OPERATING INSTRUCTIONS
(DDW-) DDSR XX
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Device variant:
(DDW-) DDSR xx
1.0
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Original
Operating instructions
e2132453
453
rev.3.2
20-11-13
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Brabender Technologie GmbH & Co. KG
© 2020, Brabender Technologie GmbH & Co. KG
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the event of contraventions, compensation for damages will be claimed. All rights reserved with regard
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2
Safety
©Operating instructions (DDW-) DDSR xx
Table of contents
Imprint.............................................................................................................................................. 2
1.
Safety ......................................................................................................................................... 7
Use of the device................................................................................................................................... 8
Intended purpose........................................................................................................................... 8
Appropriate products..................................................................................................................... 8
Suitable operating environment .................................................................................................... 9
Component groups necessary for the operation ........................................................................... 9
Component groups for weighing ................................................................................................... 9
Safety instructions............................................................................................................................... 10
Specifications for the operation of the device............................................................................. 10
Qualification of the operating personnel .................................................................................... 11
Sharp-edged components ............................................................................................................ 11
Earthing of the device .................................................................................................................. 11
Dangerous contact voltages on the device .................................................................................. 11
Definition: Disconnection of the device ................................................................................... 12
Discharge of energy reservoirs .................................................................................................... 12
Sound level ................................................................................................................................... 12
Markings on the device ................................................................................................................ 13
Residual dangers ................................................................................................................................. 14
Foreign objects in the product zone ............................................................................................ 14
Product jam .................................................................................................................................. 14
Product change ............................................................................................................................ 14
Insufficient aeration/deaeration.................................................................................................. 15
Optional quick release fastenings ................................................................................................ 15
2.
The description of the device .................................................................................................... 16
Description of the device design ......................................................................................................... 17
The modules of the device .................................................................................................................. 19
The feeding device .............................................................................................................................. 20
The screw drive motor ................................................................................................................. 20
Speed monitoring......................................................................................................................... 21
The feeding screw ........................................................................................................................ 21
The vertical outlet ........................................................................................................................ 21
The trough agitator ...................................................................................................................... 22
The gear ....................................................................................................................................... 22
Shaft sealing for DDSR40, 30........................................................................................................ 23
Shaft sealing for DDSR40B, 60 ..................................................................................................... 23
The hopper .......................................................................................................................................... 24
Execution and function ................................................................................................................ 24
©Operating instructions (DDW-) DDSR xx
Safety
3
Design of protective function ...................................................................................................... 24
Hopper fastening ......................................................................................................................... 24
Monitoring of the hopper ............................................................................................................ 24
Hopper lid .................................................................................................................................... 25
Protective grid .............................................................................................................................. 25
The weighing system ........................................................................................................................... 26
Use of a weighing system ............................................................................................................ 26
Protective equipment of the weighing system ............................................................................ 27
Technical data ..................................................................................................................................... 28
Suitable operating environment .................................................................................................. 28
Feeding device ............................................................................................................................. 28
Tightening torques of transport catch ......................................................................................... 28
Indications on the nameplate ...................................................................................................... 28
3.
Transport, delivery ................................................................................................................... 29
The place of the installation ................................................................................................................ 30
Transport to the place of the installation .................................................................................... 30
Characteristics of the place of the installation ............................................................................ 30
Equipment of the place of the installation .................................................................................. 30
The storage.......................................................................................................................................... 31
Storage conditions ....................................................................................................................... 31
Storage preparations ................................................................................................................... 31
4.
Mounting ................................................................................................................................. 32
Mounting instructions ......................................................................................................................... 33
Auxiliaries for mounting............................................................................................................... 33
Interruption of assembly ............................................................................................................. 33
Mounting work .................................................................................................................................... 34
Specifications for the assembly execution................................................................................... 34
The installation of the device ....................................................................................................... 34
Flexible connection of the inlet ................................................................................................... 35
Connection of aeration/deaeration ............................................................................................. 35
Electrical mounting ............................................................................................................................. 36
Junction boxes ............................................................................................................................. 36
Metallic cable glands.................................................................................................................... 36
Construction of a locking chain .................................................................................................... 37
Connection plans ......................................................................................................................... 37
Volumetric operation ................................................................................................................... 38
Connection of separate agitator motor ....................................................................................... 39
5.
Commissioning ......................................................................................................................... 40
Notice for commissioning ................................................................................................................... 41
Active product feeding ................................................................................................................. 41
Interruption of commissioning .................................................................................................... 41
Commissioning of the device .............................................................................................................. 42
Step 1:
Tests on the device ..................................................................................................... 42
4
Safety
©Operating instructions (DDW-) DDSR xx
Step 2:
Connection of supply media ....................................................................................... 42
Step 3:
Verification of the sense of rotation .......................................................................... 42
Test and adjustment of the weighing system ..................................................................................... 43
Step 4:
Loosen the transport catch ........................................................................................ 43
Step 5:
Check the free motion ................................................................................................ 43
Step 6:
Check the lever factor................................................................................................ 44
Step 7:
Check the function...................................................................................................... 44
Commissioning of the feeder .............................................................................................................. 45
Step 8:
Refill the hopper ......................................................................................................... 45
Step 9:
Test the feeding operation ......................................................................................... 46
Step 10: Fix the feed rate manually .......................................................................................... 46
Step 11: Determine the feed rate automatically ...................................................................... 47
Step 12: Inspection of the feeding device ................................................................................ 47
Step 13: Modifications .............................................................................................................. 48
Step 14: Terminate commissioning .......................................................................................... 48
6.
The operation of the device ...................................................................................................... 49
The volumetric feeding operation ...................................................................................................... 50
Description ................................................................................................................................... 50
Volumetric product feeding process............................................................................................ 50
The gravimetric feeding operation ..................................................................................................... 51
Description ................................................................................................................................... 51
Prerequisite for gravimetric product feeding .............................................................................. 51
Gravimetric product feeding process .......................................................................................... 51
7.
Maintenance ............................................................................................................................ 52
Preparation for maintenance .............................................................................................................. 53
Discharge the device .................................................................................................................... 53
Switch off the device for maintenance work ............................................................................... 53
Protection of the maintenance works ......................................................................................... 54
Recommissioning after maintenance work ................................................................................. 54
Care and inspection............................................................................................................................. 55
Removal of defects ...................................................................................................................... 55
Marking of the time intervals ...................................................................................................... 55
Care work ..................................................................................................................................... 55
Control of the device ................................................................................................................... 56
Control of the shaft sealings ........................................................................................................ 56
Damaged shaft sealings ............................................................................................................... 57
Activities ....................................................................................................................................... 57
Overview of the components .............................................................................................................. 58
Assembly/disassembly of the feeding screw ...................................................................................... 62
Disassembly of the screw............................................................................................................. 62
Assembly of the screw ................................................................................................................. 63
Vertical outlet with screw bearing ............................................................................................... 63
Assembly/disassembly of the agitator ................................................................................................ 64
©Operating instructions (DDW-) DDSR xx
Safety
5
Disassembly of the agitator ......................................................................................................... 64
Cover as front plate ..................................................................................................................... 65
Assembly of the agitator .............................................................................................................. 65
Exchange of the shaft sealings ............................................................................................................ 66
Exchange of shaft sealings ........................................................................................................... 66
Adjustment of the speed monitoring.................................................................................................. 67
Adjustment of speed monitoring without visual contact ........................................................... 67
Visual adjustment of the speed monitoring ................................................................................ 67
8.
Cleaning ................................................................................................................................... 68
Specifications for cleaning .................................................................................................................. 69
Design of the cleaning process .................................................................................................... 69
Cleaning place .............................................................................................................................. 69
Specifications for cleaning agents................................................................................................ 69
Cleaning processes .............................................................................................................................. 70
Matrix cleaning processes............................................................................................................ 70
Dry cleaning ................................................................................................................................. 70
Controlled wet cleaning ............................................................................................................... 71
Wet cleaning (COP) ...................................................................................................................... 71
9.
Troubleshooting ....................................................................................................................... 72
Causes of malfunctions ....................................................................................................................... 73
10. Decommissioning ..................................................................................................................... 75
11. Storage and disposal ................................................................................................................. 76
Storage of the device, of individual components ............................................................................... 77
Storage process ............................................................................................................................ 77
Storage conditions ....................................................................................................................... 77
Disposal of the device, of individual components .............................................................................. 78
Disposal process........................................................................................................................... 78
Disposal ........................................................................................................................................ 78
Index .............................................................................................................................................. 79
6
Safety
©Operating instructions (DDW-) DDSR xx
1. Safety
This chapter describes the use of the device and the safety instructions for the use of the device.
Content of the chapter “safety”:
Subject
Use of the device
Safety instructions
Residual danger
©Operating instructions (DDW-) DDSR xx
Page
8
10
14
Safety
7
Use of the device
Intended purpose
The “DDSR xx“ is a metering feeder for the feeding of bulk solids that can be fed by means of a twin
screw (feeding module) and a trough agitator. The product is filled into the hopper, from there it is
conveyed into the agitator trough, where an agitator rotates vertically to provide a better filling ratio of
the screw. The rotating screw transports the product to the outlet of the device from where it falls
freely into the downstream equipment. The screw is driven by a drive motor (= feed drive) that is
controlled by means of a suitable drive controller. The working point of the device, the feed rate (=
product quantity/unit of time) is adjusted by means of the determination of the speed of the feed drive.
