Assembly and Main- tenance instruction - NEUERO · PDF fileginning of the foundation and...

Art.-Nr.: 8600370

NEUERO Farm- und Fördertechnik GmbH Hermann-Unbefunde-Str. 6 – 49324 Melle Postfach 127 – 49302 Melle Telefon: 05422/9440-0 Fax: 05422/9440-40

Assembly and Main-tenance instruction

Storage bin for outside mounting with hopper

construction

Type: NLT

06/06

NEUERO Farm- und Fördertechnik

Betriebsanleitung NEUERO FF

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1.0 Table of contents Chapter Description

Page

1.0 Table of contents 2

2.0 Intended use 3

3.0 Assembling 4

3.1 Before assembly start 4

3.2 Provide and examining the foundation 4

3.3 Assembling instructions 5

3.4 Assembly of the first and second ring 6

3.5 Support assembly 7

3.6 Roof assembly 8

3.7 Assembly of ladder 10

3.8 Assembly of roof ladder 12

3.9 Assembly of accessories 16

3.10 Set up of the Jacks 18

3.11 Assembly of the following rings 20

3.12 Access hatch 21

3.13 Assembly of hopper construction 22

3.14 Aeration construction 24

3.15 Bin anchorage 26

3.16 Gangway 26

4.0 Accessories 27

4.1 Ladder 27

5.0 Maintenance 27

6.0 Drawings 28

7.0 Material requirements 29


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2.0 Intended use The storage bin type NL serves for the storage of grain and corn, as well as similar bulk materials. The local construction specifications are to be considered. Before be-ginning of the foundation and assembly works, a building request is to be placed.

The storage bin type NL serves for the storage of grain and corn, as well as dry and free flowing bulk materials with same characteristics: apparent density = 9 KN/m3 and friction angles = 30 °.

Each use going beyond it is not considered as intended. For damage resulting

from this the manufacturer is not responsible; the risk for this carries alone the user.

Cohesive bulk materials tending to arching may not be stored.

The bin is constructed for centric filling and emptying. When filling pay atten-

tion to sufficient exhaust to avoided bursting.

When emptying sufficient ventilation is requested, in order to avoid a negative pressure in the bin.

For the mounted unloading and filling equipment the appropriate operating in-

structions are to be considered.

The pegs for the attachment of the bin supports on the foundation are to be set according to the instruction for assembly of the peg manufacturer.

The bins are from the outside easy to damage through mechanical effect. If

the bins are placed by a passages there should on side be build a correspond-ing protection.

Entering of the bins in the filled or partly filled condition is forbidden. In the

empty condition are suitable safeguard has to be applied. See also in addition the regulations for security and health protection of the government safety or-ganisation.

If leaving of the landings, gangways and roof ladders should be necessary for

maintenance work, then safety gear has to be worn, and kept close by.

Arbitrary changes are not allowed.


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3.0 Assembly This assembly instruction describes the erection of a galvanized NEUERO storage bin on an existing foundation (concrete cover) with the appropriate anchore fixings. The local construction specifications are to be considered. Before beginning of the foundation and assembly works, a building request is to be placed. When desired we send you foundation plans and static calculation. The dimensions of the foundation for a bin depend on height and diameter of the bin, as well as on the maximum per-missible soil pressing. Up to the assembly the bins individual parts should be stored dry and not exposed to strong variations in temperature, so that condensation will form. 3.1 Before assembly start:

The location of the bin must be fixed, possibly in accordance with planning de-sign.

Specify the position of the bin ladder, the unloading tube and the access

hatch.

Provide for the current supply for the assembly. In the proximity of the bin, two power connections are needed. One single phase AC, 220 V, 16 A fuse and one three-phase AC, 3 x 400 V with 16 A fuse.

Specify location and/or position of the bin parts not used at the beginning.

3.2 Provide and examining the foundation

The bin foundation - the base plate - is on the basis one of an architect com-piled building project to establish. The architect receives in addition as working documents a foundation plan as well as a standard static calculation.

With the calculation and organization of the foundation a soil pressing of 0,2 MN/m² is

to be kept.

Appropriate is a building ground investigation before start.

Under the foundation a double building foil is to be shifted, in order to prevent ascending wetness.

The surface of the foundation must be horizontal and may at the most exhibit

a deviation from ± 5 mm.

