Machine manual

en-23261.001-E

Flat slide valve

Code Word

Order Number

POLYSIUS Order Code (POC)

Machine manual Contents
Flat slide valve

Contents

1 Technical data......................................................................................... 1-1

2 Safety...................................................................................................... 2-1
3 Components and mode of functioning.................................................3-1
3.1 Components............................................................................................. 3-1
3.2 Mode of functioning..................................................................................3-6
4 Transport and assembly........................................................................4-1
4.1 Transport and storage requirements........................................................4-1
4.2 Assembly.................................................................................................. 4-1
5 Lubrication..............................................................................................5-1
6 Preparation for the test run...................................................................6-1
6.1 Checks prior to the test run......................................................................6-1
6.2 Setting and adjustment.............................................................................6-1
6.3 Test run.................................................................................................... 6-1
7 Maintenance...........................................................................................7-1
7.1 Inspection.................................................................................................7-1
7.2 Servicing.................................................................................................. 7-2
7.3 Trouble shooting.......................................................................................7-3
7.4 Repair....................................................................................................... 7-4
8 Spare parts............................................................................................. 8-1
9 Appendix.................................................................................................9-1
9.1 Technical drawings...................................................................................9-1

en-23261.001-E
Machine manual Technical data
Flat slide valve 1

1 Technical data

NOTE
Information concerning the electrical equipment is contained in
the separate electrical documentation or in the subsuppliers'
documentation.

Information on the intended use

Bulk material.......................................................................................
Bulk density........................................................................................
Particle size.........................................................................................
Permissible temperature of conveyed material................................
Permissible moisture content of conveyed material.........................
Operating voltage................................................................................
Brake voltage......................................................................................
Control voltage....................................................................................
Mains frequency..................................................................................

Basic data

Year of manufacture............................................................................
Series/type..........................................................................................
Size......................................................................................................
Design type of actuator......................................................................
Internal slide valve seal...........................................................yes/no
Dimensions..........................................................................................
Total weight.........................................................................................
2

Design types of actuators

A = manual, hand wheel

B = manual, chain wheel
C = geared motor, coupling
D = geared motor, toothed wheels

Actuator type „C“ and „D“

Geared motor
Type.....................................................................................................
Form of construction..........................................................................
Power...................................................................................................
Speed...................................................................................................
Type of protection...............................................................................

Coupling
Type.....................................................................................................

Electrical position indicator

Limit switch
Type.....................................................................................................
Number................................................................................................
Machine manual Safety
Flat slide valve 1

2 Safety

NOTE
Be sure to comply with the general safety instructions in the
supplement Important notes on the documentation.

Use
 The flat slide valve may only be used as shut-off device for dry,
pulverulent or fine-grained bulk materials. Be sure to comply
with the information concerning the intended use of the
machinery in the section Technical data.
 Any use of the machine other than for the specified purpose, is
forbidden. POLYSIUS AG is not responsible for any damage
resulting from any other than the specified use of the machine.
All other use is at the operator’s own risk.
 The observance of these and the maintenance instructions is
part of the specified use.

Transport and assembly

 All transport instructions in this manual refer exclusively to the
transport of the machinery in the plant area.
 Use only suitable hoisting and lifting equipment, which is in
serviceable order and has a sufficient load bearing capacity.
 Never work under a suspended load.

Operation
 Any safety checks before or during operation depend on the
relevant national regulations. The operator is responsible for
the performance and recording of such checks.
 If changes in the machine or its operating behaviour relevant to
safety occur, the machine must be immediately stopped.
Safety Machine manual
2 Flat slide valve

