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P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com BRELKO CONVEYOR PRODUCTS ® Product, Installaon and Maintenance Manual Air Cannons Bulk Material Flow Acvator

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Page 1: Conveyor Belt, Conveyor Systems, Air Blasters - Brelko Conveyor … · 2020-01-09 · Air Cannons can be stored unpacked or in transportation package. Air Cannons must not be stored

P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com

BRELKOCONVEYOR PRODUCTS ®

Product, Installation and Maintenance Manual

Air CannonsBulk Material Flow Activator

Page 2: Conveyor Belt, Conveyor Systems, Air Blasters - Brelko Conveyor … · 2020-01-09 · Air Cannons can be stored unpacked or in transportation package. Air Cannons must not be stored

P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com

BRELKOCONVEYOR PRODUCTS ®

Version 8.0 – © 03/2018Product, Installation and Maintenance Manual - Air Cannons - Page 1 of 22

All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

Table of Contents1. Table of Contents ������������������������������������������������������������������������������ 1

2. Company Profile ������������������������������������������������������������������������������� 2

3. Disclaimer ������������������������������������������������������������������������������������ 3

4. Safety Note ����������������������������������������������������������������������������������� 3

5. The following symbols may be used in this manual: ��������������������������������������������������� 3

6. General Information ���������������������������������������������������������������������������� 3

7. Handling ������������������������������������������������������������������������������������� 3

7.1. Receiving the goods ��������������������������������������������������������������������� 3

7.2. Work Safety ��������������������������������������������������������������������������� 3

7.3. Handling ������������������������������������������������������������������������������ 4

7.4. Storage ������������������������������������������������������������������������������� 4

7.5. Preparations for installing Air Cannons ������������������������������������������������������ 4

7.6. Before installation, check all measurements and any of the other geometric design ������������������ 4

8. Recommended Tools List ������������������������������������������������������������������������ 4

8.1. Recommended Tools List Continued �������������������������������������������������������� 5

8.2. Recommended Tools List Continued �������������������������������������������������������� 6

9. Air Cannon ����������������������������������������������������������������������������������� 7

9.1. Air Cannon Mounting Selection Guide ������������������������������������������������������ 8

10. Air Cannon - Features and Options ���������������������������������������������������������������� 9

11. General Recommendations (See sketches 1, 2, 3, & 4) Continued ��������������������������������������� 10

11.1. Air Cannon - Assembly Instructions ������������������������������������������������������� 11

12. Air Cannon Quantities - Silo and Bunker Tables ������������������������������������������������������ 12

13. Air Cannon - Parts List Reference Drawing ���������������������������������������������������������� 13

13.1. Air Cannon - Parts List ������������������������������������������������������������������ 14

13.2. Air Cannon - Flanged and Straight Adapter Parts List ������������������������������������������ 15

14. Air Cannon - Charging / Discharging �������������������������������������������������������������� 16

15. Replacement Instructions ����������������������������������������������������������������������� 17

15.1. To replace or repair the quick exhaust valve ������������������������������������������������� 17

15.2. To replace main diaphragm �������������������������������������������������������������� 17

15.3. Spare Parts List - 1 Year of operation ������������������������������������������������������� 17

15.4. Spare Parts List - 2 Years of operation ������������������������������������������������������ 17

15.5. Replacement Instructions Continued ������������������������������������������������������ 18

16. Maintenance �������������������������������������������������������������������������������� 19

16.1. Periodic Visual Inspection (Every 2-6 Weeks) ������������������������������������������������ 19

16.2. Quarterly Maintenance ����������������������������������������������������������������� 19

16.3. Annual Maintenance ������������������������������������������������������������������� 20

16.4. Annual Inspections and Pressure Testing ��������������������������������������������������� 20

17. Trouble Shooting ����������������������������������������������������������������������������� 21

18. Contact Details ������������������������������������������������������������������������������� 23

Page 3: Conveyor Belt, Conveyor Systems, Air Blasters - Brelko Conveyor … · 2020-01-09 · Air Cannons can be stored unpacked or in transportation package. Air Cannons must not be stored

P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com

BRELKOCONVEYOR PRODUCTS ®

Version 8.0 – © 03/2018Product, Installation and Maintenance Manual - Air Cannons - Page 2 of 22

All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

Head Offi ce: Brelko Conveyor Products (Pty) Ltd.16 Harries street, Reuven Extension 1, Booysens, Johannesburg, South Africa Website: www.brelko.com, e-mail: [email protected], Tel: +27 11 013 4000

