Agitator For Silo Discharge

Machine manual
en-23155.200-D
Agitator for silo discharge
Code word
Order number
POLYSIUS Order Code (POC)

Machine manual Contents
Agitator for silo discharge
Contents
1 Technical data......................................................................................... 1-1

2 Safety...................................................................................................... 2-1
3 Components and mode of functioning.................................................3-1
3.1 Components............................................................................................. 3-1
3.2 Mode of functioning................................................................................3-12
4 Transport and assembly........................................................................4-1
4.1 Transport and storage requirements........................................................4-1
4.2 Assembly.................................................................................................. 4-1
5 Lubrication..............................................................................................5-1
6 Preparation for the test run...................................................................6-1
6.1 Checks prior to the test run......................................................................6-1
6.2 Setting and adjustment.............................................................................6-1
7 Maintenance...........................................................................................7-1
7.1 Inspection.................................................................................................7-1
7.2 Servicing.................................................................................................. 7-2
7.3 Trouble shooting.......................................................................................7-3
7.4 Repair....................................................................................................... 7-4
8 Spare parts............................................................................................. 8-1
9 Appendix.................................................................................................9-1
9.1 Technical drawings...................................................................................9-1
9.2 Subsuppliers’ documentation...................................................................9-1
en-23155.200-D
Machine manual Technical data
Agitator for silo discharge 1
1 Technical data
NOTE
Information concerning the electrical equipment is contained in
the separate electrical documentation or in the subsuppliers'
documentation.
Information on the intended use

Bulk material.......................................................................................
Bulk density........................................................................................
Particle size.........................................................................................
Admissible temperature.............................................................max.
Surface moisture content...................................................................
Ambient temperature..................................................................max.
Voltage.................................................................................................
Mains frequency..................................................................................
Basic data
Year of manufacture............................................................................
Nominal diameter of connecting flange.............................................
Cone inclination..................................................................................
Number of outlets...............................................................................
Outlet size...........................................................................................
Agitator aeration system.........................................................yes/no
Aeration system operating pressure..................................................
Number of aeration sectors................................................................
Dimensions..........................................................................................
Weight..................................................................................................
2
Drive unit (5)

Type.....................................................................................................
Driving power.................................................................................kW
Output speed...............................................................................min-1
Drive torque...................................................................................Nm
Enclosure....................................................................................IP 54
Isolation slide valve (4.1)

Number................................................................................................
Size......................................................................................................
Type.....................................................................................................
Solenoid valve for slide valve (4.2)

Number................................................................................................
Design..................................................................................................
Type.....................................................................................................
Proximity switch for slide valve (4.3)

Number................................................................................................
Type.....................................................................................................
Throttle valve (6.4) for the agitator aeration system

Number................................................................................................
Type.....................................................................................................
Machine manual Safety
2 Safety
NOTE
Be sure to comply with the general safety instructions in the
supplement Important notes on the documentation.
Use of the machinery

 The machine is exclusively intended to discharge dry, dusty to
fine-grained bulk material from the silo.
The information concerning the intended use of the machinery
in the section Technical data and the safety instructions in the
machine manual for the silo must be complied with.
 Any use of the machinery other than for the specified purpose
is forbidden. POLYSIUS AG is not responsible for any damage
resulting from any other than the specified use of the machine.
All other use is at the operator’s own risk.
 The observance of these and the maintenance instructions is
part of the specified use.
Transport and assembly