Maintenance
 During work on the installed flat slide valve the area of the
frame in which the slide valve moves when opening must be
secured in such a way that any squeezing and jamming
hazard is prevented
 Before dismounting the flat slide valve the system arranged
above the slide valve must be emptied completely.
 Ensure that all machines and motors whose operation might
endanger persons or equipment are switched off, isolated and
safeguarded against restarting for the entire duration of the
maintenance work.
 Ensure that all rotating parts of the machine have come to a
halt before removal of guards or opening of access doors or
inspection flaps.
 Keep the machine free of oily and explosive matters. Never use
benzine or other flammable substances for cleaning the
machine.
 De-energize the electrical parts before starting any
maintenance work.
 Strictly observe the welding instructions when performing any
welding work.
 If electrical welding is executed on any part within the machine,
the welding current must never be conducted through sliding
or anti-friction bearings, other moveable connections or
measuring equipment. Return lead welding current must
always be connected close to the point of welding and directly
connected to the part being welded.
 All safeguards have to be re-installed and all inspection flaps
and maintenance hatches must be properly closed when
maintenance work has been terminated.
Machine manual Components and mode of functioning
Flat slide valve 1

3 Components and mode of functioning

The flat slide valve is a shut-off device for pulverulent to fine-

grained bulk materials.

3.1 Components

NOTE
Some details of the drawings in this manual may not be identical
with the drawings supplied under the contract.

The flat slide valve consists, among other things, of the following:
 the slide plate frame
 the slide plate
 the seals
 the actuator for the operation of the slide plate including
A = manual actuation via hand wheel and spindle
B = manual actuation via chain wheel (hand chain) and spindle
C = Actuation via geared motor, coupling and spindle
D = Actuation via geared motor, toothed wheels and spindle
 the electrical position indicator (7) for the final positions
(Optional)
Components and mode of functioning Machine manual
2 Flat slide valve

Items to the actuator (4) for the operation of the slide plate

4.11 Hand wheel

4.12 Chain wheel with chain holder
4.31 Geared motor
4.32 Coupling
4.33 Coupling bolt
4.41 Geared motor
4.42 Toothed wheel
4.43 Guard

7 Electrical position indicator

Machine manual Components and mode of functioning
Flat slide valve 3

Figure 1
Components and mode of functioning Machine manual
4 Flat slide valve

Items in the drawings

1 Slide plate frame

2 Slide plate
3.1 Stuffing box
3.2 Stuffing box packing
4.1 Spindle nut
4.2 Spindle
4.3 Bush
4.4 Grooved pin
4.5 Adjusting ring
4.6 Adjusting ring
4.7 Fixing parts
4.11 Hand wheel
4.12 Chain wheel with chain holder

Slide valve seal

5.1 Strip
5.2 Seal strip

Internal slide valve seal (only in certain designs!)

6.1 Insert
6.2 Strip
6.3 Seal strip
Machine manual Components and mode of functioning
Flat slide valve 5

Figure 2
Components and mode of functioning Machine manual
6 Flat slide valve

3.2 Mode of functioning

The flat slide valve’s slide plate (2) which is moved in a right-
angled position as to the flow direction of the bulk material can
take up two final positions (OPEN/CLOSED). It totally releases the
feed material flow or stops it altogether.
A stuffing box packing prevents that any bulk material can
escape from between slide plate (2) and slide plate frame (1).
With the actuator designs „A“ and „B“ the final positions can be
monitored by limit switches.
With the actuator designs „C“ and „D“ the final positions must be
monitored by limit switches.
Actuation can be performed manually („A“ and „B“) or by means
of a geared motor („C“ and „D“).
The flat slide valve frequently serves as isolating slide valve for
the downstream unit.
Machine manual Transport and assembly
Flat slide valve 1

4 Transport and assembly

4.1 Transport and storage requirements

The flat slide valve including actuator and position indicator is
transported in a ready-assembled condition. It must be observed
that suitable lifting equipment is employed in removing the parts
from the transport vehicles and transferring them to the storage
area.
When they arrive at the site, all parts must be inspected for
transport damage and placed on wooden beams with the
provision of suitable protection against rain, contamination and
damage. The parts must not be stored directly on the ground.
The slide plate (2) and the spindle (4.2) are coated with a
corrosion protection film. If being stored for a longer period of
time, this protective coating is to be renewed, if necessary.
Motors, couplings, gear units, measurement and control
equipment must be stored in buildings which are well aerated and
must be protected against moisture.