Managing Director:Kenny PadayacheeTel: +27 11 013 4000email: [email protected]

General Manager:Jay PillayTel: +27 82 557 5998email: [email protected]

Sales & Marketing Manager: Sharon PadayacheeTel: +27 11 013 4000email: [email protected]

Africa & USA Area ManagerBrent WellerTel: +27 598 4115 email: [email protected]

Technical & CADD Manager: Riaan RyndersTel: +27 82 507 3839email: [email protected]

Service Manager:Craig AbbeyTel: +27 82 407 8581email: [email protected]

IT Manager:Grant RitsonTel: +27 82 337 8162email: [email protected]

� Founded in 1987 / Selby, Johannesburg – South Africa.

� Brelko design and manufacture conveyor belt cleaning equipment for a trouble-free fl ow of materials at transfer and load points. This is backed up by an installati on and maintenance package.

� We have over 30 years experience as a supplier and advisor on spillage control to the bulk materials handling industry and off er proacti ve and ongoing maintenance for preventati ve spillage control and opti mum belt cleaning.

� We supply and service our products throughout the world, with branches in the United Kingdom and the United States, our master distributors in Australia, Chile, Europe and Greece, and agents located in Africa and more than 40 countries.

� We are accredited with ISO 9001:2015, ISO 14001:2015 and OHSAS 18001:2007 certi fi cati on and are members of the South African Insti tute of Materials Handling and Conveyor Manufacturers Associati on Limited of South Africa.

� The company is accredited with Level 1 B-BBEE status.

Page 4: Conveyor Belt, Conveyor Systems, Air Blasters - Brelko Conveyor … · 2020-01-09 · Air Cannons can be stored unpacked or in transportation package. Air Cannons must not be stored

P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com

BRELKOCONVEYOR PRODUCTS ®

Version 8.0 – © 03/2018Product, Installation and Maintenance Manual - Air Cannons - Page 3 of 22

All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

3. Disclaimer

Brelko Conveyor Products (Pty) Ltd hereby disclaims any liability for: damage due to contamination of the material; user’s failure to inspect, maintain and take reasonable care of the equipment; injuries or damage resulting from use or application of this product contrary to instructions and specifications contained herein. Brelko’s liability shall be limited to repair or replacement of equipment shown to be defective.

4. Safety Note

Observe all safety rules given herein along with owner and Government standards and regulations. Know and understand lockout/tag-out procedures as defined by National Standards Institutes, National Standard for Personnel Protection - Lockout/Tag-out of Energy Sources - Minimum Safety Requirements and Occupational Health and Safety.

5. The following symbols may be used in this manual:

DANGER Danger: Immediate hazards that will result in severe personal injury or death.

WARNING Warning: Hazards or unsafe practices that could result in personal injury.

CAUTION Caution: Hazards or unsafe practices that could result in product or property damages.

Important: Instructions that must be followed to ensure proper installation/operation of equipment.

Note: General statements to assist the reader.

6. General Information

Brelko Air Cannons are designed to operate with minimum maintenance. However, to maintain superior performance some service is required. When the Air Cannon is installed a regular maintenance program should be set up. This program will ensure that the Air Cannon operates at optimal efficiency and problems can be identified and fixed before the Air Cannon stops working. All safety procedures for inspection of equipment (stationary or operating) must be observed. Service tasks can be done only with the conveyor stopped and by observing the correct lockout/tag-out procedures.

Note: Ensure the vessel is empty

7. Handling

7.1. Receiving the goods

Check that the shipment contains all the products specified in the delivery note. If the goods do not match the delivery note, if the goods show any transportation damage, list it on the freight bill. Describe the damage and the number of wrong or faulty goods, and contact your supplier immediately.

Do not use defective parts under any circumstances. Claims must be made within 8 days from the arrival of goods. The factory does not cover expenses caused by exchange of product when installation was not carried out according to factory instructions.

7.2. Work Safety

Always use protective gloves and clothing. Always use a lifeline and soft-sole footwear when work will be carried out on raised platforms. Before you move any equipment, check that it is securely attached to the lifting equipment. Always observe local safety regulations.

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P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com

BRELKOCONVEYOR PRODUCTS ®

Version 8.0 – © 03/2018Product, Installation and Maintenance Manual - Air Cannons - Page 4 of 22

All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

WARNINGBefore removing/installing equipment, lock out/tag out energy source to conveyor, and/or conveyor accessories.

