29843-RKS 6 - GB-preliminary-sept-2020

Operating instructions
-preliminary version
Tubular Drier
RKS 6
BA 29 843
Read the instructions prior to

performing any task!
Name: Ponndorf Anlagenbau GmbH
Leipziger Str. 374
34123 Kassel
Telephone: +49 (0) 561 5114-01
Fax: +49 (0) 561 5114-24
email: info@ponndorf-gmbh.de
Internet: www.ponndorf-gmbh.de
© Ponndorf Anlagenbau GmbH 2020
2 Tubular Drier RKS 6

Tubular Drier RKS 6-preliminary version
Table of contents
Table of contents
1 General .................................................................................... 7
1.1 Information on these instructions ................................... 7
1.2 Explanation of symbols .................................................. 8
1.3 Limitation of liability ...................................................... 10
1.4 Copyright...................................................................... 10
1.5 Declaration of incorporation ......................................... 11
1.6 Customer service ......................................................... 11
2 Safety .................................................................................... 13
2.1 Proper use ................................................................... 13
2.2 Fundamental hazards .................................................. 14
2.2.1 Electrical hazards ......................................... 14
2.2.2 Mechanical hazards ..................................... 15
2.2.3 Hazards from high temperatures .................. 17
2.2.4 Hazards from fire and explosion................... 18
2.3 Responsibility of the owner .......................................... 19
2.4 Staff requirements ....................................................... 20
2.5 Signs ............................................................................ 21
2.5.1 Overview and positions of all signs .............. 22
2.5.2 Prohibitive signs ........................................... 23
2.5.3 Warning signs ............................................... 23
2.6 Personal safety equipment and clothing ...................... 23
2.7 Safety devices.............................................................. 24
2.8 Environmental protection ............................................. 26
3 Technical data ...................................................................... 27

3.1 General information ..................................................... 27
3.2 Dimensions .................................................................. 27
3.3 Specifications ............................................................... 28
3.4 Performance values ..................................................... 28
3.5 Operating conditions .................................................... 29
3.6 Type plate .................................................................... 30
4 Construction and function .................................................. 31

4.1 Overview ...................................................................... 31
4.2 Description of process ................................................. 31
4.3 Assembly description ................................................... 32
4.3.1 Tube bundle.................................................. 32
4.3.2 Drive ............................................................. 32
5 Transportation, packaging and storage ............................ 33
Tubular Drier RKS 6 3

Table of contents
5.1 Safety notes for transportation .....................................33

5.2 Transport inspection.....................................................34
5.3 Symbols on the packaging ...........................................34
5.4 Packaging ....................................................................36
5.5 Transporting .................................................................37
5.6 Storage .........................................................................41
6 Assembly and installation ...................................................42

6.1 Safety for assembly and installation ............................42
6.2 Requirements for the location for installation ...............43
6.3 Erection ........................................................................44
6.4 Installing the fixed bearing and floating bearing ..........46
6.5 Attaching the drive .......................................................47
6.6 Securing the drier to the ground ..................................47
6.7 Installing the steam lines ..............................................48
6.8 Installing the condensation lines ..................................50
6.9 Installing the connection head .....................................51
6.10 Connecting he electrics ................................................52
7 Commissioning ....................................................................53
7.1 Safety for commissioning .............................................53
7.2 Switching on .................................................................53
7.3 Ongoing checks ...........................................................58
7.4 Removal from service ..................................................59
7.5 Shutting down in case of an emergency or fire ............62
8 Maintenance ..........................................................................63
8.1 Safety instructions for maintenance .............................63
8.2 Fault table ....................................................................65
8.3 Maintenance schedule .................................................66
8.4 Lubricating schedule ....................................................68
8.5 Ventilation and drainage of the tubular bundle ............71
8.6 Sealing of tubular bundle .............................................71
8.7 Blading of tubular bundle .............................................72
9 Disassembly and disposal ..................................................73

9.1 Safety instructions for disassembly and disposal ........73
9.2 Dismantling ..................................................................74
9.3 Disposal .......................................................................75
10 Spare part lists .....................................................................77

10.1 Fixed bearing ...............................................................78
10.2 Floating bearing ...........................................................79
10.3 Drive 80

Table of contents
10.4 Steam line .................................................................... 81

10.4.1 Dehydration DN 15 (Steam) ......................... 82
10.4.2 Steam supply ................................................ 83
10.5 Condensation line ........................................................ 85
10.5.1 Condensate .................................................. 86
10.5.2 Dehydrator DN 25 ........................................ 87
11 Index ...................................................................................... 89
12 Appendix ............................................................................... 91

General
1 General
1.1 Information on these instructions
This manual enables you to handle the machine in a safe and efficient
manner. This manual is part of the machine and must be kept in its
vicinity in order to ensure that it is available to the personnel at all
times.
The personnel must have carefully read and understood this manual
before commencing any work. The compliance with all safety infor-
mation and instructions provided in this manual is essential for safe
operation.
Furthermore, all local work protection and general safety regulations
applicable at the machine's place of installation must be observed.
The illustrations used throughout this manual are intended to provide
a general understanding and may deviate from the actual model of the
machine.

General
1.2 Explanation of symbols

safety instructions Safety instructions are marked with symbols in these instructions.
The safety instructions are always introduced by signal words which
express the extent of the danger.
DANGER!
This combination of symbol and signal word indicates an
immediately-dangerous situation which will cause death
or severe injuries if not avoided.
WARNING!
This combination of symbol and signal word indicates a
possibly-dangerous situation which could cause death or
severe injuries if it is not avoided.
CAUTION!
possibly-dangerous situation which could cause slight
injuries if it is not avoided.
NOTICE!
possibly-dangerous situation which could cause property
and environmental damage if it is not avoided.

General
safety instructions in operating Safety instructions can refer to specific, individual instructions. Such
instructions safety instructions are incorporated into the instructions so that they
do not interrupt the flow of reading when carrying out the action. The
signal words described above are used.
Example:
1. Loosen screw.
2.
CAUTION!
Risk of pinching at the lid.
Carefully close the lid.
3. Tighten screw.
tips and recommendations This symbol highlights useful tips and recommendations
as well as information designed to ensure efficient and
smooth operation.
special safety instructions The following symbols are used in the safety instructions to draw at-
tention to specific dangers:
DANGER!
This combination of symbol and signal word indicates an
immediately-dangerous situation due to electric shock. If
an instruction so marked is not heeded, severe or even
fatal injuries can be the consequence.

General
further markings The following markings are used in these instructions for emphasising
instructions for actions, results, lists, cross references and other ele-
ments:
Marking Explanation
1, 2., 3.,… Step-by-step instructions for actions
 Results of action steps
Cross references to sections of these in-

structions and to other valid documentation
Lists without a set order
1.3 Limitation of liability

All details and instructions in these instructions were compiled taking
into account the applicable standards and regulations, the state of
technology, as well as our many years of knowledge and experience.
In the following cases, the manufacturer assumes no liability for dam-
age:
 Failure to follow these instructions
 Use deviating from the proper use
 Use of untrained personnel
 Unauthorised changes
 Technical alterations
 Use of non-approved spare parts
For special models, with the usage of additional order options or due
to the latest technical changes, the actual scope of delivery can devi-
ate from the explanations and depictions provided here.
Applicable are the obligations agreed upon in the delivery contract,
the general terms and conditions, as well as the delivery conditions of
the manufacturer and the legal regulations valid at the time the con-
tract was concluded.
1.4 Copyright
The contents of these instructions are copyrighted. Their use is per-
mitted in the context of using the machine. Any use extending beyond
this is not allowed without written permission from the manufacturer.

General
1.5 Declaration of incorporation

The declaration of incorporation as per Machinery Directive
2006/42/EC is included in the appendix ( Appendix 0 ‘Declaration of
conformity and incorporation’ on page 95).
1.6 Customer service

Our customer service department is available to give technical infor-
mation:
Address Ponndorf Anlagenbau GmbH

Leipziger Str. 374
34123 Kassel
Telephone +49 (0) 561 5114-01
Fax +49 (0) 561 5114-24
e-mail info@ponndorf-gmbh.de
Internet www.ponndorf-gmbh.de
In addition, we are always interested in receiving new information

gathered from usage and which may be valuable with regard to the
improvement of our products.

Safety
2 Safety
This section provides an overview of all safety aspects that are essen-
tial to the best possible protection of the personnel and the safe and
trouble-free operation of the machine. Additional safety instructions for
specific work tasks are contained in the sections regarding the indi-
vidual life stages of the machine.
2.1 Proper use

The machine is used for drying corn flakes at a maximum heating
temperature of 175 °C (saturated steam at 8 bara) at a maximum
operation temperature of 90°C.
Proper use also includes adherence to all the stipulations in these

instructions.
Any use going beyond the proper use or any other type of use is re-
garded as improper use.
WARNING!
Danger in case of improper use!
The following uses of the machine may cause hazardous
situations:
- drying material which does not match the
specification.
- feeding product which are contaminated with plastics
and metals.
- operating with the access flaps, inspection flaps and
trough flaps open.
- cooling materials.
- operating with non-approved spare parts and
accessories.
- operating at media temperatures of more than 175 °C
or pressure levels of more than 8 bar.
- operating with safety devices disabled or
manipulated.
- operating with non-approved constructional changes
or modifications.
- operating the machine in potentially explosive areas
for which it is not engineered.
- climbing on the machine.