4.2 Assembly
The flat slide valve delivered in ready-assembled condition is
mounted according to the indications in the layout drawing. In
doing so, the mounting position which is marked by the weld bead
indication „TOP“ must be observed.
In order to prevent accidents during mounting, Section Safety
precautions must be observed!
When bolting the flanges of the flat slide valve with other units
and chutes, care must be taken to ensure that suitable,
undamaged seals are used and that the flanges are not subjected
to stresses.
The actuator and the electrical position indicator (7) can then be
connected, provided that the electrical ratings of the mains
correspond with the data on the rating plates.

CAUTION
If electrical welding is carried out in any place of the machine,
welding current must never be conducted through plain bearings
and antifriction bearings, other moveable connections or
measuring equipment to prevent damage to such parts.
Transport and assembly Machine manual
2 Flat slide valve

Return lead (of welding current) must always be directly

connected to the part being welded.
Machine manual Lubrication
Flat slide valve 1

5 Lubrication

NOTE
The POLYSIUS table of lubricants with the lubricant reference
numbers is contained in the supplement Important notes on the
documentation at the beginning of the overall documentation.
Each lubricant has a clear reference number to which the
lubrication instructions in this section relate. The table gives a
complete list of all suppliers and products approved by
POLYSIUS AG.
It is the responsibility of the lubricant supplier to select
appropriate lubricants corresponding to the reference numbers.
POLYSIUS AG is not responsible for the correctness of this data.
The use of a lubricant not explicitly stated in the table of
lubricants has to be previously approved by POLYSIUS AG.
The supplement Important notes on the documentation also
contains the generally valid Notes on lubrication.

CAUTION
Ensure that the lubricants are stored, used and disposed of in an
environmentally-friendly manner and observe your national
legislation when handling lubricants.
Lubrication Machine manual
2 Flat slide valve

Lubrication chart

Figure 3
Machine manual Lubrication
Flat slide valve 3

Lubrication points Quantity (ltr/kg) Lubrication intervals

per lubrication (weeks)
point
No. Qty. Designation Lubricant Initial Topping Topping First Further
up change changes
ref. no. filling up

1 1 Stauffer grease cup 50 0.02 as every

required
12 weeks

2 1 Stauffer grease cup 50 0.02 as every

required
12 weeks

3 Toothed wheels

[1]
4 1 Geared motor

The different makes of lubricant corresponding to the lubricant reference numbers are shown in the
table of lubricants in the supplement Important notes on the documentation. The supplement is to be
found in this folder or at the beginning of the overall documentation.

Explanation of the numbers

[1]
Also observe the manufacturer’s instructions.
Machine manual Preparation for the test run
Flat slide valve 1

6 Preparation for the test run

6.1 Checks prior to the test run

After completion of the assembly work and prior to the first test
run, check all parts of the plant according to the list below. Take
particular care that all material remnants, tools and assembly
aids are removed.

 Are all fixing bolts firmly tightened?

 Are the connecting flanges bolted air tight?
 (Have the seals intended for this purpose been inserted?)
 Are the actuator and any monitoring equipment connected
according to the circuit diagram?
 Do the electrical values of the mains correspond to the data of
the electrical equipment?

6.2 Setting and adjustment

The stuffing box (3.1) must only be tightened to such an extent
that the slide plate (2) is not obstructed.
If owing to a longer standstill the slide plate got jammed or
difficult to operate, it must never be moved by force via actuation
of the spindle (4.2).
Instead, in this case the stuffing box must be loosened by
undoing the four adjusting nuts on the stuffing box. Then, the
slide plate can be released by several back and forward
movements.
After thus having cleared the fault, the adjusting nuts must be re-
tightened such that the slide plate is not obstructed by the
stuffing box.
In the corse of this adjusting procedure the slide plate (2) should
be moved in order to check and ensure its ease of motion.
The electrical position indicator (7), if any, is to be adjusted so
that the final positions „OPEN“ and „CLOSED“, respectively, are
reached.

