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Positive Pressure Airlock for Flour Mill

Positive Pressure Airlock for Flour Mill

Rotary Valve (Air Lock) Type BFCP User's Manual Wuxi ZhongDa Machinery Equipment CO.,LTD 1. Brief Introduction Air locks in Type BFCP and BFCZ are feeding devices used in pneumatic suction system. They can continuously or intermittently force materials into the positive pressurized pipeline...

Rotary Valve (Air Lock)
Type BFCP

User's Manual

Wuxi ZhongDa Machinery Equipment CO.,LTD

1. Brief Introduction
Air locks in Type BFCP and BFCZ are feeding devices used in pneumatic suction system.
They can continuously or intermittently force materials into the positive pressurized pipeline for air conveying. They can be used as feeding devices of positive pressure conveying system for flour, chaff, bran, cereals, feedstuff, sugar, chemicals, plastic powder and granules, but not suitable for the materials with a strong adhesive force. BFCP air lock has side passways: there are passways below the bearing seats of both sides which are further connected to the conveying pipeline, and an axial directional U-shape discharge channel is equipped below the machine shell, so the materials can only be discharged from both sides. BFCZ air lock has vertical passway: there is no passway on bearing seats of both sides, the discharging port below the machine shell is the same as the feeding port above the machine shell, and the materials are discharged from the machine bottom to an acceleration room connected to the conveying pipeline, and then conveyed off.


2. Technical data & types
2.1Table of technical parameters

Type

Diameter / length of blade wheel (mm)

Volume (m3)

Work pressure (kpa)

Suitable speed (rpm)

Pressure ≤ 50kpa Flour output (t/h)

Drive with decelerator

Speed (rpm)

Power (kw)

BFCP2.5
BFCZ2.5

180/150

0.0025

BFCP

100kpa

40~50

1.8~2

50

0.75

BFCP5.5

BFCZ5.5

220/220

0.0055

BFCZ

50kpa

35~45

4~5

45

0.75

BFCP13.5 BFCZ13.5

280/300

0.0135


35~45

10~12

38

1.1

BFCP28

BFCZ28

360/380

0.028


30~40

18~22

34

1.5

BFCP56

BFCZ56

450/450

0.056


30~40

35~45

32

1.5

BFCP145

BFCZ145

600/600

0.145


25~35

80~100

28

2.2

The discharge volume G of the air lock can be calculated as per the following equation:
G=0.06VnKρ(t/h)
Wherein:
V – volume of air lock(m3)
n – rotation speed (rpm)
ρ—volume weight of material (kg/m3)
K – filling coefficient, 0.6~0.4 at work pressure of 25~100 Kpa, the bigger the pressure, the smaller the coefficient.

2.2 BFCP outer shape and installation dimensions

图片21.png


Type

A

B

C

C1

D

E

E0

E1

E2

F

F0

F1

F2

G

H

H0

Dg

L

d

BFCP2.5

80

180

245

226

180

210

130

180

80

210

130

180

100

346

280

140

45

456

30h7

BFCP5.5

150

220

300

328

220

280

200

250

150

250

170

220

120

442

340

170

65

586

30h7

BFCP13.5

220

300

365

395

280

360

270

330

200

330

240

300

180

522

435

230

100

666

30h7

BFCP28

330

315

480

402

360

450

350

415

300

350

250

315

180

640

550

305

110

800

30h7

BFCP56

390

480

545

402

450

510

410

475

360

410

310

375

200

710

640

345

120

870

30h7

BFCP145

540

600

730

450

600

680

560

635

510

520

400

475

340

946

840

440

180

1238

30h7

2.3 BFCZ outer shape and installation dimensions

图片22.jpg


Type

C

C1

D

E

E0

E1

E2

F

F0

F1

F2

G

H

H0

L

d

BFCZ2.5

245

226

180

210

130

180

80

210

130

180

100

346

280

140

456

30h7

BFCZ5.5

300

328

220

280

200

250

150

250

170

220

120

442

340

170

586

40h7

BFCZ13.5

365

395

280

360

270

330

200

330

240

300

180

522

410

205

666

40h7

BFCZ28

480

402

360

450

350

415

300

350

250

315

180

640

480

240

800

55h7

BFCZ56

545

402

450

510

410

475

360

410

310

375

200

710

580

290

870

55h7

BFCZ145

730

450

600

680

560

635

510

520

400

475

340

946

800

400

1238

70h7


3 Sructure and mechanism
The principles of Type BFCP and Type BFCZ air locks, such as structure, installation, operation, maintenance, troubleshooting and disassembling, are basically similar, The differences have been mentioned in the section of brief introduction, Now take Type BFCP air lock as an example and describe as follows.

