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en-DH.CPT.002.A
Dust hopper
Code word
Order number
Contents
1 Safety 1-1
2 Technical data 2-1
3 Components and mode of functioning 3-1
3.1 Components 3-1
3.2 Mode of functioning3-12
4 Transport and assembly 4-1
4.1 Transport and storage instructions 4-1
4.2 Assembly 4-1
4.3 Sequence of assembly 4-2
5 Lubrication 5-1
6 Commissioning 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 Safety instructions 7-1
7.2 Inspection 7-1
7.3 Servicing 7-2
7.4 Repair 7-2
8 Trouble shooting 8-1
9 Spare parts9-1
9.1 Suggestions for enquiries and orders of spare parts 9-1
9.2 Spare parts9-1
10 Appendix 10-1
10.1 Technical drawings 10-1
10.2 Subsuppliers' documentation 10-1
en-DH.CPT.002.A
Machine manual Safety
Dust hopper 1
1 Safety
Note
Be sure to comply with the general safety instructions in the supplement
Important notes on the documentation.
Use
● The dust hopper is only intended for storing dry, powdery to fine-grained,
fluidisable bulk materials.
Be sure to comply with the specifications of the intended use in the section
Technical data.
● Any use other than the intended use, such as filling with combustible or
explosive bulk materials, is forbidden. ThyssenKrupp Polysius AG is not
responsible for damage resulting from any use other than the intended use. All
other use is at the owner's own risk.
● Usage to the intended purpose also includes observance of the instructions in
the machine manual and compliance with the maintenance instructions.
Transport and assembly
● All transportation instructions in this machine manual refer exclusively to
transportation of the machine at the plant site.
● Only use suitable lifting machinery and lifting accessories which are in
condition of perfect technical serviceability and have 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 plant management is responsible for the performance and
recording of such checks.
● If safety-relevant changes in the machine or its operating behaviour occur,
shut it down immediately.
en-DH.CPT.002.A
Safety Machine manual
2 Dust hopper
Maintenance
● Make absolutely sure that all machines and motors whose operation might
endanger persons or equipment are switched off and safeguarded against
restarting for the entire duration of the maintenance work.
● Before performing any work on the machine, make sure that there is no
danger of suffering burns when touching the machine and before opening any
inspection and service covers make certain that there is no longer any hot
material inside the machines.
● Melting of polyester fabric causes hydrogen cyanide vapours. Extract the
hydrogen cyanide vapours by suction directly above the point of work.
● Keep the machine free of oily and combustible substances and materials.
Never use gasoline or other easily flammable substances to clean the
machine.
● Switch off the power supply to all electrical components before beginning any
maintenance work.
● Make absolutely sure that the pneumatic piping is relieved of pressure before
disconnecting it.
● After finishing all maintenance work, check all joints and connections for
leaks.
● Be sure to strictly comply with the welding instructions when performing any
welding work.
● The interior may only be entered after all residual material has been
completely discharged.
● When electric arc welding or cutting are being performed, you must ensure
that personnel cannot come into contact with electrically conductive
components. Use insulating packing plates for this purpose.
● Never set up the welding current source in a confined space with electrically
conductive walls. Only use 24 volt lamps to illuminate the interior of the
machine.
If you have to carry out welding work in the dust hopper, cover the aeration
surfaces to protect them against spatters.
● If you carry out electric welding on any part of the machine, never conduct the
welding current through plain or antifriction bearings, other moving connecting
elements or measuring devices. Always directly connect the welding current
return lead to the part being welded.
● Remount all protection devices when the maintenance work has been
finished. Make absolutely sure that no persons are inside the plant component
before you properly close the inspection and service covers.
● All manholes must be closed and secured.
en-DH.CPT.002.A
Machine manual Technical data
Dust hopper 1
2 Technical data
Note
Refer to the separate electrical documentation or to the subsuppliers'
documentation for information on the electrical equipment.