Turn off and lock out/tag out energy source according to local standards.

If equipment will be installed in an enclosed area, test gas level or duct content before using a cutting torch or welding. Using a cutting torch or welding in an area with gas or dust may cause an explosion.

If using a cutting torch or welding machine, test atmosphere for gas level or dust content.

7.3. Handling

When Air Cannons are unloaded from the transportation vehicle onto customer’s platform, place them on boards spaced max 1m apart at a minimum of 5cm from the ground.

7.4. Storage

Air Cannons can be stored unpacked or in transportation package. Air Cannons must not be stored on top of one another, protect the Air Cannons by storing them in a cool dry area on a flat surface.

7.5. Preparations for installing Air Cannons

7.6. Before installation, check all measurements and any of the other geometric design

8. Recommended Tools List

Tools List

QTY DESCRIPTION IMAGE

2 EXTENSION CORD (20m MINIMUM)

1 PORT-A-PACK (OXY-ACETYLENE)

1 COMBINATION GAUGE (WITH SPIRIT LEVEL)

Page 6: Conveyor Belt, Conveyor Systems, Air Blasters - Brelko Conveyor … · 2020-01-09 · Air Cannons can be stored unpacked or in transportation package. Air Cannons must not be stored

P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com

BRELKOCONVEYOR PRODUCTS ®

Version 8.0 – © 03/2018Product, Installation and Maintenance Manual - Air Cannons - Page 5 of 22

All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

Tools List

QTY DESCRIPTION IMAGE

1 STRAIGHT EDGE (1M MINIMUM)

1 90° SET SQUARE

1 5M TAPE MEASURE

2 ADJUSTABLE SPANNERS

1 PIPE WRENCH (3" MINIMUM)

1 SOCKET RATCHET SET (6mm - 30mm)

2 RINGSET SPANNERS - M13, 15, 16, 17, 18, 19, 24

Page 7: Conveyor Belt, Conveyor Systems, Air Blasters - Brelko Conveyor … · 2020-01-09 · Air Cannons can be stored unpacked or in transportation package. Air Cannons must not be stored

P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com

BRELKOCONVEYOR PRODUCTS ®

Version 8.0 – © 03/2018Product, Installation and Maintenance Manual - Air Cannons - Page 6 of 22

All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

Tools List

QTY DESCRIPTION IMAGE

1 STANLEY KNIFE

1 HARD FACE HAMMER – 4pd

1 SOFT FACE HAMMER - 1KG

3M NYLON ROPE

2 "G" CLAMPS - 6" - 8"

1 JIMMY LEVER

1 FLANGE SPANNER

Page 8: Conveyor Belt, Conveyor Systems, Air Blasters - Brelko Conveyor … · 2020-01-09 · Air Cannons can be stored unpacked or in transportation package. Air Cannons must not be stored

P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com

BRELKOCONVEYOR PRODUCTS ®

Version 8.0 – © 03/2018Product, Installation and Maintenance Manual - Air Cannons - Page 7 of 22

All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

AIR CANNON

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P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com

BRELKOCONVEYOR PRODUCTS ®

Version 8.0 – © 03/2018Product, Installation and Maintenance Manual - Air Cannons - Page 8 of 22

All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

9.1. Air Cannon Mounting Selection Guide

Air Cannon MountingOptions

Page 10: Conveyor Belt, Conveyor Systems, Air Blasters - Brelko Conveyor … · 2020-01-09 · Air Cannons can be stored unpacked or in transportation package. Air Cannons must not be stored

P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com

BRELKOCONVEYOR PRODUCTS ®

Version 8.0 – © 03/2018Product, Installation and Maintenance Manual - Air Cannons - Page 9 of 22

All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

GENERAL � Brelko Air Cannons are pneumatic, bulk material flow activating systems that quickly release compressed air into

a storage vessel to restore flow to material that is clinging, bridging, rat holing or arching. This manual provides instructions for installing Air Cannons.

APPLICATIONS � Used to remove and prevent blockages and build-up of bulk material in silos, bins, hoppers, chutes etc. � Resolve bulk flow problems where other methods are expensive, use more energy, damage the storage vessel, are

excessively noisy and unreliable.

FEATURES � Unique diaphragm main valve results in extremely rapid operation and therefore more effective size for size. � Only one moving part. � Easy maintenance, no need to remove air cannon. � Safe to operate and maintain.