●  3.1 The working part consists of such parts as machine shell, blade wheel, left and right bearing seats, etc.

3.1.1 The machine shell is the major part of the equipment. On the top of it is the feeding port. The trunk in the middle of i6t matches with the outside diameter of the blade wheel. Below it is the axial directional U-shape channel.

3.1.2 The blade wheel is made up of the shaft and blade. The trunk of the machine shell is divided into several chambers by the blade wheel, supported by left and right bearing seats in the shell.

3.1.3 The flanges of the left and right bearing seats closely match with both sides of the trunk of shell. They are fastened to the shell with bolts. Below them is the axial passway, which connects inside with the axial directional U-shape channel of the shell, and outside with the pneumatic conveying pipeline.

●  3.2 When the materials from the top of feeding port, drop into the space between blades, they will be taken into the trunk by the constant rotation of the blade wheel and form chambers with materials, then constantly be fed into the U-shape axial channel, and finally be conveyed off by air. However, the feeding port is in atmospheric pressure, while the air in the pneumatic conveying pipe is in positive pressure, because of the large pressure difference between them, the feeding of materials will be affected so as to bring about possible leakage of powder dusts, in view of this, air leakage shall be reduced as mach as possible. The following measures have been taken for the equipment.

3.2.1 The radial clearance between the blade wheel and machine shell and axial clearance between the blade wheel and left/right bearing seats are strictly controlled within certain ranges.

3.2.2 On the left and right bearing seats are the sealing device and air cleaning device. For details please see figure 4.

3.2.3 On one side or both sides of the bearing seats of Type BFCP 13.5(28/30), Type BFCP 28(36/38), Type BFCP 56(45/45) and Type BFCP 145(60/60) air lock is air circulation pipe, through which pressured air can flow into chambers with materials from chambers without materials in the blade and shell.

3.2.4 In the feeding port of the machine shell is the scraper, which is against the rotation of the blade wheel and can prevent materials from being blocked up.

●  3.3 The drive part is mostly equipped for single machine. When the air lock leaves the factory, each unit is equipped with motor drive device with decelerator, as per figure 3. the blade wheel is driven by sprocket and chain. For its rotation power, please see property parameter table.


4. Installation, adjustment, and operation
Before installation and adjustment, you are strongly recommended to read this instruction booklet carefully, and strictly follow all the instructions.

●  4.1 The equipment can be directly installed and put into use after delivered from the factory, however, it may subject to some adverse effects during transportation and long time storage. Therefore, first you should check to ensure that the type is right with your order, the parts are complete and there is no damage or impact mark, then examine if there is enough lubricating oil in the decelerator. Stick into the blade with wood bar and slowly turn the wheel. It must be prohibited to use hands or metal bar to turn the wheel, in order to prevent from hurting fingers or damaging the machine. If the blade wheel runs smoothly and has no abnormal noises, it can be installed. If the blade wheel is stuck with the machine shell, reasons must be found. It may be resulted from impurities jammed and/or rustiness. Depending upon the facts, the foreign matters or rusts must be removed. It should be avoided turning the blade wheel by force wigh wood bar, to prevent blades from deforming and damaging. When required the machine can be disassembled. For relative operation, please see the steps in the 6th section of the 5th chapter.

●  4.2 The air lock should be installed on the base with no stress. In consideration of convenience to install and dismantle without affecting other pipes, parts and devices, the air lock had better be hanged and installed below the support frame. Thus, other pipes and parts can be fixed on the support frame. Please see figure 1. But Type BFCZ air lock should be installed on the frame, so that the acceleration room and conveying pipe can be installed below it. Please see figure2. No matter where it is installed, the plane used for fixing the air lock must be flat and even, any hogging and deforming is prohibited. When fastening bolts, the force should be even, to prevent from deforming the machine shell to affect using.

