"Pneu-Flap" Flapper Valve Torque

Controller
F-K Pump 150mm to 300mm

Original instructions

Erection, Operation and Maintenance, Safety

Approved date: 12-Apr-2013

Created by: CJOE

Approved by: LKH

Doc. No.: 70010353-3.0

 "Pneu-Flap" Flapper Valve Torque Controller
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Table of contents Page

1 General information ....................................................................................... 5
1.1 Scope........................................................................................................... 5
1.2 Design basis ................................................................................................. 5
1.3 References to standards ................................................................................. 5
1.4 Documentation .............................................................................................. 5
1.5 Definitions and abbreviations .......................................................................... 5
1.6 Legend ......................................................................................................... 6
2 Design and operating principle ........................................................................ 6
2.1 Description of the “Pneu-Flap” ......................................................................... 6
2.1.1 Details on Rotary Vane ....................................................................... 7
2.2 Operating principle ........................................................................................ 7
2.2.1 Design and operating data .................................................................. 7
2.2.2 Principles of Operation ........................................................................ 7
3 Safety instructions ........................................................................................ 7
3.1 General notes................................................................................................ 7
3.1.1 Introduction ...................................................................................... 7
3.1.2 Marking of the “Pneu-Flap”.................................................................. 7
3.2 General notes on safety for “Pneu-Flap” ........................................................... 7
3.2.1 Design requirements .......................................................................... 7
3.2.2 Foreseen hazards to personnel ............................................................ 8
3.2.3 Foreseen hazards to equipment ........................................................... 8
3.2.4 Permission to work............................................................................. 8
3.2.5 Safety and planning documents ........................................................... 9
3.2.6 Scrap and waste ................................................................................ 9
3.2.7 Harmful media................................................................................... 9
3.3 Specific safety precautions concerning erection ................................................. 9
3.3.1 Transport and pre-assembly at site. ..................................................... 9
3.3.2 The use of lifting lugs ......................................................................... 9
3.3.3 Other specific erection safety concern .................................................. 9
3.3.4 Electrical isolation .............................................................................. 9
3.3.5 Electrical supply................................................................................. 9
3.4 Specific safety precautions concerning OM .......................................................10
3.4.1 Completion of erection or maintenance procedures ............................... 10
3.4.2 Isolation of energy sources ................................................................10
3.4.3 Requirements for work inside the “Pneu-Flap” ...................................... 11
3.4.4 Cleaning of equipment and building..................................................... 11
3.4.5 Fire protection ..................................................................................11
3.4.6 Consumables and discharge of waste ..................................................11
3.4.7 Other specific OM safety concern ........................................................12
4 Erection...................................................................................................... 12
4.1 General notes...............................................................................................12
4.2 Modifications ................................................................................................12
4.3 Planning and installation procedures ...............................................................12
4.3.1 Resources and documentation ............................................................12
4.3.2 Planning and schedule .......................................................................12
4.3.3 Checking the dimension of buildings and foundations ............................12
4.3.4 Auxiliary tools ..................................................................................12
4.3.5 Scaffolding .......................................................................................12
4.4 The task on a step-by-step basis .................................................................... 12
4.4.1 Introduction .....................................................................................12
4.4.2 Steps ..............................................................................................12
4.5 Erection documentation .................................................................................13
4.5.1 Quality documentation ......................................................................13

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5 Operation ................................................................................................... 13
5.1 The functions of the “Pneu-Flap” .................................................................... 13
5.2 Pre-operational check ................................................................................... 14
5.2.1 Checking adequate lubrication. .......................................................... 14
5.2.2 Checking other relevant issues. ......................................................... 14
5.3 Operation ................................................................................................... 15
5.3.1 Normal Start ................................................................................... 15
5.3.2 Control procedures ........................................................................... 15
5.3.3 Normal Stop .................................................................................... 16
5.3.4 Shutdown procedures for maintenance ............................................... 16
5.4 Consumables and discharge of waste. ............................................................ 17
5.4.1 Oil .................................................................................................. 17
5.5 Operational supervision ................................................................................ 17
6 Maintenance................................................................................................ 17
6.1 Preventive maintenance................................................................................ 17
6.1.1 Lubrication ...................................................................................... 17
6.1.2 Cleaning ......................................................................................... 18
6.1.3 Inspection and adjustment ................................................................ 18
6.1.4 Status check ................................................................................... 18
6.1.5 Replacement of spares...................................................................... 19
6.1.6 Functional test ................................................................................. 19
6.2 Trouble shooting .......................................................................................... 19
6.2.1 Fault localization .............................................................................. 19
6.2.2 Reconditioning ................................................................................. 19
6.3 Associated work ........................................................................................... 20
6.3.1 Transport ........................................................................................ 20
6.3.2 Rigging and scaffolding ..................................................................... 20
6.3.3 Demolition ...................................................................................... 20
6.3.4 Lighting .......................................................................................... 20
7 Description of components ............................................................................. 20
7.1 Components ................................................................................................ 20
7.2 Spare parts ................................................................................................. 20
8 Appendices ................................................................................................. 20

