SIMPLEX MECHANICAL MANUAL

TABLE OF CONTENTS PAGE NO

LOSS IN WEIGHT FEEDER SCHEME PINH-PSS 1/ 1 page

METHOD OF OPERATION PINH-PSS 2 / 1 page

SAFETY INFORMATION, PINH-PSS 3/ 2 pages

INSPECTION AND STORAGE

PREPARATION FOR INSTALLATION PINH-PSS 4 / 1 page

INSTALLATION OF MECHANICAL PINH-PSS 5 / 3 pages

EQUIPMENT

AERATION AND PIPING PINH-PSS 6 / 1 page

LOAD CELL AND BEARINGS PINH-PSS 7 / 1 page

LUBRICATION PINH-PSS 8 / 1 page

TRIAL RUN WITHOUT MATERIAL PINH-PSS 9 / 1 page

FIRST MATERIAL FILLING PINH-PSS 10 / 1 page

RUN WITH MATERIAL PINH-PSS 11/ 1 page.

MAINTENANCE AND INSPECTION PINH-PSS 12/ 11 pages

FACTORS THAT MAY AFFECT PINH-PSS 13 / 1 page

PERFORMANCE

TIPS ON SUCCESSFUL VENTING PINH-PSS 14 / 1 page

PINH-PSS
2. METHOD OF OPERATION

SIMPLEX Loss-in-Weight Feeder model PSS is used to feed pulverized material, like pulverized Coal
, PTA, HDPE, STUCCO, FLUORSPAR and many other pulverized solids. Explosion shock pressure
proof design or stainless steel construction is decided depending upon material to be fed.

Loss-in-Weight Feeders are designed to operate on the principle of controlled Loss-in-weight. A

hopper along with extraction screw is placed on load cells. The screw feeder along with hopper filled
with material is weighed. The extraction screw delivers material into the process. Measurement is
“Rate of Loss-in-Weight” and control is done by SCHENCK controller with the help of speed control
of screw drive motor.

High precision load cells, efficient high resolution controller in combination with speed controlled
drive with appropriately configured screw ensures feed consistency and accuracy.

To maintain continuity of feed into the process, refilling of weigh hopper takes place during brief
periods. The feeder will operate volumetrically during these brief filling periods based on control
magnitude stored during preceding gravimetric period of operation.

Filling system consisting of a fill gate, inlet cone, inlet blow-out, flexible connection and a deflector
plate inside weigh hopper underneath the inlet cone does refilling as per configuration done in the
control system. An air filter or vent connection allows air / gas to vent out from the weigh hopper.

Filling from storage bin to the weigh hopper is aided by flow pad placed at the lower conical portion
of storage bin, purged by air or inert gas pulses or by bin activator placed at the bottom of storage
bin. Silo outlet area is recommended to be lined with polished liners for flow promotion. Expected
filling time is between 8-12 seconds. Inlet cone is cleaned by air or inert gas after every filling to
ensure no material will fall into the weigh hopper during gravimetric phase.

Inert Gas connection is provided on the weigh hopper in case of explosion proof design or material to
be handled under inert atmosphere.

Screw diameter of 160 mm, 200 mm, 250 mm or 315 mm in single screw or twin screw form along
with single or twin agitator is decided depending upon feed capacity requirement and flow property of
material. Feeder model PSS-12 uses 160 mm screw, PSS-24 has 200 mm screw, PSS-50 has 250
mm and PSS-100 has 315 mm diameter screw.

PSS model feeders use three nos. SCHENCK Load Cells with suitable mounts.

Where multiple feeders are installed under common storage silo, an additional agitator at the silo
outlet is recommended.

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PINH-PSS 2 / 1 of 1
3. SAFETY INFORMATION.
INSPECTION ON ARRIVAL AND STORAGE SUGGESTION
3.1 Safety Information

3.1.1 Using System for Intended Purpose

Your SIMPLEX Feeder is designed for measurement and control of Flow rate in accordance with Loss-in
Weight rate measurement principle.
When installing and commissioning your SIMPLEX Feeder for the material specified in your order, follow
the information given in this manual and refer to the technical data supplied in the documentation.

The system has been configured to process material specified in your order. If processing of alternate
material is desired, reconfiguration of your system may be necessary.