●  4.3 When positioning the air lock, direction of the air should be taken care of. One side of the stop valve directly connects with the air lock, while the other side connects with air admitting pipe. The air exhaust pipe(conveying pipe) connects with the other side of the air lock, as per figure 3. The action of stop valve is as follows: when materials blocks up the conveying pipe or the air lock, it can prevent the dusty air from flowing backward to the blower and damage it. The rubber flange cushion with a thickness of 3-4mm should be put between the stop valve and flange of the admitting pipe to avoid air leakage. To dismantle and install the air lock conveniently, and in consideration of such factors as heat expansion of the pipe, a 2mm gap should be spared between the stop valve and the air lock, as well as the exhaust pipe(conveying pipe) and the air lock respectively. The special rubber gasket and flanges of our factory should be used for plug connection, as per figure 5. After the pipe is connected, it should be fastened on the support frame of the air lock or the ground(floor). The air source in the pneumatic conveying pipe can be used for the air cleaning pipe. The air source is connected with rubber tube from the air admitting pipe of the stop valve to the pipe joints on the side of right and left bearing seats, as per figure 3. The connection of the rubber tube and pipe joint must be fastened with the clamping ring to avoid air leakage. The air cleaning pipe must be also fastened on the support frame or ground (floor).

●  4.4 On the top of the feeding port of the air lock, the feeding hopper should be installed. The rubber flange cushion with a thickness of 3-4mm should be put between the feeding hopper and the flange of the feeding port of the shell. It must be fastened with bolts, to prevent from air leakage. On the top of the feeding hopper, the suction pipe must be installed. It can suck off the air with positive pressure taken back by the blade wheel. So the materials can smoothly drop into the shell. In the above process of installation, any impurity such as the bolt, nut, gasket, nail, welding residue, metal chips, sand fiber, wood chip, etc., must be avoided dropping into the machine. Once any impurity is dropped into the machine, it must be taken out.

●  4.5 The drive part has no need of installation. As the machine leaves the factory, it has decelerator motor matched with chain drive device. To prevent from overloading or impurities dropping into the machine to block up the blade wheel and damage the machine and motor, the overload protective device should be sued in the electrical circuit. When overloading, the power supply can be automatically cut off to prevent from damaging the equipment. But the control buttons near the machine are still necessary.

●  4.6 Before starting, carefully examine if all parts are firm and proper; if there is enough lubricating oil in the decelerator; if any impurity drops into the machine. Dismantle the motor cover, turn the fan wheel by hands to drive the blade wheel, if the blade wheel turns smoothly and there is no abnormal noise in the shell, reassemble the motor cover, and it is ready for starting. When starting, first inch the control button near the machine and examine if the blade wheel rotates properly (inverse-rotation must be prohibited), then start the machine.

●  4.7 After starting, carefully look, touch, and listen to make sure that the non-load rotation of the machine is good. The machine can be put into use only if it runs smoothly and has no noises, the temperature of bearing rises normal (without hot feeling by hand on the shell of bearing), and there is no stridulation between the machine shell and blade wheel. Otherwise, carefully examine all parts, find the reasons and shoot the troubles.

4.7.1 If the machine can not run smoothly or has noises, you should carefully examine if the connection of all parts is proper and the bolts are fastened. The machine can be re-adjusted or the bolts can be fastened again.

4.7.2 If the temperature of the bearing rises too high (feeling hot by hand or there is noise or stridulation), lack of lubrication grease shall be the first consideration; the bearing has been lubricated when delivered from the factory, but the grease may be dried after heating or long time storage, so carefully dismantle the left and right bearing seats, check them and add lubricating grease. If lack of grease is not the cause, the axial clearance of the bearing may be too small; you may loosen the screws on the adjustment covers of the left and right bearings, turn both adjustment covers anti-clockwise for 10~15 degrees (until the shaft of the blade wheel can be turned smoothly but not scraping against the machine shell), and then tighten the screws again. The work of dismantling the left/right bearing seats and adjusting the axial clearance of bearings shall be carried out by experienced technicians or trained professionals, in any case not by unqualified persons. The procedure of the work is as per the stipulations in clause 6 of chapter 5.

