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Walinga Airlock 1008 Operator's Manual

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OPERATOR'S MANUAL
Airlock 1008
English
00-144471-0 A
2023-12-06

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Summary of Contents for Walinga Airlock 1008

  • Page 1 OPERATOR’S MANUAL Airlock 1008 English 00-144471-0 A 2023-12-06...
  • Page 2 TO OUR VALUED CUSTOMERS: The Walinga network of distribution centers and authorized dealers are dedicated to providing worldwide coverage of original parts and accessories for Walinga Pneumatic Conveying Systems. Our parts reflect Walinga’s continued commitment to provide our customers with the highest quality parts and service.

  • Page 3: Table Of Contents

    OPERATOR’S MANUAL Table of Contents Contact Information [00-144471-0] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - i Table of Contents [00-144471-0] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ii Literature Information [00-144471-0] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Identification of Machine [00-144471-0] - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 4 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-2 Limitations and Exclusions of the Walinga Warranty...
  • Page 5 OPERATOR’S MANUAL Required Warranty Claim Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-3 Warranty Conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-3 Warranty Claim Rejection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Not Covered Under Warranty...
  • Page 6 Walinga airlock. information on the operating principles including starting, operating functions, and Some illustrations and diagrams may show stopping the machine, as well as clearing safety shields, guards, or covers removed any blockages.

  • Page 7: Identification Of Machine [00-144471-0]

    Identification of Machine AIRLOCK MODELS...

  • Page 8: Serial Numbers

    OPERATOR’S MANUAL SERIAL NUMBERS Be prepared to provide the serial number of the airlock to 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 the rib of the front end plate of the airlock.

  • Page 9: Introduction [00-144472-0]

    Introduction AIRLOCK MODELS...

  • Page 10: Statement Of Importance

    INTENDED USE The Walinga airlock has been designed for use in agricultural or similar operations. Use of the machine in any other manner is considered as contrary to the intended use. Compliance with and strict adherence to the methods of operation, maintenance, and repair, as specified by Walinga in this manual, also constitute essential elements of the intended use.

  • Page 11: Directional References

    Figure 2-1: Directional references AIRLOCKS IN PNEUMATIC CONVEYING SYSTEMS Pneumatic conveying systems use air to move materials, Walinga’s airlocks are designed for conveying common agricultural materials, such as cereal grains. The efficient operation depends on many factors including air flows, line sizes, source power, operating methods, and suction and discharge line arrangements, among others.
  • Page 12 OPERATOR’S MANUAL In the blow-thru model, as seen in Figure 2-2, a pressurized stream of air enters at the bottom of the rear end plate. As the filled pockets rotate to the bottom, the product enters the pressurized air stream and is carried through the outlet at the bottom of the front end plate to the discharge side of the system.
  • Page 13 OPERATOR’S MANUAL In the drop-thru model, as seen in Figure 2-3, a pressurized stream of air enters the product collection device, commonly a pan or U-trough style. As the filled pockets rotate to the bottom, the product falls into the collection device, entering the pressurized air stream, and is carried through the conveying lines connected to the collection device.
  • Page 14 OPERATOR’S MANUAL The drop-thru model, as seen in Figure 2-4, can also function with atmospheric pressure on the outlet side. In this application, as the filled 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 vacuum, or atmospheric pressure if used as a metering device.

  • Page 15: Machine Configuration [00-144473-0]

    Machine Configuration AIRLOCK MODELS...

  • Page 16: Model Sizes

    MODEL SIZES Walinga airlocks are available in a variety of sizes. To identify the size of your airlock, refer to 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.
  • Page 17 OPERATOR’S MANUAL Table 3-1: Airlock model sizes Interior Casing Inlet/Outlet Rotor Length Capacity Diameter Diameter 12.9 in 14.3 in 4 in 0.8 cu ft/rev 1314-4 (32.8 cm) (36.3 cm) (10.2 cm) (23 L/rev) 12.9 in 14.3 in 5 in 0.8 cu ft/rev 1314-5 (32.8 cm) (36.3 cm)