No change to the basic construction of the system should be performed without approval of SCHENCK.

3.1.2 Workmen’s Qualification

Any person directly or indirectly involved in installation, operation, maintenance and repair is required to
have read this manual and be familiar with it’s use.

Only trained and authorized personnel may perform the work described in this manual.

Workmen must be familiar with the construction and safe operation of crane or forklift if used in installing
the device.

Workmen are required to know all in-plant, local safety regulations and accident prevention rules.

3.1.3 Residual risk factor

The responsible personnel are required to determine if the operation of your system has the potential to
cause residual risks in conjunction with other plant component. If necessary, additional safety information
must be developed. The user must make additional information available to the operators of the system
that will augment this instruction manual.

3.1.4 Hazards Resulting from Feed Material

As a rule, every person working on SIMPLEX Feeder is required to have a material safety data in hand
which specifies the degree of risk resulting from the material used.

3.1.5 Safety for Installation, Operation and Maintenance

For safety reason, SIMPLEX Feeder may be put into operation only after having installed as per supplied
drawing under supervision of a skilled technician.

Perform work on the device (including inspection work) exclusively in the OFF state of the feeder. Check
to see that all power lines are separated from mains. Protect system from inadvertent start-up. Never
apply power unless all safety guards have been installed over rotating parts.

BE CAREFUL IN CASE OF WELDING:- In order to protect load cells, attach the negative pole of the
welder directly to the point of welding.
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PINH-PSS 3 / 1 of 2
3.2 Inspection on arrival
Check shipping document and inspect all the parts received vis-a-vis description. Appropriate report to
insurance agency or carrying agency may be made in case of any loss or damage. Major parts will be:-

Weigh hopper with deflector plate fitted inside.

Screw and agitator unit coupled with drives.
Parts for Filling system.
Parts for surge bin aeration system.
Different types of solenoid valves and accessories.
Load cells and mounting accessories.
Flexible connections for inlet and outlet.
Fasteners and gaskets.
Filter unit and its’ parts.
Completely wired Electrical panel.
Instruments and controllers.
Special devices, if any, as per contract.
Cables as ordered. .

3.3 Storage suggestions

All electrical item, controllers and instruments must be stored in dry dust free enclosed store room.

All mechanical parts to be stored under covered moisture and dust free environment.

Caution:- Keep all parts vertically during storage. Avoid rough handling during receipt, shifting
and storage.

In case storage required longer than 6 months from the date of delivery, take these steps after six months
and every subsequent six months:

- Unpack device.
- Coat all bright metal surfaces with a corrosion protection agent.
- Visually check steel parts for corrosion or damage , if need be, repaint.
- Turn motor and gear box shaft manually to distribute grease.
- Follow Motor manufacturers suggestion.
- Wrap the entire device to protect from moisture.
- Add dehydrating agent and re-seal instrument carton.

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PINH-PSS 3 / 2 of 2
4. PREPARATION FOR INSTALLATION
4.1 Installation space
First point of preparation will be to confirm vertical and horizontal space requirement as shown in the
arrangement drawing. Vertical space will be from storage silo bottom to Loss-in weight feeder’s screw
discharge level below flexible connection and horizontal space will include space for screw removal as
well as space for maintenance for drive units.

4.2 Load Bearing Structural

Load bearing capacity and size of supporting structural or RCC structure to be confirmed as per load data
of the points of supports or as per load cell’s rated capacity and dimension of load cell mount base plate.

4.3 Air and Inert Gas supply Lines

Preparation is needed for aeration and inert gas pipe lines and aeration related component installation
and maintenance access.

4.4 Installation Preparation

Ascertain lifting device requirement as per installation location and size of individual parts. Consider max
3 ton weight of a single piece to be lifted. Hence, capacity of one lifting device must be 5 ton or more. A
smaller lifting device of 3 ton capacity will also be helpful to lift comparatively smaller parts or sometime
two lifting device is used together.

Check lifting hook and use appropriate shackles and slings. Depending upon installation location,
scaffolding, a suitable ladder for entering inside the weigh hopper, safety belt and safety appliances will
be required.

Tools will include, set of flat spanners and set of ring spanners M5 to M20, set of socket head spanners,
spanners suitable for fasteners between screw and weigh hopper connecting flange, set of ratchet and
insertible socket spanners are preferred.