Bulk density
Particle size
Basic data
Year of manufacture
Inside diameter
Effective volume
Measured volume
Outlet size
en-DH.CPT.002.A
Technical data Machine manual
2 Dust hopper
Design
Type
Type
Type
en-DH.CPT.002.A
Machine manual Technical data
Dust hopper 3
en-DH.CPT.002.A
Technical data Machine manual
4 Dust hopper
Aeration ring I
Size / type
Quantity
Quantity
Aeration ring II
Size / type
Quantity
Quantity
Size / type
Quantity
en-DH.CPT.002.A
Machine manual Technical data
Dust hopper 5
Quantity
Aeration rings
Fig. 2
en-DH.CPT.002.A
Machine manual Components and mode of functioning
Dust hopper 1
en-DH.CPT.002.A
Components and mode of functioning Machine manual
2 Dust hopper
Fig. 3: Subassemblies
en-DH.CPT.002.A
Machine manual Components and mode of functioning
Dust hopper 3
No. Name
1 Bin
2 Hopper cone
3 Aeration boxes
4 Measuring devices
5 Air supply piping and fittings
en-DH.CPT.002.A
Components and mode of functioning Machine manual
4 Dust hopper
en-DH.CPT.002.A
Machine manual Components and mode of functioning
Dust hopper 5
No. Name
1.1 Bin cylinder
1.2 Hopper cone
1.3 Dedusting socket
1.4 Bin roof
1.5 Inlet opening
1.5.1 Shut-off flap
1.5.2 Flexible connection
1.6 Supporting brackets
1.7 Outlet
en-DH.CPT.002.A
Components and mode of functioning Machine manual
6 Dust hopper
en-DH.CPT.002.A
Machine manual Components and mode of functioning
Dust hopper 7
No. Name
3.1 Aeration box, size 500
3.1.1 Fastening flange
3.1.2 Fastening frame
3.1.3 Porous fabric
3.1.4 Bolts
3.1.5 Air inlet socket
3.1.6 Non-return valve
3.1.7 Hose clip
3.1.8 Sealing tape
3.1.9 Wire fabric
en-DH.CPT.002.A
Components and mode of functioning Machine manual
8 Dust hopper
en-DH.CPT.002.A
Machine manual Components and mode of functioning
Dust hopper 9
No. Name
4.1 Overpressure / negative pressure relief device
4.2 Filling level limit switch
4.3 Load cell
en-DH.CPT.002.A
Components and mode of functioning Machine manual
10 Dust hopper
Items shown in the drawing of the air supply pipes and fittings (5)
en-DH.CPT.002.A
Machine manual Components and mode of functioning
Dust hopper 11
No. Name
5.1 Air supply piping
5.2 Shut-off device
5.3 Shut-off device
5.4 Shut-off device
5.5 Manual adjusting valve
5.6 Manual adjusting valve
5.7 Manual adjusting valve
5.8 Air distribution pipe
5.9 Air distribution pipe
5.10 Air distribution pipe
5.11 Hose connection
5.12 Hose connection
5.13 Hose connection
5.14 Ball valve
5.15 Pressure measuring device
I. Aeration ring I
II. Aeration ring II
III. Aeration ring III
en-DH.CPT.002.A
Components and mode of functioning Machine manual
12 Dust hopper
en-DH.CPT.002.A
Machine manual Transport and assembly
Dust hopper 1
4.2 Assembly
Required personnel
To ensure correct performance of the work, only assign repair work to personnel
that have received special training for the tasks to be performed.
Note
It is a prerequisite of our warranty that assembly supervision and assembly
inspection are performed by a specialist from ThyssenKrupp Polysius AG.
Required tools
It is a prerequisite for the correct performance of the work that all tools and
appliances are carefully selected.
No special tools are required. However, you may need torque wrenches of a
bigger size than normal. Whether or not you need auxiliary equipment, such as
scaffolds or hoisting gear, depends on the operating conditions in your plant.
Note
Always comply with the fundamental safety instructions. Also refer to the section
Safety.
CAUTION
Welding current
Moving connecting points or sliding surfaces can be damaged.
I. Always directly connect the welding current return lead to the part
being welded.
II. Never conduct the welding current through plain or antifriction
bearings, other moving connecting elements or measuring devices.
en-DH.CPT.002.A
Transport and assembly Machine manual
2 Dust hopper
Note
The following assembly description does not detail the individual steps for
assembling the machine but rather gives an overview of the work to be
performed.