Safety
2.2 Fundamental hazards

The following section describes remaining risks which can arise from
the machine even with proper use.
In order to reduce risks of personal injury and property damage and
avoid dangerous situations, the safety instructions listed here and the
safety instructions in the other sections of these instructions must be
followed.
2.2.1 Electrical hazards
electrical current
DANGER!
Risk of fatal injury from electrical current!
In case of contact with live parts on the motor on on an
electrically actuated slider, there is an immediate risk of
fatal injury from electric shock. Damage to the insulation
can be potentially fatal.
- in case of damage to the insulation, switch off the
power supply immediately and have repairs carried
out
- never clean the machine with water in the area of the
motor. Moisture can cause a short circuit
- have work on the electrical components carried out
by qualified electricians only
- before working on the motor, switch off the machine
and secure it to prevent it from being switched back
on

Safety
2.2.2 Mechanical hazards
moving components
DANGER!
Risk of injury from moving parts.
Driven, rotating or linear moving assemblies or parts
may cause serious injuries.
- never reach into moving parts or handle moving parts
during operation
- never open the inspection and maintenance openings
during operation; there are moving parts behind them
- never open the protective covers during operation
- before starting maintenance and repair work, shut off
the energy supply at the master switch for the
respective assembly and secure it to prevent it from
being switched back on
- be aware of the run-on time: before opening
protective covers, inspection and maintenance
openings, make sure that the parts behind them are
no longer moving
- in the danger area you must wear close-fitting work
clothing with a low resistance to tearing
oObjects flying around

WARNING!
Risk of injury from objects flying around.
Objects placed on the rupture disks (e.g. tools) may be
caused to fly around due to pressure waves and may in
turn cause serious injuries.
- do not place any objects on the rupture disks
- do not enter the area above or near to the rupture
disks during operation
- only ever carry out work in the danger area when the
machine is at a standstill

Safety
chain drive
WARNING!
Danger to life due to limbs being drawn in and
trapped by the chain drive!
Running chains and rotating sprockets may draw in
items of clothing and trap body parts, causing serious or
fatal injury.
- do not reach into running chains or sprockets during
operation
- ensure that chain drives are inaccessible during
operation. Do not open covers
- observe the run-on time: Before opening the covers,
make sure that all parts have stopped moving
- when in the danger zone, wear close-fitting protective
work clothing with low tear strength
- before working on chains or sprockets, shut down the
machine and take precautions to prevent accidental
start-up. Wait until all parts have stopped moving
accumulations of liquid
CAUTION!
Danger of injury from slipping in accumulations of
liquid!
Slipping in accumulations of liquid on the floor may result
in a fall. A fall may result in injuries
- remove accumulations of liquid immediately using
appropriate means.
- wear anti-slip safety shoes
- post warnings and mandatory signs at or in the
vicinity of any area where liquid could accumulate on
the floor

Safety
2.2.3 Hazards from high temperatures
Steam jet, hot water, thermal oil

WARNING!
Hazard from highly pressurised hot steam.
Highly pressurised hot steam is used for energy
generation. The sudden expulsion, e.g. from leaks or in
case of careless actuation of valves, can cause serious
scalding injuries.
- any work on the steam circuit must only be carried
out by qualified and trained specialist staff
- never actuate valves or other control devices if you
are not certain of the consequences
- if you discover leaks, immediately inform the
responsible party on site, shut off the steam supply
and stop operation
- nlways wear personal safety equipment and clothing
when in the danger area
hot surfaces
WARNING!
Danger of injury from hot surfaces!
Component surfaces may heat up greatly during
operation. Skin contact with hot surfaces will cause
severe skin burns.
- always wear heat-resistant protective work clothing
and protective gloves as a matter of principle when
working in the vicinity of hot surfaces
- before carrying out any work, make sure that the
surfaces have cooled down to the ambient
temperature

Safety
hot consumables
WARNING!
Danger of injury from hot consumables!
Consumables may reach high temperatures during
operation. Skin contact with hot consumables will cause
severe skin burns.
- always wear heat-resistant protective work clothing
and protective gloves as a matter of principle when
carrying out any work with consumables
- always check whether consumables are hot before
working with them. Allow to cool down if necessary
2.2.4 Hazards from fire and explosion
explosion protection
WARNING!
Risk of explosion and fire.
If there are ignition sources, such as sparks, open
flames and hot surfaces, in the potentially explosive
area, there is a risk of explosion and fire
- only use the plant in potentially explosive areas for
which it is engineered
- only operate the plant within the specifications
stipulated in chapter 3 "Technical data"
- observe and adhere to the valid local organisational
measures and measures for explosion protection
- only carry out any work if a potentially explosive
atmosphere has been ruled out
Failure to adhere to these instructions will cause the loss
of the explosion protection.

Safety
2.3 Responsibility of the owner

owner The term 'owner' refers to the person who himself operates the ma-
chine for trade or commercial purposes, or who surrenders the ma-
chine to a third party for use/application, and who bears the legal
product liability for protecting the user, the personnel or third parties
during the operation.
owner's obligations The machine is used for commercial purposes. The owner of the ma-
chine is, therefore, required to observe his or her obligations with re-
gard to occupational health and safety.
In addition to the safety instructions provided in this manual, the regu-
lations regarding occupational health and safety as well as environ-
mental protection applicable at the machine's place of installation
must be observed.
The following applies in particular:
 The owner must become familiar with all applicable occupational
health and safety regulations and conduct a risk assessment to
establish any additional dangers resulting from the specific working
conditions at the machine's place of installation. The owner must
implement the results of such risk assessment into instructions for
the operation of the machine.
 Throughout the service life of the machine, it must be ensured that
the operating instructions prepared by the owner are in compliance
with the current revision of the applicable regulations and revisions
are made if necessary.
 The owner must clearly define and assign the responsibilities for
installation, operation, troubleshooting, maintenance and cleaning.
 The owner must ensure that all personnel handling the machine
have read and understood this manual. The owner is also required
to train the personnel and inform them about all hazards at regular
intervals.
 The owner must provide the personnel with the required protective
equipment and make wearing this protective equipment
mandatory.
The owner is also responsible for keeping the machine in proper tech-
nical condition. For this purpose, the following must be ensured:
 The owner must ensure that the maintenance intervals specified in
this manual are kept.
 The owner must have all safety devices checked regularly for
completeness and proper operation.

Safety
2.4 Staff requirements
WARNING!
Personnel with insufficient qualifications represent a
hazard!
Insufficiently qualified personnel are not able to assess
the risks when using the machine and expose
themselves and others to the risk of serious or fatal
injuries.
- all work must only be performed by personnel with
the appropriate qualifications
- keep insufficiently qualified personnel away from the
working area
required qualifications Staff for all work must only be made up of personnel who can be ex-
pected to carry out their work reliably. Personnel whose reactions are
affected, e.g. by drugs, alcohol or medication, are not permitted.
The following qualifications are required for all the tasks described in
these instructions:
specialist staff Specialist staff are capable of carrying out the assigned work and
identifying and preventing possible hazards independently due to their
specialist technical training, e.g. as a locksmith, and due to their
knowledge and experience and familiarity with the applicable stand-
ards and regulations.
Specialist staff have been instructed on the tasks assigned and possi-
ble hazards in case of improper conduct in training provided by the
owner.

Safety
qualified electrician All work on the electrical system must only be performed by a quali-
fied electrician. A qualified electrician is capable of carrying out work
on electrical equipment properly and identifying and preventing possi-
ble hazards and avoiding any resultant personal injury and material
damage independently as a result of specialist qualification, know-how
and experience, and knowledge of the applicable standards and
regulations.
For work which goes beyond the tasks described here, contact the
manufacturer. See  Chapter 1.6 ‘Customer service’ on page 11 for
contact details.
Adhere to the specifications of the respective manufacturer with re-
gard to the required qualifications for work on externally supplied
components.
2.5 Signs
The following symbols and instruction signs are affixed in the work
area. These symbols and instruction signs refer to the immediate vi-
cinity in which they are affixed.
WARNING!
Danger due to illegible signage!
Over time, stickers and signs can get dirty or in some
other manner become illegible, so that dangers cannot
be recognized and necessary operating instructions
cannot be followed. Thus an injury hazard occurs.
- keep all safety, warning, and operating instructions
that are affixed to the device in legible condition
- replace damaged signs or stickers immediately

Safety
2.5.1 Overview and positions of all signs
fig. 1: overview and positions of all signs

Safety
2.5.2 Prohibitive signs
No reaching in
Dangers from crushing, shearing, catching or winding, drawing-in or
trapping. Danger spots may not be visible.
2.5.3 Warning signs
Electrical voltage
Only qualified electricians are permitted to work in a work room
marked by this sign.
Unauthorised persons must not enter the workplaces thus marked and
must not open the marked cabinet.
Hot surface
Hot surfaces such as hot machine parts, containers or materials, as
well as hot liquids, may not always be detected. Never touch these
without protective gloves.
2.6 Personal safety equipment and clothing

Personal protective equipment serves to protect people against haz-
ards to their safety and health while working.
The personnel must wear the personal protective equipment while
working on and with the machine which is referred specially to in the
individual sections of these instructions.
The following is an explanation of the personal safety equipment and

clothing.
Always wear the following for all Occupational safety clothing

work:
Occupational safety clothing is close-fitting working clothing with low
resistance to tearing, with close-fitting sleeves and no protruding
parts.