Tools will also include, extension cable with plug sockets suitable for 220/ 230 volt, portable grinder for
surface preparation, drilling machine, hand lamp with battery for work inside weigh hopper, plumb with
line, measurement tape, water level pipe etc.

Requirement of welding transformer, gas cutting set is likely to come. Direct earth connection from
welding machine to be brought, i.e, -ve pole of welding transformer output will not get grounded
anywhere. This earth to be provided at the point of weld so that welding current remains localized.

4.5 Important notes

For explosion shock pressure proof, adequate precaution to be taken for connection of different parts with
sealing in between.

It is essential to protect the Loss – in – Weight feeder from wind force or strong plant vibration. Otherwise
measurement may be falsified. However, Disturbance Auto Elimination system of Schenck controller will
nullify these effects to a large extent.

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PINH-PSS 4 / 1 of 1
5. INSTALLATION OF MECHANICAL EQUIPMENT
5.1 Weigh hopper
Place the weigh hopper in ceiling or platform opening.

Set the hopper on mounting support and align horizontally as well as along fill inlet line.

Load Cells will be placed later.

5.2 Metering screw

Place completely pre-assembled metering screw below weigh hopper.
Note:-Direction of travel.

Place flange sealing on screw feeder flange and fix at four corners.

Lift the screw feeder below weigh hopper flange and bolt flanges together.

Tighten bolts starting from flange middle and end at corners.

5.3 Storage bin purging flow pads

Install and adapt these parts as per detail given in the installation drawing.

Interconnect the flow pads with piping by flexible hose, connector and adaptors supplied.

5.4 Filling system

Before installation of filling system, deflector plate inside weigh hopper to be checked and fasteners to be
tightened. Check and ensure that direction of deflector plate slope is at the back side, i.e. opposite to
screw discharge direction. Angle of downward slope will be 10 to 15 deg with respect to horizontal.

Install filling system as per installation drawing. Parts starting from storage hopper bottom flange will be:

- manual gate,
- distance piece,
- butterfly valve fill gate, (refer note below)
- inlet cone fitted with blow out nozzles
- flexible connection. (refer note below)
- sealing gasket between every joint.
(REF. SKETCH IN PINH-PSS 5 / Page 2 of 3)

Note: Before assembly of butterfly valve, ensure that butterfly valve flap is in it’s close position. If not,
use compressed air directly and close it. Otherwise, valve seal will tend to flare inward while clamping in
between the distance piece and inlet cone. Seal may get damaged during operation. Do not over tighten
assembly of this part. Hereafter, operate the valve several times by external direct air. Check and ensure
that this operation is smooth.

Inlet cone must be fitted directly below the fill gate. Any distance piece addition above fill gate will
demand additional aeration.

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PINH-PSS 5 / 1 of 3
5.5 Filter unit or Vent connection on weigh hopper:-
Depending upon design, a modular filter unit or vent connection is supplied.

In case filter unit is present with insertible filter bags, corresponding flange to accommodate the filter unit
will be available on weigh hopper top. Assembly of the unit can be done over weigh hopper if felt suitable
and vertical space permits. Alternately, the filter unit to be assembled on floor and lifted and place over
weigh hopper.

A modular Bag Filter unit essentially consists of a pressure proof casing with bottom flange along with
bag holder on top, bag separator at lower end and a metal wire mesh at the bottom to arrest fallen bag in
case of bag damage. Number of bags with cage, ventury, air purging pipe are the other parts placed
inside. Top cover will cover the housing. Vent port is available on the body of the main housing above bag
holder plate. Depending upon material, suction fan is used.

Note:- Fitment of the bag units ( bag and ventury are clamped by check disc ) need care and
inspection. Gap formation in clamping will allow dusty air to escape.

Non pressure proof construction uses a vent port from top of weigh hopper, meant for connection to
plants filter system through a flexible connection. Detail of parts will be available in arrangement drawing.

5.6 Vent connection below metering screw

Ensure vent connection below metering screw if connected to F.K.Pump or rotary Air Lock and ventury
combination. Excessive positive pressure below metering screw can lead to build-ups in the screw
discharge area and lead to jamming.

5.7 Load cell assembly

Three number SCHENCK load cells with mount will carry full load of the mechanics. Detail of assembly
will be available in the arrangement drawing.