4.7.3 If there is stridulation between the shell and the blade wheel, it maybe result from the uneven base or frame for air lock fixation. When examining, the diagonal fastening bolts shall be slightly loosened, if the stridulation disappears, it mans that the supporting plane is uneven and must be re-adjusted. If there is still stridulation, examine if there is forced connection between the air lock and both sides of the conveying pipe. The forced connection can result in the deformation of the machine shell. The reasons should be found and troubles must be shot.

●  4.8 After no-load running for 30 minutes, if there is no fault, you may start air supply equipment. The positive pressure air is flowed to the conveying pipe, and then continue no-load running for an hour. If no fault arises, the first charging-in can be started. The volume of the first charge-in is about 3-5 times of that of the air lock. At the moment, carefully examine the conveying of the materials. If the materials can be smoothly conveyed, an equal quantity of materials can be charged in once every 15-20 seconds. 15 minutes later, if no faults arise, trial production can be started. At this time, operation workers can still not leave the production site. The operating and conveying of the equipment must be closely examined. If the trial production successively runs for three shifts and no faults arise, normal production can be started.

●  4.9 The following points should be taken care of in the process of the operation.

4.9.1 Before staring, first examine if the safety shield and protective hood are covered, if all bolts are fastened, and if there is residue materials in the feeding hopper. Then start positive pressure air source and pneumatic suction equipment. When the airflow is normally flowed into the conveying pipe for about 1-2 minutes, start the machine. After running for about 1 minute, if no faults arise, start the feeding hopper.

4.9.2 In the process of production, carefully examine if the machine runs properly. Once finding that the main shaft is too hot, that there is stridulation beween the shell and the blade wheel, that the materials are blocked up, that the blade wheel stops running, or that there is no air supply, the machine must be immediately stopped and repaired. Only after trouble-shooting that you can re-start the machine. The operations can be made in the sequence of the clause 4.9.1.

4.9.3 When stopping the machine, first stop feeding materials. After rest materials in the feeding hopper and chambers are all discharged, turn off the power, close the air supply and switch off the power of the suction equipment. No residual materials should be left in the feeding hopper and chambers.


5. Maintenance, defaulting and dismantling

●  5.1 Generally 90# lubricating oil for industrial gear or #40 mechanical oil should be used in the decelerator. In winter or under the condition of low temperature, the velocity of oil can be slightly lowered. After first oiling and rotating for 300 hours, oil must be replaced and the dirty oil shall be wiped out. After that, oil it once every three months. In general, lubricating oil should be often completed.

●  5.2 The chain should be cleaned in kerosene once every three months. After drying, it must be immersed into #40 mechanical oil at a temperature of 70-80 degree Celsius for oil-filling. It has no need of lubricating oil in routine use.

●  5.3 When leaving the factory, grease lubricant has been oiled in the main bearings on both sides of the blade wheel. When using, no grease lubricant is needed. If over-heating of the bearing results from a long time use and storage, the bearings must be dismantled, wiped out of residual grease, and then oiled with 4# sodium soap grease or 4# high temperature lubricating grease.

●  5.4 If the machine is not installed or not used for a long time, the lubricating oil in the decelerator should be released and the decelerator shall be cleaned. Put the machine in a flat and dry wooden case in dry and ventilated indoor place. It should be avoided storing outdoors to prevent from weathering.

●  5.5 Most trouble-shooting measures of the machine are mentioned in the above chapter 4. Here are stated in detail the main reasons, protective methods and trouble-shooting ways about materials blocking up the air lock and stopping the blade wheel.

5.5.1 The designed flow rate of the blower, volume of the air lock, or diameter of the conveying pipe is too small, or the rise of the conveying content is beyond the normal range, so the material can not be immediately conveyed off and is air –logged.

5.5.2 The blow is in failure and air supply is off, or pipe accessories, such as two-way valve, multi-way valve, are in failure. The channel is air-logged. So the material can not be conveyed off.

5.5.3 The suction of the feeding hopper is in failure. When the material is too little, it can not be smoothly dropped. When the material is too much, it suddenly pours into the machine, so that the material is air-logged. This may result from failure of the feeding mechanism.

5.5.4 To operate and maintain well the blower, pipe valve, feeding device and wind suction device and keep them in good order is the best way to lower the trouble. Especially for the blower, a spare one had better be installed. If there is improper capacity in design, the basic solution is to replace with bigger ones and increase the flow rate of the blower, volume of the air lock and diameter of the conveying pipe. Otherwise, lower the output, limit the feeding flow rate, or lower the conveying content.