Safety
Protective gloves
The protective gloves are designed to protect the hands and forearms
from contact heat in case of contact with hot components.
Safety shoes
Safety shoes protect the feet from crushing, falling parts and prevent
slipping on a slippery floor.
Items to be worn for special tasks:

Industrial hard hat
Industrial hard hats protect the head from falling objects, swinging
loads and impacts on stationary objects.
2.7 Safety devices
WARNING!
Danger to life from nonfunctional safety devices!
If safety devices are not functioning or are disabled,
there is a danger of grave injury or death.
- check that all safety devices are fully functional and
correctly installed before starting work.
- never disable or bypass safety devices.
- ensure that all safety devices are always accessible.

Safety
The following safety devices are installed:
trough flap safeguard The trough flap safeguard is an inductive limit switch and registers the
position of the trough flaps. If a trough flap is open, the owner's con-
troller must generate a signal and switch off the tube bundle drive
immediately. There are trough flap safeguards on every trough flap.
safety valve The safety valve prevents the heating medium in the line system from
reaching an impermissibly high pressure level. If the operating pres-
sure exceeds the permitted level by 10 %, the safety valve blows off
into the environment.
standstill monitors Standstill monitors monitor the movement or position of an assembly

and have to generate a signal via the owner's controller. There are
standstill monitors in the following positions:
 at the loose bearing of the tubular bundle
PT 100 heat sensor (optional) The thermal element registers the vapour temperature inside the drier.
In case of an increased internal temperature (>100 °C) the owner's
controller must generate a signal and reduce the supply of heating
medium.
The following safety devices have to be retrofitted by the owner.
emergency stop concept The machine needs to be integrated into the owner's own emergency
stop concept (emergency stop, master switch, equipotential bonding).
Discharge and feed organs have to be installed upstream and down-
stream for supplying the wet goods and removing the dry goods. They
must also be integrated into the control system.

Safety
2.8 Environmental protection
NOTICE!
Danger to the environment from incorrect handling
of pollutants!
Incorrect handling of pollutants, particularly incorrect
waste disposal, may cause serious damage to the
environment.
- always observe the instructions below regarding
handling and disposal of pollutants
- take the appropriate actions immediately if pollutants
escape accidentally into the environment. If in doubt,
inform the responsible municipal authorities about the
damage and ask about the appropriate actions to be
taken.
The following pollutants are used:
lubricants Lubricants such as greases and oils contain toxic substances. They
must not be allowed to escape into the environment. Disposal must be
carried out by a specialised disposal company.

Technical data
3 Technical data
3.1 General information
data value unit
weight 12.500 kg
length, approx.. 8.300 mm
width, approx.. 2.000 mm
height, approx.. 3.300 mm
3.2 Dimensions
fig. 2: dimensions (sample picture)

Technical data
3.3 Specifications
data value unit
drier type RKS 6
product to be dried Corn flakes
size <G30
heating surface 150 m²
heating medium Saturated

steam
power consumption, main drive max. 11 kW
water evaporation 600 kg/h
3.4 Performance values

temperatures data value unit
wet product and ambient air 10 °C
vapors (in drier hood = 85 °C

drier Temperature)
dewpoint of vapor 73 °C
saturated steam supply data value unit
thermal capacity 690 kW
saturated steam pressure 9 bar rel.
saturated steam temperature 175 °C
saturated steam consumption ≤ 1100 kg/h
pressure in condensate line ( must be <2 bara

ensured by the operator at site)

Technical data
vapor extraction system and dust data value unit

extraction
volume flow of the vapor ≈ 2200 m³/h
3.5 Operating conditions

environment data value unit
temperature range 5–40 °C
relative air humidity, max. 15–70 %
duration data value unit
maximum continuous operation dura- continuous

tion operation
switch-on pause not required

Technical data
3.6 Type plate

The type plate is situated on the drive side of the upper section
of housing and contains the following data:
 manufacturer (Fig. 3/1)
 designation (Fig. 3/2)
 type (Fig. 3/3)
 works-N° (Fig. 3/4)
 year of construction (Fig.3/5)
 AC-voltage [V] (Fig. 3/6)
fig. 3: type plate (sample)  DC-voltage [V] (Fig. 3/7)
 frequency [Hz] (Fig. 3/8)
 electric power consumption [kW] (Fig. 3/9)
 air supply (p max.) [bar] (Fig. 3/10)
 air consumption (STP) [m3/min] (Fig. 3/11)
 transportation goods [%] (Fig. 3/12)
 max. conveyor capacity [kg/min] (Fig. 3/13)
 total weight [kg] (Fig. 3/14)
 net volume [m3] (Fig. 3/15)

Construction and function
4 Construction and function

4.1 Overview
fig. 4: overview (sample)
1 product inlet 6 vapor exhaust

2 service entry door 7 chain drive
3 product outlet 8 connection head (steam)
4 inspection flap 9 tube bundle (internal)
5 connection head (Condensate)
4.2 Description of process

The Ponndorf drier RKS 6 is an indirectly heater contact drier using a
rotating tube bundle. The heating medium is saturated steam
The tube bundle is driven by a gear motor with downstream chain
drive. The at site feeder system feeds the wet product evenly onto the
rotating bundle. Lifting shovels at the outer side of the tubular bundle
continuously lift the product and let it run thru the rotating bundle to
ensure an even heat distribution. At the same time the product is
moved forward thru the drier by transport shovels. The wet vapour
created by drying the product is sucked out of the drier thru the vapour
exhaust at the top of the drier. The needed fresh air is sucked pas-
sively by the drier itself thru its air inlet.

Construction and function
4.3 Assembly description

4.3.1 Tube bundle
The tube bundle warms up the wet product and causes the contained
water to evaporate.
The tube bundle rotates inside the drier housing and is fed with satu-
rated steam.
The outside of the tubes have physical contact with the product. Dur-
fig. 5: tube bundle ing the heating of the product steam condensates and is moved out of
the bundle thru the condensate removal system.
4.3.2 Drive
The tube bundle is driven by a chain drive and an electric gear motor.
fig. 6: drive

Transportation, packaging and storage
5 Transportation, packaging and storage
Installation and initial commissioning must only be

carried out by employees of the manufacturer or persons
authorised by the manufacturer.
Nevertheless, it may happen in the course of installation
and further use that the owner's operating or
maintenance personnel may be entrusted with handling
pack units. In this regard, it is vital to observe the
instructions listed below.
5.1 Safety notes for transportation

suspended loads
WARNING!
Danger of fatal injury from suspended loads!
During lifting operations, loads may swing out and fall
down. This may result in serious injury or death.
- never step under suspended loads, and do not step
within their pivoting range.
- only move loads under supervision.
- only use approved hoists and lifting gear with a
sufficient load-bearing capacity.
- do not use torn or abraded hoists such as ropes and
straps.
- do not place hoists such as ropes and straps against
sharp edges or corners and do not knot or twist them.
- set the load down when leaving the workplace.

improper transport
NOTICE!
Damage to property due to improper transport!
Transport units may fall or tip over as a result of
improper transport. This can cause a significant level of
property damage.
- proceed carefully when unloading transport units at
delivery and during in-house transport; observe the
symbols and instructions on the packaging.
- only use the attachment points provided.
- only remove the packaging shortly before assembly.
5.2 Transport inspection

On receipt, immediately inspect the delivery for completeness and
transport damage.
Proceed as follows in the event of externally apparent transport dam-
age:
 do not accept the delivery, or only accept it subject to reservation.
 note the extent of the damage on the transport documentation or
the shipper's delivery note.
 initiate complaint procedures.
Issue a complaint in respect of each defect immediately

following detection. Damage compensation claims can
only be asserted within the applicable complaint
deadlines.
5.3 Symbols on the packaging

The individual packages are numbered in accordance with the pack-
ing list.
As well as the numbering, the following symbols may be attached to
the packaging. Always adhere to the symbols when transporting.
protect against moisture

Protect packages against moisture and keep dry.

attach here
Lifting gear (lifting chain, lifting strap) must only be attached to points
bearing this symbol.
fragile
Marks packages with fragile or sensitive contents.
Handle the package with care; do not allow to fall and do not expose
to impacts.
centre of gravity
Marks the centre of gravity of packages.
Note the location of the centre of gravity when lifting and transporting.