Before placement of load cell and mounts, it is essential to ensure that:

-Storage bin is in it’s final position, aligned and leveled.

-Filling system is axially aligned with storage bin outlet and feed inlet port of weigh hopper. Permissible
axial alignment tolerance is 2 mm max.

Check load cell assembly installation place for horizontal and smooth surface and ensure that
carrying member is designed to carry load of total feeder with filter unit and few thousand Kg
material ( refer designed data ) and that load cell assembly will not remain projected beyond
carrying structural flange.

Check head room for load cell and mount assembly and correct deviation if any. Use jacks to lift the
feeder mechanics marginally and insert load cell with mount one by one. Check and correct axial
alignment of filling system once again. Adjust arrestors of load cell assembly as guided in detail given in
arrangement drawing.

Note:- Inappropriate alignment of load cell mount base plate or very close arrestor gap setting can
make impermissible contact between weigh hopper flange and the arrestors. Refer section 7.2 of
this manual.

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PINH-PSS 5 / 3 of 3
6. AERATION AND PIPING

Assured clean compressed air connection to be brought through suitable filter and moisture trap. Inert
gas connection to be brought where such requirement exists.

Air is required for pneumatic fill gate actuator, to be connected through suitable FRL unit. Solenoid valve
for the actuator is normally built-in with the actuator.

Air and or inert gas is required for surge bin flow pad purging and inlet blow out nozzles.

Inert gas is required on top of weigh hopper where such requirement exists.

Suitable FR unit to be placed in the air and inert gas lines as shown in arrangement drawing.

Pressure and tentative air / gas volume detail for different points is available in the arrangement
drawing.

Piping connections for FR, FRL, Solenoid valves, gate valves, non return valves, flow pads to be made
leak proof.

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PINH-PSS 6 / 1 of 1
7. LOAD CELL BEARING AND ACCESSORIES
7.1 Load cell
SCHENCK Load Cell model RT is generally used. Normally, 3 numbers of 1 ton capacity load cell is used
for PSS-12, 2.2 ton for PSS-24, 4.7 ton for PSS-50, 6.8 ton for PSS-100 and 10 ton for extended PSS-
100.

7.2 Load Cell Bearings

Load cell bearings used for PSS SIMPLEX Loss in Weight feeder are generally two types, viz. Pendulum
mount and rubberized mount. Detail of particular type used is given in arrangement drawing. Rubberized
mount is not recommended in hot zone application.

Essential properties of bearings are:-

Transfer load on load cell free from shunt force.

Absorb side force.

Provide protection to the load cell against overload.

In addition to load cell bearings, a safety support is placed beside every load cell capable of carrying load
same as that of a load cell. Safety support is in position maintaining approximately 10 to 20 mm gap with
respect to weigh hopper flange.

A hold on stud is placed beside load cell mount for safety reason. Some mounts has hold down stud built-
in with the safety support cum horizontal movement arrestor.

Maximum permissible horizontal deviation for the base plate is 2 degrees.

Shims supplied with load cell mount are meant to accommodate maximum 5 mm level difference of
supporting structure.

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PINH-PSS 7 / 1 of 1
8. LUBRICATION
Lubrication is required for following parts:-
- Gear Oil in the Gear Boxes for screw and agitators drives.
Follow lubrication instruction for the type of gear box used. Check oil level.
Check breather plug for pre-filled gear unit or geared motor unit.

- Grease the bearings at two ends of screw and agitators.

Use grease gun to pump. Grease grade EP-2 (LGEP 2) can be used.

- Re-lubricate stuffing box seals by grease gun.

Use bearing grease same as above.

- Fill oil in the FRL unit.

Lubricant grade SAE-40 or 2T can be used.

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PINH-PSS 8 / 1 of 1
9. TRIAL RUN WITHOUT MATERIAL
9.1 Preparation

Check assembly once again.

Clear all foreign matter from storage bin and feeder screw.
CAUTION:- Adhere required safety for this step.

Electrical system must be tested separately and all electrical parts are connected. Earth connection is
given to motors and other electrical devices as per rule.

Check air and inert gas connections to the source and adjust pressure at different points as
recommended in the arrangement drawing. Excess pressure can cause damage of parts.

9.2 First run

Start drives and check direction. Refer direction arrow marking.