Changes in the planning of the plant during the processing of the contract may
lead to deviations from this assembly description.
Note
This measure protects the load cells against damage.
● Lower the bin (or the support section of the bin if the bin was not completely
preassembled) with its supporting brackets (1.6) onto the spacers and align.
● Mount the complete bin (1).
Note
If you have to carry out welding or cutting work at the dust hopper, cover the
porous fabric (3.1.3/ 3.2.3) of the aeration boxes (3) and of the outlet (1.7) to
protect them against spatters.
DANGER
Welding work
Damage to health
I. When welding work is being performed inside the dust hopper, make
absolutely sure that fresh air is supplied continuously (by injection or
suction), so that the inhaled air remains free of noxious constituents.
II. Aeration with pure oxygen is forbidden.
III. When electric arc welding or cutting are being performed in a confined
space with electrically conductive walls, you must ensure with
insulating underlays that personnel cannot come into contact with
electrically conductive components.
IV. Never situate the source of the welding current in a confined space
where walls have conductive properties.
Note
Make sure that all air supply pipes, chutes, etc. have flexible connections to the
dust hopper in order to ensure free movability and prevent any forces from being
introduced into the weighing system from outside.
The ring pipeline and the valves will be delivered in preassembled form.
en-DH.CPT.002.A
Machine manual Transport and assembly
Dust hopper 3
Each unit of the aeration boxes (3.1/3.2) including fabric and fastening frame will
be delivered completely bolted together.
● Insert the aeration boxes into the hopper cone (1.2) and push the fastening
frames (3.1.2/ 3.2.1) in the cut-outs of the hopper cone(1.2) and weld.
If there are no cut-outs, they must be cut into the hopper cone on the site.
● Cut off the fastening frame part that projects to the inside.
● Mount the outlet (2.1).
● Mount the air supply piping (5) with shut-off devices and valves.
Note
Check the air supply pipes for leaks. For this purpose, charge the pipes with
compressed air and spray the connections with an easily foaming liquid (soap
suds). Seal any leaky points with sealing compound.
Note
When installing the filling level limit switches (4.2), make sure that their
electrically conductive earth connection to the bin body is good.
Each load cell has to be bridged by stranded copper (approx. 16 mm²) during or
immediately after the installation so that welding currents cannot flow via the
sensor.
en-DH.CPT.002.A
Machine manual Lubrication
Dust hopper 1
5 Lubrication
Note
This machine/unit requires no lubrication.
en-DH.CPT.002.A
Machine manual Commissioning
Dust hopper 1
6 Commissioning
Note
It is a prerequisite for our warranty that the first test run is carried out in the
presence of specialists from ThyssenKrupp Polysius AG and in accordance with
their instructions.
en-DH.CPT.002.A
Machine manual Maintenance
Dust hopper 1
7 Maintenance
7.1 Safety instructions
DANGER
Melting of polyester fabric causes hydrogen cyanide vapours.
There is danger of death.
Extract the hydrogen cyanide vapours by suction directly above the point
of work.
Note
After you have completed the repair work, you must check the machine/plant
again in accordance with section Checks prior to the test run.
7.2 Inspection
No. Work to be performed Frequency Comments
1 Visual inspection for any leaking from Annually The bin must be emptied.
the bin body, visual inspection of the Complete emptying of the
aeration boxes (3) from outside dust hopper is also
necessary in order to
prevent consolidation of the
material.
If the plant operating
conditions so demand, the
dust hopper must be
emptied more often than the
stated frequency in order to
avoid problems at the outlet.
2 Inspection of the aeration boxes (3) in Every 5 years All aeration boxes must be
open condition opened for this inspection.
3 Inspection work on the filling level limit See
switches (4.2) subsupplier's
information
4 Inspection work on the fittings See
subsupplier's
information
5 Inspection of the load cells (4.3) See
subsupplier's
information
6 Inspection of all flexible connections Annually
en-DH.CPT.002.A
Maintenance Machine manual
2 Dust hopper
7.3 Servicing
No. Work to be performed Frequency Comments
1 Maintenance work on the filling level See
limit switches (4.2) subsupplier's
information
2 Maintenance work on the valves and See
fittings subsupplier's
information
3 Maintenance work on the load cells See
(4.3) subsupplier's
information
4 Replacement of faulty hose As required
connections (5.11 to 5.13)
5 Replacement of defective porous fabric As required
(3.1.3/3.2.3)
7.4 Repair
Required personnel
To ensure correct performance of the work, only assign repair work to personnel
that have received special training for the tasks to be performed.