List of appendices
Appendix 1 “Pneu-Flap” Assembly Front View .................................................................. 21
Appendix 2 Typical Assembly ........................................................................................ 23
Appendix 3 “Pneu-Flap” Assembly Top View .................................................................... 24
Appendix 4 “Pneu-Flap” Front View ................................................................................ 26
Appendix 5 Reference Views ......................................................................................... 28

List of figures
Figure 1. “Pneu-Flap” Assembly Front View for 150, 200, & 250mm Pump .......................... 21
Figure 2. "Pneu-Flap" Assembly Front View for 300 M Pump .............................................. 22
Figure 3. "Pneu-Flap" Typical Assembly - 300 M Shown .................................................... 23
Figure 4. "Pneu-Flap" Assembly Top View - 150, 200, & 250 M Pump ................................. 24
Figure 5. "Pneu-Flap" Assembly Top View - 300 M Pump .................................................. 25
Figure 6. "Pneu-Flap" Assembly Front View - 150, 200, & 200 M Pump ............................... 26
Figure 7. "Pneu-Flap" Assembly Front View - 300 M Pump ................................................ 27
Figure 8. Shaft Seal Replacement .................................................................................. 28
Figure 9. Flapper Valve Body Mounting Location .............................................................. 29
Figure 10. Actuator Stop Adjustment ............................................................................. 30
Figure 11. Flapper Valve Body Mounting Location ............................................................ 31
Figure 12. Coupling Alignment Adjustment ..................................................................... 32
Figure 13. Open Position Stop Adjustment ...................................................................... 33

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List of tables
Table 1. Recommended Values for Startup ......................................................................15
Table 2. Maintenance ....................................................................................................17

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"Pneu-Flap" Flapper Valve Torque Controller
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NOTE !
The present instruction manual is concerned with the situations which, according to the
experience of FLSmidth, are the most likely to occur. An exhaustive enumeration of all
conceivable situations, which may occur during manufacture, installation, operation and
maintenance of the equipment, cannot be provided.
Consequently, if a situation should arise, the occurrence of which is not foreseen in the
instruction manual, and which the operator is/or feels unable to handle, it is
recommended that FLSmidth is contacted without undue delay for advice on
appropriate action.

1 General information
1.1 Scope
The purpose of this document is to provide guidance during operation and
maintenance of the Fuller-Kinyon “Pneu-Flap”™ Pneumatic Flapper Valve
Torque Controller for 150, 200, 250, and 300mm Type “M” Fuller-Kinyon™
(F-K) pumps.

1.2 Design basis

The “Pneu-Flap” is designed to provide a constant torque to the flapper arm
shaft. Through the use of oil/air tanks, it dampens the movement of the
flapper arm.

1.3 References to standards

The “Pneu-Flap” is provided as part of a F-K Type M pump, which should be
approved according to the standards applied by the regulatory authorities and
FLSmidth.
All references to design standards are given at the EC declaration of
conformity.
Local regulations, if more stringent, take precedence over instruction manuals.
For dated references to any publication, subsequent amendments to or
revisions of any of these publications apply to this instruction only when
incorporated in it by amendment or revision.
For undated references the latest edition of the publication referred to applies.

1.4 Documentation
In addition to this document, the project specific parts list, General Assembly
drawings and F-K pump instruction manual should be referenced. The vendor
documentation supplied as part of the contract instruction manual should also
be referenced for instructions.

1.5 Definitions and abbreviations

Authorized person An authorized person is a skilled person, who is qualified and who by the
responsible manager is entrusted with certain tasks.

EC European Community

MSDS Material safety data sheet

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N/A Not applicable.

OM Operation and maintenance.

SDS Safety Data Sheet (In US known as MSDS)

Skilled person A person, who after an education as a craftsman, is capable of doing

skilled work.

1.6 Legend

DANGER indicates a hazardous situation which, if not avoided, will result in

death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, could result

in death or serious injury.

