ATEX - TSR XX - Operating Instructions (Rev.2.1 - April 2016)

387 - TSR - ATEX E2121387 TSR xx - ATEX 2.
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TSR xx - ATEX
Operating Instructions
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Original operating instructions

Operating Instructions TSR xx - ATEX
Imprint
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Imprint
Document status: Original operating instructions

Type of document: Operating Instructions
Document ID: E2121387
Revision: 2.1
Date: 16-04-19
Editor: Brabender-Technologie KG
Copyright: © 2016, Brabender-Technologie KG
The contents of this document must not be copied – neither completely nor in
extracts – without prior written approval of Brabender Technologie KG and/or
transmitted to any third party. All technical documentations, drawings etc ...
fall under the copyright law: copyright reserved according to DIN 34.
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Table of contents
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Table of contents
Imprint .................................................................................................................................. 2
Table of contents ................................................................................................................. 3
1 Intended purpose........................................................................................................ 5
Intended purpose .......................................................................................................... 6
Use in ATEX environment ............................................................................................ 7
Manifest abuse ........................................................................................................... 10
Obligations of the user ................................................................................................ 11
Extended obligations for ATEX ................................................................................... 12
Content of the EC declaration of conformity ............................................................... 13
Content of the declaration of incorporation ................................................................. 14
2 Description of the device ......................................................................................... 15
3 Description of the device ......................................................................................... 16
The weighed execution ............................................................................................... 17
4 Description of the component groups of the device ............................................. 19
The hopper ................................................................................................................. 20
Drive motors ............................................................................................................... 24
Speed monitoring ....................................................................................................... 26
Agitators ..................................................................................................................... 27
The transport catches ................................................................................................. 28
Operation .................................................................................................................... 29
5 Optional component groups of the device ............................................................. 30
DE-STA-CO locks ....................................................................................................... 31
The hopper agitator .................................................................................................... 32
The rotatable execution .............................................................................................. 33
6 Safety instructions ................................................................................................... 34
Marking of hazard notes ............................................................................................. 35
Hazard notes .............................................................................................................. 36
Residual risks caused by the device ........................................................................... 40
Protective equipment .................................................................................................. 41
Safety instructions for weighing .................................................................................. 43
Marking of the device.................................................................................................. 44
7 Mounting of the device ............................................................................................. 45
Instructions for mounting ............................................................................................ 46
Instructions for electrical mounting ............................................................................. 48
Place of the installation, auxiliaries ............................................................................. 49
Transport of the device ............................................................................................... 50
General mounting work............................................................................................... 51
Electrical mounting ..................................................................................................... 53
Electrical connection of optional component groups ................................................... 58
Connection to a feeding controller .............................................................................. 59
8 Commissioning of the device .................................................................................. 60
Instructions for commissioning ................................................................................... 61
Rundown of commissioning ........................................................................................ 62
Commissioning of the feeding device ......................................................................... 64
Commissioning of the weighing system ...................................................................... 65
3
Table of contents
Determination of the discharge rate/feed rate ............................................................. 69