Required tools
It is a prerequisite for the correct performance of the work that all tools and
appliances are carefully selected.
No special tools are required for repair work on the machine.
However, you may need torque wrenches of a bigger size than normal.
Whether or not you need auxiliary equipment, such as scaffolds or hoisting gear,
depends on the operating conditions in your plant.
Consumables
en-DH.CPT.002.A
Machine manual Maintenance
Dust hopper 3
General
Before beginning any repair work, switch off the power supply to all electrical
components.
If you have to carry out welding work in the dust hopper, cover the aeration
surfaces to protect them against spatters.
The interior of the dust hopper may only be entered after all residual material has
been completely discharged.
Ensure absolute cleanliness at all times during the repair work in order to prevent
dirt from entering the bearings, the drives, the hydraulic system or other sensitive
parts of the machine or plant.
Secure the entire working area to prevent unauthorised persons from gaining
access.
Note
The following repair instructions do not detail the individual steps, but rather give
an overview of the work to be performed.
Changes in the planning of the plant during the processing of the contract may
lead to deviations from the instructions.
Note
To repair or replace the aeration boxes (3), the dust hopper must first be
emptied.
The following repair work can be carried out when the dust hopper is full:
● Repair or replacement of the load cells (4.3),
● Repair or replacement of the filling level limit switch (4.2),
● Repair or replacement of the fittings,
● Repair or replacement of the negative pressure / excess pressure relief device
(4.1).
en-DH.CPT.002.A
Maintenance Machine manual
4 Dust hopper
DANGER
Melting of polyester fabric causes hydrogen cyanide vapours.
There is danger of death.
Extract the hydrogen cyanide vapours by suction directly above the point
of work.
● Take a hot spike to melt bolt holes into the porous fabric (3.1.3/3.2.3).
● Fit and tighten the bolts (3.1.4/3.2.4).
en-DH.CPT.002.A
Machine manual Trouble shooting
Dust hopper 1
8 Trouble shooting
Note
Additional information about faults, their causes and their elimination is provided
in the subsuppliers' documentation.
en-DH.CPT.002.A
Machine manual Spare parts
Dust hopper 1
9 Spare parts
9.1 Suggestions for enquiries and orders of spare parts
Dear Customer
ThyssenKrupp 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 separate spare parts offer containing all data required by our spare
parts department to ensure optimum processing in the quickest and most trouble-
free manner.
Please copy the title page and the page with the corresponding table. Complete
the columns for quantity and units. Mark the parts you require with a cross in the
column Order or in the column Enquiry. Send the title page and the table to the
ThyssenKrupp Polysius AG spare parts department.
If the table refers 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.
en-DH.CPT.002.A
Spare parts Machine manual
2 Dust hopper
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Machine manual Spare parts
Dust hopper 3
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Spare parts Machine manual
4 Dust hopper
en-DH.CPT.002.A
Machine manual Spare parts
Dust hopper 5
en-DH.CPT.002.A
Spare parts Machine manual
6 Dust hopper
en-DH.CPT.002.A
Machine manual Spare parts
Dust hopper 7
en-DH.CPT.002.A
Spare parts Machine manual
8 Dust hopper
Items shown in the drawing of the air supply pipes and fittings (5)
en-DH.CPT.002.A
Machine manual Spare parts
Dust hopper 9
en-DH.CPT.002.A
Spare parts Machine manual
10 Dust hopper
Items shown in the drawing of the air supply pipes and fittings (5)
en-DH.CPT.002.A
Machine manual Spare parts
Dust hopper 11
en-DH.CPT.002.A
Machine manual Appendix
Dust hopper 1
10 Appendix
10.1 Technical drawings
Installation drawing
Flowsheet
Load cells
Filling level limit switch
Shut-off device, pneumatically operated
Overpressure / negative pressure relief device
Pressure measuring device
en-DH.CPT.002.A