6.3 Test run

After the completion of all checks, settings and adjustment, a
test run of the flat slide valve can be performed.
Preparation for the test run Machine manual
2 Flat slide valve

During this test the functioning of the actuator and any

monitoring equipment can be checked.
If any faults occur during the test, the test run must be
interrupted and only continued after elimination of the faults.
After successful completion of the test run the flat slide valve is
ready for operation.
Machine manual Maintenance
Flat slide valve 1

7 Maintenance

7.1 Inspection

No. Work to be performed Frequency Remarks

1 General visual check for every 12

weeks
 cracks
 leaks
 damage
2 Check the slide plate (2) for ease of every 12 never move the
motion weeks slide plate by
force;
see also 6.2
Setting and
adjustment
3 Check the leak tightness of the flat every 26
slide valve when in „CLOSED” weeks
position
4 Inspection work on the actuator every 26 according to the
weeks instructions of
the
manufacturer
5 Inspection work on the electrical every 26
position indicator (7) weeks
Maintenance Machine manual
2 Flat slide valve

7.2 Servicing

No. Work to be performed Frequency Remarks

1 Adjust the stuffing box packing every 26 see also Section

weeks
Inspection;
execution
according to 6.2
Setting and
adjustment
2 Maintenance work on the actuator according to the
instructions of
the
manufacturer
3 Maintenance work on the electrical every 26
position indicator (7) weeks
Machine manual Maintenance
Flat slide valve 3

7.3 Trouble shooting

Fault Cause Elimination

With actuator types „C” Actuator without power check electrical

and „D” equipment
Slide plate (2) does not Actuator defective repair or replace
move actuator
Electrical position Repair or replace
indicator (7) defective electrical position
indicator
only with actuator type
„C”:
replace the coupling
Coupling bolts (4.33) bolts
shorn off
Slide plate (2) operates Jamming of the slide loosen the stuffing box
with difficulty or jams plate in the stuffing box packing and readjust;
packing
see 6.2 Setting and
adjustment
Feed material blockage Feed material moist or check feed material and
in opened flat slide not suitable conveyors
valve
Foreign body jammed remove foreign body
Leakage of feed Stuffing box packing readjust or replace
material leaky stuffing box packing
Flange seal(s) defective repair flange seal(s)
Flat slide valve fails to Seal strips (5.2 and 6.3) replace the seal strips
tightly shut off of slide valve seal and
internal slide valve seal,
if any, are worn out
Slide plate (2) damaged replace the slide plate
Electrical position readjust or repair the
indicator (7) electrical position
misadjusted or defective indicator

If any faults occur which are not described above, consult the
additional information about faults, their causes and their
elimination in the subsuppliers’ documentation.
Maintenance Machine manual
4 Flat slide valve

7.4 Repair
Before performing any repair work, make sure all electrical
components are disconnected.
Ensure the utmost cleanliness at all times during the repair work
in order to guarantee that the bearings, the drive system or other
sensitive parts of the machine are kept free of contamination.
Do not remove or open any flaps or protective equipment before
all rotating parts have stopped.
If damage is established during the checks, the damaged parts
must be repaired or replaced by new ones.
The following work can be carried out at the installed flat slide
valve:

 repair or replacement of the actuator

 repair or replacement of the electrical position indicator (7)
 replacement of the stuffing box packing (3.2)
 replacement of the slide plate (2)
 replacement of the spindle drive (4.1 to 4.6)

The flat slide valve must be removed for exchange of the

following parts:
 slide valve seal
 internal slide valve seal
 slide plate frame (1)

Dismantling instructions
When dismantling the flat slide valve from the complete plant or
from the plant system, the following procedures are required:

 Disconnect the actuators „C” or „D” and any monitoring

equipment
 Support the units downstream of the flat slide valve (if
required)
 Support or suspend the flat slide valve
 Unbolt the flange connections between the flat slide valve and
the adjacent units or chutes
 Lift out or push out the flat slide valve
Machine manual Maintenance
Flat slide valve 5

Instructions for dismantling the unit

For dismantling the flat slide valve, the following steps are
required:

 Dismount the actuator parts (4.11 to 4.43) and any monitoring

equipment
 Dismount the spindle drive (4.1 to 4.6); before dismounting
these parts, set the slide plate to position „OPEN”
 Dismount the stuffing box packing
 Remove the slide plate (2)
 Remove the slide valve seals