 All transport instructions in this manual refer exclusively to the
transport of the machinery in the plant area.
 Use only suitable hoisting and lifting equipment, which is in
serviceable order and has a sufficient load bearing capacity.
 Never work under a suspended load.
Operation
 Any safety checks before or during operation depend on the
relevant national regulations. The operator is responsible for
the performance and recording of such checks.
 If changes in the machine or its operating behaviour relevant
to safety occur, the machine must be immediately stopped.
 Fire, smoking, open flame as well as any sources of heat in the
area of the roller mill are forbidden due to the danger of fire
and explosion! Observe the local regulations for explosion and
fire protection.
Safety Machine manual
2 Agitator for silo discharge
Maintenance
 The interior space of the coal silo may only be entered, if the
silo is empty.
 Remove all dust which has accumulated outside the coal silo.
 Before you start flame-cutting, grinding or welding work, you
must obtain written permission from the plant manager and
stop the plant section in which the coal silo is located.
 Make sure that the working areas are wet through with water.
 During carrying out of the work a fire watch must be provided.
After completion of the repair work extinguish and remove
possible ignition sources (e. g. glowing welding or grinding
residues) in the working areas.
 Ensure that for the entire duration of the maintenance work, all
machines and motors whose operation might endanger
persons or equipment are switched off, isolated and
safeguarded against restarting.
 Ensure that all rotating parts of the machine have come to a
halt before the removal of guards or opening of access doors or
inspection flaps.
 Keep the machine free of oily and explosive matters. Never use
benzine or other flammable substances for cleaning the
machine.
 De-energize the electrical parts before starting any
maintenance work.
 Make sure that pneumatic lines are de-pressurized before they
are dismantled.
 Check the tightness of all connections and joints after any
maintenance work.
 Strictly observe the welding instructions when performing any
welding work.
 When performing arc-welding or arc-gouging, the welding
personnel must be protected from contact with electrically
conducting parts. An insulating base must be used. Return lead
welding current must be connected close to the point of
welding and directly connected to the part being welded.
 Never place the welding current source in closed rooms with
electrically conducting walls.
Machine manual Safety
 If electrical welding is executed on any part within the

machine, the welding current must never be conducted through
sliding or anti-friction bearings, other moveable connections or
measuring equipment. Return lead welding current must
always be connected close to the point of welding and directly
connected to the part being welded.
 All safeguards have to be re-installed and all inspection flaps
and maintenance hatches must be properly closed when
maintenance work has been terminated.
Machine manual Components and mode of functioning
3 Components and mode of functioning

The agitator is located beneath the silo and acts as a discharge
aid. Its purpose is to ensure a continuous delivery of bulk
material and to prevent operational disturbances caused by
caking, blockages and bridging.
3.1 Components
NOTE
Some details of the drawings in this manual may not be identical
with the drawings supplied under the contract.
The agitator consists of the following sub-assemblies:

 Agitator housing
 Agitator blade
 Flanged bracket
 Outlet
 Drive unit
 Agitator aeration system
Components and mode of functioning Machine manual
Items in the sub-assembly diagram
1 Agitator housing
2 Agitator blade
3 Flanged bracket
4 Outlet
5 Drive unit
6 Aeration system
Figure 1
Items relating to the agitator housing (1)
1.1 Thrust washer

1.2 Bush (plain bearing)
1.3 Thrust washer
1.4 Stuffing box sleeve
1.5 Spacing sleeve
1.6 Cup spring
1.7 Plate
1.8 Flanged bearing housing
1.9 Self-aligning ball bearing
1.10 Clamping sleeve
1.11 Fixed ring
1.12 Stuffing box packing
1.13 Agitator cone
1.14 Connecting flange
1.15 Conical connection element
1.16 Electric bridging element
2 Agitator blade
5.1 Shaft
Figure 2
Items relating to the agitator blade (2)
2.1 Scraper
2.2 Pipe
2.3 Hub
2.4 Scraper
Figure 3
Items relating to the flanged bracket (3)
3.1 Pipe
3.2 Flange
3.3 Flange
Figure 4
Items relating to the outlet (4)
4.1 Isolation slide valve

4.2 Isolation slide valve actuator
4.3 Solenoid valve
4.4 Proximity switch
4.5 Outlet pipe
4.6 Expansion joint
1.16 Electric bridging element
Figure 5
Items relating to the drive unit (5)
5.1 Shaft
5.2 Bush
5.3 Parallel key
5.4 Parallel key
5.5 Geared motor
5.6 Motor suspension arrangement
Figure 6
Items relating to the aeration system (6)
6.1 Air distribution pipe