The foundation should be established in 2 phases: 1. Phase: Raw concrete - upper edge approx. 20 mm under upper edge Foundation. 2. Phase: Apply from a levelling flowing line to upper edge foundation


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After completion of the foundation it is to be examined with a hose balance or a levelling instrument whether the surface is horizontal and/or the deviation does not exceed the tolerance of ± 5 mm. With unevenness up to 10 mm can be installed, if through pressure resistant material which can be placed by oth-ers (metal strip, flat steel bar) is created reconciliation. If the unevenness is higher, the foundation must be up-fed again and evened out.

Determine and mark the center of the bin. Subsequently, the bin diameter is

noted.

NLT 2 3 4 5 ∅ in m 1,79 2,68 3,58 4,47

The NEUERO storage bin is to be installed perpendicularly. This is to be con-

trolled by a plumb bob or other suitable means. 3.3 Assembly instructions The assembly is to be accomplished with consideration of the regulations of the gov-ernment safety organisation. In the case of supply of different strength in the coat plates the thin coat plates are to be installed and in the lower silo range and the thick coat plates in the upper silo range. Exception is the highest ring, which is always 1 mm if bins that have roof. The number of the different strengths in plate and support for each silo is seen in the packing lists. It is to be made certain that the bin plates are always taken and mounted in the same direction as they lay in the pile. If the plates are rotated, the hole spacing does not fit for the subsequent ring any longer. Fig. 1: Illustration of the bin plates; hole pattern with 120 and 130 holes

By wind force 6 stop the assembly! Set the silo off on the soil and secure it against shifting and tilting.

Please do not install bin plates or parts of the roof, which exhibit points of failure. Im-prove the points of failure or change the parts.


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Damages of the silo parts are to be avoided. 3.4 Assembly of the first and second ring.

The assembly begins with the setting up the 2th Ring (seen from above). The bin plate, to which the ladder is to be fastened, is brought into the correct posi-tion.

Between the Bin plates the sealing strip is

to be placed evenly on all perpendicularly and horizontally overlapping surfaces. The sealing strip is placed from the out-side on the perpendicularly screw impact.

Fig. 2: Placing sealing strip

The coat plates are bolted. With tightening the hexagon nut the washer can

seem to be damaged. However the sealing is not impaired. Fig. 3: Bin plate bolting

The next bin plate is in-stalled and bolted with the screw impact and sealing strip in right place.

Fig. 4: Note the hole pattern

Fig. 5: The ring is completly as-

sembled.

Hexagon nut

Washer

Hexagon bolt

Inside bin

Sealing washer Sealing strip


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The assembly of the first bin ring (seen from above) begins with the taping of the sealing strip on horizontally at the bin ring that is already installed.

The coat plates with 1 mm of thickness are screwed in place displaced half bin

plate. Please do not forget the sealing strips at the screw impact! Fig. 6: Mounting of the top bin ring Before assembly of further rings the supports and the bin roof are installed. 3.5 Support assembly The thick supports are placed closed to the ground, and the thinner are mounted clo-sest to the roof with the corresponding splice plate. Pay attention to the correct direction of the supports when assembling: Top = Bigger distance between holes (Top part of support to first hole = 91 mm) Bottom = Smaller distance between holes (bottom part of support to first hole = 29 mm)


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Fig. 7: Mounting the Supports

Tighten the screws in principle to the nut. Torque of the screws M10 from 35 to 53 Nm.

Only after the assembly of all supports for 2 and/or. 3 ring the screws at the

supports and horizontal screw impacts become firmly tightened. In order to avoid damages, the has to be placed sufficiently square timbers 6 x 10 cm under the supports each time the bin is set on the ground. 3.6 Roof assembly The bin roof is installed onto the first two rings, before further assembly with jacks takes place. 3.6.1 Roof material

NLT Roof ring (Hole ring) Roof segment

Pcs. Roof clip

Pcs. Height H*

(m) 4 24 12 12 2,55 5 30 15 15 2,80 6 18 18 18 3,06

* See next page.

Splice plate

Support

Bin plate

Top

Bin plates

Splice plate

Support


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3.6.2 Assembly instructions

When assembling, three roof segments are placed in star shape and the roof crown ring is centred. Afterwards the remaining segments are inserted. Tighten the screws firmly after the installation of all segments.