AIR CANNONS - FEATURES AND OPTIONSAIR CANNON - BULK MATERIAL FLOW ACTIVATOR

General Recommendations (See sketches 1, 2, 3, & 4)

• With chimney formation and bridging (sketches 1 & 2) Air Cannons are mounted in the vicinity of the outlet as well as in the parallel part of the silo.

• When arching in the bunker/silo body or building-up on the conical part occurs (sketch 3 & 4) usually blasting on one plane is sufficient, i.e. when arching in the bunker/silo just after the parallel position commences and with build-up at the top of the cone downwards along the cone wall.

Sketch - 1 Sketch - 2

Sketch - 3 Sketch - 4

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P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com

BRELKOCONVEYOR PRODUCTS ®

Version 8.0 – © 03/2018Product, Installation and Maintenance Manual - Air Cannons - Page 10 of 22

All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

The sketches 5, 6 , 7 & 8 show further examples of blockages which can be relieved through application of Air Cannons.

The approximate effective radius of an Air Cannon on the container wall as well as into bulk material is:

BB003 Discharge Tube = dia 40mm Range R = ca 500mm at 6-8 bar

BB005 Discharge Tube = dia 40mm Range R = ca 500mm at 6-8 bar

BB010 Discharge Tube = dia 50mm Range R = ca 500mm at 6-8 bar

BB025 Discharge Tube = dia 50mm Range R = ca 500mm at 6-8 bar

BB050 Discharge Tube = dia 100mm Range R = ca 500mm at 6-8 bar

BB100 Discharge Tube = dia 100mm Range R = ca 500mm at 6-8 bar

BB200 Discharge Tube = dia 100mm Range R = ca 500mm at 6-8 bar

BULK MATERIAL - A• Bulk density less than T/m3

• Material with low internal coefficient of friction

• Dry, fine material

• Outlet cone wall angle more than 500

• Small outlet opening

BULK MATERIAL - B• Bulk density less than T/m3.

• Material that agglomerates.

• Coarse Material.

• Outlet cone wall angle more than 500.

• Large outlet opening.

Sketch - 5

Sketch - 7

Sketch - 6

Sketch - 8

Page 12: Conveyor Belt, Conveyor Systems, Air Blasters - Brelko Conveyor … · 2020-01-09 · Air Cannons can be stored unpacked or in transportation package. Air Cannons must not be stored

P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com

BRELKOCONVEYOR PRODUCTS ®

Version 8.0 – © 03/2018Product, Installation and Maintenance Manual - Air Cannons - Page 11 of 22

All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

AIR CANNONBULK MATERIAL FLOW ACTIVATOR

NOTE! Always quote silo dimensions

ASSEMBLY INSTRUCTIONSEvery installation differs according to the circumstances but the following points must always be considered: -

1. The discharge pipe (1, 2 & 3) must be attached to the container wall with its outlet flush with the inside surface. This is to prevent the introduction of a new obstacle, which can lead to further blockages.

2. There is a quick release valve on the lid of the Air Cannon. Its outlet must be kept free and preferably point downwards to prevent the accumulation of foreign material. An optional extra is the fitting of an exhaust silencer, which also acts as a filter.

3. Due to the mass of the Air Cannon, use should be made of a suspension chain supplied with models 25 litre (BB025) and larger.

4. The 3-way operating valve (manual or electric) should be no more than 10 metres from the Air Cannon. The vent port of the 3-way operating valve must have an orifice of at least 6mm diameter.

5. The discharge air pipe should be kept as short as possible with a minimum of bends. Difficult installations requiring long discharge pipes need to be investigated thoroughly, and could require a larger Air Cannon to be fitted to overcome discharge losses.

6. Supply air pressure should be at least 4 bar with a maximum of 8 bar. If there is a possibility of the air pressure exceeding 8 bar, then a safety relief valve must be fitted in the supply line. Also if the air supply drops below 4-bar then a booster is recommended to ensure efficient operation.

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P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com

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Version 8.0 – © 03/2018Product, Installation and Maintenance Manual - Air Cannons - Page 12 of 22

All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

The effective range of the Air Cannon, the size of the bunker/silo and the number and size of the outlets, together with material characteristics, determine the number and sizes of the Air Cannons required.

The following two tables give a rough indication of the number of cannons in relation to the container size and material characteristics for round silos and square or rectangular bunkers. To compare round silos with square or rectangular bunkers the diameter of the silo must be multiplied by PI (3, 14) since square or rectangular bunkers are sized by perimeter length.

