Walinga Airlock 1008, Operator'S Manual

Page 1: ...OPERATOR S MANUAL Airlock 1008 English 00 144471 0 A 2023 12 06...

Page 2: ...Carman MB carman service walinga com Wayland MI wayland service walinga com Sioux Center IA siouxcenter walinga com ORIGINAL PARTS SALES Ontario and Eastern Canada Fax 519 824 0367 1 888 925 4642 ext...

Page 3: ...2 Intended Use 2 2 Directional References 2 3 Airlocks in Pneumatic Conveying Systems 2 3 Machine Configuration 00 144473 0 3 1 Model Sizes 3 2 Model Variations 3 4 Safety 00 144474 0 4 1 Safety Alert...

Page 4: ...ng the Machine 6 5 Operating Tips and Hints 6 6 Troubleshooting 6 7 Maintenance and Adjustments 00 144477 0 7 1 Maintenance Schedule 7 2 Maintenance Safety 7 3 Maintenance Procedures 7 3 Maintenance M...

Page 5: ...tions 9 3 Warranty Claim Rejection 9 4 Not Covered Under Warranty 9 4 Accessories and Attachments 00 144480 0 10 1 Parts List 00 144481 0 11 1 Model References 11 2 Body Components 11 3 Rotor Componen...

Page 6: ...g or transporting the machine Machine Life Cycle Procedures The machine life cycle procedures section provides information on the reception assembly and initial set up transportation storage and end o...

Page 7: ...Identification of Machine AIRLOCK MODELS 1 1...

Page 8: ...o your Walinga dealer or representative when ordering parts or requesting service or other information For easy reference record the required serial number as follows Airlock Serial Number Located on...

Page 9: ...Introduction AIRLOCK MODELS 2 1...

Page 10: ...manual are subject to change and or correction without notice Contact your local dealer or Walinga representative for the most current revision of your machine s manual or if you have any questions IN...

Page 11: ...ments among others Airlocks are used in a variety of Walinga systems such as in Engineered Transportation Equipment in discharge and transfer systems as well as in Agri Vacs Central Vacs Ultra Vacs Ul...

Page 12: ...ried through the outlet at the bottom of the front end plate to the discharge side of the system The motion of the discharged product is perpendicular to the rotation of the airlock rotor Blow thru mo...

Page 13: ...otion of the discharged product is parallel to the tangential direction of motion of the rotor blade tip at the bottom of the airlock For example when viewed from the driven end of the airlock the pro...

Page 14: ...ed pockets rotate to the bottom the product will fall into a large collection device such as a bin With a system operating with atmospheric pressure on the outlet side the inlet side may be under vacu...

Page 15: ...Machine Configuration AIRLOCK MODELS 3 1...

Page 16: ...o the embossed model label on the side of the airlock casing or on the face of the end plate as seen in Figure 3 1 Figure 3 1 Model identification If your model does not have an embossed model size re...

Page 17: ...0 6 cm 18 3 in 46 5 cm 7 in 17 8 cm 1 6 cu ft rev 45 L rev 2018 7 20 in 50 8 cm 18 3 in 46 5 cm 7 in 17 8 cm 2 69 cu ft rev 76 L rev 2224 8 22 in 55 9 cm 24 in 61 0 cm 8 in 20 3 cm 4 44 cu ft rev 126...

Page 18: ...ter products or where cross contamination is a concern DROP THRU DT Product enters through the top of the airlock and drops out through the bottom The inlet can be under vacuum or atmospheric pressure...

Page 19: ...d rotor blade tips at all points during rotation EXTENDED PROFILE B The extended profile for blow thru airlocks features a lowered portion of the casing at the bottom creating an extra pocket of space...

Page 20: ...wear and damage HARD COATING HC A hard coating is applied to the interior machined surfaces of the casing and or end plates providing improved wear resistance HALAR COATING HALAR Alternative coatings...

Page 21: ...earing and lock nut This is the standard rotor style and provides decreased end plate wear FLOATING ROTOR FR The rotor is supported by a ball bearing axially fixed to prevent end plate wear with eithe...

Page 22: ...eature reduces the wear and damage to the end plates and is used with abrasive products or products mixed with sand dirt or dust OUTBOARD BEARING OB The shaft bearing is mounted outside of the end pla...