  • Page 18: Model Variations

    OPERATOR’S MANUAL MODEL VARIATIONS GENERAL BLOW-THRU (BT) Product enters through the top of the airlock (usually under vacuum) and is forced out of outlet on the bottom edge of the front end plate by a stream of pressurized air entering from the rear end plate.
  • Page 19 OPERATOR’S MANUAL STANDARD PROFILE (-*A) The standard profile for blow-thru airlocks features a circular inner surface of the casing, maintaining the same clearance between the casing and 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 OPERATOR’S MANUAL ABRASIVE (ABR) Purge ports located in both end plates provide continuous positive pressure to the bearing cavity, preventing product buildup in the bearing and seal area. This feature is used when conveying abrasive materials or powders to prevent premature wear and damage.
  • Page 21 OPERATOR’S MANUAL ROTOR FIXED ROTOR (FXR) The rotor is fixed in position along the shaft direction using a tapered bearing 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 either a locking collar integrated in the bearing, or a specialized spacer ring.
  • Page 22 OPERATOR’S MANUAL CLOSED ROTOR (CLSD RTR) Plates are permanently affixed to each end of the rotor blades to prevent product from contacting the end plates. This feature reduces the wear and damage to the end plates and is used with abrasive products or products mixed with sand, dirt, or dust.
  • Page 23 OPERATOR’S MANUAL STAINLESS STEEL ROTOR (SS RTR) The rotor shaft, blades and tips are made of stainless steel. This style is used in specialized applications to prevent product discolouration possible chemical reactions. CLOCKWISE (CW) When viewed from the driven end, the rotor rotates in a clockwise direction.
  • Page 24 OPERATOR’S MANUAL HARDOX BEVEL (HXB) The adjustable tips made of Hardox material can also have beveled edges when conveying fibrous or long grain products to allow the tip to cut through the product to reduce the risk of binding, while maintaining the clearance adjustment and replacement capabilities.
  • Page 25 OPERATOR’S MANUAL SOLID BLADE SQUARE (SOLID) The rotor blade, with squared edges, extends from the rotor shaft to the proper clearance from the casing 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 [00-144474-0]

    Safety AIRLOCK MODELS...

  • Page 28: Safety Alert Symbol

    OPERATOR’S MANUAL SAFETY ALERT SYMBOL This safety alert symbol means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! The safety alert symbol identifies important safety messages on the airlock and in the operator’s manual. When you see this symbol, be alert to the possibility of personal injury or death.

  • Page 29: General Safety

    The most important safety feature of Walinga equipment is a safe operator. It is the operator’s responsibility to read and understand all aspects of this manual and to follow all safety and operational instructions.

  • Page 30: Installation Safety

    OPERATOR’S MANUAL Replace any safety sign or instructional sign that has been damaged or become illegible. The most common locations and a reproduction of the safety signs located on pneumatic conveying systems using an airlock are outlined later in this section. In addition to the design and configuration of this implement, including safety signs and safety equipment, hazard control and accident prevention are dependent upon the awareness, concern, prudence, and proper training of personnel involved in the operation, transport, maintenance, and storage of the machine.

  • Page 31: Storage Safety

    ● Coat internal surfaces with a rust inhibitor to prevent damage upon use after storage. PRE-OPERATION SAFETY ● Safety is a primary concern in the design and manufacturing of Walinga products. However, these efforts can be negated by a single careless act of an operator or bystander.

  • Page 32: Operational Safety

    OPERATOR’S MANUAL OPERATIONAL SAFETY ● Read and understand the operator’s manual and all safety signs before use. ● Do not operate when any guards are damaged or removed. Install and secure all guards before operating. ● Do not open any access door to the airlock while in operation. ●...

  • Page 33: Machine Safety Signs

    ● Informational safety signs are white or blue in color ● Each safety sign is printed with its respective Walinga part number located in the bottom right corner. Reference this number on the safety sign, or identified in the following reproductions, to obtain replacement safety signs.
  • Page 34 OPERATOR’S MANUAL Figure 4-1 Part Number: 53-17704-6 Approximate Location: Located on the 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 the airlock including the inlet, outlet, and any access doors...
  • Page 35 OPERATOR’S MANUAL Figure 4-3 Part Number: 53-18542-6 Approximate 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 the pneumatic conveying system SAFETY 00-144474-0 A...
  • Page 36 OPERATOR’S MANUAL Figure 4-5 Part Number: 53-04733-6 Approximate Location: Located at the driven end of the airlock, positioned so the arrow indicates the correct rotational direction (points to left side airlock standard counter-clockwise rotation) Figure 4-6 Part Number: 53-82427-6 Approximate Location: Located on the discharge line, positioned...