The trough agitator is driven by the 2nd drive motor of the device and during the feeding operation it
runs with a constant speed in the standard version.
Appropriate products
An appropriate product for the operation of the device must have the following product characteristics:
•
•
•
•
•
•
•
•
8
Bulk product, no liquid
Suitable size of product particles
Appropriate flow characteristics
Free from contaminations, foreign bodies etc.
There is no ignition capability due to friction or strokes.
No explosive characteristics
No change of the product characteristics due to
- any feeding operation of a screw feeder
- any operation of an agitator
No inadmissibly high wear of the machine parts in contact with the product.
Safety
©Operating instructions (DDW-) DDSR xx
Use of the device, continuation
Suitable operating environment
Temperature:
0°C to +45°C
Humidity:
Medium:
up to 85% without condensation
Air or inert gas
Wind/draught:
Max. overpressure/underpressure:
Product temperature:
Protection class:
Voltage supply:
< 0.3 m/s
2 mbar (20mm water column)
0°C to +60°C
IP65
AC 230/400V
Component groups necessary for the operation
The following electrical groups are required for the following control functions (minimum requirement):
•
•
Start/stop of the operation of the device
Determination of the working point of the device (= speed setting)
Component groups for weighing
For the weighing operation the feeder requires other or additional assemblies:
•
•
An additional evaluation unit is required, if the weighing is employed as filling level monitoring
(“MS- …“).
A feeding controller type Congrav® or a system with comparable functions is required for the
operation of a loss-in-weight feeder (“DDW-…”).
©Operating instructions (DDW-) DDSR xx
Safety
9
Safety instructions
Specifications for the operation of the device
General specifications for the permissible operation of the device:
•
•
•
•
•
•
The indications on the operating instruction have been complied with.
Mounting and commissioning have been carried out correctly.
The device must only be used for its intended purpose.
The device is maintained regularly.
For necessary repairs original spare parts of the manufacturer or spare parts with identical technical
characteristics have to be employed (has to be enabled by the manufacturer).
Modifications of the device for varying or changed operating conditions require the approval of the
manufacturer as far as the limits of feasibility and the correct execution are concerned. The use of
the released modification is allowed, if
- the operating conditions taken into account for the release are prevailing.
- the modification is carried out correctly.
Special specifications for the operation of a screw:
•
•
•
•
A screw must only be operated with a mounted screw pipe. A freely rotating screw has considerable
potential for injury.
A screw must only be operated with a screw pipe with appropriate dimensions. Any inappropriate
combination screw-screw pipe may cause operational failures and damage to the device.
The combination screw-screw pipe must only be employed for suitable product. If you employ some
inappropriate product (e.g. too large grain size) this might cause operational failures and damage to
the device.
If the screw is not filled with product the screw must only be operated with low speed. A higher
speed might lead to radial deflections of the screw and cause damage to the device.
Special specifications for the operation of an agitator:
•
10
The agitator has to be started in feeding operation because an inactive agitator
- hinders the free product flow.
- causes an uneven filling ratio of the feeding module.
Safety
©Operating instructions (DDW-) DDSR xx
Safety instructions, continuation
Qualification of the operating personnel
The following qualifications are required for the operating personnel:
•
•
•
•
Trained on the device and its operation
Authorised to carry out the required operations
Knowledge of the regulations concerning the operator protection
Knowledge of the actual operating conditions as far as the device and its environment are concerned
Sharp-edged components
The device contains components that are sharp-edged or that get sharp edges due to wear. There is a
risk of injuries (cut injuries) even if the drive motor is off. These are in particular
•
•
the vertically rotating agitator and
the feeding screw.
Earthing of the device
The device must only be operated with a correct earthing. The main earth connection point is connected
to the equipotential bonding on site in a standard-compliant manner. Earth connections between the
device and assembled components that have been mounted in our works must not be interrupted or
removed on site.
Dangerous contact voltages on the device
Dangerous contact voltages are required for the operation of the device. The following specifications
have to be respected for the protection of the operating personnel:
•
•
•
•
The device must not be operated with freely accessible terminals.
Before you start any work on the electrical connections, you must first disconnect the device from
the mains.
The device must not be operated with damaged electrical components.
Damaged component groups have to be repaired or exchanged immediately.
©Operating instructions (DDW-) DDSR xx
Safety
11
Safety instructions, continuation
Definition: Disconnection of the device
In the operating instructions below use the term "disconnection". “Disconnection” means:
•
•
•
Disconnect the device from all supply media.
Protection against unauthorised reconnection.
Discharge all kinds of energy stocks (manually or due to sufficient dwell times).
Discharge of energy reservoirs
Depending on the execution, different energy reservoirs are mounted to the device. The table lists the
energy reservoir types, the potential risk and the discharge measure.
Type
Component (example)
Electric
Condenser, coil
Mechanic
Pneumatic
Thermic
Spring
Compressed air line
Dissipator, surface
Danger
Electric shock
Mobile component
Mobile component
Mobile component
Burns
Discharge
Observe the discharge time
Relieving
Deaeration
Observe the cooling time
Sound level
The sound level of the device is < 70dB (acc. to DIN45635)
12
Safety
©Operating instructions (DDW-) DDSR xx
Safety instructions, continuation
Markings on the device
Depending on the corresponding execution of the device and the corresponding operating conditions,
sources of danger on the device are marked by the corresponding standardised warning symbols.
In general, the following markings are on the device:
Main earthing point
The marked earthing screw is connected to the earthing potential on site.
Disconnection
Before the start of any work the device has to be disconnected from the mains and
protected against unauthorised reconnection.
In case of non-respect there is a considerable danger of injuries caused by active
component groups and dangerous voltages.
Allowed sense of rotation
Marks the allowed sense of rotation for the corresponding drive motor.
In case of a wrong sense of rotation the rotating component groups risk to be torn out of
their fastening during the operation.
Sharp-edged agitator
•
•
The operation of a freely accessible agitator is not allowed.
Never put hands or arms into a rotating agitator.
»
WARNING! Danger of injuries caused by an idling agitator
Wear long shaft gloves.
©Operating instructions (DDW-) DDSR xx
Safety
13
Residual dangers
Foreign objects in the product zone
Effects:
•
•
Operational failures
Damage of the device
Measures:
»
»
»
Employ clean product
Circumspection/special care must be taken when working on the device
If foreign bodies entered the device
- Immediately stop and lock the operation of the device.
- Eliminate the foreign bodies from the product zone.
- Inspect the device for possible damage and repair any damage, if necessary.
Product jam
Effects
•
•
Operational failures
Damage of the device
Measures
»
»
The free product flow into the device and out of the device has to be guaranteed.
Stop the operation of the device if connected equipment on site is troubled.
Product change
Effects
•
•
Operational failures
Damage of the device
Measures
»
»
»
Operation only with approved products
Management of product/device equipment
Required modification has to be carried out properly
14
Safety
©Operating instructions (DDW-) DDSR xx
Residual dangers, continuation
Insufficient aeration/deaeration
Effects
•
•
•
The product discharge (feeding) causes a negative pressure in the hopper.
Product supply (refilling) causes an overpressure in the hopper.
Pressure loads may cause operational failures or damage of the device.
Measures
»
»
The device must only be operated with an adequate aeration.
Cleaning intervals of ventilation filter units have to be adjusted to the degree of
contamination.
Stop the operation of the device if connected equipment on site (e.g. vacuum
systems) is disturbed.
»
Optional quick release fastenings
When using quick release fastenings for the fastening of a component the position of this component
has to be monitored by a safety switch, if the disassembly/the opening of the component causes a
hazard for the operating personnel by opening of the component (e.g. by freely rotating components).
During the disassembly/opening of the component the operating release of the device is locked by
means of the safety switch (electric interlocking chain) and thus prevents the hazard. The safety switch
detects/monitors
•
•
the allowed mounting position of the component,
but not the correct mounting of the connection.
Danger:
Effects:
Measures:
Wrong understanding of security of the operating personnel
Improper use
Train the operating personnel. Quick release fastenings always have to be mounted
correctly. I.e.:
• tighten with sufficient attraction force.
• always tighten completely (all connections).
©Operating instructions (DDW-) DDSR xx
Safety
15
2. The description of the device
This chapter describes the construction and the individual component groups of the device.
Content of the chapter “The description of the device“:
Subject
Description of the device design
The modules of the device
The feeding device
The hopper
The weighing system
Technical data
16
The description of the device
Page
17
19
20
24
26
28
©Operating instructions (DDW-) DDSR xx
Description of the device design
The figure shows the structure of the DDSR40 with the following markings:
No.
1
2
3
4
5
6
7
8
9
10
11
Meaning
Hopper cover
a Inlet pipe
Hopper
Agitator drive motor
Screw drive motor
Twin-shaft gearing
Base plate
Vibration isolation mounting pads
Downstream connection point
Flexible connection (here: step bellow)
Screw pipe with vertical outlet
Twin screw
12
Agitator (one-piece)
©Operating instructions (DDW-) DDSR xx
b
Vent pipe
The description of the device
17
Description of the device design, continuation
The figure shows the structure of the DDSR60 without hopper with the following markings:
No.