Assembly instructions
The flat slide valve must be assembled in the following order (all
parts must first be checked and cleaned):

 Bolt the spindle nut (4.1) on to the slide plate (2)

 Push the stuffing box (3.1) on to the slide plate, push the slide
plate into the slide plate frame (1).
 Front-side chamfering of the slide plate must be on the bottom
side!
 Push the spindle (4.2) from outside through the bush (4.3) into
the slide plate frame (1); beforehand push on the adjusting ring
(4.5), bolt the spindle (4.2) into the spindle nut (4.1) and mount
the adjusting ring (4.6).
 Mount the actuator parts - depending on the design type of
actuator -
A = hand wheel (4.11)
B = chain wheel (4.12)
C = coupling (4.32)
D = toothed wheel (4.42)
each with the pertaining fixing parts on to the spindle (4.2).

 Install the stuffing box packing (3.2), mount the stuffing box
(3.1) and tighten it such that the slide plate (2) can still be
moved.
 Insert the slide valve seal and the internal slide valve seal, if
any; seal strips (5.2) and seal strips (6.2), if any, must rest upon
the slide plate, when the flat slide valve is closed.
Maintenance Machine manual
6 Flat slide valve

 Mount the remaining actuator parts (4.11 to 4.43).

 Mount the electrical position indicator (7), if any.

CAUTION
After you have completed the repair work, you must check the
machine/plant again according to the section Preparation for the
test run.
Machine manual Maintenance
Flat slide valve 7

Consumables

Description Manufacturer Remarks

Special lubricant for stuffing box packing

(3.2)
grease/graphite 40/60

Tools and auxiliary devices

No special tools are required for repair work on the machine.
However, torque wrenches of a bigger size than normal may be
necessary.
The need for scaffolds or hoists depends on the conditions in your
plant.
Machine manual Spare parts
Flat slide valve 1

8 Spare parts

Notes for enquiring about and ordering spare parts

Dear Customer,
POLYSIUS AG strive to render your enquiring about and ordering
of spare parts as easy, and as a consequence, as efficient as
possible. For this purpose we have prepared a table summarising
all data required by our spare parts department to ensure
optimum processing in the most speedy and trouble–free manner.
Please copy the page with the respective table and mark those
parts which you require with a cross in the column Order or
Enquiry.
If the table relates to more than one machine, please also inform
us of the POLYSIUS Order Code (POC) of the machine for which
you require the spare parts.
Spare parts Machine manual
2 Flat slide valve

Figure 4
Machine manual Spare parts
Flat slide valve 3

Code word: Order no.: POC:

Item Designation Qty. Unit Order Enquiry

2 Slide plate 1 piece

3.1 Stuffing box 1 piece

3.2 Stuffing box packing 1 set

with sealing cord

4.1 Spindle nut 1 piece

4.2 Spindle 1 piece

4.3 Bush 1 piece

4.4 Grooved pin 4 piece

4.5 Adjusting ring 1 piece

4.6 Adjusting ring 1 set

with grooved pin

4.7 Fixing parts 1 piece

4.8 Stauffer grease cup 2 piece

5.1 Strip 1 piece

5.2 Seal strip 1 set

6.1 Insert 1 piece

6.2 Strip 1 set

6.3 Seal strip 1 set

Spare parts Machine manual
4 Flat slide valve

Items in the drawings

Figure 5
Machine manual Spare parts
Flat slide valve 5

Code word: Order no.: POC:

Item Designation Qty. Unit Order Enquiry

4.11 Hand wheel 1 piece

4.12 Chain wheel with chain 1 set

holder

4.31 Geared motor 1 piece

4.32 Coupling 1 piece

4.33 Coupling bolt 1 piece

4.41 Geared motor 1 piece

4.42 Toothed wheel 1 set

4.43 Guard 1 piece

7 Electrical position 1 piece

indicator
Machine manual Appendix
Flat slide valve 1

9 Appendix

9.1 Technical drawings

NOTE
For drawing numbers, please refer to the table of contents of this
folder.

Designation Drawing no.

Assembly drawing