6.2 Aeration nozzle
6.3 Hose
6.4 Throttle valve
6.5 Hose
6.6 2/2-way-ball valve
6.7 Hose cock
6.8 2/2-way-ball valve
6.11 Pressure gauge
6.12 Non-return valve
6.13 Pressure reducing valve
6.14 Filter
6.15 Ball valve
6.16 Ball valve
Figure 7
3.2 Mode of functioning

A radially arranged system of vanes consisting of scrapers (2.1
and 2.4) rotates in the agitator housing (1) which is lined with
high-grade steel. The design is such that the bulk material is
discharged evenly as a mass flow. The flat irons brush past the
insideof the agitator cone (1.13) in quick succession.
The outlets (4) are welded to the outer wall of the vessel and the
bulk material is discharged through them.
The sockets located on the circumference of the agitator housing
and on the outlet pipes can be connected to an aeration system
as required.
The aeration system for the silo discharge consists of aeration
nozzles (6.2) with built-in filter elements which are arranged on
the agitator cone, as well as the throttle valves (6.4).
The aeration system for the agitator cone is arranged on two
levels and is sub-divided into aeration sectors. These sectors are
aerated alternately. A throttle valve is located in front of each
aeration nozzle and these allow the volume of air to be adjusted.
The outlets (4) are provided with isolation slide valves (4.1) which
are actuated electro-pneumatically by signals from a flow
regulating device. The air distribution pipes are the final
components in the outlets (4), whereby the expansion joints (4.6)
serve as intermediate elements.
As an optional extra, the agitator can be provided with a flat slide
valve located between the silo outlet and the agitator cone for
repair work.
Figure 8
Machine manual Transport and assembly
4 Transport and assembly
4.1 Transport and storage requirements

The machine is transported in single parts or in sub-assemblies.
It must be observed that suitable lifting equipment is employed in
removing the parts from the transport vehicles and transferring
them to the storage area.
When they arrive at the site, all parts must be inspected for
transport damage and placed on wooden beams with the
provision of suitable protection against rain, contamination and
damage. The parts must not be stored directly on the ground.
Motors, couplings, gear units, measurement and control
equipment must be stored in buildings which are well aerated and
must be protected against moisture.
4.2 Assembly
It is essential to check the free rotation of the agitator blade (2)
before installing it at the point indicated in the general
arrangement diagram. There must be no foreign bodies in the
inner chamber of the agitator housing (1).
When bolting the flanges of the agitator to other units, ensure
that suitable and undamaged seals are used and that the flanges
are not under any kind of stress.
Mount the aeration system in accordance with the drawing. The
closed-circuit piping is delivered to the erection site ready for
installation.
Valves, hoses, nozzles and screw connections are delivered as
individual components.
After fittting the nozzles to the agitator housing, align the closed-
circuit piping and secureit to the silo cone with the individually
delivered steel straps and retainers as shown in the drawing.
After mounting the closed-circuit piping, install the throttle
valves and hose connections.
Providing the electrical values of the local grid agree with the
data on the rating plates, connect the cables for the drive unit of
the agitator and for the flat slide valve to the mains power supply.
Transport and assembly Machine manual
CAUTION
If electrical welding is carried out in any place of the machine, welding
current must never be conducted through plain bearings and antifriction
bearings, other moveable connections or measuring equipment to prevent
damage to such parts.
Return lead (of welding current) must always be directly connected to the
part being welded.
Machine manual Lubrication
5 Lubrication
NOTE
The POLYSIUS table of lubricants with the lubricant reference
numbers is contained in the supplement Important notes on the
documentation. The supplement is contained in this folder or at
the beginning of the overall documentation. Each lubricant has a
unique reference number to which the lubrication instructions in
this section relate. The table gives a complete list of all
suppliers and products approved by POLYSIUS AG.
It is the responsibility of the lubricant supplier to select
appropriate lubricants corresponding to the lubricant reference
numbers. POLYSIUS AG accepts no liability for the correctness
of these data.
If you wish to use a lubricant that is not included in the Table of
lubricants, you have to first obtain the express permission of
POLYSIUS AG.
The supplement Important notes on the documentation also
contains the generally valid Notes on lubrication.
CAUTION
Ensure that the environment is not polluted when lubricants are stored,
used and disposed of and carefully observe the relevant national
legislation for the protection of the environment when handling lubricants.
Lubrication Machine manual
Lubrication chart
Figure 9
Lubrication points Quantity (ltr/kg) Lubrication intervals

per lubrication (weeks)
point
No. Qty. Designation Lubricant Initial Topping Topping First Further

ref. no. filling up up change change
s
1 1 Bearing assembly 50 after every

2 years 2 years
[1]
2 1 Drive unit after every
2 years 2 years
3 Isolation slide valve 50