1
2
3
4
5
6
7
8
9
10
Meaning
Agitator drive motor
Screw drive motor
Cover toothed coupling
Twin-shaft gearing
Screw pipe
Vertical outlet
Front screw bearing
Cover vertical outlet
Twin screw
Cleaning hole
11
12
Agitator (two-piece)
Agitator trough
18
The description of the device
©Operating instructions (DDW-) DDSR xx
The modules of the device
The device design is modular and consists of
•
•
•
the feeding device (1) feeds the product.
the hopper (2) permits to store the product to be fed.
the weighing system (3), if the device is weighed (executions
“DDW-“ or “MS-“).
The figure shows only one possible execution of the individual
modules. The actual execution is determined by
•
•
•
the type of device (e.g. DDSR40, DDSR60),
the execution of the module (e.g. construction size/design),
the requirements of the corresponding operating conditions.
The individual modules are described in the following chapters.
©Operating instructions (DDW-) DDSR xx
The description of the device
19
The feeding device
No.
1
2
3
Standard
Screw drive motor (three-phase current)
Speed monitoring (proximity switch)
Screw
4
5
Screw pipe
Vertical outlet
6
7
8
Agitator trough
Agitator
Agitator drive motor (three-phase current)
The screw drive motor
The drive motor is a three-phase current drive that is operated via a drive controller (frequency
converter). The adjustment of the motor/drive controller to the field of application is made in our works
by means of the parameterisation of the drive controller.
The working point of the device is adjusted via the determination of the operating speed (= default
speed) of the drive motor. The speed specification is a function of the execution of the drive controller
and is made by means of an analogue or serial control signal.
20
The description of the device
©Operating instructions (DDW-) DDSR xx
The feeding device, continuation
Speed monitoring
The speed monitoring is an inductive proximity switch that scans a pulse generator mounted on the
drive shaft. The pulses of the proximity switch are evaluated by a suitable electrical unit. The speed
monitoring has the function to monitor the specified limit values, minimum and maximum speed.
NOTICE!
Observe the execution!
always available
optional
loss-in-weight feeder (“DDW-“), ATEX-execution
other variation with three-phase motor
The feeding screw
The feeding screw “twin screw“ type is driven by the drive motor via a twin-shaft gearing. The rotating
movement of the twin screw generates a product feed that conveys the product out of the agitator
trough (6) to the end of the screw pipe.
•
•
•
Feeding screw and screw pipe are a matched combination.
The dimensioning of the combination determines the field of application and operation of the
feeding device.
The working point (the feed rate) is determined via the default speed value.
The vertical outlet
The vertical outlet as termination of the screw pipe
•
•
is a safety device.
prevents anyone from reaching into the rotating screw.
NOTICE!
With an execution that is not equipped with a vertical outlet the protection has to be
achieved by the connection/installation on site (e.g. safety distance).
©Operating instructions (DDW-) DDSR xx
The description of the device
21
The feeding device, continuation
The trough agitator
For an improved and more even filling ratio of the feeding module an agitator that is rotating vertically
runs in the agitator trough. The agitator is driven by a separate drive motor with a constant speed.
NOTICE! Operation with a frequency converter
As a special design the speed of the drive motor is controlled by a drive controller. The adjustment of
the motor to the drive controller and the field of application is made by means of the parameterisation
of the drive controller. The selected adjustment of the operating speed
•
•
does not endanger the operational safety of the device.
fulfils the operating function (improvement of the filling ratio of the screw) of the agitator.
The gear
The drive shafts of the twin screw are driven by the drive motor via a twin-shaft gearing. The
transmission of the gear determines the working range of the device and is part of the dimensioning of
the device. The gear features lifetime lubrication and a mounting flange connects the gear to the screw
trough where the twin screw operates.
22
The description of the device
©Operating instructions (DDW-) DDSR xx
The feeding device, continuation
Shaft sealing for DDSR40, 30
Feeding devices with a construction size ≤ “40“ (e.g. DDSR40) have
•
•
a twin-shaft gearing (1) that is connected to the trough via the sealing plate (2).
a separate bearing block for the bearing/sealing of the agitator drive shaft on the trough.
The sealings are structured as follows
•
•
Both radial packing rings (3) are used in the sealing plate for
the drive shafts of the screws.
In case of a leaking shaft sealing product leaks out via the
product outlet openings (4).
One radial packing ring in the separate bearing block (basic
structure see size > “40“).
Shaft sealing for DDSR40B, 60
Feeding devices with a construction size > “40“ (e.g. DDSR 60) have a
common bearing block for the bearing/sealing of the agitator drive shafts
and the screw drive shafts.
No. Description
1
Agitator shaft sealing
2
Screw shaft sealing
Control zones for product deposits:
A=
B=
©Operating instructions (DDW-) DDSR xx
leaking agitator shaft sealing
leaking screw shaft sealings
The description of the device
23
The hopper
Execution and function
•
•
•
Product storage for feeding
Protective equipment against intervention into rotating component groups
Operating conditions determine the hopper dimensioning, e.g.:
- the required storage quantity
- connection possibilities on the upstream equipment for product supply and deaeration on site
Design of protective function
The protective function is obtained by different measures (combinations are possible):
•
•
•
the construction size of the hopper
a mounted safety grid
a safe screwing of the hopper or the hopper cover.
Hopper fastening
•
•
•
The hopper is screwed to the agitator trough.
Sealing material is employed between both components.
The sealing is obtained by an appropriate tapering force.
Monitoring of the hopper
For a hopper fastening that can be loosened without auxiliaries (e.g. clamping fasteners):
•
•
The position of the hopper is monitored by means of a magnetic field sensor or similar.
The integration of the sensor signal into the electrical interlocking chain for the operating release of
the device.
The sensor does not monitor the hopper fastening.
» The fastening always has to be mounted correctly.
24
The description of the device
©Operating instructions (DDW-) DDSR xx
The hopper, continuation
Hopper lid
•
•
Protection against foreign objects
The refill method determines the execution
Refill method
Manual refilling
Carried out by
operating personal
Execution of the lid
• removable or foldable
Automatic refilling
feeding controller
•
•
•
•
fixed mounting
connecting branch for the product supply
connecting branch for the ventilation
sealing via the flexible connection to the
equipment on site
Protective grid
The hopper is equipped with a protective grid, if
•
•
the hopper cover is not screwed tightly (e.g. loose and/or flap function) and
the construction size of the hopper cannot prevent from reaching into rotating components.
CAUTION! The protective grid does not replace a hopper cover (= protection against foreign
bodies)
» The device must only be operated with a closed hopper cover.
©Operating instructions (DDW-) DDSR xx
The description of the device
25
The weighing system
The illustration shows the design of a possible weighing system (here: DLS)
No.
1
2
3
A
Description
Transport catch
Hood (protection of load cell)
Vibration isolation mounting pads
mounted transport catch
No.
4
5
6
B
Description
Downstream connection point
Flexible connection (step bellow)
Vertical outlet
loosened transport catch*
*push the front transport catch forward, rotate the transport catch through 180°.
Use of a weighing system
Device executions with a weighing system (= weighing) are:
•
•
the execution as loss-in-weight feeder (DDW-….)
the monitoring of the hopper filling level (MS-…)
The weighing system senses the actual weight of the device and sends it as an electrical weighing signal
to a connected evaluation. The product weight is computed from the difference (actual weight – empty
weight of the device).
The type of the weighing system is determined by the load cell employed.
Type
MD x, DLS x
Load cell
digital load cell
MS x
H1_, H3_
analogue load cell
(x = construction size, weighing range)
NOTICE! Please observe the separate description of the weighing system!
26
The description of the device
(x = construction size, weighing range)
©Operating instructions (DDW-) DDSR xx
The weighing system, continuation
Protective equipment of the weighing system
Transport catch
The transport catch forms a strong mechanical connection between the base plate of the device and the
mounting plate of the weighing system. It protects the weighing system from unallowed loading and
torsions.
Execution
Use
Fastening
•
•
•
•
Loosening
•
Red metal elements (number/shape depend on the design of the device)
Always fix or loosen all elements completely.
Are kept within reach of the place of use of the device.
Before the start of the
- transport of the device
- storage of the device
- maintenance/repair work
Before the start of the feeding operation
Overload protection screw (if available)
Limits the freedom of movement of the load cell and is adjusted in our works.
©Operating instructions (DDW-) DDSR xx
The description of the device
27
Technical data
Suitable operating environment
Temperature:
0°C to +45°C
Humidity:
Medium:
up to 85% without condensation
Air or inert gas
Wind/draught:
Max. overpressure/underpressure:
Product temperature:
Protection class:
Voltage supply:
< 0.3 m/s
2 mbar (20mm water column)
0°C to +60°C
IP65
AC 230/400V
Feeding device
Sound level:
Feeding module:
Gear:
< 70dB(A)
Twin screw
Lifetime lubrication
Screw
Agitator
Drive:
Drive controller:
Three-phase motor
Frequency converter
Three-phase motor
Optional
Speed monitoring:
Scanning distance:
Pulse scanning r
d = 1 mm
-
Operating range:
2% - 99% x nominal speed
Nominal speed (= standard)
Tightening torques of transport catch
Screw M6:
Screw M8:
8 Nm
20 Nm
Indications on the nameplate
Marking of the device:
Support requests require:
28
Device type, machine number, year of construction
Type of device, machine number
The description of the device
©Operating instructions (DDW-) DDSR xx
3. Transport, delivery
This chapter describes the specifications for the place of the installation of the device or the storage
after delivery.