Observe any running noise.

Observe temperature of gear boxes, bearings and stuffing boxes.

Check Fill valve open close operation. Set fill gate feed back sensors.

Check storage bin flow pad air purging. Set pressure not exceeding 2.5 bar.

Check filter unit functioning. Set air pressure to 4 bar at the filter unit inlet.

Keep screw and agitators in running for few hours if above tests are satisfactory.

Now, the feeder is ready for Calibration. This step to be performed and checked before taking
material. Refer Controller Manual.

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PINH-PSS 9 / 1 of 1
10. FIRST MATERIAL FILLING
Fill material in the storage bin.

Ensure that electrical system is correctly set ( parameterized ) for fill control and other functions.

Set Inlet cone blow out nozzle air pressure to 0.5 bar.

Keep shut off device installed at downstream closed to avoid uncontrolled flow material during first filling
operation. It is likely that metering screw will be flooded with material during first fill.

Carry our filling by inching command from electrical controller. Check that automatic stop of filling has
taken place without overfilling.

In the event of successful completion of above steps, the feeder will be considered as ready to put into
plant operation.

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PINH-PSS 10 / 1 of 1
11. RUN WITH MATERIAL
Open the shut off gate below metering screw.

Run downstream conveying system.

Keep agitator off for low rate.

Start the feeder at low feed rate. Observe delivery of the metering screw and current drawn by the screw
motor. Increase feed area slowly as per plant running need. Keep close watch on delivery of screw
feeder, its running speed and current drawn by the motor, feed consistency. Decide agitator operating
point as per feed consistency behavior at different rates.

Check automatic refilling as per configuration in the electrical controller. Expected filling time is 8-15
seconds for weigh hopper with suction filter dust collection and approximately 12-20 seconds for weigh
hopper with pressure filter dust collection.

Set pulsed aeration system at storage bin outlet as below:-

Air pressure = 1.5 to 2.0 bar.

Pulse duration = 1 second.
Pause duration = 2-3 seconds.

Set air pressure for filter unit to approximately 2 bar and check sequential purging during filling cycles.

Simulate and check inert gas fill into the weigh hopper.

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PINH-PSS 11 / 1 of 1
12. MAINTENANCE AND INSPECTION
SIMPLEX Loss-in weight feeder is nearly a maintenance free equipment. Practically, no wear occurs in
the screw or agitator even after several years of operation.

Routine lubrication or re-lubrication and inspection and replacement of flexible connections are important.
Notable technical point is - feeder performance remain unaffected on tare shift due to any reason.
However, maintenance and inspection tips given below for following parts:-

Pulsed aeration system.

Filling system and fill gate.

Weigh hopper.

Screw feeder

Screw outlet.

Agitator

Flexible connection.

Filter unit

12.1 Maintenance and Inspection – Pulsed Aeration System

Each aeration nozzle (flow pad) generates multiple air flows along the hopper wall. This reduces wall
friction. Air pulses are sufficient to improve material discharge as required.

Correct arrangement of air nozzles is important in combination with smooth hopper inside surface area
(flow promoting liner).

Maximum permissible air pressure for aeration nozzles is 2.5 bar. At higher pressure, rubber caps may
jump out of place causing nozzle and piping may get plugged with material. Recommended operating air
pressure is 1 bar.

Maintenance of aeration nozzle is possible by inspection when storage bin is empty.

Replace rubber or complete nozzle as required.

Check solenoid valves for safe ON / OFF operation.

Check air service unit (FR) and water separator perform properly.

Check air hose and connections for proper tightness.

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PINH-PSS 12 / 1 of 11
12.2 Maintenance and Inspection – Filling System
As weigh hopper is to be refilled, the feeding accuracy of the Simplex feeder can be affected by any of
the following factors:-

- Filling time too long.

- Filling time too short.
-Material falling after.

Filling time is influenced by Mass flow in storage bin, flow behavior in the storage bin, discharge aid in the
conical outlet area of the bin, opening and closing time of fill valve, diameter of the filling funnel (inlet
cone) and air pressure of inlet blow out system.

Filling times will remain 10 to 20 seconds for weigh hoppers fitted with pressure filter dust collection and 5
to 15 seconds for weigh hopper with suction filter dust collection.