5.4 Packaging
about packaging The individual packages are packaged in accordance with anticipated
transport conditions. Only environmentally-friendly materials have
been used in the packaging.
The packaging is intended to protect the individual components from
transport damage, corrosion and other damage prior to assembly.
Therefore do not destroy the packaging and only remove it shortly
before assembly.
handling packaging materials Dispose of packaging material in accordance with the relevant appli-
cable legal requirements and local regulations.
NOTICE!
Danger to the environment due to incorrect disposal!
Packaging materials are valuable raw materials and in
many cases can continue to be used or can be properly
processed and recycled. Incorrect disposal of packaging
materials may pose risks to the environment.
- dispose of packaging materials in accordance with
the environmental regulations.
- observe locally applicable waste disposal regulations.
If necessary, outsource the disposal to a specialist
company.

5.5 Transporting
weights assembly group total
in kg
lower housing section with tube bundle, shovels and tba
bearings (10.000)
upper housing section with front walls tba

(1.500)
accessories and small parts tba

(1.000)
drier, complete tba

(12.500)
NOTICE!
Risk of material damage as a result of incorrect
lifting!
The drier may tip when lifting and be damaged. Single

sided lifting the drier housing leads to damage.
- only ever fasten and transport the drier as described.
- never tilt the drier housing or lay it on its side.
- fasten the drier correctly and make sure that the lifting
harness is tensioned evenly.
- when lifting and setting down, load both sides
evenly and keep the drier housing horizontal.
lifting the machine with a crane The drier is either supplied in one complete piece or in two pieces
depending on its size. If the drier is supplied in one piece, the tube
bundle is lifted inside the drier housing in order to avoid loading the
fixed bearing and floating bearing.

1. To lift with a crane, use a crossbeam.
2. Fasten the lifting belts to the lugs with shackles and make sure
that the lifting belts are of equal length (Fig. 7(1).
3. Carry out further transportation on the floor with transport rollers

(Fig. 7/2).
The complete drier can be lifted either using two cranes or a cross-
beam with the holding lugs on the respective bearing blocks and is
thus placed on the substructure provided by the owner.
fig. 7: transportation using a crane

lifting the machine with two cranes

1. To lift the tube bundle drier with two cranes, fasten the lifting belts
to the lugs on the bearing block with shackles (Fig. 8/1).
2. Lift and set down the drier in a horizontal position.
3. Carry out further transportation on the floor with transport rollers

(Fig. 8/2).
fig. 8: transportation using two cranes
transporting packages with the Packages that have lifting lugs can be transported with a crane under
crane the following conditions:
 Crane and lifting equipment must be configured for the weight of
the packages.
 The operator must be authorized to operate the crane.
fasten protective equipment:  industrial hard hat
1. Attach the ropes, straps or multi-point suspension elements Fig. 9

appropriately.
2. Ensure that the package hangs straight; pay attention to possible

eccentric centre of gravity.
3. Start the transport.
fig. 9: transport with crane
transporting pallets with the forklift transport packages that are attached to pallets can be transported
with a forklift under the following conditions:
 The forklift must be configured appropriately for the weight of the
transport packages.
 The transport package must be securely fastened on the pallet.
 The forklift driver must be authorised to operate floor conveyors
with driver seat or driver stand in accordance with locally
applicable regulations.

transport
1. Drive the forklift with the forks between or under the spars of the
pallets.
2. Drive the forks in so that they protrude on the opposite side.
3. If there is an eccentric centre of gravity, ensure that the pallet

cannot tilt.
4. Lift the pallet with the transport package and start the transport.
fig. 10: transport with the fork lift
transporting pallets by crane Packages for transportation which are fastened to pallets can be
transported by crane under the following conditions:
 The crane and lifting gear have the suitable load bearing capacity
for the weight of the packages for transportation.
 The operator must be authorised to operate the crane.
fastening protective equipment:  industrial hard hat
1. Fasten ropes, belts or a multiple-point harnesses to the pallet as

per Fig. 11 and secure the pallet to prevent it from slipping.
2. Check to make sure that the packages are not damaged by the
fastening equipment. If necessary, use different fastening equip-
ment.
3. Make sure that the pallet cannot topple in case of an off-centre

centre of gravity.
4. Begin transportation.
fig. 11: fastening lifting gear

5.6 Storage
storage of the packages Store the packages under the following conditions:
 do not store outdoors.
 store in dry and dust-free conditions.
 do not expose to aggressive media.
 protect against direct sunlight.
 avoid mechanical shocks.
 storage temperature: 15 to 35 °C.
 relative humidity: max. 60 %.
 if stored for longer than 3 months, regularly check the general
condition of all parts and the packaging. If necessary, top-up or
replace preservatives.
Under certain circumstances, storage instructions may

be affixed to packages which go further than the
requirements specified here. Comply with these
accordingly.

Assembly and installation
6 Assembly and installation

6.1 Safety for assembly and installation
The drier has to be integrated into a plant concept by the owner. For
feeding the wet goods and removing the dry goods, feed and dis-
charge organs have to be installed upstream and downstream respec-
tively.
Assembly and installation can be performed by the

customer. However, it is recommendable to have
assembly and installation performed by employees of
Ponndorf or personnel authorised by Ponndorf only. On
request, the owner's operators or maintenance staff can
become involved under the instruction of the agents and
in accordance with the following instructions.
electrical system
DANGER!
Danger to life from electric power!
Contact with live parts may prove fatal. When switched
on, electric components can be subject to uncontrolled
movements and may cause grave injury or death.
- switch off the power supply before starting work and
make sure that it cannot be switched on again.

improper assembly
WARNING!
and installation
Risk of injury from improper assembly and
installation.
Improper assembly and installation can cause serious
injuries and considerable material damage.
- before starting the work, make sure that there is
sufficient installation space.
- handle exposed, sharp components with care.
- keep the installation area clean and tidy. Loose
components and tools lying around or on top of each
other are a potential source of accidents.
- install components properly. Adhere to the stipulated
tightening torque values for screws.
- secure components to prevent them from falling or
toppling.
6.2 Requirements for the location for installation
WARNING!
Risk of explosion if the potentially explosive area is
unsuitable.
When erecting the machine in an unsuitable area, there
is an acute risk of explosion.
- never use the machine in potentially explosive areas
for which it is not engineered.
location The location for installation of the plant must:

 provide sufficient room on all 4 sides of the machine.
When erecting the machine in a hall, it is

recommendable to install a duct above the rupture disks
leading out of the hall.
Any pressure waves can thus be directed out of the hall.

foundation The floor for erection of the machine must:

 have sufficient load bearing capacity.
 be flat.
erection conditions Erect the machine so that:

 all components are guaranteed to be stable.
 escape routes and emergency equipment are freely accessible.
 the safety of staff is guaranteed.
 there is sufficient lighting.
 all parts of the machine are easily accessible and there is sufficient
space for installation, maintenance and measures for dealing with
faults.
 access is effectively denied to unauthorised personnel.
6.3 Erection
preparations Before starting assembly, check:
 that the local energy supply matches the stipulations in the
technical data.
 that the stipulated erection requirements are met.
 that the local environmentally conditions are compliant.
 that responsibilities for assembly and installation are clearly set
out.
 that all required documents are available.
 that all required tools and aids are complete and in perfect
condition.
 that all local valid safety regulations are adhered to.
erection the drier 1. Fasten the lifting equipment to the lugs on the bearing blocks.
2. Lift the drier and set it down on the substructure provided by the
owner.
3. Use a water level to check whether the drier housing is positioned

horizontally.
4. If necessary, even out any unevenness by shimming with strips of

sheet metal and align the drier housing.
5. Fasten the drier housing to the substructure provided by the

owner.

removing the transport

securing devices
fig. 12: arrangement of the transport securing devices (sample)
binding wire support
1. Remove all marked transport securing devices (Fig. 12).
2. Position the hydraulic lifting device (Fig. 13/3) between the jour-
nal (Fig. 13/4) and the bearing block (Fig. 13/1).
The hydraulic lifting device is no included in the

scope of delivery.
Make sure that the lifting device is suitably
engineered for the load to be lifted (tube bundle).
3. Lift the tube bundle and remove the transport securing devices
(Fig. 13/2) on the side of the floating bearing and fixed bearing.
4. Lower the tube bundle again.
fig. 13: remove the support

6.4 Installing the fixed bearing and floating bearing

The floating bearing and fixed bearing are pre-installed on the journal
of the tube bundle.
fixed bearing
1. Fasten the bearing housing to the bearing blocks using the
clamping sleeve (Fig. 14/1).
2. Tighten the foot screws (Fig. 14/2) on the bearing housing with
790 Nm.
fig. 14: fixed bearing
3. Evenly tighten the threaded pins (Fig. 15/1) with 8 Nm and secure
them with adhesive.
fig. 15: tightening the threaded pins
floating bearing
1. Evenly tighten the threaded pins (Fig. 16/5) with 8 Nm and secure
them with adhesive.
fig. 16: Floating bearing

6.5 Attaching the drive

(subject to be changed!)
1. Position the drive (Fig. 17/3) so that the chain wheels (Fig. 17/1)
align.
2. The clamping block must be fixed to the foundation. It can either

be fixed thru the 4 wholes in the frame, external weld on plates
and at side installed fasteners or anchors.
3. Place the roller chain (Fig. 17/2) over the chain wheels (Fig. 17/1)
and tension it.
4. Attach the safety equipment.
fig. 17: attaching the drives
6.6 Securing the drier to the ground

The drier must be secured to the ground at least at its 4 corners using
appropriate ground fasteners.