Content of the chapter “Transport, delivery“:
Subject
The place of the installation
The storage
©Operating instructions (DDW-) DDSR xx
Page
30
31
Transport, delivery
29
The place of the installation
Transport to the place of the installation
Suitable lifting equipment (fork lift truck, crane, etc.) permits to transport the following items to the
place of the installation.
CAUTION!
#
The device is to be transported suspended.
• Danger caused by inadmissible fixing of the carrying aid (belts etc.)
• Risk of tipping during lifting/transport
»
»
»
Fix the carrying aid to the transport eyelets (if available).
Avoid causing any damage with the carrying aids.
Observe the centre of gravity of the assembly.
Characteristics of the place of the installation
The place of the installation has the following characteristics:
•
•
•
•
•
•
corresponds to the valid standards
stable, dry, free from vibrations and sufficiently suitable to take weight
protected against weather conditions
permissible ambient temperature
free from oils, fats, gases, vapours etc.
no explosive atmosphere
Equipment of the place of the installation
The place of the installation is equipped as follows:
•
•
•
sufficient illumination
sufficiently dimensioned for all necessary workflow paths
possibilities for connecting the required supply media
30
Transport, delivery
©Operating instructions (DDW-) DDSR xx
The storage
Storage conditions
Storage conditions for the storage of the device or of individual assemblies:
Temperature:
+10°C to +40°C
Humidity:
Medium:
40% to 70% no standing moisture
air
Storage room:
weather-proof, enclosed building
suitably ventilated
clean, possibly free from dust
free from UV light, ozone, chemicals, solvents
suitable packaging box, provide spacers under the cover (air
circulation)
Packaging:
Storage preparations
For a delivered device:
•
Put down the device at the storage place with a suitable packaging.
For a device after decommissioning:
•
Store the device according to the chapter “Storage“.
©Operating instructions (DDW-) DDSR xx
Transport, delivery
31
4. Mounting
This chapter describes the mounting work required to make the system ready for operation.
NOTICE!
The descriptions were formulated in a very general manner and only take into account the
standard assemblies of the manufacturer.
Content of the chapter “Mounting”:
Subject
Mounting instructions
Mounting work
Electrical mounting
32
Page
33
34
36
Mounting
©Operating instructions (DDW-) DDSR xx
Mounting instructions
WARNING!
Connection work has to be carried out with active supply media.
• Danger caused by dangerous life voltage
• Danger caused by uncontrolled actions during the connection of the supply medium
»
»
All connection points have to be disconnected by the corresponding supply medium.
Supply media must only be connected after completion and checking of the work (see “commissioning“).
Auxiliaries for mounting
The following auxiliaries are required for mounting:
Work equipment
Auxiliary equipment:
General locksmith’s tools, level
General electrician’s tools
Lining sheets
Cover tarpaulin, cleaning rags, suitable detergents
Interruption of assembly
In case of an assembly interruption the following measures have to be taken:
•
•
•
•
Close opened component groups of the device.
Protect the device against foreign bodies.
Mark that the device is partly mounted.
Protect the device against an unauthorised commissioning.
©Operating instructions (DDW-) DDSR xx
Mounting
33
Mounting work
Specifications for the assembly execution
In general, the following requirements apply to the assembly execution:
•
•
•
Horizontal alignment
Max. 2mm offset for the connection of the device to equipment on site
The connections to the equipment on site have to be carried out in a flexible manner between a
fixed point on site and a fixed point on the device. The description of the connection of the inlet
shows the principle of the flexible connection.
NOTICE!
For a secure product flow in and out of the device the following dimensioning of the line
cross-sections on site is allowed:
Connection of the inlet
Connection of the outlet
Line cross-section on site
≤ Inlet cross-section (e.g. inlet pipe hopper)
≥ Outlet cross-section (e.g. vertical outlet)
The installation of the device
Assembly of the device at the place of the installation:
1.
2.
3.
4.
Transport the device to the place of the installation.
Align the device at the place of the installation.
Align the device in horizontal position.
Screw the device to the floor construction.
NOTICE! Mounting frame with adjustable feet
This execution permits to adjust the 4 feet individually with an appropriate wrench. The adjustment has
to be executed in such a manner that
•
•
34
a horizontal alignment is given.
all 4 feet have a safe contact with the base construction.
Mounting
©Operating instructions (DDW-) DDSR xx
Mounting work, continuation
Flexible connection of the inlet
NOTICE!
Requires a corresponding execution of the hopper/cover.
The materials for a flexible connection are delivered with the device. The assembly has to be carried out
as follows:
1.
2.
3.
4.
5.
Slide the step bellow (3) over the connecting branch (5).
Fix the step bellow by means of tightening strap (4).
Slide the tightening strap (2) over the step bellow.
Slide the step bellow over line (1).
Fix the step bellow by means of tightening strap (2).
Assembly process for other flexible connections
Carry out the assembly according to the process described.
Connection of aeration/deaeration
The assembly of the aeration/deaeration equipment is a function of the corresponding execution.
Please find below the activities for the standard executions:
Standard
Vent pipe + delivered filter bag
• Fix the filter bag to the vent pipe by means of the tightening strap.
Available option of the manufacturer (e.g. Jet-Filter)
• Mounting according to the corresponding description
Alternative
Suction on site
• flexible connection to the vent pipe
• contactless via the vent pipe (e.g. suction funnel)
or
NOTICE!
For the dimensioning of the suction the following rule has to be
complied with: “Only as strong as necessary and as light as possible!”“
©Operating instructions (DDW-) DDSR xx
Mounting
35
Electrical mounting
WARNING!
Working with voltages that are hazardous upon contact
• Hazard caused by open junction boxes
• Danger caused by improper execution of the work
»
»
Employ only trained and qualified electricians.
After the connection work or in case of any interruption of the work the junction boxes have to be
closed correctly.
Junction boxes
The connections of the electrical component groups of the device are cabled in our works with the
junction boxes of the device. The equipment of the junction boxes is a function of the electrical
execution of the device or the corresponding use:
•
•
Connection to an external control cabinet/box
The cabling between the junction boxes and the control cabinet/box permits to connect the device
with the corresponding electrical assemblies in the control cabinet/box.
Connection to a serial bus system
The junction boxes contain the electrical component groups for the operation of the device (feeding
controller, drive controller etc.). The connection terminals are required for the connection of the
bus system, the supply voltage etc.
Metallic cable glands
The use of a metallic cable gland:
1.
2.
3.
4.
5.
36
Mounting
Strip the cable.
Open the cable gland.
Slide the loose parts onto the cable in the order
shown here.
Slip the screening (A) over (M).
Insert the cable into the cable gland and screw fast.
©Operating instructions (DDW-) DDSR xx
Electrical mounting, continuation
Construction of a locking chain
The implementation of a locking chain is a function of the hardware used on site (programmable logic
controller, relay etc.) and has to comply with the applicable regulations concerning the safety of man
and machine. The locking chain:
•
is an electrical cabling with the feeding controller of the device.
»
•
•
•
CAUTION! The component groups of the device must not be controlled individually.
The feeding controller of the device permits to control the device.
takes into account additional start conditions for the start enable of the feeding operation (e.g.
closed circuit breaker or operational readiness of the connected equipment).
stops the feeding operation immediately, if one operating condition is not complied with (e.g.
tripping of a circuit breaker).
takes into account the possibilities of the feeding controller type Congrav®, if employed. The
possibilities are a function of
- the available hardware,
- the available functionality (= software of Congrav®).
NOTICE! The disconnection of the mains supply of Congrav® can cause a loss of data and is only
allowed in the corresponding situations (e.g. emergency stop).
Connection plans
In the following the connection plan for a simple control of a three-phase motor for a volumetric
operation (= constant default speed) will be illustrated. For other executions the connection plans are
enclosed as a separate document of the documentation provided. For instance:
•
•
•
General description of connections in the technical manual of the feeding controller that is included
in the scope of supply.
General description of connections in the technical manual of the drive controller that is included in
the scope of supply.
Connection plans as component of the scope of supply (e.g. for a control cabinet).
©Operating instructions (DDW-) DDSR xx
Mounting
37
Electrical mounting, continuation
Volumetric operation
In “volumetric” operation the feed drive (M) is
controlled via a frequency converter (A2) that
permits to adjust the operating speed via a
potentiometer (P1). The device will feed with this
operating speed as soon as it is enabled (switch S1).
The frequency converter is no component of the
device but is mounted in a control cabinet or similar
and connected on the device to the feed drive via
the junction box (JB2).
Explanation of the markings employed (“mark“):
Mark.