CAUTION, used with the safety alert symbol, indicates a hazardous situation
which, if not avoided, could result in minor or moderate injury.

This sign is shown in the instruction manual where specific attention and
caution is needed to avoid damage to or destruction of the equipment and/or
parts or components.

2 Design and operating principle

2.1 Description of the “Pneu-Flap”
The “Pneu-Flap” system is comprised of a partially oil filled rotary vane
actuator connected to the blow out lever shaft. A set of air tanks with hoses is
connected to the actuator. One air tank is supplied plant air through a
filter/regulator and relief valve and contains a pressure gauge mounted on top
of the tank. The other tank has a vent breather.

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2.1.1 Details on Rotary Vane

The rotary vane actuator is a double acting pneumatically controlled device
with a single vane that is rotated about a shaft with stops at each end of
the travel. The rotary unit is partially filled with oil to produce a
dampening effect.
See Appendix 1, Pos 03

2.2 Operating principle

2.2.1 Design and operating data
Maximum design temperature is 80°C
Maximum design pressure is 100 psi
2.2.2 Principles of Operation
A vane actuator partially filled with oil provides a constant torque to the
blow out lever shaft. Oil provides lubrication and dampening. A special
curved jaw coupling with a rubber spider further dampens vibration. Two
tanks are used to separate the oil from the air and to absorb pressure
variations to insure a constant torque transmits to the blow out lever shaft
at all times.

3 Safety instructions
3.1 General notes
3.1.1 Introduction
The “Pneu-Flap” must only be used under the intended technical
circumstances as defined in current instructions manuals.
It is a prerequisite for the safety that all relevant rules and regulations for
the prevention of accidents are held available at all times.
FLSmidth will not assume responsibility for any damage resulting from
abuse or improper operation or inadequate maintenance of the “Pneu-Flap”
or resulting from its operation or maintenance by unqualified personnel,
including personnel who have not acquired the skills required to operate or
maintain the equipment on the basis of the directions provided in the
technical documentation.
3.1.2 Marking of the “Pneu-Flap”
See marking of F-K pump.

3.2 General notes on safety for “Pneu-Flap”

3.2.1 Design requirements

Devices for switching off for the prevention of unexpected start-up

shall be used (e.g. where, during maintenance or trial run, a start up
of the machine may create a hazard).
Devices must be provided for disconnecting (isolating) electrical
equipment to enable work to be carried out without any attendant
risk of electrical shock or burn.

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 "Pneu-Flap" Flapper Valve Torque Controller
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Devices for switching off for the prevention of unexpected start-up

shall be used for the conveying air source. If this is impossible due
to use of the same air source for other conveying systems than a
manual, lockable isolation valve must be used.

Devices for switching off for the prevention of unexpected start-up

shall be used for the material feed devices.

3.2.2 Foreseen hazards to personnel

Before doing any maintenance on the “Pneu-Flap”, the following

Personal Protection Equipment must be worn: hard hat, safety
goggles or face shield, safety shoes (protective-tipped), hearing
protection, gloves, non-flammable long sleeved clothing and no loose
clothing.

Before doing any maintenance or opening any maintenance covers

lock out all power sources. System will be pressurized lock out all
air pressure sources and allow all pressure to bleed off before
proceeding with maintenance.

Before doing any maintenance allow the F-K Pump to which the
“Pneu-Flap” is attached to cool down to ambient temperatures to
reduce the risk of injury.

3.2.3 Foreseen hazards to equipment

3.2.4 Permission to work
It is the responsibility of the erection supervisor or maintenance supervisor
to ensure that all personnel involved have studied and fully understand:
 The permission given to perform work in the specific area.
 All relevant instructions concerning health and safety and the
contents of this instructions manual.

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
"Pneu-Flap" Flapper Valve Torque Controller
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3.2.5 Safety and planning documents

Proper Lock Out, Tag Out and Try Procedures must be established
and followed before any maintenance or inspections can be
performed on the “Pneu-Flap”.

3.2.6 Scrap and waste

Scrap and Waste must be handled according to local regulations.
3.2.7 Harmful media
The process media and the lubricants may cause danger to health. The
material safety data sheet (MSDS) informs any danger and precautions.

3.3 Specific safety precautions concerning erection

Any erection activity must be carried out by skilled persons and is subject to
the supervision of authorized personnel. See sub-section 1.5.

The directions outlined in instruction manual 32031 “General safety

regulations on erection site” must be strictly observed at the site of erection.