9 The operation of the device ..................................................................................... 70
The operation of a volumetric execution ..................................................................... 71
The operation of a gravimetric execution .................................................................... 72
10 Decommissioning of the device .............................................................................. 73
Switch-off with untroubled operation ........................................................................... 74
Alarm cut-outs ............................................................................................................ 75
11 Malfunctions of the device ....................................................................................... 76
Malfunction and remedy.............................................................................................. 77
12 Maintenance .............................................................................................................. 80
Maintenance instructions ............................................................................................ 81
Maintenance jobs........................................................................................................ 83
Cleaning of the device ................................................................................................ 85
13 Setting-up and exchange ......................................................................................... 86
Safety and preparatory work ....................................................................................... 87
Assembly/disassembly of the agitator(s) ..................................................................... 89
Shaft seals: Readjust the tension or renew ................................................................. 90
Adjustment of speed monitoring ................................................................................. 91
14 Storage and close-down .......................................................................................... 92
Instructions for storage/disposal ................................................................................. 93
Storage ....................................................................................................................... 94
Disposal ...................................................................................................................... 95
15 Spare parts lists ........................................................................................................ 96
16 Technical data ........................................................................................................... 97
General data ............................................................................................................... 98
Product data ............................................................................................................... 99
Identification key, nameplate .................................................................................... 100
Appendix A: Wiring plans ............................................................................................... 102
Connection to a Congrav® CB .................................................................................. 103
Connection of ISC execution .................................................................................... 105
Connection of a volumetric feeding device................................................................ 106
Terminal function junction box -JBn (n=2, 3,…) ........................................................ 107
Annex B Indications concerning the manual ........................................................... 110
Marking ..................................................................................................................... 111
Revisions .................................................................................................................. 112
Annex C Forms .......................................................................................................... 113
Certificate of nonobjection ........................................................................................ 114
Spare parts order ...................................................................................................... 115
Annex D Addresses and index .................................................................................. 116
Addresses................................................................................................................. 117
Index......................................................................................................................... 119
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Intended purpose
1 Intended purpose
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Introduction This chapter deals with the “intended purpose” and the “manifest
abuse“ of the device.
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Prerequisite for Prerequisite for the type approuval of the device:

the
type-approval • the use has to comply with the intended purpose
Any disrespect of the intended purpose has the following effect:

• the type-approval immediately ceases to be effective
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Content of the The chapter is divided into 7 parts.

chapter
Subject Page
Intended use 6
Use in ATEX environment 7
Manifest abuse 10
Obligations of the operating company 11
Extended obligations for ATEX 12
Content of the EC declaration of conformity 13
Content of the declaration of incorporation 14
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Intended purpose
Intended purpose
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The use The feeding device is employed for the feeding of bulk solids. If the
of the device use of the device complies with its intended purpose
• the device does not cause any danger for the operating staff, the
machine and the environment.
• the device is
- in a flawless condition as far as safety is concerned
- fully functional
• only appropriate products are fed.
• the application conditions for the dimensioning of the device are
complied with.
• the specifications of the documentation are complied with.
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Appropriate Products that are appropriate for being discharged/fed by means of

products the device have the following product characteristics:
• Not ignitable due to friction or strokes
• No explosive characteristics
• Appropriate flowability
• No change of the product characteristics due to
- the feeding operation of a screw feeder
- the agitator operation (trough and/or hopper!)
• No inadmissibly high wear of the device, e.g.
- screw feeder and/or
- agitator(s)
• No impediment or endangerment of the safety of operations
• Free from contaminations, foreign bodies etc.
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Dimensioning of The device is dimensioned according to the known operating

the device conditions. They result from the customer’s indications concerning
• the products employed and their characteristics,
• the environmental and operating conditions.
After any modification of the operating conditions a renewed

release for the operation of the device by the manufacturer is
required.
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Intended purpose
Use in ATEX environment
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Warning Modification of the ATEX zone in the production periphery

» No type approval for the device
» Danger for the operating personnel and the environment
• Use of the device only according to the marking of the allowed
zone.
• In case of zone distortions:
- Stop the device.
- Provide additional protective measures for
establishing/complying with the allowed zone.
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Requirements, If the device is used in an ATEX environment the following

conditions requirements/conditions have to be complied with:
• The device must only be employed according to the marking of
the device.
• Permissible ambient temperature (if there is no other information
on the nameplate) Ta: -20°C ≤ Ta ≤ + 40°C
• The minimum ignition temperature of deposited combustible
dusts (determined according to DIN EN 50281-2-1) has to
exceed the maximum surface temperature (according to the
marking of the device) by at least 75K. The thickness of the dust
layer must not exceed a value of 5 mm.
• The maximum surface temperature (according to the marking of
the device) must not exceed 2/3 of the minimum ignition
temperature of the whirled up dusts (determined according to
DIN EN 50281-2-1).
To be observed additionally for the application in areas with gas

explosion hazard:
• Chargeable plastic parts have a surface resistance Ro < 109Ω.
• Do not convey electrostatically charged dusts (e.g. from a
pneumatic conveyor) through the devices.
• With gases and vapours from the explosion class IIB the
maximum feed rate is 2000 dm³/h.
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Intended purpose
Use in ATEX environment, continuation
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Field of The field of application of the device is determined by the marking of

application the device on the nameplate.
Attention Operation outside the determined field of application