Page 23: ...r rotates in a clockwise direction This style can be used in special circumstances where there may be conflicts due to limited space and mounting the motor gearbox and the direction of the product flo...

Page 24: ...material such as rubber or urethane to allow the tip to flex around any debris that may be present in the product reducing casing and rotor wear This style is beneficial for use with dirty products or...

Page 25: ...without the need for adjustable tips SOLID BLADE BEVEL BVL The rotor blade with beveled edges extends from the rotor shaft to the proper clearance from the casing without the need for adjustable tips...

Page 26: ...OPERATOR S MANUAL PAGE INTENTIONALLY LEFT BLANK 3 12 00 144473 0 A MACHINE CONFIGURATION...

Page 27: ...Safety AIRLOCK MODELS 4 1...

Page 28: ...t in death or serious injury This signal word is limited to the most extreme situations typically for machine components that for functional purposes cannot be guarded The associated color is red WARN...

Page 29: ...rized to operate an airlock Untrained operators expose themselves and bystanders to potential serious injury or death Before servicing adjusting repairing or unplugging an airlock place all controls i...

Page 30: ...y time This equipment is dangerous to children and individuals unfamiliar with its operation The operator must be a responsible properly trained and physically able person familiar with farm machinery...

Page 31: ...auxiliary equipment quickly in the event of an emergency Properly train all new personnel and review instructions frequently with existing workers Ensure only a properly trained and physically able in...

Page 32: ...r an obstruction All power sources must be disconnected and or locked out before any guards or access points are opened to manually dislodge obstructions MAINTENANCE SAFETY Read understand and follow...

Page 33: ...ing paper 5 Align the safety sign over the correct position and carefully press the small portion with the exposed adhesive backing in place 6 Slowly peel back the remaining paper and carefully smooth...

Page 34: ...he inner surface of the airlock inlet area below the guards as well as around the drive shaft if equipped with a guard Figure 4 2 Part Number 53 18289 6 Approximate Location Located at all openings of...

Page 35: ...proximate Location Varies depending on the type and the model of the pneumatic conveying system Figure 4 4 Part Number 53 137850 6 Approximate Location Varies depending on the type and the model of th...

Page 36: ...ned so the arrow indicates the correct rotational direction points to left side of airlock for standard counter clockwise rotation Figure 4 6 Part Number 53 82427 6 Approximate Location Located on the...

Page 37: ...individual to operate this equipment until such information has been reviewed Annually review this information with personnel Make periodic reviews of safety and operations a standard practice for all...

Page 38: ...OPERATOR S MANUAL DATE EMPLOYEE S NAME EMPLOYEE S SIGNATURE EMPLOYER S SIGNATURE 4 12 00 144474 0 A SAFETY...

Page 39: ...Machine Life Cycle Procedures AIRLOCK MODELS 5 1...

Page 40: ...is covers The covers as seen in Figure 5 1 must be removed from the airlock during assembly and before any operation of the airlock is started Do not dispose of the debris covers as they may be used d...

Page 41: ...t limited to a hard hat protective shoes with slip resistant soles protective glasses or goggles heavy gloves wet weather gear and hearing protection Long hair and loose clothing must be secured and j...

Page 42: ...ce and wait for all moving parts to stop 3 Re torque and tighten all fasteners and hardware 4 Turn the airlock by hand ensuring it rotates freely 5 Listen for excessive noise produced by the bearings...

Page 43: ...llow all interior surfaces to completely dry e When conveying materials with oily characteristics or high moisture content including milled feeds the airlock may need to be flushed on a more regular b...

Page 44: ...feature A re machined casing to correct out of round wear or damage Re machined end plates to correct any damage and properly align with the casing New hard coating treatments to required components R...

Page 45: ...Operation AIRLOCK MODELS 6 1...

Page 46: ...Rear End Plate F Air Vent Plug G Outlet H Seal Plate Figure 6 1 Airlock key components A Rotor Shaft Keyway B Shaft Plate Seal C O Ring Seal D Tapered Bearing E V Seal F Set Screw G Lock Nut H Rotor...

Page 47: ...iary equipment to ensure the airlock is sufficiently powered and that the airlock is properly connected to the system 4 Ensure the airlock rotates freely and is not obstructed and has not accumulated...