3.3.1 Transport and pre-assembly at site.

N/A
3.3.2 The use of lifting lugs
The "Pneu-Flap" is provided as part of the F-K pump, and therefore does
not require the use of lifting lugs.
3.3.3 Other specific erection safety concerns

A final erection check must result in a release note to commence test

or operation of the equipment. See sub-section 4.5.1.

3.3.4 Electrical isolation

As this “Pneu-Flap” is attached to the F-K pump, it should already be
properly connected to the plant grounding system in accordance with
EN60204-1.
3.3.5 Electrical supply
N/A

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3.4 Specific safety precautions concerning OM

Any operational or maintenance activity must be carried out by skilled

persons and is subject to the supervision of authorized personnel.

3.4.1 Completion of erection or maintenance procedures

Before any operation or test activity commences an authorized

person (See sub-section 1.5) must declare that erection or
maintenance has been completed and that the equipment has been
released for operation or test.

3.4.2 Isolation of energy sources

It is dangerous to perform test or maintenance activities before it is

ensured that it will be impossible to restart the “Pneu-Flap” or any
adjacent equipment in the process e.g. locally or by means of a
remote control unit.
Gravity force may constitute a risk. It must be ensured that neither
mechanical components nor media may constitute a risk to any
person.
See shut down procedure in sub-section 5.3.4.

Shut off the valve and bleed the compressed air line to the “Pneu-
Flap”.

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"Pneu-Flap" Flapper Valve Torque Controller
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3.4.3 Requirements for work inside the “Pneu-Flap”

Media does not flow through the “Pneu-Flap” itself, however media
does flow through the F-K pump to which the system is attached.
Media flow through the F-K pump constitutes a risk to personnel
working on the “Pneu-Flap”.
Ensure that no media rush, flue gas/air flow to or through the F-K
pump may occur. Gravity force may cause media rush.
Ensure a permit to work system for work inside the F-K pump.
Wait for cooling of the F-K pump before maintenance activity.
See the F-K pump instruction manual for additional warnings.

3.4.4 Cleaning of equipment and building

Mechanical equipment, steel structures and surfaces of

compartments must be kept clean from dust, scrap and dirt.
In particular all kinds of combustible material constitute a risk of fire
or dust explosion.

3.4.5 Fire protection

When using any open flame for heating, welding or cutting make sure all
combustible material are secured and a fire extinguisher is available.

3.4.6 Consumables and discharge of waste

Consult the MSDS for any solvents used during maintenance and
dispose of according to the manufacturers recommendations.

Consult the MSDS for the grease and oil, and dispose of according to the
manufacturer's recommendations.

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3.4.7 Other specific OM safety concern

N/A

4 Erection
4.1 General notes

Quality control! The words “Erection inspection” in any drawing or text

mean that the erection supervisor must carry out an inspection and approve
erection status before continued erection may commence.

4.2 Modifications

Do not make any changes or modifications to the equipment without consulting

FLSmidth first.

4.3 Planning and installation procedures

4.3.1 Resources and documentation
Part lists for the “Pneu-Flap” and accessories
F-K pump instruction manual
General Arrangement Drawings
General Assembly Drawings
4.3.2 Planning and schedule
N/A
4.3.3 Checking the dimension of buildings and foundations
N/A
4.3.4 Auxiliary tools
N/A
4.3.5 Scaffolding
N/A

4.4 The task on a step-by-step basis

4.4.1 Introduction
The following steps should be followed when an F-K pump equipped with a
"Pneu-Flap" is installed.
4.4.2 Steps
Check that the flapper valve arm is pushing hard against the flapper valve
before contact is made with the full open actuator stop. If this is not the
case, steps 1-9 must be followed to adjust the actuator stops. If no
adjustment is required, only step 10 must be completed.