  • Page 37: Safety Training Sign-Off Form

    OPERATOR’S MANUAL SAFETY TRAINING SIGN-OFF FORM Walinga Inc. follows the general safety standards specified by the American Society of Agricultural Engineers (ASAE) and the Occupational Safety and Health Administration (OSHA). Anyone who will be operating and/or maintaining the airlock must read and clearly understand all safety, operating and maintenance information presented in this manual.
  • 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 [00-144475-0]

    Machine Life-Cycle Procedures AIRLOCK MODELS...

  • Page 40: Reception, Assembly And Initial Set-Up

    Figure 5-1: Airlock debris covers Due to the wide range of applications and systems in which a Walinga airlock may be used, refer to the operator’s manual of the auxiliary equipment for any additional procedures required for assembly upon initial reception of the airlock.
  • Page 41 ● Ensure the dust hazard analysis as required by NFPA 652 has been completed and the incorporation of the Walinga equipment complies with all relevant standards and regulations. ● Ensure the area is clear of any bystanders and individuals not involved in the operation of the machine, especially small children.
  • Page 42 OPERATOR’S MANUAL BREAK-IN INSPECTIONS There are no operational restrictions on airlocks when used for the first time, however, during the initial break-in period, the following mechanical features should be inspected more frequently than the recommended maintenance schedule. There may be additional break-in inspections required for auxiliary equipment;...

  • Page 43: Storage

    OPERATOR’S MANUAL STORAGE To prevent unnecessary down-time when preparing the airlock for use after storage, it is important to carefully follow the storage preparation procedures. To prepare the airlock for storage, proceed as follows: 1. Clear the area of bystanders, especially small children. 2.

  • Page 44: End Of Life

    OPERATOR’S MANUAL END OF LIFE Upon completion of the functional life of the airlock, Walinga offers a rebuilding program as a cost-effective means of keeping your airlock in optimal operating condition. Contact your Walinga dealer or representative to submit your airlock and join the rebuild program.

  • Page 45: Operation [00-144476-0]

    Operation AIRLOCK MODELS...

  • Page 46: Machine Features And Components

    OPERATOR’S MANUAL MACHINE FEATURES AND COMPONENTS A Front End Plate B Casing C Wiper Blade D Inlet E 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...

  • Page 47: Controls And Displays

    OPERATOR’S MANUAL CONTROLS AND DISPLAYS Due to the wide range of applications in which a Walinga airlock may be used, refer to the operator’s manual of the auxiliary equipment for specific details pertaining to controls and displays. OPERATION Pre-Operation Machine Preparation...

  • Page 48: Operation Of The Machine

    OPERATOR’S MANUAL Operation of the Machine The operation procedures for the airlock are heavily dependent on the auxiliary equipment. Refer to the operator’s manual of the auxiliary equipment for operation procedures. The following are the general operating guidelines: 1. Clear the area of bystanders, especially small children. 2.

  • Page 49: Stopping The Machine

    OPERATOR’S MANUAL Stopping the Machine The stopping procedures for the airlock are heavily dependent on the auxiliary equipment. Refer to the operator’s manual of the auxiliary equipment for stopping procedures. The following are the general stopping guidelines for normal operation: 1.

  • Page 50: Operating Tips And Hints

    OPERATOR’S MANUAL OPERATING TIPS AND HINTS To achieve the best performance from your airlock keep the following in mind: ● Keep intake lines as full as possible for maximum capacity. ● Maximum capacity is achieved when using large diameter conveying lines. Only use the smaller rubber lines for final clean-up.

  • Page 51: Troubleshooting

    If you encounter a problem that is difficult to solve, even after having referenced the following table and the troubleshooting guide of any auxiliary equipment’s operator’s manual, please contact your Walinga dealer or representative. Before you call, please have your operator’s manual and your airlock’s serial number ready and available.
  • Page 52 OPERATOR’S MANUAL Adjust the tips to decrease the clearance to the required specifications. Excessive clearance causes operating problems including bridging and loss through airlock due to erratic flow. Prolonged operation with excessive clearances will cause excessive tip clearance uneven casing wear, resulting in lower performance even after tip adjustment.
  • Page 53 OPERATOR’S MANUAL The airlock operates continuously in one direction only. Check that the shaft rotates in a counter-clockwise direction when viewed from the Incorrect direction of rotation driven end of the unit. Continuous operation in reverse will cause excessive wear and may damage the rotor tips, tip wiper, casing, and bearings.
  • Page 54 OPERATOR’S MANUAL PAGE INTENTIONALLY LEFT BLANK 6-10 00-144476-0 A OPERATION...

