyrulesinforcemustbeobserved.

8.1. Periodicmaintenance
InorderfortheExtypeapprovaltobeguaranteedbythemanufacturer,maintenancemust
becarriedoutbythemanufactureroradistributorappointedbythemanufacturer.
Maintenancemustalwaysbeincompliancewiththedirectionsinthemanual.

10



8.2. Overhaul
Inorderforthemanufacturer’sguaranteeforexplosion‐safeguardtoapply,thecustomer
musthaveregularmaintenancecarriedoutbythemanufactureroradistributorappointed
bythemanufacturer.
Inorderfordistributorstobeapprovedtocarryoutmaintenanceforthemanufacturer,they
mustbetrainedbythemanufacturer.
Thefollowingmustbechecked:Sealingblades,bearings,coupling,gearandmotor.
Note!!!Sealingbladesandsealingringmustbeimpermeable!

Overhaulmustminimumtakeplaceevery6monthsoraccordingtothisschedule:
MaterialO
p
eration hours annuall
y
No. o
f
timesannuall
y

Softwood1600 2
Hardwood1600 3
Softwood3200 4
Hardwood3200 6
Softwood4800 6
Hardwood4800 8

8.3. Motor,gear&bearings
Maintenanceaccordingtotheattachedsupplierdocumentation.

8.4. Rotor
Ifthesealinglamellasarenotimpermeable,theymustbereplaced.Visualinspectionis
carriedout.

8.5. Noise
Thenoiseratioofthecomponentinourscopeofsupplyinconnectedconditionandwithout
mediaisbelow70dB(A)measuredatadistanceof1meterfromthecomponent.
Noisefromtransportedmediaisnotincluded.
Important:
Ahighernoiselevelmayoccurdependingonlocalconditions,likeamachinewhich
isconnectedwithothermachines.Inthiscaseseparatemeasurementsmayberequired.
Ifthetotalnoiselevelintheareaexceeds85dB(A),hearingprotectionmustbeused.






11



9. TROUBLESHOOTING

FailurePossiblecausesProposedsolutions
Rotaryvalve
switchesoff
thermally
- Foreignbodygotstuck
- Rotorfrozen

- Gearmotordefective
- Rotordefective
- Motorprotectionsetincorrectly
- Fusedefective
- Bigvoltagedropinpowersupply
- Removeforeignbody
- Thawontheoutsidewithhot
airorwater
- Replacethegearmotor
- Replacetherotor
- Adjustthemotorprotection
- Replacethefuse
- Replacethecablestoalarger
square
Rotaryvalveis
notrunning
- Workingswitchisoff

- Motorprotectionswitchedof
thermally
- Conditionsofoperationarenot
metinthecontrolsystem
- Fusedefective
- Stoptheinstallation,switchon
theworkingswitch
- See”Rotaryvalveswitchesoff
thermally”
- Investigatewhyconditionsare
notmet
- Replacethefuse
Rotaryvalve
makes
“screaming”
sound
- Foreignbodygotstuck
- Rotor/rotorhousingdefective
- Removeforeignbody
- Replacedefectivepart
Thematerialwill
notpassthevalve
without
accumulation
- Volumeofmaterialpertimeunitin
periodslargerthanplanned




- Airflowoppositethroughthe
valvepreventspropermaterial
flow
- Settlingvelocityofmaterialless
thanexpected
- Thematerialaccumulatesin
lumpswhichcannotpass
- Thematerialisnotremovedfast
enoughattheoutletofthevalve
- Reducethevolumeofmaterial
feed,e.g.atchainfilter.
- Morefrequentregeneration
- Shorterstep‐intervalofchain
conveyor
- Replacesealinglamellae



- Adjusttheproductionmachineto
changetheflowofmaterial
- Checkthefunctionofthe
emptyingsystem


12



10. SPAREPARTS
Pos.PartNo.RS‐3PartNo.RS‐7,5PartNo.RS‐9Quan. Description
180106‐073180106‐072680106‐07198Sealingblades
280106‐071880106‐071880106‐07182Sealingring
380106‐073080106‐072580106‐07208bladeretainer
480106‐073380106‐073480106‐07351Shaftcomplete
580105‐009380105‐009380105‐00932Feltplatefordustsealing
680105‐010880105‐010880105‐01082Basefordustsealing0,63mm
780105‐008880105‐008880105‐00882Basefordustsealing2mm
885282‐001685282‐001685282‐00162Flangebearing
985285‐001885285‐001885285‐00182Coupling,half
1085177‐002185177‐002185177‐00212Bushforcoupling
1185285‐001985285‐001985285‐00191Couplingelement
1280106‐042980106‐042980106‐04291Couplinghousing
1385277‐010385277‐004185277‐00411Gear
1485271‐000285271‐004785271‐00471Electricmotor
1580106‐073280106‐072180106‐07101Rotorcasing
1680106‐071380106‐071380106‐07131Endplateforrotorcasing
1780106‐012280106‐009680106‐04481Counterflange

13



11. DISMANTLINGANDRECYCLING

Whendismantlingaunit,besuretokeepinmindthefollowingimportantinformation:
Astheunitisdismantled,setasideallstillfunctioningpartsinordertore‐usethemon
anotherunit.
Youshouldalwaysseparatethedifferentmaterialsdependingontheirtype:iron,rubber,
oils,greases,etc…
Recyclablepartsmustbedisposedofintheappropriatecontainersorbroughttoalocal
recyclingcompany.
Therubbishmustbecollectedinspecialcontainerswithappropriatelabelsanddisposedof
incompliancewiththenationallawsand/orlocallegislationsinforce.
CAUTION!Itisstrictlyforbiddentodisposeoftoxicwastesinmunicipalsewerageanddrain
systems.Thisconcernsalloils,greases,andothertoxicmaterialsinliquidorsolidform.











14



12. CONTACTS
ForsparepartspleasecontactFormulaAirGroup.
FormulaAir
TheNetherlands
Bosscheweg 36
SX 5741 Beek en Donk
The Netherlands
Tel: [phone]
Fax: [phone]
[email protected]
view Google Map
FormulaAir
Belgium
Rue des Dizeaux 4
1360 Perwez
Belgium
Tel: [phone]
Fax: [phone]
[email protected]
view Google Map
FormulaAir
Baltic
Televizorių G.20
LT-78137 Šiauliai
Lithuania
Tel: [phone]
Fax: [phone]
[email protected]
view Google Map
FormulaAir
France
Zac de la Carrière Doree
BP 105, 59310 Orchies
France
Tel: [phone]
Fax: [phone]
[email protected]
view Google Map
FormulaAir
EstAgenceFrance
2, rue Armand Bloch
25200 Montbeliard
France
Tel. [phone]
Fax [phone]
[e-mail]
view Google Map
FormulaAir
FranceAgenceOuest
19a rue Deshoulières
44000 Nantes
France
Tel. [phone]
Fax [phone]
[email protected]
view Google Map
FormulaAir
FranceAgenceSud
Chemin de Peyrecave
09600 Regat
France
Tel: [phone]
Fax: [phone]
[e-mail]
view Google Map
AirFormula
Russia
Нижний Новгород
Россия
Tel: [phone]
Fax: [phone]
[email protected]
View Google Map
FormulaAir
Vietnam
# 33, Lot 2, Den Lu 1
Hoang Mai District, Hanoi,
Vietnam
Tel: [phone]
Fax: [phone]
[email protected]
www.vinaduct.com
View Google Map
NOTE:Alldrawingsandreferencescontainedwithinthismanualarenon‐contractualand
aresubjecttochangewithoutpriornoticeatthediscretionoftheFormulaAirgroupandits
partners.