Page 48: ...raulic fluid to warm before transitioning to operating at full capacity It should be noted that product must be conveyed for the hydraulic fluid to properly warm 5 To operate at maximum capacity the a...

Page 49: ...Adjustments review the maintenance schedule and perform any required maintenance on the airlock 4 Proceed to prepare the airlock for storage or transportation with reference to Section 5 Machine Life...

Page 50: ...ugh the reverse direction or the system is not equipped to operate in the reverse direction the obstruction must be manually removed as follows Shut down and lock out the power unit If equipped discon...

Page 51: ...er tip clearances Check that the tip clearance matches the specifications Adjust or replace tips as required Slow discharge of material Improper tip clearances Check that the tip clearance matches the...

Page 52: ...ug removed 4 If flow improves fit a pressure vent kit Refer to Section 7 Maintenance and Adjustments Custom designed vented hoppers may also be used for fine products such as milled meals Airlock tip...

Page 53: ...and clears DO NOT change the direction of rotation by reversing the wiring on 3 phase electric motors impact damage may result If the obstruction does not clear follow the procedure for units without...

Page 54: ...OPERATOR S MANUAL PAGE INTENTIONALLY LEFT BLANK 6 10 00 144476 0 A OPERATION...

Page 55: ...Maintenance and Adjustments AIRLOCK MODELS 7 1...

Page 56: ...15 Check Rotor and Tip Clearances 7 15 Check Operating Temperatures 7 20 Check Airline Seals 7 22 Every 2000 HOURS or ANNUALLY Adjust Blade Tip Clearance 7 27 The above schedule is the minimum basis t...

Page 57: ...aintaining Support the machine with blocks or safety stands when working beneath the machine Follow good shop practices a Keep the service area clean and dry b Ensure electrical outlets and tools are...

Page 58: ...must be performed during the initial break in period To assess the functionality of the purge system proceed as follows 1 Ensure the system is equipped with the correct fittings and components as det...

Page 59: ...per blade is located at the top left side of the inlet It functions to level the material for each rotor pocket as it moves out of the inlet area and into the casing This ensures even flow reduced wea...

Page 60: ...ll children 2 Place all controls in neutral stop and lock out the power source and wait for all moving parts to stop 3 Gain access to the airlock inlet by opening an installed access or removing a por...

Page 61: ...rds in place Rotor Shaft Bearing Grease Packing To maintain smooth rotation of the airlock rotor the rotor shaft bearing must remain properly lubricated For abrasive style airlocks it is important tha...

Page 62: ...the lock nut and the lock nut from the rotor shaft Figure 7 6 Removal of set screw and lock nut 5 Loosen and remove the fasteners securing the end plate to the casing Figure 7 7 Removal of end plate...

Page 63: ...the opposite end plate and bearing Figure 7 8 Removal of end plate and shaft support 7 Remove the bearing cone assembly from the bearing cup Use care and caution when using tools to prevent damage to...

Page 64: ...ny way the entire bearing assembly must be replaced 10 If necessary clean the bearing cup and cone with a non residual solvent to remove any contaminants 11 Thoroughly clean your hands or wear a pair...

Page 65: ...e to drive the bearing cup into position this can damage the bearings and cause premature failure Figure 7 12 Proper installation of bearing cup 17 Position the end plate against the casing and secure...

Page 66: ...talled and secured before operation of the airlock Bearing and Seal Cavity Inspection To reduce damage and wear to the bearing it is important that the bearing cavity is kept clean and free of dirt du...

Page 67: ...ft Reference Figure 7 6 b Loosen and remove the fasteners securing the end plate to the casing Reference Figure 7 7 c Carefully remove the end plate from the airlock and support the rotor shaft Refere...

Page 68: ...for all other airlock styles the face of the seal should rest against the inner shoulder of the end plate Figure 7 15 Standard airlock seal Figure 7 16 Abrasive style seals g If equipped check the co...

Page 69: ...orque the fasteners to maintain full functionality and preserve the safety of the airlock Refer to Section 8 Specifications for the required torque for each fastener Rotor and Blade Tip Clearances To...

Page 70: ...laced 5 Use a feeler gauge to check the clearance between the tip and casing along the blade s entire length Measure the clearance with reference to the casing edge opposite to the wiper blade as show...