» Endangering the operating staff and the environment
» Cancellation of the type-approval
• The device must only be operated in an approved zone.
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Design of the The approved field of application is designated on the nameplate of

device marking the device.
Without type examination With type examination
Marking Meaning
Conformity mark according to appendix X of directive 94/9/EC
Explosion protection identification mark
II Equipment group (II = above-ground use)
2D/3G Category (inside/outside the device)
(here: inside 2D / outside 3G)
c Type of ignition protection “constructional safety“, EN 13463-5
IIA Explosion subgroup (with gas) classified according to the
minimum ignition energy
T135°C Max. allowed surface temperature of the device
(with dust: possible values 135°….250°C; here: 135°C)
T4 Temperature class (possible values: 2…4)
TA Allowed environmental temperature
(is only indicated, if it differs from the standard indication
-20°…+40°C)
A1 “0158“ marks the “notified body”
A2 Nr of ATEX certificate (combination of letters and numbers)
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Intended purpose
Use in ATEX environment, continuation
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Circumferential Rotating component groups in explosion-hazard areas must

speed of rotating not exceed the allowed circumferential speed in no operating
component situation (Smax = 1m/s).
groups
Measures for the compliance with Rmax:
• Dimensioning of the drive (drive + housing) and/or
• command of the drive (drive controller)
- Setting of parameters
- Sealing
- Clear assignment/marking
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Degree of cleaning Manufacturer’s instructions concerning the degree of cleaning of the

device:
• The formation of dust deposits on the device has to be
prevented, as this could produce an explosive mixture if whirled
up.
• Thickness of dust layer < 1mm
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Intended purpose
Manifest abuse
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Definition “Manifest abuse” means that the device is used for applications that
are “manifest” due to the possibilities and executions of the device
but that are inappropriate and thus not allowed.
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Improper use The use is to be considered as improper in case of non-compliance

with the following points:
• the intended use
• the documentation
• the operational safety by
- a deactivation of a protective equipment
- incorrect operating/environmental conditions.
Examples for an improper use:

Improper mounting
• no flexible connection of inlet/outlet
Improper operation
• unallowed combination screw/screw pipe
• operation with freely accessible rotating component groups
• operation without cover on the product zone (foreign bodies!)
• operation with a closed outlet
• operation of an empty device with high speeds
• operation with open electrical assemblies
*
Modifications to the device without release
• modification of the construction of the device
• modification of the equipment of the device
• reduction or elimination of protective functions
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Effects Any abuse of the device

• endangers the operating staff and the machine
• the type approval of the device ceases to be effective
• has an effect on the manufacturer’s liability.
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d
*
to be released by the manufacturer of the device
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Intended purpose
Obligations of the user
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Statutory During the operation the following national and international

provisions regulations/guidelines concerning:
• the protection of persons
• the safety of persons
• the EMC directive
• the state of the art
• the acknowledged engineering rules
have to be observed.
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The use Be sure to observe the following points for the use of the device:
of the device
• the intended purpose
• the indications given in the manual
• the safe state of the device
• the prescriptions concerning an untroubled operation
• trouble and damage has to be eliminated immediately
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Qualification of Required qualification of the operating staff:

the operating staff
• 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
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Simple cleaning and maintenance work:

• The work can be carried through by well-trained operators.
Extensive mounting and repair work:
• A specialist with necessary technical knowledge is required for
this work.
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Intended purpose
Extended obligations for ATEX
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Introduction With an ATEX execution the user has to comply with further
obligations in order to protect the operating personnel and the
equipment.
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Danger Potentially explosive gas mixtures or dust concentrations