Q1
F1
S1
P1
A2
A2.1
JB2
M
B3
38
Meaning
Main switch, maintenance switch
Fuse
Switch “operating release”
Potentiometer “speed specification“
Frequency converter type “FC-Vx“
Frequency converter IO module “standard“
Junction box on the device
Feed drive
PTC thermistor (if available)
Mounting
©Operating instructions (DDW-) DDSR xx
Electrical mounting, continuation
Connection of separate agitator motor
In standard, the agitator motor is operated with a constant
nominal speed. The agitator motor (-M2) is connected via a
motor protection relay (-Q1) to the voltage supply. The electrical
cabling of the contactor coil (-K1M) permits to actuate the
agitator motor. The cabling is executed in such a manner that
•
•
the agitator drive starts, if the feeding operation is started
and all conditions for an existing interlocking chain (e.g.
circuit breaker) have been complied with.
the agitator motor stops, if the feeding operation is stopped.
NOTICE! Special execution with variable speed
The agitator motor is operated with a frequency converter (see
example of feed drive).
©Operating instructions (DDW-) DDSR xx
Mounting
39
5. Commissioning
This chapter describes the activities required for the commissioning of the device.
NOTICE!
The descriptions were formulated in a very general manner and only take into account the
standard assemblies of the manufacturer.
Content of the chapter “Commissioning”:
Subject
Instructions for commissioning
Commissioning of the device
Check and compare the weighing
(NOTICE!
Does not apply for a device without weighing)
Commissioning of the feeding
40
Commissioning
Page
41
42
43
45
©Operating instructions (DDW-) DDSR xx
Notice for commissioning
DANGER!
Product with hazardous characteristics
• Hazard caused by leakages or malfunctions of the device
• Hazard caused by necessary adjustment work
»
»
Employ a replacement product with non-hazardous, otherwise identical product characteristics.
Take all necessary security measures, if no replacement product is available.
Active product feeding
During commissioning the product feeding is started to determine the feed rate of the device. An active
product feeding requires
•
•
•
a sufficient product quantity,
a free product flow into/out of the device,
a receptacle for collecting the product quantity that has been fed.
For this purpose two possibilities are available:
1.
2.
Feeding into downstream parts of the installation
Feeding into a collecting receptacle (possibly requires an additional bypass line)
Interruption of commissioning
NOTICE!
In case of an interruption due to corrections of the assembly
» Disconnect the device.
» Comply with the specifications for the assembly.
» After the execution start the new commissioning with step 1.
In case of an interruption the following measures have to be taken:
•
•
•
•
Disconnect the device.
Close opened component groups of the device.
Protect the device against foreign bodies.
Protect the device against an unauthorised commissioning.
©Operating instructions (DDW-) DDSR xx
Commissioning
41
Commissioning of the device
Step 1:
Tests on the device
Check whether the specifications for the operational readiness have been complied with:
1.
2.
3.
4.
5.
6.
7.
8.
The mounting work has been finished.
All supply media have been connected.
All supply media are available as required.
Sufficient product quantities are available.
All foreign bodies and contaminations have been removed.
All necessary measures to ensure the safety of operations have been taken.
The device and the other equipment required are ready for operation.
Sample measurements can be carried through.
Step 2:
1.
2.
3.
Connection of supply media
Connect all supply media.
Wait until a warm up of approx. 30 min. is finished.
Continue the commissioning.
Step 3:
Verification of the sense of rotation
Check the direction of rotation for all drive motors of the device. The marking
motor shows the correct sense of rotation.
1.
2.
3.
on the drive
Enter a small speed (~10%).
Start the device and check the sense of rotation.
Stop the device.
In case of a wrong sense of rotation it has to be changed.
4.
5.
6.
7.
8.
Switch off the power supply.
Protect against unauthorised reconnection.
Exchange two of the connection lines (U, V, W), (e.g. U, V).
Switch on the voltage supply.
Check the sense of rotation once again.
42
Commissioning
©Operating instructions (DDW-) DDSR xx
Test and adjustment of the weighing system
Indications on the performance of the check:
•
•
•
Skip the check for a device without weighing.
During the check three known test weights are required
- Ideal:
10%, 50% and 90% of the weighing range of the load cell
- General:
cover the widest possible range of the weighing range
The processing of the weighing signal requires a suitable evaluation unit.
- Included in the scope of supply:
parameterised at the factory
- Provided by the customer:
adaptation to the technical data of the load cell
Step 4:
Loosen the transport catch
Loosen all elements of the transport catch.
Step 5:
1.
2.
3.
4.
5.
Check the free motion
Read the weight loading of the weighing system.
Place an additional weight on the weighing system.
Take off the additional weight.
Read the weight loading of the weighing system.
Weight value (1) = weight value (4):
Continue commissioning.
Weight value (1) ≠ weight value (4):
1. Find and eliminate the cause.
2. Carry out the test once again.
Reasons for missing free motion:
•
•
•
•
The transport catch has not been loosened completely.
The flexible connection of the inlet/outlet is not sufficient.
The weighing system is impeded by foreign bodies/contamination.
The cabling of the assemblies of the device, the adjustment of the overload protection screw or
other executions of the device are inaccurate.
©Operating instructions (DDW-) DDSR xx
Commissioning
43
Test and adjustment of the weighing system,
continuation
Step 6:
Check the lever factor
The lever factor (LF) permits to adjust the weight display of the evaluation unit to the actual weight
loading. The check of the lever factor is as follows:
1.
2.
3.
4.
5.
Read the actual weight value (W0).
Place on a known test weight (WT).
The force shall be applied centrically on the weighing system.
Read the new weight value (W1).
Compute the difference (W1 - W0).
(W1 - W0) = WT:
Continue commissioning.
(W1 - W0)  WT:
6. Read the actual lever factor (LFact).
7. Compute the new lever factor (LFnew).
LFnew = LFact x (WT / (W1 - W0))
8.
9.
Step 7:
Enter and memorise the new lever factor.
Check the new lever factor.
Check the function
The function of the weighing system is tested by means of three load measurements over the complete
weighing range. Each test measurement checks the free motion and the lever factor.
NOTICE!
The three selected test weights should cover the weighing range to the extent possible
(ideal: 10%, 50%, and 90%).
44
Commissioning
©Operating instructions (DDW-) DDSR xx
Commissioning of the feeder
Step 8:
Refill the hopper
CAUTION!
First filling of the hopper
• Leaky connections
- Contamination of the environment
- Formation of an explosive mixture (dust/air mixture)
• Malfunctions e.g. by cabling, product supply etc.
»
»
The refill process has to be stopped immediately.
The reason for the malfunction has to be eliminated taking into consideration the specifications.
Refilling controlled by the feeding controller (“automatic refilling“)
1.
2.
3.
The operating personnel activate the refilling on the feeding controller.
The feeding controller enables the product supply.
The feeding controller locks the product supply, if the weighing reaches the fixed maximum filling
level.
Refilling carried out by the operating personnel (“manual refilling“)
1.
2.
3.
The operating personnel open the hopper cover and fills product into the hopper with a suitable
device.
- Take care when filling in the product.
- A possibly available protective grid impedes the product flow into the hopper. It is not allowed
to remove the protective grid to simplify refilling.
- The filling level is monitored visually (hopper content or alternatively via the display of an
evaluation unit during weighing).
Terminate refilling if the hopper is approx. 80 % filled.
- The indication “80%“ is an indicatory value. The actual maximum filling level is determined by
the actual product characteristics (e.g. bulk density) and the operating conditions.
Remove possible impurities and close the hopper lid.
©Operating instructions (DDW-) DDSR xx
Commissioning
45
Commissioning of the feeder, continuation
Step 9:
1.
2.
3.
4.
5.
6.
7.
Test the feeding operation
If necessary, place a suitable receptacle under the outlet.
Enter a small speed (~10%).
Start the device and wait until product flows out of the outlet and the feeding screw is filled evenly
with product.
Increase the speed specification (e.g. 50%).
Watch the feeding behaviour (product flow, grinding noises, leakages etc.).
After an undisturbed operating process stop the operation of the device.
Check the sealings, bearings etc. (tightness, temperatures etc.)
CAUTION!
Inadmissible operating behaviour
• Danger for the operating staff and the environment
»
»
Immediately stop the operation of the device.
Locate and remedy cause and repeat the test.
Step 10:
Fix the feed rate manually
During “gauging” the feeding operation is started for a fixed measuring period and the product quantity
fed during this period will be weighed.
The discharge rate [kg/h] is computed from both values – measuring time and product quantity.
“Gauging” runs down as follows:
1. Choose a suitable collecting receptacle with a known empty weight.
2. Place the collecting receptacle under the outlet.
3. Adjust the speed (setpoint).
4. Start the feeding operation for the measuring time (e.g. 2 min.).
5. Stop the feeding operation after expiry of the measuring time.
6. Weigh the collecting receptacle and compute the product weight (weight - empty weight).
7. Calculate the feed rate [kg/h] (here: product weight x 60/2).
NOTICE!
“Gauging” permits to find the feed rate for the corresponding speed. The determination of
the feed rate of different speeds results in a characteristic line (speed – feed rate) for a speed range.
46
Commissioning
©Operating instructions (DDW-) DDSR xx
Commissioning of the feeder, continuation
Step 11:
Determine the feed rate automatically
A feeding controller type Congrav® permits an automatic determination of the characteristic line of the
feed rates with the function “Checking of max. output“ . During a feeding operation with different speed
values the feeding controller calculates and memorises the feed rate (= “output“) for the corresponding
speed value. The characteristic curve that has thus been memorised is employed by the feeding
controller for the control of the feeding operation.
NOTICE!
controller.