Page 71: ...19 Reference Table 7 2 for tip clearance requirements Rotate the rotor by hand and repeat the clearance measurement for each tip Figure 7 19 Outlet bottom tip clearance 7 If the clearance between the...

Page 72: ...007 in 0 18 mm Blow Thru Top 0 005 in 0 13 mm 0 007 in 0 18 mm Bottom 0 004 in 0 10 mm 1618 Drop Thru 0 004 in 0 10 mm 0 008 in 020 mm Blow Thru Top 0 006 in 0 15 mm 0 008 in 0 20 mm Bottom 0 004 in...

Page 73: ...nstalled access point or removing a portion of the inlet structure Refer to the auxiliary equipment s operator s manual to determine the correct method of access to the airlock inlet 4 Use a feeler ga...

Page 74: ...ocedures for end of life instructions Operating Temperature To prolong component and airlock life the airlock must not be operated at elevated temperatures for extended periods Operation at elevated t...

Page 75: ...e to allow all components to stabilize at their operating temperature 3 Measure the temperature of the following areas a Rotor bearings b Drive motor c Airlock casing 4 Ensure the temperature of the a...

Page 76: ...itor and inspect the airline joints of the airlock for any apparent leaks listen for any hissing whistling or other signs of leaking 3 Check the condition of the inlet seal as follows a With reference...

Page 77: ...ve wear or accumulation of dirt dust or debris Figure 7 22 Drop thru outlet seal c Clean or replace the seal as required d Reinstall any components that were removed and ensure all guards are installe...

Page 78: ...excessive wear or accumulation of dirt dust or debris e Clean or replace the seal as required f Reinstall any components that were removed and ensure all guards are installed and secured 6 Inspect the...

Page 79: ...seal e Clean or replace the seals as required f Loosen and remove the lock nut set screw and bearing cone and cup as required g Visually inspect the inner rotor shaft seals looking for any nicks tears...

Page 80: ...ns of thermal degradation or accumulation of dirt dust or debris Figure 7 28 End plate V seal k Clean or replace the seals as required l Reinstall all end plate and rotor components with reference to...

Page 81: ...area of bystanders especially small children 2 Place all controls in neutral stop and lock out the power source and wait for all moving parts to stop 3 Gain access to the airlock inlet by opening an...

Page 82: ...OPERATOR S MANUAL 5 Loosen the retaining fasteners holding the tip on the blade but do not fully remove the screws Figure 7 30 Tip fasteners 7 28 00 144477 0 A MAINTENANCE AND ADJUSTMENTS...

Page 83: ...levels of normal operational wear meaning adjustments made in reference to this edge may result in clearances lower than the minimum allowable clearance resulting in scraping or damage between the ti...

Page 84: ...ing 4 in 10 cm from one end of the blade tip place a second feeler gauge of the same size 4 in 10 cm between the tip and the casing at the other end of the tip Figure 7 32 Feeler gauge placement 8 Gen...

Page 85: ...eats fully during the first few hours of normal operation 11 Repeat Step 4 through Step 10 for each blade until all tips have been adjusted Check the identifying numbers marked in Step 4 to ensure eac...

Page 86: ...it for all moving parts to stop 3 Gain access to the airlock inlet by opening an installed access point or removing a portion of the inlet structure Refer to the auxiliary equipment s operator s manua...

Page 87: ...Repeat Step 4 through Step 9 for each blade ensuring each blade has been replaced and properly adjusted as required 11 Refer to the section Inlet Wiper Blade for instructions on the reinstallation or...

Page 88: ...th high bulk densities such as cereal grains however some materials such as milled meals or other light materials may cause uneven flow or reduced performance due to air blow back in the inlet area To...

Page 89: ...LEX HOSE STAINLESS STEEL 1 1 2 ID 36 03147 6 As Required C SADDLE CLAMP PLTD 1 3 4 28 08133 6 As Required D STEEL TUBE 1 1 2 OD 89 00291 1 As Required E A L INLET ASSEMBLY VARIOUS 1 F RUBBER HOSE 5 8...

Page 90: ...all tube Item A ends are smooth beveled to prevent product build up and flow restriction Figure 7 37 Smooth beveled tube 7 Install the vent pipe Item A into the vent hole Figure 7 38 Vent pipe install...