Material falling after can be due to Fill valve seal damage, plugged dust collector pipe above weigh
hopper or from modular filter unit or inlet blow out system operating unreliably.

Preventive maintenance essentially calls to ensure lubricant is topped up in FRL unit for fill gate.
Otherwise, no periodic maintenance is required for the fill valve unless there is problem. Air pressure to
be maintained as per recommendation of fill valve manufacturer. Normally, pressure required is 4-5 bar.

Follow maintenance instruction of fill valve manufacturer. Before starting any repair work, shut off gate
above fill valve must be shut to ensure that no material will come down from storage bin. Prevent
accident risk by shutting off compressed air and bleeding the air trapped. Any maintenance in fill valve
part is possible after removal of the unit.

Fault in the solenoid valve can cause problem or mal-operation of the fill valve.

Fault in solenoid valve for inlet blow out system can lead material fall after filling cycle.

In case of abrasive material, blow out nozzles and filling funnel inspection will be required. Renew this
part as needed.

12.3 Maintenance and Inspection – Weigh Hopper.

This part of the feeder is meant for mass flow of bulk solids in weigh hopper and stable load application
without shunt force to the load cells.

Mass flow is achieved by proper hopper configuration and smooth hopper inside surface.
Check weigh hopper inside surface smoothness periodically. In the case of pulverized coal, hopper cone
is fully or partly lined with stainless steel liners – grade of finish, III c (polished).

Inspection and repair inside weigh hopper is possible after empty out only. Safety measure must be
taken against accidental material entry. It is essential to close the shut off gate and close air
connection to the fill valve. Oxygen (air) must be sufficiently blown-in before anyone is allowed to
enter inside weigh hopper for inspection. In case, repair work for inside polish or to change liner
is required, it is essential to lower the screw feeder unit for maintenance personnel’s safety.

Load Cell connection to electrical unit must be removed and local earth connection to be given (at the
point of weld) in case any welding is involved for repair.

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PINH-PSS 12 / 2 of 11
12.4 Maintenance and Inspection – Screw Feeder
Schenck screw is designed to provide constant material discharge by volume per shaft rotation over a
large speed range. Progressively increased pitch avoids screw jamming under normal conditions. A
dosing star placed immediately after conveying flights breaks material lumps formation and make
discharge nearly homogeneous. A reverse flight placed at the end of screw casing cleans the discharge
area. Refer sketch in PINH-PSS 12 / 4 of 11.

If stuffing box packing (1) can no longer be tightened, replace packing before shaft seal becomes
permeable due to material entering underneath packing, as this would cause great risk of wear for
protective bushing (2).

When fitting new packing :-

Remove used packing leaving no residues using suitable extractor.

Clean split lantern ring (3), packing space (4), and protective bushing (2). Unscrew grease nipples (5) and
clean grease duct.

Check protective bushing surface (2) for wear.

Spread new anti-friction bearing grease on new packing(1) and insert.

Insert lantern ring (3) as shown, to permit re-lubrication.

Run in stuffing box packing.

Note: Installation of a new protective bushing (2) requires removal of bearing case (15) from
screw shaft (6), and of the drive unit.

When replacing bearings:-

Use suitable tools and ensure proper cleanliness.

The fixed bearing (7) is located on the drive side of the shaft.

On the float bearing side, turn pressure screw (8) to stop against the bearing (10) before driving back the
clamping sleeve (9), to enable the clamping sleeve to come free of the bearing.

After clamping the new bearing in place with clamping sleeve (9), restore pressure screw (8) to their initial
position to provide axial play for bearing (10) in bearing casing (15).

On the fixed bearing side, blind plugs (11) are screwed in, as the bearing is held in place with the use of
fixed rings (12).

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PINH-PSS 12 / 3 of 11
Extracting the screw shaft:-

Extract screw shaft from the shaft tube (screw casing) to either side with Simplex feeder cleared and
screw shaft drive removed.

Remove flange rings (20) on both sides.

To extract, support the screw shaft by means of suitable lifting gear.

Place screw shaft on rolling fixtures, and lock round-run spring.

Bent or deformed screw flights can be cold straightened. If new flights need to be welded in place, the
screw shaft must be straightened.

Place screw shaft into screw tube exercising utmost care to prevent flights from being deformed.