Filling nozzel

Roof hood

Screw M10x20 Washer A11 Sealing

Roof ring

3 holes for for mounting roof hood must be made

Leave 7 holes, with the dis-tance of 120 mm, fort he next roof clip free

Between the roof segments there should not be any sealing

Screw M10Washer A11

Screw M10 x 20 Washer All Sealing

Bolting of roof Seal the roof ring and roof segments on side

Center Support

Screw M10 x 20Washer All Sealing


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3.7 Assembly of ladder After that the top two bin rings and the roof are completely installed with roof crown ring and roof vents, the assembly of the ladder follows. Fig. 8: Arrangement of the climbing and final leaders to the silo

The end ladder is pre-mounted (at the bot-tom) with back protection, steps (screws M10 x 20) and ladder mounting plates. The ladder mounting plates are screwed on to the bin wall in such a way that the pre-mounted end ladder is mounted concise with the lower edge of the second ring and the screw connection on a wave mountain.

The two upper ladder brackets of the end

ladder must be drilled (on site) and bolted with the bin and the ladder cross-beam.

Fig. 9: Screw joint on wave mountain

The end ladder has shortened back truss and rises up approx. 80 cm above the eave height.

Extention Ladder

The arrangement of the ladder depends on the position of the roof inspection hatch.

a) The roof and ladder always beside the roof segment, in which the inspection hatch is, however centrically installed in the roof segment.

b) If a roof ladder is installed, then this is to be

installed in extension after the final leaders.

Protection tie bar

Hinged tie bar

Vertical Ladder

End ladder End ladder

Attachment Ladder

Attachment Ladder

Protection tie bar

Hinged tie bar

VerticalLadder


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With progressive assembly of the bin rings the ladder segments are attached

and screwed on to the bin plates. The ladder ends approx. 2.5 m over the foundation.

Fig. 10: End ladder 2520 mm long - complete


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3.8 Assembly of roof ladder Depending upon bin type the roof ladder is made up from connection ladder and if necessary one or several extension ladders in accordance with following table:

It is advisable to pre-install and bolt the ladder steps with the ladder sides when still on the ground.

The support brackets are bolted with the ladder cross-beams and set (lower

edge ladder cross-beam to lower edge support angle = 106 mm) the pre-mounted roof ladder on the silo roof. The roof ladder is pulled so far down that the ladder cross-beams rest against the ladder extensions of the ascent lad-ders. The upper two support brackets are drilled and bolted to the roof.

Now you install the banister post, banister and impact borders to the roof lad-

der. The lower end of the roof ladder is adapted in such a way that the height of the banister ends on the highest protection guard of the end ladder.

Now you drill and bolt the other support brackets with roof and roof ladder.

Subsequently, the ladder extensions of the end and roof ladder with the con-necting metal are bolted. Connect the banister with the protection guard and the knee- and skirting boards with an extension nut M10 as spacer with the ladder extensions of the end ladder.

At the end of the roof ladder the roof ladder brackets are installed. They con-

sists of the following parts: - Banister: a pipe, 620 mm long + two angle clips 90° - Knee and skirting board each: a pipe, 690 mm long + two angle clips 90°

With NLT 3 the roof and/or connection ladder must be shortened on site.

NLT 3 4 5 6 Connection ladder 1250 mm long 1750 mm long 2250 mm long 1500 mm long

1 - - -

- 1 - -

- - 1 -

1 - - 1


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Fig. 11: Arrangement roof lad-der to the vertical ladder; Lower edge roof ladder meas-ured to upper edge roof seg-ment

Fig. 12: Side view roof ladder and safety bracket

Fig. 13: Front view and bird view of roof ladder and safety bracket


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Pos. Description Amount 1 2 3 4 5

Rung Ladder beam 1250 mm Hand-Knee-Foot rail 1345 mm Reinforcement for roof ladder, U50x20x618 mm Banister post 1007 mm

5 2 6 3

4 6 7 8 9

10

Connection plate for roof lad-der, 3x70x150 mm T- clamp 1’’ Pipe clamp Type 155 1’’ Extension nut M10 Angle support roof ladder