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1. Loosen the clamping bolts on the driver coupling hub so that

the actuator can be turned freely.
2. Loosen the jam nuts on the actuator stops (See Appendix 5
Figure 10) and adjust both the open stop and closed stop all
the way “IN” by rotating the stops clockwise (Minimum actuator
stroke).
3. Remove the position indicator and rotate the actuator by hand
using an adjustable wrench to the full closed flapper valve
position. The actuator vane must be against the closed stop.
4. Rotate the blow out lever shaft on the pump by hand (Using the
blow out lever) to the full closed flapper position (See Appendix
5 Figure 11).
5. Rotate the actuator by hand to insure the actuator position is
against the closed stop.
6. Insure the flapper valve is fully seated inside the pump Flapper
Valve Body.
7. Tighten the clamping bolts to lock the driver coupling hub to
the square drive coupling adapter. Mark the closed position on
the actuator mounting bracket. See Appendix 2 Figure 3.
8. Adjust the closed actuator stop fully out (Counter-clockwise).
Adjust the stop to the maximum position so that it remains in
the housing. Tighten the jam nut.
a. This adjustment allows the actuator to hold the flapper
valve fully closed as the blow out lever wears.
b. This adjustment must be set up to allow the actuator to
hold the flapper valve fully closed at the maximum
allowable wear on the blow out lever and flapper arm. If
there is any doubt, mark the shaft, loosen the coupling,
and check for ample rotation before proceeding.
c. Tighten the closed stop jam nut when complete.
9. Rotate the blow-out lever to the fully open position by hand.
Mark the open position on the actuator mount bracket. See
Appendix 2 Figure 3.
10. Adjust the open actuator stop (See Appendix 5 Figure 13).
a. Adjust the open actuator stop OUT (counter-clockwise) to
the maximum position so that it remains in the housing.
b. Tighten the open stop jam nut.
11. Fill the actuator with oil (See section 5.2.2).

4.5 Erection documentation

4.5.1 Quality documentation
N/A

5 Operation
5.1 The functions of the “Pneu-Flap”
The “Pneu-Flap” provides a constant torque to the blow out lever shaft of a
Fuller-Kinyon Type M pump in a pneumatic conveying system.

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 "Pneu-Flap" Flapper Valve Torque Controller
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5.2 Pre-operational check

5.2.1 Checking adequate lubrication.
N/A
5.2.2 Checking other relevant issues.
Oil Level Check and Filling Procedures:

Never connect compressed air to the regulator, either tank, or directly to

the actuator while installing, servicing, or filling with oil.
Tanks may contain pressurized oil.
Relieve all pressure before servicing.
Stop the flow of compressed air, relieve all pressure, and disconnect the
supply piping from the regulator before opening the windbox access door
or servicing the "Pneu-Flap" actuator.
Serious injury may occur.

1. Rotate the locking shut off valve to the OFF position and insure all
compressed air has been relieved from the regulator, tanks, and
actuator. Bleed all remaining pressure and use a padlock to lock
the valve in the off position.
2. Remove the position indicator.
3. Insure no pressure remains in both tank “A” and tank “B”.
4. Remove the tank “A” and tank “B” oil fill plugs (See Appendix 4
Figures 6 and 7).
5. Rotate the actuator by hand (Using a wrench or square drive socket
on the position indicator shaft) to the fully closed position.

Use only Dextron II automatic transmission fluid.

Incorrect fluid will result in shorter actuator life.

6. Fill tank “B” with about 1 liter (Or 1 quart) of DEXTRON II automatic
transmission fluid.
7. Rotate the actuator by hand to the fully open position.
8. While holding the actuator in the fully open position, fill tank “A” with
1 liter (Or 1 quart) of DEXTRON II automatic transmission fluid.
9. Slowly rotate the actuator by hand fully open and fully closed at least
10 times to remove all trapped air from the system.
10. Rotate the actuator by hand to the fully closed flapper valve position.
11. While holding the actuator with the flapper valve in the fully closed
position, remove the oil level (Drain) plug at the bottom of tank “B”
(See Appendix 4 Figures 6 and 7). There should be more fluid than

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necessary in Tank “B”, so allow all extra oil to drain. If no oil drains,
add more fluid to both tanks and return to step 8.
12. Rotate the actuator by hand to the fully open flapper valve position.
13. While holding the actuator in the fully open flapper valve position,
remove the oil level (Drain) plug at the bottom of tank “A”. There
should be more oil than necessary in Tank “A”, so allow all extra fluid
to drain. If no fluid drains, add more fluid to both tanks and return
to step 8.
14. With both oil drain plugs removed, SLOWLY rotate the actuator by
hand fully closed to fully open at least 5 times to insure all extra oil
drains from the tanks.

Always follow the oil filling procedure stated above when filling the
actuator with oil.
See Appendix 1 Figures 1 and 2 for the maximum allowable oil level.
Excess oil in the tanks may cause equipment damage.