  • Page 55: Maintenance And Adjustments [00-144477-0]

    Maintenance and Adjustments AIRLOCK MODELS...

  • Page 56: Maintenance Schedule

    OPERATOR’S MANUAL MAINTENANCE SCHEDULE HOUR READING AT TIME OF SERVICE: SERVICED BY: Every 40 HOURS or WEEKLY Check Wiper Blade [7-5] Every 200 HOURS or MONTHLY Repack Rotor Shaft Bearings with Grease [7-7] Every 400 HOURS or 2 MONTHS Check Bearing/Seal Cavity [7-12] Every 500 HOURS or 3 MONTHS Tighten Bolts and Fasteners...

  • Page 57: Maintenance Safety

    OPERATOR’S MANUAL MAINTENANCE SAFETY Unsafe workshop and servicing practices increase the risk of injury around machinery. Review the following safety guidelines for important information regarding safety involved with maintenance operations. ● Read, understand and follow all operating, maintenance and safety information in the operator’s manual.
  • Page 58 1. Ensure the system is equipped with the correct fittings and components as detailed in Figure 7-1 and Table 7-1. Figure 7-1: Purge system set-up Table 7-1: Purge system components Figure 7-1 Reference Description Walinga Part Number 3/4” AIR TUBE, RED 73-103315-6 9/16” - 1-1/4” GEAR CLAMP 28-00578-6 3/4” HOSE BARB, 1/2” NPT 81-18800-6 1/2”...
  • Page 59 OPERATOR’S MANUAL 2. Ensure the supply lines are connected immediately after the blower outlet and before the muffler (if present) and are approximately equal in length. 3. Loosen the gear clamps and remove the airline from the barb fittings. 4. Examine the interior of the airline and fittings. a.
  • Page 60 OPERATOR’S MANUAL Figure 7-2: Polymer wiper overlap Figure 7-3: Solid wiper clearance 5. Inspect the condition of the wiper blade. Look for any signs of nicks, tears, significant pitting, wear or other damage. Replace the blade if it is damaged in any way. To replace the wiper blade, proceed as follows: 1.
  • Page 61 OPERATOR’S MANUAL 5. Remove the old wiper blade from the airlock. 6. Insert the new wiper blade into the airlock and loosely install the mounting hardware. 7. Adjust the position of the wiper blade to achieve the correct position in relation to the tips.
  • Page 62 OPERATOR’S MANUAL 4. Loosen and remove the set screw from 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 fasteners 00-144477-0 A MAINTENANCE AND ADJUSTMENTS...
  • Page 63 OPERATOR’S MANUAL 6. Remove the end plate and provide a support to the rotor shaft to prevent unnecessary strain on 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 the bearing cup and cone.
  • Page 64 OPERATOR’S MANUAL 8. Inspect the inner surface of the bearing cup for signs of excessive wear or heat, flaking, fretting, cracking or chipping, brinelling or nicks, and scuffing or scratching. If the cup is damaged in any way, the entire bearing assembly must be replaced. 9.
  • Page 65 OPERATOR’S MANUAL 14. Rotate the bearing cone assembly slightly and repeat Step 12 around the entire circumference of the assembly until the grease is evenly forced out of the small diameter end of the assembly. Figure 7-11: Packing bearing cone assembly with grease 15.
  • Page 66 OPERATOR’S MANUAL 20. Install the set screw into the lock nut, reference Figure 7-6, and tighten to the required torque as specified in Section 8: Specifications. 21. Rotate the rotor assembly by hand to ensure it rotates smoothly and there are no abnormal sounds from the bearing assembly such as crunching or grinding.
  • Page 67 OPERATOR’S MANUAL 5. If there are excessive levels of dirt, dust or debris in the cavity, the seal(s) must be replaced. To replace the inner seal(s), proceed as follows: a. Loosen and remove the lock nut and set screw from the rotor shaft. Reference Figure 7-6.
  • Page 68 OPERATOR’S MANUAL Install the new shaft seal(s) into the end plate, refer Section 11: Parts List to identify the required seal. For abrasive style airlocks, the face of the first seal should be flush with the inner face of the end plate, for all other airlock styles, the face of the seal should rest against the inner shoulder of the end plate.
  • Page 69 OPERATOR’S MANUAL 6. If necessary, repack the bearing with grease, refer to Step 8 to Step 15 of the above section Rotor Shaft Bearing Grease Packing. 7. If necessary, refer to Section 11: Parts List to identify the correct replacement for the seal plate if it shows any signs of damage or wear, and replace the seal plate.
  • Page 70 OPERATOR’S MANUAL 4. Rotate the rotor by hand to inspect the condition of each blade, looking for any that are bent, chipped, cracked, or otherwise broken. Replace any damaged blades with reference to the section Rotor Blade Tip Clearance Adjustment. Note: if only one edge of the tip is minimally damaged, it may be possible to use the other edge.