Table 1

Cannon Type Material DIAMETER OF SILO IN METRES

1.5 3 4.5 6 7.5 10

BB010 Coarse 2 * * * * *

Fine 2 2 * * * *

BB025 Coarse 2 3 * * * *

Fine 2 2 3 * * *

BB050 Coarse * * 3 4 6 *

Fine * * 2 3 5 *

BB100 Coarse * * 3 4 5 6

Fine * * 2 2 4 5

BB200 Coarse * * * 3 4 5

Fine * * * 2 3 4

Table 2

Cannon Type Material PERIMETER OF SQUARE OR RECTANGULAR BUNKERS IN METRES

5 9 14 19 23 31

BB010 Coarse 5 * * * * *

Fine 3 3 * * * *

BB025 Coarse 2 4 * * * *

Fine * 3 4 * * *

BB050 Coarse * * 3 4 * *

Fine * * 2 3 * *

BB100 Coarse * * * 3 5 *

Fine * * * 2 4 *

BB200 Coarse * * * * 4 5

Fine * * * * 3 4

A further development is the use of internal air lances to dissipate the Air Cannon blast down and sideways along the internal surface of the container. This is particular useful when there may be a tendency for the blocked material to consolidate, cling to the container walls and in corners and the Air Cannon blast a hole through it without moving much of the stagnant material.

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P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com

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All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

AIR CANNON - PARTS LIST REFERENCE DRAWING6178910

5

4

3

LEGENDITEM

I.D DESCRIPTION

1 Pressure Valve2 Pressure Guage3 Safety Valve4 Non Return Valve5 Quick Exhaust Valve6 Safety Chain7 Diaphram Seat8 Diaphram9 Air Cannon Lid

10 Lid Hold Down Bolts & Nuts

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P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com

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All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

AIR CANNON - PARTS LIST

ITEM No. ITEM PART No.

1 Pressure Vessel Specify Capacity2 Pressure Gauge Specify Capacity3 Safety Valve Specify Capacity4 Non Return Valve Specify Capacity5 Quick Exhaust Valve Specify Capacity6 Safety Chain N/A7 Diaphragm seat Specify Capacity8 Diaphragm Specify Capacity9 Air Cannon Lid Specify Capacity

10 Lid Hold Down Bolts N/A

AIR LANCE/KNIFE NOZZEL - PARTS LIST

AIR CANNONS AIR LANCE/KNIFE OPTIONS

PART NUMBER25 LITRE 50 LITRE 100 LITRE 200 LITRE

● 50mm x 800mm Long 3/1.25● ● 50mm x 1000mm Long 3/1.26

● ● 50mm x 1500mm Long 3/1.27● ● 100mm x 1500mm Long 3/1.27.1● ● 100mm x 1000mm Long 3/1.27.1

● 100mm x 2000mm Long 3/1.28● 100mm x 2500mm Long 3/1.28.1

● 100mm x 3000mm Long 3/1.29● 100mm x 3500mm Long 3/1.30● 100mm x 4000mm Long 3/1.30.1

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P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com

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Version 8.0 – © 03/2018Product, Installation and Maintenance Manual - Air Cannons - Page 15 of 22

All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

90 DEGREE FLANGED ADAPTER ASSEMBLY OPTIONS - PARTS LIST

PART NUMBER DESCRIPTION3/1.31 C/W Gaskets, Bolts & Nuts: Air Cannon 5 LTR - 40mm3/1.32 C/W Gaskets, Bolts & Nuts: Air Cannon 10 LTR - 50mm3/1.32 C/W Gaskets, Bolts & Nuts: Air Cannon 25 LTR - 50mm3/1.34 C/W Gaskets, Bolts & Nuts: Air Cannon 50 LTR - 100mm3/1.34 C/W Gaskets, Bolts & Nuts: Air Cannon 100 LTR - 100mm3/1.34 C/W Gaskets, Bolts & Nuts: Air Cannon 200 LTR - 100mm

STRAIGHT ADAPTER ASSEMBLY OPTIONS - PARTS LIST

PART NUMBER DESCRIPTION035-510-0001 Straight Adaptor Assy - 5 LTR035-510-0002 Flanged Straight Adapter Assy - 10 - 25 LTR035-510-0003 Flanged Straight Adapter Assy - 50 - 200 LTR

OPERATING INSTRUCTIONS1. Once installed (see instructions) the Air Cannon should remain pressurised even when not operating. This is to prevent the ingress of

material up the discharge pipe and fouling the main diaphragm.2. Where the Air Cannons are electrically operated, the power supply should be isolated when they are out of use or during

maintenance. The air supply need only be interrupted during maintenance.3. Frequency of firing is determined from actual conditions and should be reduced to the effective minimum to conserve air.4. The Air Cannon should not be fired when there is no discharge from the container or if it is empty. Not only is this wasteful but it

could be detrimental to the overall effectiveness of the system.5. At least once a year the Air Cannon should be inspected and opened to check the main diaphragm condition and for internal

corrosion. See maintenance instructions for correct procedure.