(piston rod) [1]
The different makes of lubricant corresponding to the lubricant reference numbers are shown in the
table of lubricants in the supplement Important Notes on the Documentation at the beginning of the
overall documentation.
Machine manual Lubrication
Explanation of the numbers

[1]
Also observe the manufacturer’s instructions.
Machine manual Preparation for the test run
6 Preparation for the test run
NOTE
It is a prerequisite of our warranty that the first test run is
carried out in the presence of specialists from POLYSIUS AG and
in accordance with their instructions.
6.1 Checks prior to the test run

After completion of the assembly work and prior to the first test
run, check all parts of the plant according to the list below. Take
particular care that all material remnants, tools and assembly
aids are removed.
 Have all foreign bodies been removed from the inner chamber
of the agitor?
 Has the free movement of the agitor blade (2) been checked?
 Have all bolts been tightened?
 Have the connecting flanges been bolted on tightly?
(Have their seals also been fitted beforehand?)
 Is the drive unit (5) wired up as specified in the circuit diagram
and has its functioning been checked?
 Are the isolation slide valves (4.1) wired up as specified in the
circuit diagram and has their functioning been checked ?
 Do the electrical specifications of the local grid agree with the
data given for the electric devices?
 Are the downstream transport units ready for operation?
 Has the aeration system (screwed and hose connections,
aeration nozzles) been checked for leaks?
Seal leaks with LOCTITE (or a similar product).
6.2 Setting and adjustment

Open all the manually-adjustable valves in the aeration system at
the start of commissioning. Fine adjustment can only be carried
out during commissioning when the agitator is operating.
Having checked the functioning of the agitator, open the isolation
slide valves (4.1).
Machine manual Maintenance
7 Maintenance
7.1 Inspection
DANGER
Beware of fire and explosion hazards in the vicinity of the coal silo.
The explosion and fire protection regulations must be observed.
Remove all dust which has accumulated outside the coal silo.
No. Work to be performed Frequency Remarks
1 Drain the condensate from the weekly open

piping system hose cocks
2 Check air hoses every 4

weeks
3 Check the functioning of throttle every 4

valves (6.4) weeks
4 Inspection work see

 on the isolation slide valves manufacturer’s
 on the drive unit instructions
5 General visual check for yearly

 Cracks
 Leaks
 Damage
6 Check the aeration system (6) yearly empty the silo

completely
7 Check the yearly

 Agitator blade (2)
 Agitator housing (1), inside
for damage or wear
8 Check aeration nozzles (6.2) yearly

Maintenance Machine manual
7.2 Servicing
No. Work to be performed Frequency Remarks
1 Maintenance work on the see

 Isolation slide valves manufacturer’s
 Drive unit instructions
2 Maintenance work on the valves see

manufacturer’s
instructions
3 Replace soiled filter elements as required

in the aeration nozzles (6.2)
7.3 Trouble shooting
Fault Cause Elimination
Agitator blade (2) not No power to motor Check electrics

rotating
Motor defective Repair or replace motor
Proximity switch (4.4) Repair proximity switch

defective
Agitator blade (2) blocked Remove foreign bodies

by foreign bodies
No or too little bulk No aeration air because:

material flowing from
outlet pipes  Blower not operating  Put blower back
into operation
 Manually-adjustable  Open manually-

valves closed adjustable valves
 Solenoid valves not triggered  Check controls and

or defective wiring
 Repair or replace
solenoid valves
 Piping defective  Repair piping
Foreign bodies blocking Remove foreign bodies

outlet (4)
Conveyed material Stuffing box packing Replace

escaping (1.12) worn out stuffing box packing
Flange seal(s) defective Repair flange seal(s)
If faults occur that are not described above, additional

information regarding causes and eliminations of faults can be
taken from the subsuppliers’ documentation.
Maintenance Machine manual
7.4 Repair
Before performing any repair work, make sure all electrical
components are disconnected.
Ensure the utmost cleanliness at all times during the repair work
in order to guarantee that the bearings, the drive system, the
hydraulic system or other sensitive parts of the machine are kept
free of contamination.
Do not remove or open any flaps or protective equipment before
all rotating parts have stopped.
Removing the agitator from the plant as a whole