  • Page 71 OPERATOR’S MANUAL 6. Blow-thru models have a different clearance requirement for the inlet and outlet side of the airlock, measurements for the ‘bottom’ should be taken from the outlet, as seen in Figure 7-19. Reference Table 7-2 for tip clearance requirements. Rotate the rotor by hand and repeat the clearance measurement for each tip.
  • Page 72 OPERATOR’S MANUAL Table 7-2: Rotor blade tip and casing clearance Airlock Minimum Maximum Clearance Clearance Model Style 0.003 in 0.006 in 1008 Drop-Thru (0.08 mm) (0.15 mm) 0.004 in 0.007 in 1210 Drop-Thru (0.10 mm) (0.18 mm) 0.004 in 0.007 in Drop-Thru (0.10 mm) (0.18 mm)
  • Page 73 OPERATOR’S MANUAL To check the rotor clearances, proceed as follows: 1. Clear the 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 installed access point or removing a portion of the inlet structure.
  • Page 74 OPERATOR’S MANUAL Table 7-3: Rotor and end plate clearance Airlock Minimum Maximum Clearance Clearance Model Style 0.004 in 0.006 in 1008 Drop-Thru (0.10 mm) (0.15 mm) 0.005 in 0.007 in 1210 Drop-Thru (0.13 mm) (0.18 mm) Drop-Thru 0.005 in 0.007 in 1314 (0.13 mm) (0.18 mm)
  • Page 75 OPERATOR’S MANUAL Table 7-4: Maximum operating temperatures Airlock Style Seal Style Maximum Temperature “V” seal 140 °F Standard [60 °C] “CR” seal “CR” seal 212 °F Abrasive [100 °C] “AVT” seal To check the operating temperature, proceed as follows: 1. Clear the area of bystanders, especially small children. 2.
  • Page 76 OPERATOR’S MANUAL Airline Seals To maintain the intended pressure/vacuum levels on each side of the airlock to achieve smooth and high capacity product conveyance, the airlines must be well sealed. Each joint in the airline of a pneumatic conveying system is equipped with a seal. To check the condition of the airline seals, proceed as follows: 1.
  • Page 77 OPERATOR’S MANUAL 4. For drop-thru style airlocks, inspect the outlet seal as follows: a. With reference to the auxiliary equipment’s operator’s manual, remove any components connected to the airlock outlet. b. Visually inspect the seal, looking for any nicks, tears, abraded areas, excessive wear, or accumulation of dirt, dust or debris.
  • Page 78 OPERATOR’S MANUAL b. Visually inspect the airlock outlet seals, looking for any nicks, tears, abraded areas, excessive wear, or accumulation of dirt, dust or debris. Figure 7-23: Blow-thru outlet seal c. Clean or replace the seal as required. d. Visually inspect the seal of any removed adapters, reducers or couplers, looking for any nicks, tears, abraded areas, excessive wear, or accumulation of dirt, dust or debris.
  • Page 79 OPERATOR’S MANUAL c. Clean or replace the seal as required. d. Visually inspect the end plate-seal plate seals, looking for any nicks, tears, abraded areas, excessive wear, or accumulation of dirt, dust or debris. Figure 7-25: Inner seal plate seal e.
  • Page 80 OPERATOR’S MANUAL h. Clean or replace the seals as required. For standard style airlocks, loosen and remove the fasteners securing the end plate in place and remove the end plate. Visually inspect the “V” seals, looking for any nicks, tears, abraded areas, excessive wear, signs of thermal degradation, or accumulation of dirt, dust or debris.
  • Page 81 OPERATOR’S MANUAL Rotor Blade Tip Clearance Adjustment To maintain the seal between the inlet and outlet and efficient operation, the airlock requires a close fit between the tips of the rotors and the casing. As the tips wear during operation, they must be adjusted or replaced to maintain the required clearances.
  • 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 OPERATOR’S MANUAL 6. Rotate the rotor assembly until the loosened tip is approximately 1 in (25 mm) inside the casing on the side opposite to the wiper blade. The casing edge on the side of the wiper blade experiences greater 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 tips and casing.
  • Page 84 OPERATOR’S MANUAL 7. Place the appropriate feeler gauge, with reference to Table 7-2, between the tip and the casing 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.
  • Page 85 OPERATOR’S MANUAL 9. Tighten the tip retaining fasteners starting with the center fastener and moving outwards, alternating sides from the center to maintain the proper positioning until all fasteners have been tightened to the required torque as specified in Section 8: Specifications. Figure 7-33: Reference fastener tightening order 10.
  • Page 86 OPERATOR’S MANUAL To replace a tip that has been damaged or has insufficient adjustment remaining in the mounting slots, proceed as follows: 1. Clear the 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.
  • Page 87 OPERATOR’S MANUAL 5. Loosen and remove the tip retaining fasteners and remove the first tip from the casing. It may be beneficial to gain access to the outlet of the airlock for easier removal of the tips. Figure 7-35: Removal of blade tip 6.