Step 12:
The “checking of max. output” is described in the software description of the feeding
Inspection of the feeding device
After the determination of the feed rate check the state of the device and of the individual component
groups (bearing, sealings etc.) as far as tightness, temperatures etc. are concerned. Look for the reason
and remedy any defects identified. If necessary, the feed rate has to be determined once again (e.g. if
the defect could have a negative effect on the product flow).
©Operating instructions (DDW-) DDSR xx
Commissioning
47
Commissioning of the feeder, continuation
Step 13:
Modifications
It is necessary to modify the device, if the execution of the device does not comply with the actual
operating conditions/requirements.
CAUTION!
Inadmissible modifications
• Danger for the operating staff and the environment
• No proper use
»
»
Obtain the approval from the manufacturer.
Make sure that the modification is tied to the operating conditions.
NOTICE! If the cabling that has been provided in the factory is to be changed on site, this requires an
approvement by the manufacturer (protective functions provided by the cabling!).
Step 14:
Terminate commissioning
To complete commissioning the device will be prepared for the operation (= product feeding). The
preparation includes the following final work:
•
•
•
•
•
•
48
Remove auxiliary equipment (collecting receptacle etc.).
Possibly reconnect separated connections (e.g. outlet).
Undo possible retrofitting (e.g. bypass).
Discharge the device completely, if a replacement product has been employed.
If required, clean the device and the environment.
Refill the device.
Commissioning
©Operating instructions (DDW-) DDSR xx
6. The operation of the device
This chapter describes the two main operating modes and the way they run.
Content of the chapter “The operation of the device“:
Subject
The volumetric feeding operation
Page
50
(The feed rate will not be seized and controlled.)
The gravimetric feeding operation
(The feed rate will be seized and controlled.)
©Operating instructions (DDW-) DDSR xx
51
The operation of the device
49
The volumetric feeding operation
Description
With volumetric product feeding the feed drive is driven with a constant default speed (fixed working
point). The feed rate will not be controlled. I.e. feed rate variations e.g. caused by a variating filling
degree of the feeding module will not be detected and corrected. The field of application of a volumetric
product feeding are feeding processes that are not affected by variations of the feed rate (e.g. refill
device for a loss-in-weight feeder (execution “DDW-“)).
CAUTION!
No monitoring of the feed rate
• Permits a feeding operation without product. Damage of the device by radial deflections of the
screw in the screw tube.
»
»
Refill the hopper before reaching the minimum allowed filling level.
Increased attention during a feeding operation with a high speed.
Volumetric product feeding process
1.
2.
3.
4.
Adjust the working point (e.g. potentiometer = 50%).
Start the feeding operation.
If required, adjust the feed rate by a corresponding modification of the default value
(here: potentiometer).
Stop the feeding operation, if the required product quantity has been fed out.
NOTICE! This is how the manual operation by the operating personnel runs. In an automatic process the
functions of product feeding (start/stop, default feed rate) are integrated into the feeding process.
50
The operation of the device
©Operating instructions (DDW-) DDSR xx
The gravimetric feeding operation
Description
During gravimetric product feeding the feeding operation is started with a determined discharge rate
(product quantity /time unit). During feeding the feed rate will be measured and controlled via a control
circuit. The control circuit modifies the control of the feed drive and thus tries to correct variations– e.g.
due to a fluctuating filling degree of the feeding module - promptly.
Prerequisite for gravimetric product feeding
For gravimetric product feeding the equipment and the control of the device have to comply with the
following required conditions:
•
•
The device is a loss-in-weight feeder (“DDW - …”) and is thus equipped with a weighing system.
A feeding controller type Congrav® or with comparable functions has to be employed.
- The hardware of the feeding controller is suitable for the operation of the device.
- The software of the feeding controller is adapted to the operation of the device.
CAUTION!
Parameterisation of the feeding controller
• Malfunctions by inappropriate parameter setting
• Firm connection of the feeding controller to the device
»
»
Be sure to observe the documentation of the feeding controller.
Adjust the parameters according to the connected device.
Gravimetric product feeding process
1.
2.
Set the desired feed rate as setpoint.
Start the feeding operation.
The further sequence of control and monitoring of the feeding operation depends on the functions of
the feeding controller and is described in its documentation.
©Operating instructions (DDW-) DDSR xx
The operation of the device
51
7. Maintenance
This chapter describes the activities required for the care/inspection and for the maintenance/servicing
of the device.
Markings used
In the following descriptions important activities and warnings are identified by symbols
(see left) with the following meaning:
1.
2.
3.
NOTICE!
activities.
Disconnect the device.
Wear long gloves as a protection.
WARNING! Sharp-edged components due to the function or due to wear
In the descriptions you will only find the symbols that are required for the corresponding
Content of the chapter “Maintenance”:
Subject
Preparation for maintenance
Care and examination
Overview of the components
Assembly/disassembly of the feeding screw
Assembly/disassembly of the agitator
Exchange of shaft sealings
Adjustment of speed monitoring
52
Maintenance
Page
53
55
58
62
64
66
67
©Operating instructions (DDW-) DDSR xx
Preparation for maintenance
Discharge the device
NOTICE! With an integration of the device into a feeding process the upstream/downstream equipment
for the maintenance operation/the discharge of the device has to be set.
For carrying out the disassembly work of components in contact with the product, the feeder has to be
discharged by means of a “cleaning operation” before the start of work. The “cleaning operation“ is a
feeding operation where
•
•
•
the monitoring of the filling level limits is deactivated.
the refilling of the device is deactivated.
the feeding device is discharged as far as possible by means of the feeding module.
WARNING!
Residual product in/on the device (loose and adhering)
• Product contact during disassembly of the device /individual assembly groups
• Reactions during cleaning (cleaning agent, friction etc.)
»
Please observe the product data sheet!
- Take suitable safety measures.
- Properly remove residual product.
- Correct disposal of residual product.
Switch off the device for maintenance work
1.
2.
3.
4.
5.
Indicate maintenance work in progress.
Discharge the device.
Mount/lock the transport catch.
Disconnect the device (see (see page 12)
Remove residual product.
»
WARNING! Sharp-edged components
Wear long shaft gloves.
©Operating instructions (DDW-) DDSR xx
Maintenance
53
Preparation for maintenance, continuation
Protection of the maintenance works
Protect the maintenance work by
•
•
a clearly visible marking of the maintenance works.
a protection against any unauthorised commissioning.
CAUTION! Partly assembled device
Hazard potential by a disassembly of individual components due to
• exposed and freely accessible component groups.
• missing safety measures against the penetration of foreign bodies.
»
»
Be sure to employ suitable protective equipment during works.
During an interruption of the work or when the workplace is left (e.g. changing the workplace for
another task) the following measures have to be taken in addition:
- Cover/lock open component groups by means of suitable measures.
- Protect the device against foreign bodies.
- Mark that the device is partly mounted.
Recommissioning after maintenance work
After maintenance/inspection work (without assembly/disassembly work):
1.
2.
3.
4.
Make sure that the device is ready for operation.
Clean the operating environment of the device and remove all foreign objects.
Connect all supply media.
Start the operation.
After a change/disassembly of individual components:
1.
2.
3.
54
Make sure that the device is ready for operation.
Clean the operating environment of the device and remove all foreign objects.
Carry out the commissioning (see chapter “commissioning“) of the device.
Maintenance
©Operating instructions (DDW-) DDSR xx
Care and inspection
Removal of defects
Allowed possibilities for the removal of identified defects:
1.
2.
Damaged component is professionally repaired.
Damaged component is replaced by a new component.
NOTICE! Factory cabling of the device
When working on or replacing the factory cabling of the device
»
»
the execution concerning the laying of the cables, cable lengths etc. must be retained.
damaged cables have to be replaced by an identical cable or a cable with identical characteristics
(also with regard to flexibility!).
Marking of the time intervals
W
M
Y
weekly
monthly
yearly
2W
3M
H
every 2 weeks
every 3 months
biannually
NOTICE!
The time specifications are average estimations based on experience and have to be
adapted to the corresponding operating conditions.
Care work
Time
W
2W
Activities
Clean the filter bag/deaeration (if available)
Clean the device.
- Dust and loose contaminations have to be removed by means of an industrial vacuum
cleaner.
- Solid impurities have to be removed with a (damp) cloth.
©Operating instructions (DDW-) DDSR xx
Maintenance
55
Care and inspection, continuation
Control of the device
Time
W
Component
Flexible connections
Examination
Damages
W
2W
Fastenings
Screw
Tight fit
Wear, tear
2W
2W
2W
2W
2W
M
Agitator
Mobile parts
Sealings
Shaft sealings
Locks
Electrical connections
Wear, tear
Functionality
Tightness
Tightness
Attraction force, tight fit
Tight fit
Electric cables
Damages
Control of the shaft sealings
Shaft sealings construction size ≤ 40
No.
1
2
56
Shaft sealings construction size > 40
Description
Agitator shaft sealing
Screw shaft sealings
Maintenance
©Operating instructions (DDW-) DDSR xx
Care and inspection, continuation
Damaged shaft sealings
Product deposits
A: on the twin-shaft gearing
Damaged shaft sealing
agitator
B: under the twin-shaft gearing
screws
Activities
Deposit
None
Product
Activity
None
Exchange radial packing ring(s)
Oil
Exchange the gear
©Operating instructions (DDW-) DDSR xx
Maintenance
57
Overview of the components
58
Maintenance
©Operating instructions (DDW-) DDSR xx
Overview of the components, continuation
The markings in the illustration have the following meaning:
No.