2

4 8 4 4

11 12 13 14 15

Hexagon bolt M8 x 55 Hexagon nut M8 Bin-Hexagon bolt M10 Hexagon bolt M10x80 Hexagon bolt M10x50

16 16 46 4 10

Fig. 14: Connection roof ladder 1250 mm long

16 17 18 19 20

Bin- Hexagon bolt M10x20 Bin-DIsc A11 Angle clamp 90° 1’’ Banister bracing 620 mm Knee-Foot rail bracing 690 mm

32 8 6 1 2

Pos. Description Amount

1 2 3 4 5


7 2 6 3

4 6 7 8 9

10

Connection plate for roof lad-der, 3x70x150 mm T- clamp 1’’ Pipe clamp Type 155 1’’ Extension nut, M10 Angle support roof ladder

2

4 8 4 4

11 12 13 14 15

Hexagon bolt M8 x 55 Hexagon nut M8 Bin- Hexagon bolt M10 Hexagon bolt M10x80 Hexagon bolt M10x50

16 16 50 4 10


16 17 18 19 20

Bin- Hexagon bolt M10x20 Bin-Scheibe A11 Angle clamp 90° 1’’ Banister bracing 620 mm Knee-Foot rail bracing 690 mm

36 8 6 1 2


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Rung Ladder beam 2250 mm Hand-Knee-Foot rail 2345 mm Reinforcement for roof ladder U50x20x618 mm Banister post 1007 mm

9 2 6

4

6 6 7 8 9

10

Connection plate for roof ladder, 3x70x150 mm T-clamp 1’’ Pipe clamp Type 155 1’’ Extension nut M10 Angle support roof lad-der

2

6 12 4 6

11 12 13 14 15


24 24 64 4 14

Fig. 16: Connection ladder 2250 mm long

16

17 18 19 20

Bin-Hexagon bolt M10x20 Bin-Disc A11 Angle clamp 90° 1’’ Banister bracing 620 mm Knee-Foot rail bracing 690 mm

46

12 6 1 2

Pos. Description Amount

1 2 3 4 5


6 2 6

3

4 6 7 8 9

10

Connection plate for roof ladder, 3x70x90 mm T- clamp 1’’ Pipe clamp Type 155 1’’ Pipe coupling outside 1’’ Angle support roof lad-der

2

4 8 6 4

11 12 13 14 15


16 16 42 8 34


16 17 18 19

Bin-Disc A11 Angle clamp 90° 1’’ Banister bracing 620 mm Knee and foot rail brac-ing 690 mm

8 6 1 2


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3.9 Assembly of accessories

The NEUERO sign is fastened to the second bin ring. 3.9.1 Roof vents Fig. 18: Roof vents

The opening for the roof exhaust vents (angularly 290 x 290 mm) is to be cut on site into a roof seg-ment. Drill 12 holes in 12 mm Ø, insert sealing tape and bolt the exhaust vent onto the silo roof.

3.9.2 Filling nozzel Fig. 19: Sketch for installing the filling nozzle in the roof hood

3.9.3 Roof inspection hatch Fig. 20: Inspection hatch

1 Attachment sleeve 2 Inspection hatch lid 3 Inspection hatch frame 4 Sealing tape

With bins with roof ladder the roof inspec-tion hatch is installed directly beside it, with bins without roof ladder directly be-fore the ladder.

1. Roof segment 2. Roof vent 3. Attachmwnt frame 4. Sealing tape

Filling nozzle

Roof cover

Hexagon bolt

Disc

Sealing disc


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3.9.4 Safety bracing Fig. 24: Safety cross beam for inspection hatch

b: Drill on site ∅ 12 mm k: Shorten on site


Banister post for safety beam Bracket for safety cross beam Hand-Knee-Foot rail Banister post vertical for roof ladder, reinforcement for roof ladder T- Clamp 1’’

1

3

3 1

5 6 7 8 9

10

Pipe connection 120° 1’’ Boundary chain for safety cross beam Ring nutM10 Connection pipe short Connection pipe long

1 1

2 1 1

11 12

13 14 15

Standard step 800x240 mmAngle support left for Stan-dard step Angle support right Hexagon bolt M10x80 Hexagon bolt M10x55

1 1

1 2 2

Fig. 25: Exploded view of the safety bracing

16 17 18 19 20 21

Hexagon bolt M10x50 Bin- Hexagon bolt M10x20 Bin- Hexagon nut M10 Hexagon bolt M12x25 Hexagon nut M12 Disc A13

4 16 22 4 4 4


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3.10 Placing of the Jacks Before the assembly of the further bin rings can continue, the necessary jacks are set up. Jacks consist of: Jack, clamping chain, winch and hauling cable. How many jacks that are necessary for mounting your bin, please look in the following overview:

NLT 2 3 4 5 6 Amount Jacks

3

3

4

5

6

The jacks are in principle fastened to the supports (see fig. 23 and 24).