6.7 Installing the steam lines

The steam lines are pre-installed in the factory
fig. 18: steam circuit; side view and top view (sample)
1 connection head 4 steam control valve DN65*

2 corrugated pipe 5 steam bypass valve DN15*
3 safety valve 6 steam dehydration
*subject to be changed
NOTICE!
Risk of material damage from line laying.
- lay the lines so that there is no additional pressure on
the hose mount.

WARNING!
Risk of burns from hot surfaces.
Steam lines which are not insulated can cause serious
burns in case of contact.
- The owner must provide the steam lines with heat
insulation.
1. Check the spatial arrangement of the construction components

as per the technical drawing.
2. Connect the steam lines to the supply lines provided by the own-
er.
Adhere to the technical data sheets for the steam lines and fit-
tings.

6.8 Installing the condensation lines

The condensation lines are pre-installed in the factory.
fig. 19: condensation line; side view and top view (sample)
1 connection head 4 condensation separator

2 corrugated pipe 5 non-return valve
3 dirt trap
NOTICE!
Risk of material damage from line laying.
- lay the lines so that there is no additional pressure on
the hose mount.
WARNING!
Risk of burns from hot surfaces.
Condensation lines which are not insulated can cause
serious burns in case of contact.

- The owner must provide the condensation lines with

heat insulation.
1. Check the spatial arrangement of the construction components

as per the technical drawing.
2. Connect the condensation lines to the supply lines provided by

the owner.
Adhere to the technical data sheets for the condensation lines
and fittings.
6.9 Installing the connection head

installing the connection head
This instruction applies the steam inlet (floating bearing side) as well
as for the condensate outlet (drive side).
NOTICE!
Risk of material damage from contamination.
The surfaces must not be smeared with grease, oil or
other lubricants as the residue from these substances
(e.g. resin) does not only have a negative influence on
the slip value but also compromises the sealing effect.
fig. 20: connection head
1. The mounting hole in the shaft extension must be controlled be-

fore beginning the installation. It must be free of dirt and grease.
Place a graphite gasket (Pos. 6 )into the mounting hole of the
shaft extension (Pos. 1).
Insert the spacer(Pos. 5) and the second graphite gasket (Pos. 6)
Push the spitted inner ring (Pos. 3) on the connection pipe of the
head (Pos. 2).
Finally insert the connection pipe of the conection head into the
mounting hole of the shaft extension (Pos. 1) and secure the
flange ring (Pos. 3) with the hex screws (Pos. 4) at the end of the
shaft.
Torque Pos. 4 hex screws M16 MA = 85 Nm

Torque Pos. 4 hex screws e M12 MA = 35 Nm

6.10 Connecting he electrics

The following electrical modules have to be connected to the control
system by a qualified electrician on behalf of the owner in accordance
with the VDE, UVV and local regulations.
 tube bundle drives
 trough flap safeguard (inductive limit switch)
 PT 100 heat sensor
 standstill monitor
 optional: PID-controller for the steam control valve
(circuit: PT100  controller  steam control valve)
1. Compare the data of mains power supply with the technical data
for the machine. Only establish the electrical connection if they
match.
2. Isolate the electrical supply line from the voltage from the mains
supply power provided by the owner.
3. Earth all plant parts (equipotential bonding).
4.
NOTICE!
Risk of material damage due to incorrect
connection.
If the tube bundle has the wrong direction of
rotation, malfunctions and material damage may be
caused.
When connecting the drives, make sure that the motors have the
correct direction of rotation.

Commissioning
7 Commissioning
7.1 Safety for commissioning
improper initial commissioning
WARNING!
Risk of injury due to improper initial commissioning.
Improper initial commissioning can cause serious injuries
and considerable material damage.
- before initial commissioning, make sure that all
installation work has been performed and completed
in accordance with the stipulations and instructions in
these instructions.
- before initial commissioning, make sure that there is
nobody in the danger area.
7.2 Switching on
initial commissioning Before initial commissioning, make sure that the following require-
(conditions for switching on) ments have been met:
 the machine is erected in a horizontal position and is permanently
connected to the foundation.
 all bearings are supplied with lubricating grease. (Some lubricating
grease must ooze out of the side of the bearing).
 contact between the tube bundle and the drier housing is
impossible in both a cold and warm state.
 all fastening screws on the shovel system are tightened and firmly
in place.
 the fittings provided and connected by the owner are connected
correctly and ready for operation.
 the drives are supplied with sufficient oil.
 all the bearing screws are firmly tightened.
 all the safety devices are installed properly.
 all the parts of the machine are earthed and all earthing elements
are connected to the building.
 the direction of rotation of the tube bundle matches the directional
arrow.
 all electrical modules are connected properly.
 on the inside of the machine there are no tools, aids or transport
securing devices.

Commissioning
start-up
WARNING!
Start-up sequence
WARNING!
Damage caused by incorrect heating medium or
unsuitable water vapor composition
The drier must be heated with saturated steam. A

heating with superheated or wet water vapor is not
allowed.
The steam must be suitable for damage-free usage
in pressure equipment made of unalloyed steels.
The required vapor composition must be
guaranteed by the operator.
Among other the following steam properties are
essential to be monitored and set correctly during
the steam conditioning:
 pH value
 oxygen content
 salinity / conductivity
The operator must take certain measures to prevent
damage to the drier during downtimes, see chapter
7.4 "removal from service".
A heating of the drier with other heating media than
saturated steam or improper vapor composition lead
to significant damage to the drier.
WARNING!
Hazard from hot steam
All drain plugs must be screwed back in dense and
tight after a decommissioning:
 2 pieces in the tubular bundle (1 piece per
dished bottom)
 1 piece per condensate separator
All screens must be used again in the dirt trap. Then
tighten strainer densely.
1. Switch on vapor suction plant (and -if installed-dust removal

plant)
WARNING!
No drying operation without continuous vapor
extraction
The drier must not be operated without permanent

Commissioning
running vapor removal plant.

A possible concentration of harmful gases is avoided
through the vapor extraction. Such gases may be
generated when the material to be dried is
decomposed by thermal contact with the tube
bundle (pyrolysis).
In normal operation, the drying vapor removal is
required in order to discharge the water vapor out of
the drier.
2. Switch on the drive motor of the tube bundle and operate at 50

Hz.
The motor of the tube bundle is frequency

adjustable. A frequency of 50 Hz corresponds to a
beam speed of 6 min-1.
3. Heat the tube bundle via the DN 15 steam bypass valve to an

operating temperature of 5 ° C below the setpoint operating tem-
perature.
example:
nominal operating temperature = 85 ° C
heat up to an operating temperature of 80 ° C.
The heating via the steam bypass valve allows a

controlled and steady preheating of the tubular
bundle.
The operating temperature is the temperature of the
air / vapor, which is measured above the tube
bundle next to vapor removal flange.
The nominal operating temperature depends on
amount, type and moisture content of the material to
be dried. It is set during operation such a way that
the desired moisture content is achieved at the
outlet of the drier. The maximum operating values
are to be considered in section 3.
Orientation value for the nominal operating
temperature: 80 ± 10 ° C
4. When reaching an operating temperature of 5 ° C below the set-

point operating steam supply switch:
 close steam bypass valve DN 15
 open steam control valve DN 65 slowly
Nominal operating temperature = 85 ° C
Heat up to an operating temperature of 80 ° C.

Commissioning
The control of the steam control valve can be a PID

controller:
The operating temperature is measured in the drier
hood with a PT100 element, and compared with the
nominal operating temperature of the controller.
The controller adjusts the valve position, to the
desired operating temperature is reached.
The orientation values of PID control are:
Orientierungswerte der PID-Regelung sind:
 proportional coefficient KP = 5
 Reset time TN = 120 s
 derivative time TV= 1,5 s
The values are to be adjusted in the drying operation
such a way that a constant supply of wet product
keeps the desired operating temperature to a
maximum oscillation amplitude of ± 3 ° C.
example:
nominal operating temperature = 85 ° C
actual operating temperature = 82 to 88 ° C
5. Check if a stable operating temperature is reached
It may be advantageous to start the supply of wet

product in the drier before it reaches the desired
operating temperature, to avoid an overshoot of the
temperature.
example:
target operating temperature = 85 ° C;
start of the product supply already at 80 ° C.
The overshoot behavior is largely determined by the

control of the steam control valve, possibly by the
settings of the parameters of the PID controller.
6. Switch on machines for the removal of the dried product
This applies to all machines of the drying system

downstream of the dry product outlet.
7. Switch on wet product supply

upstream of the wet product inlet.