Page 91: ...ir to be discharged back into the inlet material collection area 10 Install solid tubing Item D along the vent discharge path to minimize the number of bends 11 Install the discharge flex hose Item B...

Page 92: ...assembly Item E and vent pipe Item A Figure 7 41 Connector hose installation 14 Secure the connector hose in place using hose clamps Item G Figure 7 42 Gear clamp installation 15 Ensure all components...

Page 93: ...t Number Quantity A HALF COUPLING 4FP 58 08815 6 1 B FITTING PUSH IN 4T 4MP 81 18109 6 1 C PRESSURE GAUGE 4MP 0 TO 15 PSI 27 00718 6 1 D COUPLING 103 B 1 4 81 07112 6 1 E FITTING PUSH IN 4T 4MP 90 81...

Page 94: ...tting Item B into the half coupling Item A applying thread sealant Figure 7 44 Half coupling fitting installation 6 Mount the pressure gauge Item C in a position that allows easy viewing by the operat...

Page 95: ...90 push in fitting Item E into the coupling of the pressure gauge Figure 7 46 Pressure gauge fitting 9 Install the 1 4 air tube Item F onto both push in fittings avoiding any sharp bends in the tubing...

Page 96: ...rranty It is the responsibility of the owner operator to ensure that all moving parts and inlets are adequately guarded if an intake method substitution is made The blades of the rotating airlock are...

Page 97: ...s Figure 7 48 Inlet guard 6 During operation ensure there is a continuous flow of product into the intake hopper Gradually adjust the airlock speed to find the ideal balance between air and product fo...

Page 98: ...isrupts the flow of product either reduce the depth of product in the intake hopper install an intake hopper equipped with a vent or refer to the above section to install a Pressure Vent Kit Ensure an...

Page 99: ...Specifications AIRLOCK MODELS 8 1...

Page 100: ...n 20 3 cm Length B 25 500 in 64 8 cm 25 500 in 64 8 cm 29 375 in 74 6 cm 29 375 in 74 375 cm 34 813 in 88 4 cm 39 375 in 100 0 cm Height C 16 875 in 42 9 cm 16 875 in 42 9 cm 19 250 in 48 9 cm 19 875...

Page 101: ...3 cm 25 313 in 64 3 cm 27 450 in 69 7 cm 37 140 in 94 3 cm Height B 15 000 in 38 1 cm 16 125 in 41 0 cm 17 750 in 45 1 cm 21 000 in 53 3 cm 28 000 in 71 1 cm Casing Diameter C 12 375 in 31 4 cm 14 250...

Page 102: ...8 2224 Blade Tip Bolts Figure 8 3 24 ft lb 32 5 Nm 24 ft lb 32 5 Nm 24 ft lb 32 5 Nm 24 ft lb 32 5 Nm 24 ft lb 32 5 Nm Wiper Blade Bolts Figure 8 4 24 ft lb 32 5 Nm 24 ft lb 32 5 Nm 24 ft lb 32 5 Nm 2...

Page 103: ...OPERATOR S MANUAL Figure 8 3 Blade tip bolts Figure 8 4 Wiper blade bolts Figure 8 5 Rotor shaft lock collar Figure 8 6 Rotor shaft lock nut SPECIFICATIONS 00 144478 0 A 8 5...

Page 104: ...OPERATOR S MANUAL Figure 8 7 Lock nut set screw Figure 8 8 End plate bolts Figure 8 9 Seal plate bolts Figure 8 10 Air vent plug 8 6 00 144478 0 A SPECIFICATIONS...

Page 105: ...ft Nm lb ft 1 4 8 6 12 9 17 12 5 16 13 10 25 19 36 27 3 8 27 20 45 33 63 45 7 16 41 30 72 53 100 75 1 2 61 45 110 80 155 115 9 16 95 60 155 115 220 165 5 8 128 95 215 160 305 220 Figure 8 11 Imperial...

Page 106: ...Nm lb ft M3 5 4 1 8 1 3 M4 3 2 2 4 5 3 3 M5 6 4 9 7 M6 10 7 15 11 M8 25 18 35 26 M10 50 37 70 52 M12 90 66 125 92 M14 140 103 200 148 M16 225 166 310 229 Figure 8 12 Metric bolts M20 435 321 610 450...