Fig. 23: Position of the Jacks

Fig. 24: Mounting of the winch cable

With silos, whose ring number is divisible by 3, the supports are only supplied over 3 rings (2,52m). In this case no supports can be installed and the jacks are fastened to the screw impact (fig. 25 and 27) with a connection plate (fig. 26). Fig. 25: Jacks on screw impact

Fig. 26: Connection plate

Fig. 27: Fastening of jacks to screw impact

Screw impact

Hexagon bolt M12x120

Screw impact


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The jacks must be set up on the same height as the foundation at the bin wall and for safety be bolted to the foundation.

The clamping chain is embodied in the greatest possible distance to the jack

at the soil. Peg the mooring ring on or strike them into the soil.

The bin has to be lifted evenly.


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3.11 Assembly of the following rings

At wind force 6 the errection has to be terminated! Set the bin down on the ground and secure it against shifting and tilting.

With the Jacks the bin roof and the first 2 rings are being lifted approx. 0,85 m.

Fig 28: Schematic representation of lifting

The bin plates of the third ring is shifted half a bin plate length and provided with sealing strips, screwed on from the inside under the second ring.

If no supports could be installed, this is first accomplished between the jacks. Subsequently, you set the silo off and screw the remaining supports on. Now the jacks can be fastened in accordance with section 3.10.

With the jacks the bin can be raised now "pull after pull", in order to install fur-ther rings. These are always attached shifted when looking at the ring installed above. After each third ring the supports for the installed rings are mounted and the jacks are rearranged.

The assembly of the ladder takes place section wise, parallel to the structure of bin.

Before assembly of the latest bin plate the different accessories, like measur-ing connecting pieces, aeration pipes, unloading hatch and inspection hatch into the two last rings.


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3.12 Access hatch Fig. 29: Inspection hatch at 702 mm support dis-tance

The inspection hatch is mounted between the supports. A piece with the size 642 mm has to be cut out

The inspection hatch is mounted

from the inside.

Drill the Bolt holes in the bin pla-te.

Between the inspection hatch

and the bin plate sealing tape is inserted and every thing is bolted together.

Fig. 30: Inspection hatch at 1404 mm distance between support

If the inspection hatch is placed at the end of a bin plate, this has to be shortend with 762 mm. If the hatch has to be installed between the supports, a piece of the size 642 mm has to be cut out.

The inspection hatch is mounted

from the outside.

Drill the bolt holes in the bin plate.

Between the inspection hatch and the bin plate sealing tape is inserted and every thing is bolted together.

Bin plate

Drill on site screw holes (Ø12) in the bin plates

Cut-out in bin plate

Inspection hatch Ø560

Outside Hatch lid Hatch frame

Support Distance 702

Bin plate

Drill on site screw holes (Ø12) in the bin plates

Cut-out in bin plate

Inspection hatch Ø560

Support Distance 1404


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3.13 Assembly of hopper construction 3.13.1 36°-Hopper

NLT Size Y(mm)

2

1370

3 1730 4 2090 5 2450

Fig. 31: Assembly drawing for hopper substructur

Fig. 32: Placing of the hopper segments Fig. 33: Screw connection as in the section

3.5 described

The bin walls are installed completely like already described and raised so far

that the hopper supports can be mounted on the lowest bin ring.

Subsequently, the hopper segments are installed with seal tape and bolted with the unloading hopper.

Before mounting the last hopper segment the aeration cross has to be placed

in the bin.