Commissioning
8.
WARNING!
Damage caused by product jam
If product accumulates at a point of the entire drying

system (eg drier or conveyor) immediately reduce or
stop completely the supply of wet product material and
set the drier inoperative if necessary.
Monitor product flow:

 open the inspection flaps on the driers hood carefully and
watch the product flow. Check for any kind of product jams.
 check if the dry product at the outlet of the drier is conveyed
out continuously, so that the risk of product jams is detected
early.
Reasons for a product jam can be:

 failure of the product discharging equipment
downstream of the drier
 procuct infeed to high
 bonding material at the tube bundle
9. If the operating temperature falls more than 10°C below the nom-
inal operating temperature and for longer than 15 minutes after
beginning the wet product infeed, proceed as follows:
 adjust parameters of the PID controller and / or
 increase saturated steam pressure and / or
 reduce material supply and / or
 reduce speed of the tube bundle
The speed of the tube bundle must be more than 2

min-1, because otherwise the product transport is not
guaranteed by the shovels.
The current consumption of the drive motor provides
information on the filling level of the drier.

Commissioning
7.3 Ongoing checks
In normal operation, regular checks by the operating

personnel are necessary to achieve a safe machine
operation and a constant moisture content of the
dried product.
When changes to the operating parameters such as
material feed, speed and temperature are done, a
time period between 30 and 60 minutes must be
taken into account until a steady state operation, ie
constant operating values have been reached
again.
1. regularly check the dried product moisture

If too much moisture:
 increase saturated steam pressure and / or
 reduce wet product infeed
 reduce speed of tubular bundle
2.
WARNING!
Fire hazard due to high operating temperatures
The operating temperature of the drier must not be
higher than 120 ° C for security reasons,.
When operating at temperatures of more than 120 ° C
can be observed:
 completely shut off the steam supply
 keep operating all other machines
Check whether an operating temperature less than 120 ° C is

maintained
3.
WARNING!
Damage caused by product jam
If product accumulates at a point of the entire drying

system (eg drier or conveyor) immediately reduce or
stop completely the supply of wet product material and
set the drier inoperative if necessary.
Monitor product flow:

 Open the inspection flaps on the driers hood carefully and
watch the product flow. Check for any kind of product jams.
 Check if the dry product at the outlet of the drier is conveyed
out continuously, so that the risk of product jams is detected
early.

Commissioning
7.4 Removal from service
WARNING!
Order of the decommissioning
The entire drying system is to be shut down in the
direction of material flow, that is, of taking "front to
back". This means in particular that material feeding
machine first and material laxative machine must be
switched off last.
CAUTION
Corrosion damage caused by oxygen during
downtime
Each decommissioning, in which the tube bundle
and the steam valves of the drier will not be
completely drained immediately after reaching
standstill, requires the addition of a corrosion
protection agent to preclude damage by oxygen
corrosion during downtime of the drier.
The operator must implement a corresponding
oxygen corrosion protection agent to the steam in
the steam treatment. Recommendations for
appropriate corrosion protection agents are
available from the manufacturer of the vapor
preparation plant.
1. Close all the valves of the steam supply

 control valve DN 65
 steam bypass valve DN 15
2. Stop the supply of wet product about 5 to 10 minutes after closing

the steam valves
After the closure of the steam valve, the stored

thermal energy of the drier is still large enough to
dry the remaining amount of wet product to the
desired moisture.
The best time for stopping the product feed is to be
determined in practice.
3. Continue to operate the drive motor of the tube bundle until no

more product is conveyed out of the drier
4. Switch off dry product conveyors when they do not contain any
material anymore.

Commissioning

downstream of the dry product outlet..
5. Only switch off the drive of the tube bundle, if the operating tem-
perature is less than 50 ° C.
ATTENTION!
damage caused by early switch off the tube
bundle drive
To avoid damage caused by thermo-mechanical
stresses on the tube bundle, the drive motor may
only be turned off when the operating temperature
is less than 50 ° C.
6. Switch off vapor suction plant as last machine in the chain
The vapor suction unit must then be kept in

operation until the interior of the drier and the dust
removal plant (if appl.) are completely dry.
7.
CAUTION!
Damage caused by freezing water
At ambient temperatures <5 ° C, the tube bundle
and all steam fittings must be completely drained
immediately after the decommissioning to avoid
frost damage.
CAUTION!
Damage caused by corrosion
For a downtime of the drier for more than 5 days the
tube bundle and all steam fittings must be
completely drained immediately after the
decommissioning to prevent corrosion damage.
DANGER!
Danger to life by working inside of the drier
Before performing any work in the drier the tube
bundle must be secured against rotation. The shaft
of the drive motor must be fixed and he drive motor
must be protected against switching on.
We recommend hiring a specialist of the company
Ponndorf Anlagenbau GmbH for work inside of the
drier.
Under no circumstances may persons be in the drier
when the tube bundle can not be secured against
rotation reliably.

Commissioning
Proceed to drain the tube bundle as follows:

 Allow tube bundle to cool to ambient temperature
 Open flaps at the trough of the drier, so that water can
drain freely.
Caution: After removing the drain plug from the tube bun-
dle several thousand liters of water can stream down!
on the front side of the condensate discharge:
 open entry door and remove security grid
 Turn tube bundle in position until the drain plug is accessi-
ble from above.
 Remove the drain plug from the dished bottom
on the front side of the steam supply:
fig. 21: entry door condensate side  open entry door and remove security grid
 Turn tube bundle by 180 degrees until the drain plug is ac-
cessible from above.
 Remove the drain plug from the dished bottom
 let water drain completely from the tube bundle
 screw back into the bundle just in time before commission-
ing so that the tube bundle can dry out
Proceed to drainage of the steam and condensate valves as fol-
lows:
 open strainer, remove the screens and clean
 keep steam supply valves closed, open all other valves
fig. 22: drain plug  unscrew plug of the condensate drain
 close valves again after complete dehydration, but no later
than prior to re-starting the drier
fig. 23: entry door steam side

Commissioning
7.5 Shutting down in case of an emergency or fire

In dangerous situations, the movements of components have to be
stopped and the energy supply has to be shut off as quickly as possi-
ble.
Shutting down in case of an Proceed as follows in the event of an emergency or fire:

emergency or fire
1. Immediately trigger an emergency stop with an emergency stop
device.
2. Continue to operate the vapour extraction system.
3. Open the fresh air flap.
4. Activate manual extinguishing.
5. If there is no risk to health, remove personnel from the danger

zone.
6. Administer first aid as necessary.
7. Alert the fire services and/or emergency services.
8. Inform the responsible party at the location of use.
9. Clear access routes for emergency vehicles.
10. Direct emergency vehicles.
After emergency measures 11. If the gravity of the emergency requires it, inform the respective
authorities.
12. Instruct specialist staff to clear the fault.
WARNING!
Risk of fatal injury if the system is switched back on
without authorisation or in an uncontrolled manner!
If the machine is switched on without authorisation or in
an uncontrolled manner, serious or even fatal injuries
may be caused.
- Before switching on, make sure that all safety devices
are fitted and fully functional and that there are no
hazards for personnel.
13. Check the machine before re-commissioning and make sure that
all safety devices are installed and fully functional.

Maintenance
8 Maintenance
8.1 Safety instructions for maintenance
electrical system
DANGER!
on, electric components may be subject to uncontrolled
movements and may cause grave injury.
- switch off the power supply before starting work and
make sure that it cannot be switched on again.
moving parts
WARNING!
Danger of injury from moving parts!
Rotating parts and/or parts moving in linear fashion may
cause serious injuries.
- before carrying out any maintenance work on moving
parts, shut down the machine and take precautions to
prevent restarting. Wait until all parts have stopped
moving.
- when in the danger zone, wear close-fitting protective
work clothing with low tear strength.

Maintenance
improperly performed
WARNING!
maintenance work
Risk of injury from improperly performed
maintenance work.
Improper maintenance can cause serious injuries and
considerable material damage.
- before starting the work, make sure that there is
sufficient installation space.
- before starting the work, make sure that the work
space sufficient lighting.
If necessary, use a headlamp for work inside the
machine.
- keep the installation area clean and tidy. Loose
components and tools lying around or on top of each
other are a potential source of accidents.
- if components are removed, make sure that they are
installed properly, re-install all fastening elements and
use the correct tightening torque values for screws.
- adhere to the following before re-commissioning:
- make sure that all maintenance work has been
performed and completed in accordance with the
stipulations and instructions in these instructions.
- make sure that there is nobody in the danger area.
- make sure that all covers and safety devices are
install and are working properly.
environmental protection Observe the following environmental protection instructions during

maintenance work:
 in respect of all lubrication points supplied manually with lubricant,
remove any escaping, used or surplus grease and dispose of in
accordance with applicable local regulations.
 catch replaced oils in suitable containers and dispose of in
accordance with applicable local regulations.