 Empty the silo completely
(Only in cases where the agitator inlet is not provided with an
isolation slide valve)
 Make sure that the conveyed material transport to the agitator
is switched off
 Close the isolation slide valves and the shut-off devices above
the silo and below the agitaor
 Disconnect the power to the isolation slide valves (4.1)
 Disconnect the power to the drive unit (5)
 Support the units and piping connected to the agitator (if
necessary)
 Support and/or suspend the agitator
 Unfasten the agitator’s flange connections to the neighbouring
units, chutes and piping
 Remove or disconnect the supports as appropriate and remove
the agitator
Assembly instructions
All parts must be checked and cleaned beforehand.
 Slide the shaft (5.1) with the parallel keys (5.3, 5.4) on the
agitator and bolt to the shaft
 Slide the bush (1.2) on the shaft up to the thrust washer (1.1)
and insert the stuffing box packing (1.12)
 Slide the stuffing box sleeve (1.4), cup springs (1.6) and plate
(1.7) on the shaft
 Slide the flanged bearing housing (1.8 to 1.11) on the shaft
together with the 4 spacer sleeves (1.5) which are positioned
between the plate (1.7) and the agitator cone (1.13) and secure
with hexagonal bolts
 Mount the flanged bracket (3) to the agitator housing (1)
 Slide the drive unit (5) on the shaft and secure the gearbox
flange to the flange bracket; fit the motor suspension
arrangement (5.6) to the flange of the agitator cone
CAUTION
After you have completed the repair work, you must check the
machine/plant again according to the section Preparation for the test run.
Tools and auxiliary devices

No special tools are required for repair work on the machine.
However, torque wrenches of a bigger size than normal may be
necessary.
The need for scaffolds or hoists depends on the conditions in your
plant.
Machine manual Spare parts
8 Spare parts
Suggestions for enquiries and orders of spare parts

Dear Customer,
POLYSIUS AG want to make spare part enquiries and spare part
order placement as easy and efficient as possible. For this
purpose we have prepared a table containing all data required by
our spare parts department to ensure optimum processing in the
most speedy and trouble-free manner.
Please copy the title page and the page with the table. Fill in the
columns Quantity and Unit. Please mark those parts which you
require with a cross in the column Order or Enquiry. Send the title
page together with the table to the Spare Parts Department of
POLYSIUS AG.
If the table relates to more than one machine, please also inform
us of the POLYSIUS Order Code (POC) of the machine for which
you require the spare parts.
Spare parts Machine manual
Items relating to the agitator housing (1)
Figure 10
Code word: Order-No.: POC:
Item Designation Qty. Unit Order Enquiry
1 Agitator housing, complete 1 piece
1.1 Thrust washer 1 piece
1.2 Bush (plain bearing) 1 piece
1.3 Thrust washer 1 piece
1.4 Stuffing box sleeve 1 piece
1.5 Spacing sleeve 1 piece
1.6 Cup spring 1 piece
1.7 Plate 1 piece
1.8 Flanged bearing housing 1 piece
1.9 Self-aligning ball bearing 1 piece
1.10 Clamping sleeve 1 piece
1.11 Fixed ring 1 piece
1.12 Stuffing box packing 1 set
1.13 Agitator cone with connecting 1 piece

flange (1.14)
1.15 Conical connection element 1 piece
1.16 Electric bridging element 1 piece