Inspection hatch Optional

Brackets (on bins with supports

Bin plate

Hopper segment

Support cross beam

Hopper support

Support foot

Hopper segments mount from the in-side and bolt together


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3.13.2 45°-Hopper

NLT Size X (mm)

Size Y (mm)

3

764

2085

4 793 2565 5 710 2925 6 730 3390

Fig. 34: Assembly drawing of the hopper subconstruction

Fig. 35: Placing of the hopper segments Bild 36: Screw connection as in the section

3.5 described

The bin walls are installed completely like already described and raised so far

that the hopper supports can be mounted on the lowest bin ring.

Subsequently, the hopper segments are installed with seal tape and bolted with the unloading hopper.

Before mounting the last hopper segment the aeration cross has to be placed

in the bin.

Inspection hatch Optional

Brackets (on bins with supports

Bin plate

Hopper segment

Support cross beam

Hopper support

Support foot

Hopper segments mount from the in-side and bolt together


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3.14 Aeration construction

The bin aeration nozzle is placed in the shown height in the bottom ring. Seal the aeration nozzle with sealing tape.

The aeration channels are going to be bolted with the support tube to the hop-per sub construction on side. Place the bracket on the aeration channel and the bottom ring.

3.14.1 Aeration construction for NLT 2 and NLT 3 Fig. 37: Aeration system for NLT 2 and 3

Aeration channel with supports

Support pipe

Drill on site

Detail Y

Detail W

Detail X

Aeration nozzle Mount and seal On site

Bracket Right and left

Support frame loose

Bracket Right and left

Bin type Support pipe distance A

NL2 800 mm NL3 600 mm


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3.14.2 Aeration construction for NLT 4, 5 and 6 The ventilation channels with supporting tubes and the ventilation cross are onsite screwed onto the sub construction of the hopper. Please seal the inlet pipe. The mounting plate is screwed on to the ventilation channel and the lowest silo ring.

Fig. 38: Aeration system for NLT 4,5 and 6

Bin type

Support distance

A B

NL 4 832 mm 800 mmNL 5 832 mm 600 mmNL 6 832 mm 600 mm

Aeration channel with support

Detail W

Support pipe

Aeration nozzle Mount and seal On site Detail X

Detail Y

Bracket

Bracket

Pipe angle 90° Size 300

Clamp Size 300

Drill on site


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3.15 Bin anchorage

In the bottom supports the support feet are being inserted, bolt and anchor to the foundation with chemical anchors.

Fig. 39: Drawing of the anchorage

3.16 Gangway At bin plants with gangway and conveyor catwalk a strengthened support rows must be installed for static reasons. The number and arrangement comes out from the planning design and special packing list. Fig. 40: Gangway over singel bin and bin plant

1. Gangway support 2. Center hole bracket 3. Supporting stilts bracket, bottom left 4. Supporting stilts bracket, bottom right 5. Stilts bracket, above 6. Gangway support

Support

Bin plate


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4.0 Accessories 4.1 Ladder Fig. 41: Vertical ladder 2520 mm long – com-plete

Fig. 42: Vertical ladder 1680 mm long – complete

5.0 Maintenance The corrosion protection must be kept sufficiently intact. If rust has developed on parts of a bin, in accordance with DIN 53210 - correspond to strength Ri 4, then sta-bility is no longer ensured.


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6.0 Drawings Fig. 43: Placing of the roof reinforcement


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Fig. 44: Cut-out X from page 29

Fig. 45: Cut-out Y from page 29

7.0 Material requirements NLT Bin-∅

(m) lges (m)

Nr. of rips Length in m

Anglepcs.

Bracketpcs.

Wire (m)

Shackle pcs.

Wire clamp

Swivel

4 3,58 1,737 2 x 1,737

- - 2 - 1 x 4,0

2 6 1

5 4,47 2,250 2 x 1,500

2 x 0,750

- 2 4 1 x 5,0

2 6 1

6 5,36 2,764 2 x 1,500

2 x 1,264

- 2 4 1 x 6,0

2 6 1


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With

Your Partner in the future

NEUERO Farm- und Fördertechnik GmbH Hermann-Unbefunde-Str. 6 - 49324 Melle Postfach 127 - 49302 Melle Telefon: 05422/9440-0 Fax: 05422/9440-40 E-Mail: [email protected] - Internet: www.neuero-farm.de

Assembly and Main- tenance instruction - NEUERO · PDF fileginning of the foundation and...

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Transcript of Assembly and Main- tenance instruction - NEUERO · PDF fileginning of the foundation and...