12.5 Maintenance and Inspection – Screw Outlet

Ref. SKETCH FOR SCREW OUTLET, INH-PSS 12/ 6 of 11.

The screw outlet’s essential functions are to:-

Establish flexible connection (1) to stationary environment, ensuring that force applied to load cells is
hardly falsified.

Provide an even material stream by appropriately set feed star (2).

Provide a checking possibility through cover (3).

Normally, no maintenance is required.

Inspection:-

When replacing flexible union (1), also renew rubber strips below tensioning belts / clamp.

Note:- See to it that flexible union is at no point of it’s circumference is stiff.

Initial position of feed star (2) is centrally to the discharge edge. Depending upon material properties, a
readjustment may be necessary. Lock the feed star by screw (4).

Check to see that cover (3) is tightened.

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PINH-PSS 12 / 5 of 11
12.6 Maintenance and Inspection – Agitator
Functions of agitator are:-

Keep bulk solids in agitator trough in movement.

Prevent material build-ups in the approach area to the metering screw.

Maintenance

Keep stuffing box packing and bearings lubricated as per lubrication instruction.

Inspection

1) Stuffing box Packing

If stuffing box packing (1) can no longer be retightened, replace packing before the shaft seal becomes
permeable due to material entered underneath packing, as this would cause a great risk for wear for the
protective bushing (2).

When fitting new packing, note:-

Remove used packing so as to leave no residue using a suitable extractor.

Clean split lantern ring (3) , packing space (4) and bushing (2). Unscrew grease nipples (5) and clean
grease duct.

Check protective bushing surface (2) for wear.

Note:-
Installation of a new protective bushing (2) requires removal of the bearing case (15) from agitator trough
and agitator shaft (6) and drive unit.

Insert lantern ring (3) as shown, to permit re-lubrication.

Run in stuffing box packing.

2. Bearings

When replacing bearings, use suitable tools and ensure proper cleanliness.

The fixed baring (7) is located on the drive side of the shaft.

On the float bearing side, turn pressure screw (8) to stop against the bearing (10) before driving back the
clamping sleeve (9), to enable the clamping sleeve to come free of the bearing.

After clamping the new bearing in place with clamping sleeve (9), restore pressure screw (8) to their initial
position to provide axial play for bearing (10) in bearing casing (15).

On the fixed bearing side, blind plugs (11) are screwed in, as the bearing is held in place with the use of
fixed rings (12).

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PINH-PSS 12 / 7 of 11
3. Agitator Arms

Access for inspection is possible by entering the cleared Simplex feeder or separating the metering screw
from weigh hopper. Take precaution against accident protection as explained for maintenance of weigh
hopper.

Agitator arms are fastened with bolts and nuts.

When replacing arms, watch for proper direction of rotation, consulting the numbering scheme.

The agitator shaft (6) can be lifted out of the agitator trough after removal of:-

Agitator arms
Drive unit.
Flange bearing case (15).

Note:-

If reinforcements are welded to discs to compensate wear, shaft must be re-straightened for proper round
run in area of stuffing box and packing and bearings.

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PINH-PSS 12 / 8 of 11
12.7 Maintenance and Inspection – Flexible Connections
Ref. SKETCH IN PINH-PSS 12 / 6 of 11

1. Principle of operation
Feed accuracy of Simplex feeders essentially depends on:

Rigidity of material used for flexible connections at inlet and outlet.

Play of flexible connection must be more than that of respective connection of feeder, i.e., weigh hopper
inlet, feeder outlet and dust collection.

Flexible connection should also be dust tight and meet the requirement of respective application.

Approved material, sewed together to form hose sections:

Nylon fabric, rubber lined, aprox 0.2 mm thick.

Polyester fabric, Hypalon - lined, aprox 0.5 mm thick.

2. Maintenance
Flexible connections are free from maintenance.

3. Inspection and Repair

Check for proper sit of hose clamp.

Proceed as shown in graphic representation when installing flexible connections:

- For first installation, remove possible burrs from connection.

- Pull flexible union carefully through connections without turning them inside out.
- Push flexible onto connections.
- Cut rubber band to length such that ends abut.
- Facilitate attachment to hose clamps with rubber band by bonding the rubber band to the inside
of hose clamp such that joint lies a the inner end of hose clamp at .
Now, align flexible union for sufficient play and that it is not taut at any point of it’s circumference.