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Version 8.0 – © 03/2018Product, Installation and Maintenance Manual - Air Cannons - Page 16 of 22

All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

AIR CANNON - CHARGING / DISCHARGING

CHARGING

3 WAY VALVE

AIR SUPPLY4 TO BAR

VARIABLE CONTROL OPTIONS

-REMOTE DIAPHRAGM-DIAPHAGM IS THE ONLY MOVING PART-NON STICK SELF CLEANING SEAT-INSTRINSICALLY SAFE OPERATION -MORE EFFECTIVE, EXTREMELY RAPIDACTION

EASY INTERNAL INSPECTION &REPLACEMENT OF DIAPHRAGM

1

2

3

4

DISCHARGING

AIR

AIR

SIZE RANGE

STANDARD EQUIPMENT

BB005 - 5 LITRES BB050 - 50 LITRESBB010 - 10 LITRES BB100 - 100 LITRESBB024 - 25 LITRES BB200 - 200 LITRES

1. QUICK EXHAUST VALVE2. NON RETURN VALVE3. PRESSURE GUAGE - (OVER 10 LITRES ONLY)4. SAFETY VALVE - (OVER 10 LITRES ONLY)5. TEST CERTIFICATE - (OVER 10 LITRES ONLY)

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Version 8.0 – © 03/2018Product, Installation and Maintenance Manual - Air Cannons - Page 17 of 22

All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

15. Replacement Instructions

15.1. To replace or repair the quick exhaust valve

15.1.1 Isolate Air Cannon.

15.1.2 Fire Air Cannon.

15.1.3 Disconnect air supply pipe to quick exhaust valve.

15.1.4 Unscrew quick-exhaust valve from lid.

15.1.5 Replace with a new or reconditioned unit.

15.1.6 Reverse above procedure.

15.1.7 To repair quick-exhaust valve, open valve, clean thoroughly and replace seal, lubricate with silicone grease.

15.2. To replace main diaphragm

15.2.1 Isolate Air Cannon.

15.2.2 Fire Air Cannon.

15.2.3 Disconnect air supply pipe to quick exhaust valve.

15.2.4 Undo lid bolts and remove lid.

15.2.5 Check diaphragm seat (end of discharge pipe) and clean if necessary.

15.2.6 Check diaphragm condition.

15.2.7 Fit new diaphragm.

15.2.8 Replace lid on the Air Cannon.

15.2.9 Ensure that the lid is centred on Air Cannon body before tightening bolts.

15.2.10 Tighten bolts evenly (cross-over sequence).

15.2.11 Reconnect air supply.

15.3. Spare Parts List - 1 Year of operation

Item No. Part Type Number of parts1 Diaphragm 1 off required per Air Cannon

1 off extra (buffer stock) per Air Cannon

2 Quick Exhaust Valve 1 off required per Air Cannon (optional)

3 3-Way Valve 1 off required per Air Cannon (optional)

4 Non-return Valve 1 off required per Air Cannon (optional)

5 Pressure Gauge 1 off required per Air Cannon (optional)

6 Safety Valve 1 off required per Air Cannon (optional)

7 Air Supply Tube 8mm Nylon tube x 5m (optional) per Air Cannon

15.4. Spare Parts List - 2 Years of operation

Item No. Part Type Number of parts1 Diaphragm 2 off required per Air Cannon

1 off extra (buffer stock) per Air Cannon

2 Quick Exhaust Valve 1 off required per Air Cannon (optional)

3 3-Way Valve 1 off required per Air Cannon (optional)

4 Non-return Valve 1 off required per Air Cannon (optional)

5 Pressure Gauge 1 off required per Air Cannon (optional)

6 Safety Valve 1 off required per Air Cannon (optional)

7 Air Supply Tube 8mm Nylon tube x 5m (optional) per Air Cannon

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P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com

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All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