Maintenance
8.2 Fault table
fault description cause remedy
temperature in drier too supply of wet product reduce or shut off steam supply
high stopped and tube bun-
dle continues to be
heated.
heat build-up in the check the complete vapour extraction and dust
drier due to reduced or extraction system at the set intervals so that no
insufficient vapour larger caking forms.
extraction.
final humidity of the dry drier temperature (ex- increase steam pressure to maximum allowed
product too high haust vapour) too low. pressure.
reduce wet product input.
dwelling time for the check the speed of the tube bundle and, if nec-
wet goods too short. essary, reduce it to 4 rpm. Check whether the
vapours are visibly extracted and whether the
fresh air supply is sufficient
supply of wet product reduce the supply of wet product

too high.
the fresh air supply is clean air inlet

too low.
final humidity of the dry dwelling time for the increase the speed of the tube bundle to a max-
product too low. wet goods too long. imum of 6.8 rpm.
initial humidity of the increase the supply of wet product as long there
wet product too low. is no product jam building up in the drier.
steam pressure to high reduce steam pressure of the bundle
failure of supply of wet feeder broken immediately stop the drier heating by shutting
product. feeder jammed closing steam valves.
drive not rotating. power failure. continue to operate t drier using an emergency
power supply.
tube bundle not rotating. drive chain broken shut off steam supply. Open trough flaps to al-
low material to fall out of the drier.
material blockage at the failure of discharge If the material blockage cannot be cleared im-
dry product outlet. assemblies mediately, immediately shut off the supply of
wet product and the drier heating. At the same

Maintenance
fault description cause remedy

time open all trough flaps so that the material
can fall out of the drier.
material blockage at the supply of wet goods reduce the supply of wet goods using the rotary
wet product inlet. too high. feeder.
current consumption of supply of wet goods reduce the supply of wet goods using the rotary
the drives too high. too high. feeder.
condensation build-up. faulty valve. replace faulty valve.
contamination in the check the condensation separator and the pipe-

line or in the condensa- line system for contamination and clean as nec-
tion separator. essary.
condensate pressure to lower condensat pressure, for example by by

high, that fore to low lowering the pressure of the feeding water res-
pressure difference at ervoir
the condensation sepa-
rator.
Installing bigger Condensate line
motor protection triggered motor protection set check the electrical fuse protection of the motor.
or the rotor blocked in incorrectly.
operation.
product contains for- remove foreign bodies,
eign bodies, causing monitor product for foreign bodies
high power conump-
tions and even block-
ages
bearing broken replace bearing
8.3 Maintenance schedule

The following table describes the maintenance work required for opti-
mum and fault-free operation of the machine. If you identify increased
wear during regular checks, you must reduce the length of the re-
quired maintenance intervals to match the actual signs of wear. In
case of questions regarding maintenance work and intervals, contact
the manufacturer (see service address on page 2).

Maintenance
maintenance assembly group task

interval
daily tube bundle carry out a listening check on the drier housing to check
the lifting and conveyor shovels on the tube bundle for
scratching noises.
pipeline system visually inspect the steam and condensation lines to

check for contamination and remove any dust which has
settled.
housing visually inspect the drier and bearing housing to check for
contamination and remove any dust which has settled.
bearings remove any used grease.
1x weekly after drives re-tighten the tensioning screws for the gear unit on the
commissioning for 5 drive console.
weeks
weekly vapour extraction check the owner's vapour extraction unit for deposits of
system dust. Clean as necessary.
bearings carry out a hearing check on the floating bearing and

fixed bearing to check for running noises.
monthly drives check the chain drive for the gear unit on the tube bundle
drive for damage and replace as necessary.
pipeline system check the connection fittings for leaks, replace seal as
necessary.
housing carry out a visual inspection of the inside via the inspec-
tion flaps to check for soiling and damage.
tube bundle carry out a visual inspection of the tube bundle via the
inspection flaps to check for soiling and damage.
every 6 months flaps check all flaps for leaks.
tube bundle check the fastening screws on the conveyor shovels by

opening the inspection openings and re-tighten them as
necessary.

Maintenance
8.4 Lubricating schedule

The following tables describe the lubrication work (re-application of
lubricant and application of fresh lubricant) required for optimum and
fault-free operation of the machine. All the rolling bearings on the drier
are lubricated in the factory before assembly so that they are ready for
operation. The fixed bearing has to be re-lubricated when the bearing
has reached its operating temperature and is running.
drier and fittings
fig. 24: lubricating schedule for the drier

Maintenance
number lubrication point lubrication interval lubricant quantity of

lubricant
1 transmission type drive supplied by customer /
see manual of drive
2 rolling bearings drive supplied by customer /

on the motor see manual of drive
3 fixed bearing re-application of lubricant: Chevron Re-fill

floating bearing every 150operating hours SRJ 2
application of fresh lubricant:
every 3000 operating hours
4 chain drive every 500 operating hours Lubricant oil or spray or brush
Shell Darina 2 on

Maintenance
table of lubricants The following table lists the lubricants supplied by other manufacturers
which have the equivalent quality of the lubricants specified in the
lubricating schedule. These lubricants can be used alternatively.
If the lubricants below are mixed, you may cause structural damage.
You can ignore the mixing problem if the bearings:
 are washed out and then greased with fresh lubricant.
 are re-greased with the new lubricant until the fresh grease is
expelled from the bearing.
specification
as per
lubricating
schedule
SHELL gear oil Spartan Mobilgear BP Energol Degol
OMALA oil 220 EP 220 630 GR-XP 220 BG 220
SHELL-Alvania Esso Mobilux BP Ener- Aralub

grease R 3 multi- EP 2 grease LS HL 3
purpose 3
grease
BEACON
2
SHELL-Fett Darina 2 UNIREX BP Ener- Chevron Petamoghy

N3 grease SRJ 2 133 N
HTB 2
All lubrications: Subject to be changed

Maintenance
8.5 Ventilation and drainage of the tubular bundle

For ventilation and drainage of the tubular bun-
dle, there are sockets with threaded plugs weld-
ed into the elliptical bottom plates. These con-
nections are accessible through flaps in the front
wall.
For venting the tubular bundle, unscrew the plug

in the socket until air can escape through the
transverse hole.
fig. 25: ventilation plug
To drain the bundle, the plugs are to be removed

completely.
8.6 Sealing of tubular bundle
Thoroughly clean flanges. Minimal notches or dents on the

seat surfaces do not need to be reworked, as STA-
TOTHERM adjusts itself to the unevenness.
Fix seal to the surface.
The use of usual commercial adhesives such as UHU or

EPPLE 22 as fitting aid is permitted. The seals are set to-
gether by segments; the joints must be covered with the
STATOTHERM-LEAVES supplied ( See sketch ).
The joints become invisible when the screws are tightened.
1 sealing 2 hex screw

Adjust mate flange accordingly, evenly tighten screws
3 disk 4 nut crosswise.
5 head piece 6 pipe plate
fig. 26: Sealing

Maintenance
8.7 Blading of tubular bundle
fig. 27: blading
The paddles are arranged in a standard position by the manufacturer.

In case that it seems necessary to adjust individual paddles when com-
missioning the drier, it is essential that the fuses of the drive motor are
removed in order to prevent the bundle from unintentional rotation.
The space between paddles and the housing bottom should be approx.
25 mm.
The oblong holes on the paddles allow an adequate adjustment.

Disassembly and disposal
9 Disassembly and disposal

Once the machine has reached the end of its useful life, it must be
disassembled and disposed of appropriately.
Dismantling must only be carried out by employees of

the manufacturer.
WARNING!
Danger to life from incorrect dismantling!
Errors during dismantling can result in potentially fatal
situations or may cause significant damage to property.
- Only allow dismantling to be be carried out by
employees of the manufacturer
- Also consult the manufacturer in the case of
subsequent location changes.
- Desist from unauthorised dismantling and location
changes.
9.1 Safety instructions for disassembly and disposal

Electrical system
DANGER!
on, electric components may be subject to uncontrolled
movements and may cause grave injury.
- Before starting the dismantling, switch off the electric
power supply and disconnect completely.

Improper dismantling
WARNING!
Danger of injury due to improper dismantling!
Stored residual energy, angular components, points and
edges on or in the machine or on the tools needed can
cause injuries.
- Ensure sufficient space before starting work.
- Handle exposed, sharp-edged components with care.
- Pay attention to orderliness and cleanliness in the
workplace! Loosely stacked or scattered components
and tools could cause accidents.
- Dismantle the components properly. Note that some
components may have a high intrinsic weight. Use
hoists if necessary.
- Secure components so that they cannot fall down or
topple over.
- Consult the manufacturer if in doubt.
9.2 Dismantling
Before starting dismantling:
 shut down the machine and secure to prevent restarting.
 physically disconnect the power supply from the machine;
discharge stored residual energy.
 remove consumables, auxiliary materials and other processing
materials and dispose of in accordance with the environmental
regulations.
Then clean assemblies and parts properly and dismantle in compli-
ance with applicable local occupational safety and environmental pro-
tection regulations.

9.3 Disposal
If no return or disposal agreement has been made, send the disman-
tled components for recycling.
 scrap metals.
 send plastic elements for recycling.
 sort and dispose of other components in accordance with their
material composition.
NOTICE!
Danger to the environment due to incorrect disposal!
Incorrect disposal may pose risks to the environment.
- electrical scrap, electronic components, lubricants
and other auxiliary materials must be disposed of by
authorised specialist companies.
- If in doubt, obtain information about disposal in
accordance with the environmental regulations from
the local municipal authorities or specialised waste
disposal companies.