5.5.5 Once the materials is air-logged, the machine must be immediately stopped, and the feeding device should also be stopped. If it results from the downstream passway of air lock blocked up, the blower must be stopped too. The trouble-shooting is as per the following: if the material is air-logged only upstream the air lock, first disassemble the sprocket cover and take off the chain, then turn the blade wheel around and let the material drop off and taken away by the air flow. If the material is air-logged in downstream passway of the air lock, the conveying pipe must be disassembled, the material must be pulled out from the axial passway.

●  5.6. When the machine is in failure and the air lock must be disassembled, the disassembling and installing steps must be as follows:
5.6.1 Disassembling: first disassemble the sprocket and keys, screw off all the fastening bolts in the opposite bearing seat. Put two of the bolts into the two tap holes and screw them in by force, then the gearing seat can be pushed out. When dismantling the bearing seat, take care that materials and dusts and not entering into the rolling column of the cone bearing on the shaft. The rolling column had better be wrapped with clean cloth. The other bearing seat needs not to be disassembled, and the blade wheel can be pushed out from the shell. Precautions: the bearing adjustment covers on both sides with screw must be avoided disassembling! Thus, when the blade wheel and bearing seat are re-assembled, the axial clearance at both sides of the blade wheel is as proper as what it is when leaving the factory.

5.6.2 Assembling: clean the disassembled parts and wash the bearing parts, then coat grease lubricant on it. Operate as per the adverse steps of disassembling. It should be noted that the shaft of the blade wheel not be inversely assembled.

5.6.3 If adjustment of axial clearance on both sides of the blade wheel is required, please operate as per the following steps: disassemble the feeding hopper, and you'll find the wheel. Then loosen the screws in the left and right bearing adjustment covers, retreat both adjustment covers by about 2-3mm, tighten all the fastening bolts in the left and right bearing seats by force and make sure that the seats are closely combined with the machine shell. Measure the gaps between the blade and the bearing seat with feeler gauge, and make sure that the two gaps are even. At the moment, the two adjustment covers can be fastened by quite a force. Rotate the blade wheel and measure the two gaps at both sides repeatedly. If the two gaps are even and there is no stridulation between the blade wheel and the shell, the screws in the two adjustment covers can be fastened to extreme. Rotate the blade wheel again and measure the gaps for proof. If the gaps are even and the blade wheel runs smoothly, the machine can be put into use again.


Our Advantage
a. Extensive production experience: we are specialized in positive pneumatic conveying system in milling industry for over 25 years, .

b. Complete production facilities: owning laser cutter, plasma cutter, automatic pipe welder, plate shears, bending machine, flanger, all kinds of welding methods for all kinds of materials, such as argon arc welding, carbon-dioxide arc welding, electro welding, oxyacetylene welding and other advanced equipment. Our technicians will do regular scheduled maintenance on these machines to guarantee them work well.

c. High quality raw material: we mainly choose raw material from big steel factory, such as TPCO, BAO STEEL, SHA STEEL, which are best and largest raw material manufacturer in China.

d. Strict Physical/Chemical testing procedures: meeting the requirements of the product design and process, providing reliable testing data.

g. Best after-sale service: Over 60% products are sold to the Southeast Asia, Middle East and Europe, and all products are trusted by domestic and foreign customers.


FAQ
Q1:Can your products be customized?
We are specialized in all non standard sheet metal fabrication for over 20 years. We have a strong designing team, so any conventional product can be customized.
Q2:What about the after-sale services?
We have We provide 12 months quality warranty after dispatch. We also offer long-time technical advisory services.
Q3.What about the transpotation?
We can take any type of transpotation according to the customer's demand.


Please feel free to send us your detailed requirements, you would be satisfied with our service.
Contact Below:
Wuxi zhongda machinery Equipment Co., Ltd.
Add: Yangjian Town, Xishan District, Wuxi city, jiangsu, china
Contact: Mr.peng
Mobile: (+86) 15251501754
Tel: +86-510-510-88731537
Fax: +86-510-510-88340005
E-mail: wxzd@wxzd.com
Web: http://www.zdsheetmetalfab.com

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