1
2
3
4
5
6
7
Meaning
Screw drive motor
Drive console
Twin-shaft gearing
Proximity switch (option speed monitoring)
Radial packing rings
Sealing plate
Agitator trough
8
9
Sealing of screw pipe
Twin screw
10
11
12
13
14
15
16
17
Screw pipe with vertical outlet
Cover vertical outlet
Agitator drive motor
Bearing cover
Shaft sealing
Bearing shell
Agitator drive shaft
Agitator
Notice: Execution as DDSR40B
The DDSR40B is a DDSR40 that is equipped with the agitator trough DDSR60. The design of the agitator
trough with a cleaning access and the design of the bearing block of the drive shafts is shown in the
figure (DDSR60).
Notice: Screw bearing
In case of a special design of the twin screw (greater length) an additional bearing of the screw shaft
may be required. The design of the front bearing is shown in the illustration (DDSR60).
©Operating instructions (DDW-) DDSR xx
Maintenance
59
Overview of the components, continuation
60
Maintenance
©Operating instructions (DDW-) DDSR xx
Overview of the components, continuation
The markings in the illustration have the following meaning:
No.
1
2
3
4
5
Meaning
Screw drive motor
Spur gear
Proximity switch
Cover (coupling)
Toothed coupling
6
7
Twin-shaft gearing
Bearing cover, shaft sealings
8
9
Shaft sealings (screw)
Bearing block
10
11
12
13
14
15
Agitator trough
Twin screw
Sealing
Screw pipe
Sealing
Front screw bearing
16
17
Vertical outlet
Cover vertical outlet
18
19
Cleaning hole
Agitator
20
21
Agitator drive shaft
Shaft sealing
22
23
Bearing cover, shaft sealing
Agitator drive motor
©Operating instructions (DDW-) DDSR xx
Speed monitoring
Maintenance
61
Assembly/disassembly of the feeding screw
Disassembly of the screw
1.
2.
3.
4.
If available, loosen the connection at the vertical outlet.
Undo the fastening of the screw pipe.
NOTICE! Additional activities are possibly required.
The illustration shows a possible execution of the fastening of the screw pipe/vertical outlet. With
other executions additional activities (e.g. loosening of the front transport catch) are possibly
required in order to loosen the screw pipe.
Remove the screw pipe with the vertical outlet.
Loosen both screws at the same time by means of a brief clockwise rotation and pull them out.
NOTICE!
•
•
62
Auxiliary means for stuck screw
In case of twin screws without an additional front bearing a M6
screw is screwed into the thread at the head of the screw (A) and
thus the screw is loosened.
Twin screws with an additional front bearing are equipped with a
wrench flat (B) at the front end of the screw shaft for the use of a
wrench.
Maintenance
©Operating instructions (DDW-) DDSR xx
Assembly/disassembly of the feeding screw,
continuation
Assembly of the screw
1.
Clean both screws and check for defects (damage, wear).
»
2.
3.
4.
5.
6.
7.
CAUTION! No operational safety with a defect screw.
Exchange both screws in case of damage/heavy wear.
Clean and slightly grease the shaft journal and the location bore.
Both screws have to be aligned.
Slide both screws at the same time on the shaft journals.
Turn both screws in anti-clockwise direction.
Clean the connection surfaces of the screw pipe.
Mount the screw pipe.
If the device is equipped with a vertical outlet:
8. Slide on the vertical outlet and fix it.
9. Connect the flexible connection to the outlet.
Vertical outlet with screw bearing
Vertical outlet
1
Vertical outlet
2
Screw pipe
Screw bearing
5
Labyrinth sealing
6
Groove ball bearing
3
4
Sealing
Sealing
7
Bearing housing
The illustration shows a possible structure of the screw bearing at the vertical outlet. If the screw is
mounted, the assembly steps are as follows:
1.
2
3.
4.
Disassemble the shaft bearing at the vertical outlet.
Clean and check the components, exchange damaged components.
Slide on the screw pipe and the vertical outlet and fasten it.
Assemble the shaft bearing at the vertical outlet.
©Operating instructions (DDW-) DDSR xx
Maintenance
63
Assembly/disassembly of the agitator
Disassembly of the agitator
Disassembly of a one-piece agitator:
1. Loosen the connections of the hopper cover.
2. Disassemble the hopper.
3. Loosen the agitator with a clockwise rotation.
4. Pull the agitator slightly forward.
5. Remove the agitator from the screw trough.
Disassembly of a two-piece agitator:
1. Loosen the fastening of the cover of the cleaning access (1).
2. Loosen the locking screw (2) of the agitator.
3. Depending on the size of the cleaning opening:
- Opening > agitator blade:
Remove the agitator to the front (A).
- Opening < agitator blade:
Remove the agitator in upward direction (B).
64
Maintenance
©Operating instructions (DDW-) DDSR xx
Assembly/disassembly of the agitator, continuation
Cover as front plate
No. Description
1
Vertical outlet
2
3
Screw
Sealing
4
5
6
7
Cover
Sealing
Agitator
Agitator trough
The figure schematically shows the disassembly of the agitator, if the cover of the cleaning access also
serves as front plate of the agitator trough. With this execution the following additional activities are
required before opening the cover:
1.
2.
3.
4.
If required, disassemble the hopper.
Disassemble the vertical outlet with the screw pipe.
Disassemble the screw.
Undo the screwings of the cover.
Assembly of the agitator
1.
2.
3.
4.
5.
6.
Clean the agitator and check for defects (damage, wear).
The threaded bolt and the thread of the agitator have to be cleaned thoroughly and greased
slightly.
Cautiously insert the agitator into the trough.
Fix the agitator by turning it to the left (one-piece) by means of the locking brake (two-piece).
If available, close the cleaning access.
Make sure that the device is ready for operation.
©Operating instructions (DDW-) DDSR xx
Maintenance
65
Exchange of the shaft sealings
Exchange of shaft sealings
How to exchange a damaged shaft sealing.
1.
2.
3.
4.
Disassemble the twin screw.
Disassemble the agitator.
Disassemble the drive motors (+ speed monitoring).
Disassemble the damaged shaft sealing.
Figure A: construction size ≤ 40 (40, 30 etc.)
- Disassemble the fastenings (1) of the twin-shaft gearing (2).
- Loosen the bearing cover (3).
- Loosen the shaft sealings (4) from the bearing seat (5).
5.
6.
7.
Figure B: Construction size ≤ 40 (40B, 60 etc.)
- Disassemble the fastenings (1) of the twin-shaft gearing (2).
- Loosen the sealing plate (3; screw) or rather the adjusting collar (3; agitator).
- Loosen the shaft sealings (4) from the bearing seat (5).
Clean all components and bearing seats.
Slightly grease the drive shaft.
Insert new radial packing rings.
CAUTION! Observe the mounting direction (figure C) of the shaft sealing!
8. Mount the bearing cover.
9. Assemble the drive motor (+ speed monitoring).
10. Mount the twin screw.
11. Mount the agitator.
12. Make the device ready for operation.
66
Maintenance
©Operating instructions (DDW-) DDSR xx
Adjustment of the speed monitoring
Adjustment of speed monitoring without visual contact
The scanning distance of the proximity switch is not visible. Therefore, the adjustment is carried out
without sight.
1.
2.
3.
4.
5.
Pull the plug of the proximity switch.
Undo the locknut of the proximity switch.
Slightly rotate the proximity switch against the toothed wheel.
1-2 rotations anticlockwise.
If available: Observe the position of the angular plug.
Lock the proximity switch by means of the counternut.
Visual adjustment of the speed monitoring
In case of a visual adjustment the scanning distance “d” becomes visible after the disassembly of a cover
or similar. In this case the scanning distance is adjusted by means of a feeler gauge according to the
indication in the chapter “Technical data” (see page 28).
©Operating instructions (DDW-) DDSR xx
Maintenance
67
8. Cleaning
This chapter deals with the cleaning of the device.
Mount/demount components
NOTICE!
See chapter “Maintenance“ for mounting/demounting of individual component groups of
the device.
Content of the chapter “Cleaning”:
Subject
Specifications for cleaning
Cleaning methods
68
Page
69
70
Cleaning
©Operating instructions (DDW-) DDSR xx
Specifications for cleaning
Design of the cleaning process
The dimensioning of the cleaning process by the user helps to prevent any danger to persons, the
environment and the machine
•
•
•
because appropriate/allowed cleaning tools are employed.
because the cleaning personnel functions with the necessary protective equipment.
no cross contaminations (feeding products, cleaning agents etc.) will be produced.
Cleaning place
The cleaning place must be suitable for
•
•
the safe execution of the cleaning of the device.
the correct neutralization and disposal of the resulting wastewaters.