15.5. Replacement Instructions Continued

d1

d2

A

D

A

C

D

B

E

G

H

A : AIR SUPPLY

B : CHECK VALVE

C : LOCKOUT BALL VALVE

D : SOLENOID CONNECTION

E : QUICK EXHAUST VALVE

F : NON RETURN VALVE

G : SAFETY VALVE

H : PRESSURE VALVE

D

OPTIONAL VARIANCES

* MANUAL PUSH BUTTON

* SINGLE TIMER WITH SOLENOID

* CONTROLLER / SOLENOID ENCLOSURE (UP TO 10 AIR CANNONS)

DIMENSION TABLE

MODEL BB005 BB010 BB025 BB050 BB100 BB200

CAPACITY (LTRs) 5 10 25 50 100 200

A 413 421 631 688 1128 1323

B 285 285 285 395 395 395

d1 150 165 165 220 220 220

d2 110 125 125 180 180 180

d3 18 18 18 18 18 18

No. HOLES ON FLANGE 4 4 8 8 8 8

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Version 8.0 – © 03/2018Product, Installation and Maintenance Manual - Air Cannons - Page 19 of 22

All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

16. Maintenance

Brelko air Cannons are designed to operate with minimum maintenance. With all of the parts that could possibly require attention being fitted to or under the lid of the Air Cannon, therefore it is not necessary to remove the Air Cannon for maintenance or repair. When the Air Cannon is installed a regular maintenance program should be set up. This program will ensure that the Air Cannon operates at optimal efficiency and problems can be identified and fixed before the Air Cannon stops working. All safety procedures for inspection of equipment (stationary or operating) must be observed. The Air Cannon operates in silos, bins, hoppers, chutes etc. Only visual observations can be made while the belt is running. Service tasks can be done only with the conveyor stopped and by observing the correct lockout/Tag-out procedures.

The only moving parts are:

• The seal in the quick-exhaust valve.

• The main outlet diaphragm.

These parts require no lubrication but it is recommended that the air supply is fitted with an air-filter, lubricator and self draining water trap. The following steps will ensure maximum operation of the installed Air Cannon; and will greatly reduce wear and fatigue of the moving components as well as increasing the life of the Air Cannon. Frequency of these checks will depend on the plant’s maintenance policy but it is recommended that it be done at least once every two weeks.

Before any physical maintenance the following must be completed, failing to do so can lead to severe personal injury or even loss of life.

• Isolate air supply to Air Cannons and disconnect air supply pipe from quick exhaust valve.

• Discharge / fire Air Cannons.

16.1. Periodic Visual Inspection (Every 2-6 Weeks)

16.1.1 Air Supply

b. Check air supply, it should be at least 4 bar (gauge) and all supply line valves to be open.

c. Check self draining water taps and ensure that they are free from any blockages and that no water build-up is present in the receiver. If so, replace water trap or remove blockage and drain water.

d. Check air filters, if air filters are dirty replace or clean them.

e. Listen for air filling the Air Cannon; if not, see trouble shooting below.

16.1.6 3-Way Valve

g. The vent port should exhaust a small quantity of air; if not, repair or replace (see instructions below).

h. Electric 3-Way solenoid valve should be heard to “click”; if not, repair or replace (see instructions below).

16.1.9 Quick-exhaust Valve

j. Check if the quick exhaust valve on the lid vents, if not; repair or replace (see instructions below).

16.2. Quarterly Maintenance

16.2.1 Main Diaphragm

b. Remove Air Cannon lid and check main diaphragm, if damaged replace (see instructions below).

16.2.3 Discharge pipes

d. Check connecting pipes, nozzles, lances etc. for excessive material build-up and blockages, if this is the case; remove and clean.

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P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com

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All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

16.3. Annual Maintenance

16.3.1 Main Diaphragm

b. Replace main diaphragm (see instructions below).

16.3.3 Valves, and fittings

d. Replace any components that show excessive wear and tear.

16.3.5 Air Cannon Body

f. A qualified engineer specialising in pressure vessels to inspect the Air Cannon shell for signs of fatigue or corrosion.

IMPORTANT NOTE: Re-Certification for Air Cannon, 25LTR and above, must be carried within a 36 month period from the date of installation or last certification date.

16.4. Annual Inspections and Pressure Testing

Important:

16.4.1 First year of operation

b. Re-certification required - A qualified engineer specialising in pressure vessels to inspect Air Cannon shell for signs of fatigue or corrosion

16.4.3 Second year of operation

d. A qualified engineer specialising in pressure vessels to inspect the Air Cannon shell for signs of fatigue or corrosion.