15. Install the oil level (Drain) plugs in both tank “A” and tank “B”.
16. Install the oil fill plugs in both tank “A” and tank “B”.
17. Install the position indicator.
18. Close the Flapper Valve Body inspection cover and tighten all of the
bolts.
19. Remove the padlock from the locking type shut off valve and supply
compressed air to the filter regulator.
20. Check for and repair any leaks.
21. Test operation as required.

5.3 Operation
5.3.1 Normal Start
Supply Compressed air to the “Pneu-Flap” assembly
Follow start-up procedures for F-K pump
5.3.2 Control procedures
1. Adjust the pressure in tank “A” to the recommended starting set
point shown in Table 1.

Pump Recommended Number of Turns Compressed Air

Open – Bleed
Size Starting Setpoint Usage
150 mm 50 psi / 345 kPa ½ turn 3 scfm / 4.8 Nm³/hr
200 mm 35 psi / 240 kPa ½ turn 3 scfm / 4.8 Nm³/hr
250 mm 55 psi / 380 kPa ½ turn 3 scfm / 4.8 Nm³/hr
300 mm 55 psi / 380 kPa 1 turn 5 scfm / 8 Nm³/hr
Table 1. Recommended Values for Startup

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2. Adjust the bleed screw to the recommended number of turns open

shown in Table 1 (See Appendix 1 Figures 1 and 2). Lock the jam
nut. There should be a slight consistent bleed of compressed air to
atmosphere.
3. Start the F-K pump.
4. Observe operation.
a. Blowback (Flapper valve position is unstable) – increase flapper
valve torque by increasing the regulator setting.
b. High motor amps – decrease flapper valve torque by
decreasing the regulator setting.
c. When adjusting the pressure set point, change in 5 psi
increments and observe operation.

Do not exceed 90 psi pressure setting to prevent the relief

valve from opening.

Never operate with the bleed completely closed. Unexpected

pump operation may occur.

5. Observe the pressure tank “A”. The pressure tank in “A” should be
stable at all times during operation.
a. If the pressure increases when the flapper valve strokes open,
increase the amount of compressed air bleed by opening the
air bleed adjustment valve.
b. If the amount of bleed seems excessive, close down the bleed
until slight pressure variations are observed. Open the bleed
again until the variations are minimized. CAUTION: The bleed
must be open at least a ½ turn at all times.
c. Lock the bleed adjustment screw in the desired position using
the jam nut.
5.3.3 Normal Stop
Follow normal stop procedures for F-K pump
Turn off supply of compressed air to the “Pneu-Flap” assembly.
5.3.4 Shutdown procedures for maintenance
Follow sequence for normal stop.
A start-stop switch installed next to the F-K pump and adjacent equipment
must be switched off and locked.
Shut off the compressed air valve and relieve the air pressure both to the
“Pneu-Flap” and adjacent equipment.

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Gravity force:
It must be ensured that neither mechanical components nor media may
move and thereby constitute a risk to any person.
Fix movable mechanical components.
Clean up the adjacent system for media both loose and caking.
Manually operated components:
Lock out all manual isolation valves in the compressed air lines and any
material feed chutes or convey lines.

5.4 Consumables and discharge of waste.

5.4.1 Oil
Refer to MSDS for proper handling and disposal of oil.

5.5 Operational supervision

The “Pneu-Flap” is intended to operate unattended with only periodic
observations as per the maintenance schedule section 6.1.

6 Maintenance
6.1 Preventive maintenance

Replacement of

Functional test
Status check
adjustments
Inspection,
Lubrication

Equipment
Pos Job designation Cleaning
description

spares
Tank “A” Pressure Check D

Tank “B” Pressure Check D

Rotary
Oil Change T
Actuator

Rotary
Actuator Check D D
Actuator

Table 2. Maintenance

Explanation: D = every 8 hours of operation

S = weekly
M = monthly
A = annually
T = see explanation in text below
Ts = see separate manuals.
A preceding number to a letter in the table indicates the
frequency of the activity in question. (Example: 2M means
twice a month)
6.1.1 Lubrication
The oil level in the rotary actuator should be checked every 3 months and
changed every 3,000 hours of operating time or once per year.

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 "Pneu-Flap" Flapper Valve Torque Controller
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6.1.2 Cleaning

Before doing any cleanup check MSDS for any materials being conveyed
and wear proper Personal Protective Equipment.