Page 107: ...Health and Safety Standards OH S and American National Standards Institute ANSI Be aware that there may be additional local or federal laws and regulations that require compliance based on operational...

Page 108: ...OPERATOR S MANUAL PAGE INTENTIONALLY LEFT BLANK 8 10 00 144478 0 A SPECIFICATIONS...

Page 109: ...Warranty AFTERMARKET PARTS AND SERVICE 9 1...

Page 110: ...date of sale to the original customer LIMITATIONS AND EXCLUSIONS OF THE WALINGA WARRANTY The Walinga Warranty applies to material and workmanship only With respect to any component parts that are sup...

Page 111: ...r associated with part removal or installation performed by the customer or service providers other than Authorized Dealers and Service Centers or the costs of parts and labor associated with the repa...

Page 112: ...any direct indirect loss of time incidental or consequential expenses including but not limited to equipment rental expenses towing downtime inconvenience or any losses resulting from the inability t...

Page 113: ...Accessories and Attachments AIRLOCK MODELS 10 1...

Page 114: ...t styles and sizes ADAPTERS AND REDUCERS To accommodate the different coupling styles that are used in varying industries as well as the couplings of different hoses lines and nozzles various adapters...

Page 115: ...contaminated with metallic debris magnetic inlet covers are available to remove the contaminants from the product PRESSURE VENT KIT To accommodate the varying conveyed product characteristics especial...

Page 116: ...OPERATOR S MANUAL PAGE INTENTIONALLY LEFT BLANK 10 4 00 144480 0 A ACCESSORIES AND ATTACHMENTS...

Page 117: ...Parts List AIRLOCK 1008 MODEL 11 1...

Page 118: ...top level assembly numbers of each airlock and their respective key features The reference codes for each model assigned in Table 11 1 will be used as the top level model identification for the remain...

Page 119: ...A 1 PLUG 12MP HEX SOCKET 58 14005 6 2 TIP WIPER WASHER PLATE 1008 30 137504 4 3 PLATE WASHER 1 4 PLTD 94 04258 6 4 LOCK WASHER 1 4 PLTD 94 04259 6 5 BOLT 1 4 20 1 GR 8 PLTD 94 05281 6 6 TIP WIPER 1008...

Page 120: ...OPERATOR S MANUAL END PLATE Model Description Part Number A 1 END PLATE 1008 DT OB 30 137491 5 2 BOLT 5 16 18 1 GR 8 PLTD 95 05284 6 11 4 00 144481 0 A PARTS LIST...

Page 121: ...OPERATOR S MANUAL ROTOR COMPONENTS ROTOR Model Description Part Number A 1 ROTOR 1008 OB SOLID 30 137492 5 PARTS LIST 00 144481 0 A 11 5...

Page 122: ...umber A 1 KEY 3 8 x 3 8 x 1 3 4 97 80192 6 2 BEARING NSK AEL208 108x1 1 2 96 137502 6 3 LOCKING COLLAR 1 7 8 ID OB 96 137507 6 4 SHAFT SEAL TEFLON 1008 OB 96 137498 6 5 CAP SCREW 1 4 28 3 4 94 14744 6...

Page 123: ...scription Part Number A 1 SHAFT SEAL TEFLON 1008 OB 96 137498 6 2 LOCKING COLLAR 1 7 8 ID OB 96 137507 6 3 BEARING NSK AEL208 108x1 1 2 96 137502 6 4 QUAD RING QN7 134 1008 OB 96 137496 6 5 CAP SCREW...

Page 124: ...ber A 1 INNER SHAFT GUARD 1008 11 137544 4 2 DEBRIS COVER IN OUT 1008 11 138535 4 3 PLATE WASHER 5 16 PLTD 94 04240 6 4 LOCK WASHER 5 16 PLTD 94 04241 6 5 BOLT 5 16 18 1 GR 8 PLTD 94 05284 6 6 OUTER S...

Page 125: ...PAGE INTENTIONALLY LEFT BLANK...

Page 126: ...S 938 Glengarry Crescent Fergus ON Canada N1M 2W7 PHONE 519 787 8227 FAX 519 787 8210 1190 Electric Avenue Wayland MI USA 49348 PHONE 800 466 1197 FAX 616 877 3474 70 3rd Avenue N E Box 1790 Carman MB...