  • Page 88: Maintenance Materials

    MAINTENANCE MATERIALS Grease Use an SAE multi-purpose high temperature grease with extreme pressure (EP) characteristics. An SAE multi-purpose lithium-based grease is also acceptable. Walinga airlocks are manufactured using Unirex EP 2 (98-01959-6). Thread Sealant Use a high performance thread sealant for fittings, Permatex High Performance Thread Sealant (92-03141-6).
  • Page 89 3. Ensure all required components, as detailed in Table 7-5, are ready and available. Table 7-5: Pressure-vent kit components Item Description Walinga Part Number Quantity A/L VENT PIPE ASSEMBLY 40-04944-5 FLEX HOSE, STAINLESS STEEL, 1 1/2” ID...
  • Page 90 OPERATOR’S MANUAL 6. Ensure the internal surfaces of 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 installation 7-36 00-144477-0 A MAINTENANCE AND ADJUSTMENTS...
  • Page 91 OPERATOR’S MANUAL 8. Position and secure the vent discharge flex hose [Item B] to the vent pipe using a U-clamp [Item C]. Figure 7-39: Flex hose installation 9. Identify the desired vent discharge point. The discharge point should be located in the product inlet structure above maximum capacity level to allow the small amount of material in the vented air to be discharged back into the inlet material collection area.
  • Page 92 OPERATOR’S MANUAL 13. Use the rubber connector hose [Item F] to join the spigot of the air inlet 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.
  • Page 93 2. Place all controls in neutral, stop and lock-out the power source, and wait for all moving parts to stop. 3. Ensure all required components, as detailed in Table 7-6, are ready and available. Table 7-6: Pressure monitoring kit components Item Description Walinga Part Number Quantity HALF COUPLING, 4FP 58-08815-6 FITTING, PUSH-IN, 4T-4MP 81-18109-6...
  • Page 94 OPERATOR’S MANUAL Figure 7-43: Half coupling positioning 5. Install the straight push-in fitting [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 operator, such as with the airlock motor controls.
  • Page 95 OPERATOR’S MANUAL 7. Install the coupling [Item D] onto the stem of the pressure gauge, applying thread sealant. Figure 7-45: Pressure gauge coupling 8. Apply thread sealant and secure the 90° push-in fitting [Item E] into the coupling of the pressure gauge.
  • Page 96 In some instances, it may prove beneficial or necessary to alter the intake method of the airlock. Walinga provides a variety of hopper style intake assemblies specially designed to properly match each airlock model, refer to Section 10: Accessories and Attachments.
  • Page 97 OPERATOR’S MANUAL 5. Fit a mesh or slotted guard into the base of the intake hopper. The guard must be capable of supporting a minimum load of 270 lbs (123 kg) without permanent deformation with opening sizes in compliance with local or international guarding standards.
  • Page 98 OPERATOR’S MANUAL 7. Some pressurized air will ‘blow-back’ through the airlock. This may cause bridging in the intake hopper. If the bridging disrupts 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.