Severe or fatal injuries
• Component groups mounted on site comply at least with the
required category of device.
• Product supply/discharge lines are dust-proof/gas-proof.
• Continuous earthing of the device that is conforming to
standards.
• Do not bring ignition sources into the device.
• Avoid spark formation.
• Foreign bodies must not enter the device.
• Do not cause a product jam in the device.
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Ambient The allowed ambient temperature according to EN13463 has to be

temperature complied with. Overstepping puts at risk the safety of operations by
possible functional failures of the electrical safety components (PTC
resistors etc.).
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Compliance with Be sure to comply with the determined zone allocation:

the zone
allocation • The device does not comply with the new zone allocation.
• The type approval of the device ceases to be effective
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Intended purpose
Content of the EC declaration of conformity
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Introduction If the execution of the device corresponds to the terms of

MRL2006/42/EG an EC declaration of conformity for a machine will
be enclosed. Here the manufacturer declares that
• the machine is corresponding to all relevant provisions of this
directive.
• that the machine complies moreover with the mentioned
directives and/or relevant provisions.
Moreover this declaration includes further indications concerning the

manufacturer and the machine.
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Data provided by The declaration includes the following information:

the manufacturer
• Name and address of the manufacturer
• Indication of the duly authorised person responsible for compiling
the technical file
• Name and signature of the duly authorised person responsible
for issuing the declaration.
• Indication of place and date of issue
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Designation Indications given in the declaration that serve to designate the

machine:
• Designation of the machine
General designation of the machine
• Type of machine
Type/execution of the machine.
The type designation code is explained in the chapter "Technical data".
• Marking of the machine
ATEX marking of the machine
• Year of construction
The year of construction of the machine
• Serial number
The unique serial number of the machine
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Intended purpose
Content of the declaration of incorporation
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Introduction If the device is executed as a partly completed machine in the terms

of MRL2006/42/EG an EC declaration for the mounting of a partly
completed machine will be enclosed. Here the manufacturer
declares:
• which basic requirements of the directive are applied and are
complied with.
• that the technical documentation has been established and can
be submitted in response to a justified request of a national
authority.
• the other directives the partly completed machine complies with.
• that the partly completed machine must only be commissioned
after incorporation into a machine that complies with the
requirement of directive MRL2006/42/EG.
Moreover this declaration includes further indications concerning the
manufacturer and the machine.
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Data provided by The declaration includes the following information:

the manufacturer
• Name and address of the manufacturer
• Indication of the duly authorised person responsible for compiling
the technical file
• Name and signature of the duly authorised person responsible
for issuing the declaration.
• Indication of place and date of issue
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Designation Designation of the partly completed machine:

• Designation of the partly completed machine
General designation of the partly completed machine
• Type of machine
Type/execution of the partly completed machine.
The type designation code is explained in the chapter "Technical data".
• Marking of the machine
ATEX marking of the partly completed machine
• Year of construction
The year of construction of the partly completed machine
• Serial number
The unique serial number of the partly completed machine
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2
Description of the device
2 Description of the device
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Introduction This chapter describes the feeding devices "troughed screw conveyor
with trough agitator" (short: TSR).
The executions of the feeding devices TSR vary as far as size and
construction are concerned.
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The type designation indicates the construction size and the

execution. The type designation code is explained in the
chapter "Technical data".
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Content The chapter is divided in 2 sections.