See that the lower hose clamp is aligned flush with the end of connection to avoid material deposits.

12.8 Maintenance and Inspection – Filter Unit

The Principle of Simplex feeder requires nearly atmospheric air pressure to prevail in the weigh hopper.

During fillings phases, air is to be allowed to escape from the weigh hopper and during gravimetric phase
air is allowed to flow into the weigh hopper to assist decreasing material volume. Filter unit fitted on weigh
hopper cover functions to assist both the conditions.

Material entering the weigh hopper causes an increase in air pressure inside the hopper. Magnitude of
pressure increase depends upon permeability of filter cloth. Clan-out operation of the filter during filling
counteracts build-ups on the filter cloth and maintains permeability of filter cloth.
During gravimetric feed, weigh hopper inside will prevail a low negative pressure. Permissible tolerance of
air pressure variation during gravimetric cycle is +/- 5 mm water column (WC).
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Inspection:

When dust egress, replace filter bags.

Maintenance:

After the feeder has been commissioned, determine filter maintenance intervals.

Clear filter clothes using dry and oil-free compressed air.

Air purging system and pressure will have to be monitored if filter cloths get clogged at quick interval.

Material build-ups surrounding the bags hint for need of a suction fan or increase of suction by adjusting
dampers.

Periodical maintenance will need cleaning of the housing inside, cleaning of bags and check pulse valve.
Filter bags which cannot be cleaned, are to be replaced.

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13. FACTORS THAT MAY AFFECT PERFORMANCE.
Performance of a Loss-in-Weight feeder is judged mainly by feed consistency. Following factors can
affect:-

Leakage from fill gate due to damaged seal of the gate. Material entered into the weigh hopper in
gravimetric phase will falsify loss-in-weight rate measurement.

Packing of material at the inlet flexible joint will make weigh hopper stiff with non weighing part.

Material drop from filter unit or vent port in gravimetric phase will cause wrong measurement and
fluctuation.

Stiff connections of inert gas line on weigh hopper top or stiff connection to the motor cables, earth
connection etc.

Any physical arrest on the weigh hopper or screw wall.

Stiff Load Cell assembly, particularly compression piece sitting over load button or thick dust settlement
surrounding the load cell assembly.

Venting problem below metering screw will lead jamming in the flexible connection. THIS MAY ARISE
DUE TO FAULT DEVELOPMENT IN THE DELIVERY PUMP / ROUTE OR INAPPROPRIATE VENTING
LINE CONFIGURATION.

Flow property deterioration due to moisture or low temperature will cause feed fluctuation.

Long filling time due to incorrect operation of filling aid or material flow property deterioration.

External factors which are not eliminated by DAE system will cause measurement problem.

Partial flushing out of material due to pressurization or insufficient buffer material will cause performance
problem.

Electrical interference , like EMI pick-up in the load cell cable or load cell signal cable’s insulation leakage.

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14. TIPS ON SUCCESSFUL VENTING.
Vent line connection is given below screw discharge flexible connection, e.g., from the vent port of
downstream conveying pump hopper. Vent connection is also given from LIW weigh hopper in case of
non-pressure proof construction.

Leak air from conveying pump or air escaped from weigh hopper during filling is not sufficient to give
required minimum conveying velocity through the vent line. In case of insufficient conveying media,
vent lines are likely to get choked due to shortfall in conveying velocity irrespective of filter unit’s capacity.

A vent system is successful only when sufficient conveying media is allowed into the vent line. Fresh air
entry allowed as conveying media through the fresh air port or false air hood does this job. THIS
ENSURES FILTER UNIT TO WORK EFECTIVELY DUE TO LOW DUST CONCENTRATION IN THE
COLLECTED AIR. This also ensures stability of suction magnitude and maintains the same at optimum
low level.

Filter unit’s suction capacity must be in accordance with size of the vent line to ensure that conveying
velocity in the vent line will remain above critical velocity of Pn conveying for the type of dust to be
collected.

Two types of arrangement is done for fresh air entry. A branch line to the vent line open to atmosphere
through one adjustable damper. The other type is an adjustable false air hood.

Note:- Some material does not permit Oxygen to come in contact.

Downstream route in such cases are normally pressurized by inert gas to a very small magnitude.

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