  • Page 99: Specifications [00-144478-0]

    Specifications AIRLOCK MODELS...

  • Page 100: Technical Data

    OPERATOR’S MANUAL TECHNICAL DATA Table 8-1: Blow-thru airlock specifications 1314-4 1314-5 1618-6 1618-7 2018-7 2224-8 0.8 cu ft/rev 0.8 cu ft/rev 1.6 cu ft/rev 1.6 cu ft/rev 2.69 4.44 cu ft/rev cu ft/rev Capacity (23 L/rev) (23 L/rev) (45 L/rev) (45 L/rev) (76 L/rev) (126 L/rev)
  • Page 101 OPERATOR’S MANUAL Table 8-2: Drop-thru airlock specifications 1008 1210 1314 1618 2224 0.28 0.55 4.44 cu ft/rev cu ft/rev cu ft/rev cu ft/ rev cu ft/rev Capacity (8 L/rev) (16 L/rev) (23 L/rev) (45 L/rev) (126 L/rev) 200 lbs 223 lbs 340 lbs 521 lbs 1481 lbs...

  • Page 102: Bolt Torques

    OPERATOR’S MANUAL BOLT TORQUES The critical required torque values for the airlock fasteners are identified in Table 8-3. For any fasteners not specified in Table 8-3, refer to Table 8-4 and Table 8-5 for imperial and metric bolt torque requirements respectively. Check the tightness of bolts periodically.
  • 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...
  • 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 00-144478-0 A SPECIFICATIONS...
  • Page 105 OPERATOR’S MANUAL Table 8-4: Imperial torque specifications Bolt Bolt Torque Diameter SAE 2 SAE 5 SAE 8 “A” [in] [Nm] [lb-ft] [Nm] [lb-ft] [Nm] [lb-ft] 5/16 7/16 9/16 Figure 8-11: Imperial bolts 1320 SPECIFICATIONS 00-144478-0 A...
  • Page 106 OPERATOR’S MANUAL Table 8-5: Metric torque specifications Bolt Torque Bolt Diameter 10.9 “A” [Nm] [lb-ft] [Nm] [lb-ft] Figure 8-12: Metric bolts 1050 1495 1103 2100 1550 2600 1917 3675 2710 00-144478-0 A SPECIFICATIONS...

  • Page 107: Standards And Regulations

    OPERATOR’S MANUAL STANDARDS AND REGULATIONS Walinga follows the general safety standards specified by the American Society of Agricultural Engineers (ASAE) and the Occupational Safety and Health Administration (OSHA) with consideration of standards outlined by the National Fire Prevention Agency (NFPA), International Organization for Standardization (ISO), Occupational Health and Safety Standards (OH&S), and American National Standards Institute (ANSI).
  • Page 108 OPERATOR’S MANUAL PAGE INTENTIONALLY LEFT BLANK 8-10 00-144478-0 A SPECIFICATIONS...

  • Page 109: Warranty [00-145861-0]

    Warranty AFTERMARKET PARTS SERVICE...

  • Page 110: The Warranty

    (the “Walinga Warranty”). WARRANTY PERIOD The warranty period for Walinga parts shall expire six (6) months after the date of sale to the original customer; with the exception of parts purchased from a Walinga authorized dealer. In these situations, the warranty period shall expire six (6) months after the date of sale recorded on the dealer’s Sales Order to their customer.

  • Page 111: Required Warranty Claim Information

    Sales Order to their customer. ● The buyer is responsible for promptly notifying Walinga of any defects to the parts to the parts or workmanship, and making the equipment available to Walinga or its authorized facility for evaluation or repair.

  • Page 112: Warranty Claim Rejection

    OPERATOR’S MANUAL WARRANTY CLAIM REJECTION Without limitation, Walinga reserves the right to reject a warranty claim for any one or more of the following reasons: ● The warranty claim information provided is insufficient. ● The product evaluation does not substantiate the claim.