Specifications for cleaning agents
Permitted cleaning agents for the cleaning of components in contact with the product have to comply
with the following specifications:
•
•
•
•
•
•
Not combustible
Do not form any explosive or flammable vapours
No scouring additives
Temperature of use/working temperature ~ 20°C
PH value between 4 - 10pH
Complies with the requirements for the field of application of the device (e.g. conformity to food
processing regulations acc. to “NSF White Book ™“)
©Operating instructions (DDW-) DDSR xx
Cleaning
69
Cleaning processes
Cleaning quality
For a consistent cleaning quality during the cleaning sequence be sure to observe the “Sinner’s circle“.
The cleaning quality is defined as the total sum from the relation of the parameters temperature, time,
chemistry and mechanics.
Matrix cleaning processes
The following matrix lists possible cleaning procedures as a function of the application of the device.
Dry cleaning
Plastics/Global industries
X
ATEX
X*
Hygienic, FOOD/Pharma
X
X
X
X
X
X
Controlled wet cleaning
Wet (COP)
* only with an industrial vacuum cleaner that is approved for the ATEX zone.
Dry cleaning
During dry cleaning, contaminations will be eliminated without use of a liquid cleaning agent.
•
•
Remove loose contaminations by means of an appropriate auxiliary (e.g. industrial vacuum cleaner).
Remove adhesive contaminations by means of a cloth.
CAUTION!
Electrostatic charging by friction
• Damage of the device caused by electrical energy
»
70
Employ materials that do not generate electric charging.
Cleaning
©Operating instructions (DDW-) DDSR xx
Cleaning processes, continuation
Controlled wet cleaning
During a “controlled wet cleaning“ only components in product contact are wet cleaned. The following
specifications apply to a “controlled wet cleaning“:
•
•
•
The following components have to be cleaned by means of a cloth, if required the cloth can be
moistened with water or a suitable cleaning agent:
- Bearings and electrical components
- Components that are not in contact with the product
- lacquered components
During wet cleaning of the components in product contact, the components stated above have to
be protected from humidity.
After cleaning
- the device/the component has to be dried thoroughly,
- remove standing moisture,
- possibly grease degreased components.
Wet cleaning (COP)
All components to be cleaned are disassembled and cleaned at the provided cleaning place (COP = clean
out of place). The following example shows the process of cleaning that meets very high standards:
•
•
•
•
•
•
Preclean with water
Clean with a lye solution
Periodical cleaning with water
Neutralisation (possibly disinfection)/acid cleaning
Final cleaning with low-germ (distilled) water
The correct neutralization and disposal of the resulting wastewaters.
©Operating instructions (DDW-) DDSR xx
Cleaning
71
9. Troubleshooting
CAUTION!
Immediate stop of feeding
• Effects on upstream/downstream production processes
»
Take suitable measures for the complete production process.
Causes for a shutdown due to a malfunction
Fault shutdowns occur in operational situations that do not permit to continue the operation of the
device. They are
•
•
either triggered manually by the operation personnel (e.g. “emergency stop”“)
or automatically by a monitoring function/interlocking chain.
How to continue the operation after a fault shutdown
Steps to be taken in order to continue the operation after a fault shutdown:
1.
2.
3.
4.
Find the cause for the malfunction.
Eliminate the cause for the malfunction.
Eliminate the effects of the malfunction.
Make sure that the device is ready for operation.
NOTICE!
Commissioning (see chapter “Commissioning “) must only be carried out, if
• components have been exchanged.
• components have been disassembled/assembled.
72
Troubleshooting
©Operating instructions (DDW-) DDSR xx
Causes of malfunctions
Discharge operation does not start
•
Voltage supply is missing
» Connect the voltage supply.
» Replace defective fuses if required.
•
Execution of connection lines is incorrect
» Eliminate errors in the connections.
» Eliminate interruptions/damage.
» Replace wrong cable types.
•
Drive components damaged (motor, drive controller etc.)
» Replace damaged components.
•
Required releases are missing
» Comply with demands of interlocking chains and other operating requirements.
Grinding noises
•
Screw diameter too big
» Change the combination screw/screw pipe.
•
Product deposits in the screw pipe
» Clean the screw pipe.
•
Product jam between screw and pipe wall
» Change the combination screw/screw pipe.
•
Grinding noises of the agitator
» Eliminate deposits on the agitator/agitator trough.
Uneven filling ratio
•
Screw type not suitable
» Employ other screw type.
•
Product quantity not sufficient
» Refill the hopper.
» Check/restore the agitator functions (exchange damaged agitator).
» Take measures against product bridges in the hopper.
©Operating instructions (DDW-) DDSR xx
Troubleshooting
73
Causes of malfunctions, continuation
Screw jammed
•
Foreign bodies in the product zone
» Remove foreign bodies and replace damaged components.
» Eliminate the reason for the penetration of the foreign body.
•
Screw diameter too big
» Change the combination screw/screw pipe.
•
Screw type not suitable
» Employ other screw type.
Feed rate too low
•
Wrong combination screw/screw pipe
» Change the combination screw/screw pipe.
•
Changed product characteristics
» Adjust the combination screw/screw pipe.
» Adjust the operating parameters.
•
Activation of the drive
» Increase the speed of the drive.
74
Troubleshooting
©Operating instructions (DDW-) DDSR xx
10. Decommissioning
Decommissioning
Disconnect the device for storage or disposal.
1.
2.
3.
4.
Discharge the device.
Disconnect the device ( (see page 12)
Disconnect the device from all supply media, connections, etc.
Disassemble the device.
»
5.
6.
WARNING! Sharp-edged components
Wear long shaft gloves.
All components have to be cleaned and dried thoroughly.
NOTICE!
Correct disposal of residual product (product data sheet!).
For the rest of the process please see “storage and disposal”
©Operating instructions (DDW-) DDSR xx
Decommissioning
75
11. Storage and disposal
This chapter describes the conditions for the storage and the disposal of the device or of its individual
components.
Content of the chapter “Storage and disposal”:
Subject
Storage of the device, of individual assemblies
Disposal of the device, of individual assemblies
76
Storage and disposal
Page
77
78
©Operating instructions (DDW-) DDSR xx
Storage of the device, of individual components
Storage process
•
•
•
•
•
Decommission the device correctly.
The device has to be discharged completely and cleaned thoroughly.
NOTICE!
Correct disposal of residual product (product data sheet!).
In case of a weighed execution the transport catch has to be mounted.
If necessary, renew/touch up the protective coating of the lacquered components.
Disassemble the following components:
- In general all sleeves and compensators have to be disassembled and have to be stored
together with the device under appropriate storage conditions.
- Components with special storage conditions
Storage conditions
Storage conditions for the storage of the device or of individual assemblies:
Temperature:
Humidity:
+10°C to +40°C
40% to 70% no standing moisture
Medium:
Storage room:
air
weather-proof, enclosed building
suitably ventilated
clean, possibly free from dust
Packaging:
©Operating instructions (DDW-) DDSR xx
free from UV light, ozone, chemicals, solvents
suitable packaging box, provide spacers under the cover (air
circulation)
Storage and disposal
77
Disposal of the device, of individual components
Disposal process
•
•
•
•
Decommission the device correctly.
The device has to be discharged completely and cleaned thoroughly.
NOTICE!
Correct disposal of residual product (product data sheet!).
Disassemble the device.
Dispose the disassembled device.
Disposal
The individual components of the device have to be disposed separately:
Component
Drive, gear
Electrical cables
Sleeves, compensator etc.
Hopper, pipes, sheets
Insulations
Boards
Disposal
see manufacturer's indications
Cable scrap
PU, EPDM, silicone or similar
Metal scrap
according to material specifications
Special waste
Accumulators, batteries
Plastic
Special waste
Disposal of plastics
78
Storage and disposal
©Operating instructions (DDW-) DDSR xx
Index
Aeration
Aeration, filter bag
Agitator
Agitator, trough
Assembly, execution
Connection, step bellow
Disconnection, warning symbol
Drive
Drive shaft
Drive shaft, agitator
Drive shaft, screw
Earthing, correct
Gear
Intended purpose
Load cell, free movement
Load cell, lever factor
Locking chain
Operating personnel, protection
Operating personnel, qualification
Operation, no start
Product outlet opening
Product, appropriate
Product, characteristics
Safety grid
Safety switch
Screw
Shaft sealing
Speed monitoring
Use in accordance with the intended purpose
Ventilation
Ventilation, filter bag
Ventilation, vacuum system
Vertical outlet
©Operating instructions (DDW-) DDSR xx
15, 35
35, 55
8, 10, 11, 13, 17, 18, 20, 21, 22, 23, 24, 28, 39,
52, 56, 57, 59, 61, 64, 65, 66, 73
8, 18, 20, 21, 22, 24, 59, 61, 65, 73
34
17, 26, 35
11
8, 11, 13, 17, 18, 20, 21, 22, 42, 59, 61, 66
21, 22, 23, 59, 61, 66
23, 56
23, 56, 59, 62
11
22, 28, 57, 61, 78
10
43, 44
44
37
11
11
73
23
8
8, 41, 45, 74
24
15
8, 10, 11, 13, 17, 18, 20, 21, 22, 23, 27, 28, 34,
36, 43, 46, 50, 52, 56, 59, 61, 62, 63, 64, 65, 66,
73, 74
23, 52, 56, 57, 59, 61, 66
20, 21, 28, 52, 59, 61, 66, 67
8
15, 25
35, 55
15
17, 18, 20, 21, 26, 34, 59, 61, 62, 63, 65
Storage and disposal
79