IMPORTANT NOTE: Re-Certification for Air Cannon, 25LTR and above, must be carried within a 36 month period from the date of installation or last certification date.

Note: All inspections and testing can be done on site by a qualified engineer specialising in pressure vessels, recertification must be carried out under supervision of a registered inspection company.

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Version 8.0 – © 03/2018Product, Installation and Maintenance Manual - Air Cannons - Page 21 of 22

All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

17. Trouble Shooting

If the Air Cannon fails to operate, check the following in sequence:

17.1. Air Supply

a. At least 4 bar (gauge) pressure.

b. All supply valves to be opened.

c. Listen for air filling the Air Cannon.

17.2. 3-Way Valve

a. The vent port should exhaust a small quantity of air.

b. Electric solenoid 3-way valve should be heard to “click”, if not; repair or replace (see instructions above).

17.3. Exhaust Valve

a. Check if the quick exhaust valve on the lid vents, if not; replace or repair (see instructions above).

17.4. Remove lid and check diaphragm (see instructions above)

17.5. Disconnect Air Cannon from discharge pipe and fire into atmosphere; take care as to direction and wear ear protection.

17.6. Clean discharge and connecting pipes, nozzles, lances etc.

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Version 8.0 – © 03/2018Product, Installation and Maintenance Manual - Air Cannons - Page 22 of 22

All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

NOTES:

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P.O. Box 62392 Marshalltown 2107 Tel: +27 11 013 4000 Fax: +27 11 013 4150 E-Mail: [email protected] Web: www.brelko.com

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Version 8.0 – © 03/2018Product, Installation and Maintenance Manual - Air Cannons - Page 23 of 22

All technical and dimensional information subject to change. All general Terms and Conditions of sale, including limitations of our liability, apply to all products and services sold.

Head Offi ceSouth AfricaBrelko Conveyor Products (Pty) Ltd16 Harries Street, Reuven Extension 1, Booysens, Johannesburg, South AfricaWebsite: www.brelko.com, E-Mail: [email protected], Tel: +27 11 013 4000

BranchesUnited States of AmericaBrelko Conveyor Products Inc.Telephone:+1 303 544 0817, Telefax: +1 303 544 0818Mobile: +1 720 771 4035, E-mail: [email protected]

United KingdomSimm Conveyor Services LTDTelephone: +44 170 981 8511, Telefax: +44 170 981 2557, E-Mail: [email protected]

Agents: AfricaBotswanaEtubaMobile: +267 297 2305, E-Mail: [email protected]

DRCMickem Consulti ngTelephone: +243 812 666 404, E-Mail: mickemconsulti [email protected]

GhanaAlshtechTelephone: +233 30 330 4231, Mobile: +233 26 283 3604, E-Mail: [email protected]

NamibiaSepp ThalmaierTelephone: Windhoek +264 61 225 808, Oranjemund: +264 63 233 111 Telefax: +264 63 232 015, E-Mail: [email protected]

ZambiaConveyor Engineering & EquipmentMobile: +260 96 811 1646, +260 97 729 6288, E-Mail: [email protected]

ZimbabweHilmaxTelephone: +263 77 213 4610/1/2/3, Telefax: +263 4 620 670, E-Mail: [email protected]

Master Distributors: Internati onalAustraliaOrefl owTelephone: +61 8 9472 0800, Telefax: +61 8 9472 0811, E-Mail: sales@orefl ow.com.au

ChileMantexTelephone: +56 2 212 9475, Telefax: +56 2 212 8260, E-Mail: [email protected]

EuropeOFC - Opti m’ For ConveyorsTelephone: +32 69 64 74 38, Telefax: +32 69 64 74 41, E-Mail: [email protected]

GreeceSolergon Ltd.Telephone: +30 210 86 75 229, E-Mail: [email protected]

Malaysia & IndonesiaMax Classics (M) SDN. BHD.Telephone: +60 35 635 6212, Telefax: +60 35 636 1190, E-Mail: [email protected]

MexicoConstrumacTelephone: +52 55 53 281 700, E-Mail: [email protected]

Portugal & SpainMasanés ServindustriaWeb: www.masanes.com

Saudi ArabiaSynergies TechTelephone: +971 4 4275069, Telefax: +971 4 4324256, E-Mail: [email protected]

United KingdomMillenium Conveyor Services LTDTelephone: +44 191 456 5700, Telefax: +44 191 456 3300