Figure 11
2 Agitator blade, compele 1 piece
3 Flanged bracket 1 piece
5.1 Shaft 1 piece
5.1.1 Parallel key 3 piece
5.1.2 Washer with 1 piece

screwed connection
5.2 Bush 1 piece
5.3 Parallel key 1 piece
5.4 Parallel key 1 piece
5.5 Geared motor 1 piece
5.6 Motor suspension 1 set

arrangement, complete
Items relating to the outlet (4)
Figure 12
4.1 Isolation slide valve 1 piece
4.1.1 Sealing 1 set
4.2 Isolation slide valve actuator 1 piece
4.3 Solenoid valve 1 piece
4.4 Proximity switch 1 piece
4.5 Outlet pipe 1 piece
4.6 Expansion joint 1 piece
4.6.1 Sealing 1 set

Items relating to the aeration system (6)
Figure 13
6.1 Air distribution pipe set
6.2 Aeration nozzle set
6.2.1 Filter insert (4 knitted round set

wires per aeration nozzle)
6.2.2 Fabric washer filter piece
6.3 Hose piece
6.4 Throttle valve set
6.5 Hose meter
6.6 2/2-way ball valve set
6.7 Hose cock set
6.8 2/2-way ball valve set
Figure 14
6.11 Pressure gauge piece
6.12 Non-return valve piece
6.13 Pressure reducing valve piece
6.14 Filter piece
6.15 Ball valve piece
6.16 Ball valve piece
6.17 Tee piece
6.18 Plug piece
6.19 Double nipple piece
6.20 Screwed connection piece
6.21 Pipe fastening piece
Figure 15
Machine manual Appendix
9 Appendix
9.1 Technical drawings
NOTE
For drawing numbers, please refer to the table of contents of
this folder.
Designation Drawing no.
Assembly drawing
9.2 Subsuppliers’ documentation
Drive unit
Isolation slide valve
2/2-way-ball valve

Agitator For Silo Discharge

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Machine manual

Agitator for silo discharge

POLYSIUS Order Code (POC)

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

Information on the intended use

Drive unit (5)

Isolation slide valve (4.1)

Solenoid valve for slide valve (4.2)

Proximity switch for slide valve (4.3)

Throttle valve (6.4) for the agitator aeration system

Use of the machinery

Transport and assembly

 If electrical welding is executed on any part within the

3 Components and mode of functioning

The agitator consists of the following sub-assemblies:

Items in the sub-assembly diagram

Items relating to the agitator housing (1)

1.1 Thrust washer

Items relating to the agitator blade (2)

Items relating to the flanged bracket (3)

Items relating to the outlet (4)

4.1 Isolation slide valve

1.16 Electric bridging element

Items relating to the drive unit (5)

Items relating to the aeration system (6)

6.1 Air distribution pipe

3.2 Mode of functioning

4 Transport and assembly

4.1 Transport and storage requirements

Lubrication points Quantity (ltr/kg) Lubrication intervals

No. Qty. Designation Lubricant Initial Topping Topping First Further

1 1 Bearing assembly 50 after every

3 Isolation slide valve 50

Explanation of the numbers

6 Preparation for the test run

6.1 Checks prior to the test run

6.2 Setting and adjustment

No. Work to be performed Frequency Remarks

1 Drain the condensate from the weekly open

2 Check air hoses every 4

3 Check the functioning of throttle every 4

4 Inspection work see

5 General visual check for yearly

6 Check the aeration system (6) yearly empty the silo

7 Check the yearly

8 Check aeration nozzles (6.2) yearly

No. Work to be performed Frequency Remarks

1 Maintenance work on the see

2 Maintenance work on the valves see

3 Replace soiled filter elements as required

7.3 Trouble shooting

Fault Cause Elimination

Agitator blade (2) not No power to motor Check electrics

Proximity switch (4.4) Repair proximity switch

Agitator blade (2) blocked Remove foreign bodies

No or too little bulk No aeration air because:

 Manually-adjustable  Open manually-

 Solenoid valves not triggered  Check controls and

 Piping defective  Repair piping

Foreign bodies blocking Remove foreign bodies

Conveyed material Stuffing box packing Replace

Flange seal(s) defective Repair flange seal(s)

If faults occur that are not described above, additional