6.1.3 Inspection and adjustment

1. Check the operation each day when greasing the flapper valve.
a. Insure the pressure in tank “A” is correct (Adjust regulator).
b. Insure the pressure in tank “A” is stable (Adjust bleed as
required).
c. Drain condensate from the filter regulator (If equipped with
manual drain).
2. Perform the oil level check and filling procedure once every 3 months
(Or more often, if needed).
3. Use care to prevent dirt from entering the system.
4. Change the oil every 3,000 hours of operating time or once per year,
whichever comes first. Clean the system of all dirt and debris.
a. Drain oil from the tanks and hoses.
b. Remove the actuator from the support bracket, drain all fluid
from the actuator, clean, and flush actuator with fresh oil.
c. Install the actuator and connect the oil hoses.
d. Fill the actuator with oil using the oil fill procedure.
5. Oil leakage from tank “A” to tank “B” indicates the seals in the vane
actuator require replacement.
a. Order an actuator rebuilding kit or complete spare vane
actuator.
b. Remove the actuator from the support bracket.
c. Rebuild the actuator using the seal kit or replace the entire
unit.
d. Observe the condition of the internal parts to determine mode
of failure. Incorrect oil and dirt are the two main causes of
failure.
6. Unexpected pump performance may indicate the flapper valve shaft
may have excessive drag. The shaft must rotate freely at all times.
Debris will enter the shaft clearances when the seal is worn and
leaks. The shaft must be removed and cleaned. Shaft seals must be
replaced when excessive drag is observed or each time the blow out
lever shaft is removed.
6.1.4 Status check
N/A

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
"Pneu-Flap" Flapper Valve Torque Controller
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6.1.5 Replacement of spares

Contents under pressure make sure all air sources are LOCKED OUT and
the air pressure is allowed to bleed off before servicing equipment.

When removing worn parts there will be sharp edges, avoid contact and
wear protective gloves.

When removing heavy parts make sure they are secure and properly rigged
before removing from the pump refer to the contract parts list for weights
of the components.

When using solvents for cleaning of parts refer to the MSDS for proper
Personal Protective Equipment.

If using a torch or open flame for heating parts, follow proper hot work
procedures check for flammable materials and remove from area. One
should have a fire extinguisher available in the work area.

6.1.6 Functional test

N/A

6.2 Trouble shooting

6.2.1 Fault localization
6.2.1.1 Blowback
Increase flapper valve torque by increasing the regulator setting.

6.2.1.2 High Motor Amps

Decrease flapper valve torque by decreasing the regulator setting.
6.2.2 Reconditioning
N/A

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 "Pneu-Flap" Flapper Valve Torque Controller
70010353-3.0

6.3 Associated work

6.3.1 Transport
N/A
6.3.2 Rigging and scaffolding
N/A
6.3.3 Demolition
Oil from the “Pneu-Flap” must be emptied before the device is demolished.
6.3.4 Lighting
In accordance with prEN 12464-2 and ISO 8995 FLSmidth recommends to
customer minimum 200 lx and the use of movable lighting equipment
during overhaul maintenance of the “Pneu-Flap”.

7 Description of components
7.1 Components
 “Pneu-Flap” actuator assemblies use different actuators, tanks,
couplings, and brackets for each size pump. Parts are not
interchangeable between pump sizes.
 Size 150, 200, 250, and 300 mm F-K pumps use the same actuator
assemblies for right hand or left hand discharge configurations.
 Actuator assemblies are interchangeable for parallel and right angle
discharge configurations for each pump size.

7.2 Spare parts

Please see the Spare Parts List provided separately with this order for the
listing of suggested spare parts for your particular pump assembly.

8 Appendices
See next page.

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
"Pneu-Flap" Flapper Valve Torque Controller
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Appendix 1 “Pneu-Flap” Assembly Front View

Pos 01 Air Tank “A” Pos 11 Oil Level Plugs

Pos 02 Air Tank “B” Pos 12 Hydraulic Hose
Pos 03 Rotary Actuator Pos 13 Tank "A" Connection
Pos 04 Filter/Regulator Pos 14 Tank "B" Connection
Pos 05 Relief Valve Pos 15 Rotation To Close Flapper
Pos 06 Locking Shut Off Valve Pos 16 Oil
Pos 07 Air Bleed Adjustment Pos 17 Air
Pos 08 Pressure Gauge Pos 18 Maximum Oil Level
Pos 09 Oil Fill Ports Pos 19 ¼" NPT Air Supply Connection
Pos 10 Vent Breather

Figure 1. “Pneu-Flap” Assembly Front View for 150, 200, & 250mm Pump

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 "Pneu-Flap" Flapper Valve Torque Controller
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Pos 01 Air Tank “B” Pos 11 Oil Level Plugs