Spare part lists
10 Spare part lists
WARNING!
Danger of injury due to use of incorrect spare parts!
The use of incorrect or defective spare parts can lead to
personal injury, material damage, malfunction or total
failure.
- use only original manufacturer's spare parts or spare
parts that have been approved of by the
manufacturer.
- always contact the manufacturer if in doubt.
Loss of warranty
The manufacturer's warranty will be rendered null and
void if spare parts are used that are not approved.
Spare parts must be procured through an authorised dealer or directly

from the manufacturer. Contact details, see page 2.
The spare parts list can be found in the Appendix.
When ordering a spare part, always specify the type, the

year of manufacture and the factory number of the
machine and the list number of the assembly. Refer to
the type plate for the type, year of manufacture and
factory number. The list number precedes every spare
part list.

Spare part lists
10.1 Fixed bearing
fig. 28: components of the fixed bearing
listing.: 2/10692b (subject to be changed!)
item number designation short description/

no. additional information
1 1 lower housing section GG 51 280
2 1 upper housing section GG 51 280
3 1 cylinder roller bearing SL 05 036 EC551B
4 1 support disk Ø 200/180– 30 thick
5 1 adjusting ring Ø 250/180 -32 thick
6 3 threaded pin M20x40
7 6 threaded pin M8 x 30
8 1 support disk Ø 220/180– 30 thick

Spare part lists
10.2 Floating bearing
fig. 29: components of the floating bearing
list no.: 2/10691b (subject to be changed!)
item no. number designation short description/

additional information
1 1 lower housing section GG 51 280
2 1 upper housing section GG 51 280
3 1 cylinder roller bearing SL 06 036E
4 1 support disk Ø200/180 30 thick
5 2 adjusting ring Ø250/180, 32 thick
6 3 threaded pin M 20 x 40
7 3 threaded pin M8 x 30
8 1 support disk Ø200/180 30 thick

Spare part lists
10.3 Drive
fig. 30: components of the drives
list no.: 2/12180 (subject to be changed!)

1 2 SEW spur gear motor R 137 DV132M4 TF V – 7,5 kW, n2 = 19 U/min, 400 V, 50
HzM1, IP 55 – supplied by customer
2 2 chain wheel, 17 teeth pitch44,45, DIN 8187, bore ø 90 mm H7 with groove as per
DIN hub length 100 symm. St 52-3
3 2 chain wheel, 60 teeth pitch 44,45, DIN 8187, bore ø 175 mm H7

with groove 36 x 8.4 hub length 120 symm.
St 52-3
4 1 clamping block St 37-2 -1/10527
5 2 high-performance pitch 44,45 - DIN 8187 length each approx. 3850

roller chain
6 2 closing link, straight pitch 44,45
7 1 closing link, offset pitch 44,45

Spare part lists
10.4 Steam line
fig. 31: components of the steam line

1 1 Maier Connection head HW 165 K-400
2 1 Dehydration DN 15 (Steam) 3/5836
3 1 Steam supply DN 65 2/12178

Spare part lists
10.4.1 Dehydration DN 15 (Steam)
fig. 32: dehydration DN 15 (steam)

additional
information
1 1 manual shutoff valve DN 15
2 1 dirt trap DN 15
3 1 condensate trap DN 15
4 4 Seal Ø 60/22x2 Sigraflex

Spare part lists
10.4.2 Steam supply
fig. 33: steam supply
list no: 2/12178 (subject to be changed!)

additional
information
1 1 pressure gauge Ø160 0-16bar
4 1 safety valve DN25/40

Spare part lists
7 1 seal Ø 92/49x2 Sigraflex
25 1 hose DN 65, 650lg Rattay
30 1 dirt trap DN 65
31 1 shut off valve DN 65
32 1 steam control valve DN 65
33 1 steam bypass valve DN 15

Spare part lists
10.5 Condensation line
fig. 34: components of the condensation line
list no: 2/12176 (subject to be changed!)

additional information
1 1 condensator 2/12175
4 1 metal hose DN 50, 900 lg Rattay
5 1 Maier connection head HW 150K-400

Spare part lists
10.5.1 Condensate
fig. 35: condensate

additional
information
1 2 manaul shut off valve DN 40
2 1 dirt trap DN 40
3 1 condensat trap DN 40
4 1 no return flap DN 40
12 1 manaul shut off valve DN 15
26 1 dehydrator DN 25 3/5775

Spare part lists
10.5.2 Dehydrator DN 25
fig. 36: dehydratorg DN 25
lst no: 3/5775 (subject to be changed!)

additional
information
7 1 manual shut off valve DN 25
8 1 starting valve AK 45 DN 25

Index
11 Index
A L
Antriebe Lifting lugs ...........................................................39
anbauen .......................................................... 47 Loads ..................................................................33

Location for installation .......................................43
C Lubricating schedule ...........................................68
Connecting he electrics ...................................... 52
Contact ............................................................... 11 M
Copyright ............................................................ 10 Maintenance schedule ........................................66
D O
Dismantling ......................................................... 74 Output values ..........................................27, 28, 29
Disposal .............................................................. 75 Overview .............................................................31
Drives .................................................................. 32 Owner .................................................................19
attaching.......................................................... 47 P
E Packaging .....................................................33, 36
Electrical current ................................................. 14 Proper use ..........................................................13
Emergency ......................................................... 62 Protective equipment ..........................................23
Emergency measures......................................... 62 Q
Emergency stop .................................................. 62 Qualification ........................................................20
Environmental protection
Lubricants ....................................................... 26 R
Remaining risks ..................................................14
F
Fault table ........................................................... 65 S
Safety devices ....................................................24
H Service ................................................................11
Hazards .............................................................. 14 Signs ...................................................................21
I Spare parts .........................................................77
Improper use ...................................................... 13 Staff.....................................................................20
Inspection at delivery .......................................... 34 Storage .........................................................33, 41
Installing the condensation lines ........................ 50 Symbols
Installing the connection head ............................ 51 in the instructions .............................................. 8
Installing the fixed bearing .................................. 46 in the work station ...........................................21
Installing the floating bearing .............................. 46 T

Installing the steam lines .................................... 48 Transport ............................................................33

Index
Crane ...............................................................39 Tube bundle ....................................................... 32

Pallets ..............................................................39
U
Transportation
Use ..................................................................... 13
Pallets ..............................................................40

Appendix
12 Appendix

Appendix

Appendix
Documents in the appendix
Declaration of conformity/incorporation
Training report
Supplier documentation

Declaration of conformity and incorporation
Declaration of conformity and incorporation


Training report
Training report
date name type of training training provided signature
by


In addition to these operating instructions, the following separately
supplied documentation for externally supplied parts also applies.
component manufacturer's
designation
manual shut off Gestra
valve
dirt trap Gestra
condensate trap Gestra
non return valve Gestra
rhombus Gestra
safety valve Leser
probes IFM
G1501 IFM
connection head Maier
drive SEW Eurodrive
controller Trovis Samson
probe Samson
valve Schubert und

Salzer
positioner Schubert und

Salzer
pressure switch SGV

29843-RKS 6 - GB-preliminary-sept-2020

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Operating instructions

Read the instructions prior to

© Ponndorf Anlagenbau GmbH 2020

2 Tubular Drier RKS 6

3 Technical data ...................................................................... 27

4 Construction and function .................................................. 31

5 Transportation, packaging and storage ............................ 33

Tubular Drier RKS 6 3

5.1 Safety notes for transportation .....................................33

6 Assembly and installation ...................................................42

9 Disassembly and disposal ..................................................73

10 Spare part lists .....................................................................77

4 Tubular Drier RKS 6

10.4 Steam line .................................................................... 81

Tubular Drier RKS 6 5

Tubular Drier RKS 6 7

1.2 Explanation of symbols

8 Tubular Drier RKS 6

Carefully close the lid.

Tubular Drier RKS 6 9

 Results of action steps

Cross references to sections of these in-

Lists without a set order

1.3 Limitation of liability

10 Tubular Drier RKS 6

1.5 Declaration of incorporation

1.6 Customer service

Address Ponndorf Anlagenbau GmbH

Telephone +49 (0) 561 5114-01

Fax +49 (0) 561 5114-24

In addition, we are always interested in receiving new information

Tubular Drier RKS 6 11

2.1 Proper use

Proper use also includes adherence to all the stipulations in these

Tubular Drier RKS 6 13

2.2 Fundamental hazards

2.2.1 Electrical hazards

14 Tubular Drier RKS 6

2.2.2 Mechanical hazards

oObjects flying around

Tubular Drier RKS 6 15

16 Tubular Drier RKS 6

2.2.3 Hazards from high temperatures

Steam jet, hot water, thermal oil

Tubular Drier RKS 6 17

2.2.4 Hazards from fire and explosion

18 Tubular Drier RKS 6

2.3 Responsibility of the owner

Tubular Drier RKS 6 19

2.4 Staff requirements

20 Tubular Drier RKS 6

Tubular Drier RKS 6 21

2.5.1 Overview and positions of all signs

fig. 1: overview and positions of all signs

22 Tubular Drier RKS 6

2.5.2 Prohibitive signs

2.5.3 Warning signs

2.6 Personal safety equipment and clothing

The following is an explanation of the personal safety equipment and

Always wear the following for all Occupational safety clothing

Tubular Drier RKS 6 23

Items to be worn for special tasks:

2.7 Safety devices