  • Page 113: Accessories And Attachments [00-144480-0]

    Accessories and Attachments AIRLOCK MODELS 10-1...
  • Page 114 A wide variety of accessories are available for your airlock model to improve your operational experience. Below are some of the available accessories and a general description of their function. Please contact your Walinga dealer or representative for accessories compatible with your specific airlock, availability and ordering, or if you have any questions.
  • Page 115 OPERATOR’S MANUAL INLET HOPPERS To accommodate operation of an airlock with a more open and accessible inlet, an inlet hopper may installed. Guards inlet assemblies equipped with pressure vents to prevent ‘blow-back’ bridging are also available. MAGNETIC INLET COVERS operations where conveyed products may be contaminated with...
  • Page 116 OPERATOR’S MANUAL PAGE INTENTIONALLY LEFT BLANK 10-4 00-144480-0 A ACCESSORIES AND ATTACHMENTS...

  • Page 117: Parts List [00-144481-0]

    Parts List AIRLOCK 1008 MODEL 11-1...

  • Page 118: Model References

    OPERATOR’S MANUAL MODEL REFERENCES Refer to Section 3: Machine Configuration for detailed information regarding the naming and short forms of various key features of the airlock. Refer to Table 11-1 for the 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 remainder of this section.

  • Page 119: Body Components

    OPERATOR’S MANUAL BODY COMPONENTS CASING Model Description Part Number PLUG, 12MP, HEX SOCKET 58-14005-6 TIP WIPER WASHER PLATE, 1008 30-137504-4 PLATE WASHER, 1/4”, PLTD 94-04258-6 LOCK WASHER, 1/4”, PLTD 94-04259-6 BOLT, 1/4-20-1, GR 8, PLTD 94-05281-6 TIP WIPER, 1008 30-137501-4 CASING, 1008 DT 30-137503-6 PARTS LIST...
  • Page 120 OPERATOR’S MANUAL END PLATE Model Description Part Number END PLATE, 1008 DT, OB 30-137491-5 BOLT, 5/16-18-1, GR 8, PLTD 95-05284-6 11-4 00-144481-0 A PARTS LIST...

  • Page 121: Rotor Components

    OPERATOR’S MANUAL ROTOR COMPONENTS ROTOR Model Description Part Number ROTOR, 1008, OB, SOLID 30-137492-5 PARTS LIST 00-144481-0 A 11-5...
  • Page 122 OPERATOR’S MANUAL DRIVEN END SHAFT COMPONENTS Model Description Part Number KEY, 3/8” x 3/8” x 1-3/4” 97-80192-6 BEARING, NSK AEL208-108x1-1/2” 96-137502-6 LOCKING COLLAR, 1-7/8” ID, OB 96-137507-6 SHAFT SEAL, TEFLON, 1008, OB 96-137498-6 CAP SCREW, 1/4-28-3/4 94-14744-6 QUAD RING, QN7 134, 1008, OB 96-137496-6 11-6 00-144481-0 A...
  • Page 123 OPERATOR’S MANUAL IDLE END SHAFT COMPONENTS Model Description Part Number SHAFT SEAL, TEFLON, 1008, OB 96-137498-6 LOCKING COLLAR, 1-7/8” ID, OB 96-137507-6 BEARING, NSK AEL208-108x1-1/2 96-137502-6 QUAD RING, QN7 134, 1008, OB 96-137496-6 CAP SCREW, 1/4-28-3/4 94-14744-6 PARTS LIST 00-144481-0 A 11-7...
  • Page 124 OPERATOR’S MANUAL MISCELLANEOUS Model Description Part Number INNER SHAFT GUARD, 1008 11-137544-4 DEBRIS COVER, IN/OUT, 1008 11-138535-4 PLATE WASHER, 5/16”, PLTD 94-04240-6 LOCK WASHER, 5/16”, PLTD 94-04241-6 BOLT, 5/16-18-1, GR 8, PLTD 94-05284-6 OUTER SHAFT GUARD, 1008 11-137557-4 11-8 00-144481-0 A PARTS LIST...
  • Page 125 PAGE INTENTIONALLY LEFT BLANK...
  • Page 126 CORPORATE HEAD OFFICE: 5656 Highway 6N RR#5 Guelph, Ontario, N1H 6J2 PHONE (519) 824-8520 (519)0824-5651 www.walinga.com FACTORY DISTRIBUTION AND SERVICE CENTERS: 938 Glengarry Crescent 1190 Electric Avenue Fergus, ON, Canada, N1M 2W7 Wayland, MI, USA, 49348 PHONE (519) 787-8227 PHONE (800) 466-1197...

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