Pos 02 Air Tank “A” Pos 12 Hydraulic Hose
Pos 03 Rotary Actuator Pos 13 Tank "B" Connection
Pos 04 Filter/Regulator Pos 14 Tank "A" Connection
Pos 05 Relief Valve Pos 15 ¼" NPT Air Supply Connection
Pos 06 Locking Shut Off Valve Pos 16 Rotation To Close Flapper
Pos 07 Air Bleed Adjustment Pos 17 Oil
Pos 08 Pressure Gauge Pos 18 Air
Pos 09 Oil Fill Ports Pos 19 Maximum Oil Level
Pos 10 Vent Breather

Figure 2. "Pneu-Flap" Assembly Front View for 300 M Pump

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
"Pneu-Flap" Flapper Valve Torque Controller
70010353-3.0

Appendix 2 Typical Assembly

Pos 04 Filter Regulator Pos 08 Pressure Gauge

Pos 05 Relief Valve Pos 12 Hydraulic Hose
Pos 06 Locking Shut Off Valve Pos 13 ¼" NPT Air Supply Connection
Pos 07 Air Bleed Adjustment Pos 14 Position Indicator

Figure 3. "Pneu-Flap" Typical Assembly - 300 M Shown

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 "Pneu-Flap" Flapper Valve Torque Controller
70010353-3.0

Appendix 3 “Pneu-Flap” Assembly Top View

Pos 03 Rotary Valve Pos 17 Coupling Hub Driven Half

Pos 15 Coupling Hub Driver Half Pos 18 Horizontal/Angular Coupling
Pos 16 Rubber Coupling Spider Alignment

Figure 4. "Pneu-Flap" Assembly Top View - 150, 200, & 250 M Pump

24/33 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
"Pneu-Flap" Flapper Valve Torque Controller
70010353-3.0

Pos 03 Rotary Valve Pos 17 Coupling Hub Driven Half

Pos 15 Coupling Hub Driver Half Pos 18 Horizontal/Angular Coupling
Pos 16 Rubber Coupling Spider Alignment

Figure 5. "Pneu-Flap" Assembly Top View - 300 M Pump

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 "Pneu-Flap" Flapper Valve Torque Controller
70010353-3.0

Appendix 4 “Pneu-Flap” Front View

Pos 01 Tank "A" Oil Fill Plug Pos 04 Vertical Coupling Alignment
Pos 02 Tank "B" Oil Fill Plug Adjustment
Pos 03 Max Oil Level Pos 05 Tank "B" Oil Level Plug
Pos 06 Tank "A" Oil Level Plug

Figure 6. "Pneu-Flap" Assembly Front View - 150, 200, & 200 M Pump

26/33 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
"Pneu-Flap" Flapper Valve Torque Controller
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Pos 01 Tank "B" Oil Fill Plug Pos 04 Vertical Coupling Alignment
Pos 02 Tank "A" Oil Fill Plug Adjustment
Pos 03 Max Oil Level Pos 05 Tank "A" Oil Level Plug
Pos 06 Tank "B" Oil Level Plug

Figure 7. "Pneu-Flap" Assembly Front View - 300 M Pump

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 "Pneu-Flap" Flapper Valve Torque Controller
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Appendix 5 Reference Views

Pos 01 Install Seal As Shown With Lip Pos 03 Flapper Valve Side
Facing Flapper Valve Body Pos 04 Install New Bolts
Pos 02 Vane Actuator Side Pos 05 Install New Seal Retainer

Figure 8. Shaft Seal Replacement

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"Pneu-Flap" Flapper Valve Torque Controller
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Pos 01 Flapper Valve Body Mounting Location

Figure 9. Flapper Valve Body Mounting Location

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 "Pneu-Flap" Flapper Valve Torque Controller
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Pos 01 Actuator Stop Adjustment

Figure 10. Actuator Stop Adjustment

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"Pneu-Flap" Flapper Valve Torque Controller
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Pos 01 Tank "A" Connection Pos 03 Direction To Close Flapper

Pos 02 Tank "B" Connection

Figure 11. Flapper Valve Body Mounting Location

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 "Pneu-Flap" Flapper Valve Torque Controller
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Pos 01 Horizontal And Vertical Coupling Adjustment

Figure 12. Coupling Alignment Adjustment

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"Pneu-Flap" Flapper Valve Torque Controller
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Pos 01 Location Of Open Position Actuator Stop

Figure 13. Open Position Stop Adjustment

---o0o---

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