of the chapter
Subject Page
Description of the feeding device 16
The weighing of the feeding device 17
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15
3
3 Description of the device
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The illustration shows the

construction of a TSR.
No Meaning
1 Mounting plate
2 Cover of coupling
3 Speed monitoring
4 Rear bearing of screw shaft
5 Troughed screw conveyor
6 Outlet
7 Front bearing of screw shaft
8 Vent pipe
9 Agitator trough
10 Cleaning hole
11 Trough agitator
12 Reinforcing sheets
13 Drive motor agitator
14 Coupling
15 Drive motor screw
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The construction The TSR is a feeder for the feeding of bulk solids that can be fed by
means of a screw. A characteristic feature of the TSR is the trough-
shaped screw pipe. Due to the construction size of the screw the
screw is born on two points. The product is conveyed via the agitator
trough into the screw, then the screw transports the product to the
outlet. For an improved and more even filling ratio of the screw an
agitator that is rotating vertically, runs in the agitator trough. The
agitator is mounted on one side to the drive shaft. In order to achieve
the required stability the side wall of the agitator trough is reinforced
by means of sheets in this area. Agitator and screw are driven by one
motor each.
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16
3
The weighed execution
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Definition: The technical term “weighing” designates the computation of the

weighing product weight by measuring the hopper weight by means of one or
several load cell(s).
Application examples for weighing:
• Loss-in-weight feeder (DDW)
• Monitoring of hopper filling level (MS-…)
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Construction of For this purpose, the feeding device is mounted on a weighing

the weighing system. Two weighing systems are available:
system
Weighing Description
system
H3x Hybrid weighing frame system with 1 load cell
Load cell: digital or analogue
MSx Platform weighing system with 3 or 4 load cell(s)
Load cell: analogue
x = Identification number for the construction size and the max. weighing range
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Load cell types As a function of the signal transmission 2 different load cell types are
employed:
Signal type Features
digital • serial weight signal
analogue • analogue mV-signal
• load cell functions according to the “EMS“ principle1.
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Additional The weighing requires additional electrical component groups:

component
groups Level monitoring Loss-in-weight feeder
Suitable evaluation unit Congrav® with weighing module2
1
EMS = elongation measuring strip
2
Congrav® = feeding controller;
Weighing module (is a function of the load cell type) = weight signal transmission to Congrav®
17
3
The weighed execution, continuation
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Weighing system The weighing system DDW-H3x:

H3x
No Description
1 Transport eyelets
2 Weighing frame
3 Base frame
4 Junction box
5 Mounting surface feeding device
6 Transport catch
7 Load cell
8 Vibration isolation mounting pads
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Weighing system The weighing system DDW-MSx:

MSx
N°Description
(4 load cells)
1 Load cell
2 Overload protection screw
3 Transport eyelets
4 Vibration isolation mounting pads (mounting of
the feeding device)
5 Mounting plate
6 Vibration isolation mounting pads (ground
assembly)
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18
4
Description of the component groups of the device
4 Description of the component groups of the device
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Introduction This chapter describes the component groups of the device.

• Description of the construction and function
• Description is not a function of the execution
• Marking of a specific modification: indication of the execution of
the device.
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Content of the The chapter is divided in 6 parts.

chapter
Subject Page
The hopper 20
The drive motors 24
Speed monitoring 26
Agitators 27
The transport catches 28
The operation 29
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19
4
The hopper
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Introduction The hopper permits to store the product to be fed. The execution of
the hopper is determined by the application.
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Safety equipment The hopper serves as a protection against the rotating trough
agitator. It prevents the operating personnel from reaching into the
rotating trough agitator. This is achieved by various measures, a
combination of the measures is possible:
• the size of the hopper
• a mounted safety grid
• a safe screwing of the hopper or the hopper cover
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Fastening, The hopper cover is screwed tightly to the screw trough. A sealing
sealing profile between the trough and the hopper flange serves for the
sealing.
Optional execution:
• Hopper fastening with tightening clamps
• Electric contact switch as safety equipment
• Integration of the contact switch into the operating
release of the feeding device.
- Feeding device stops if hopper is removed
- Feeding device cannot be started if the hopper is not
mounted
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Hopper cover Execution of the hopper cover for refilling

Automatic filling Manual filling
• Screwed tight • Removable or foldable
• Inlet pipe • Safety grid in the hopper
• Vent pipe
20
4
The hopper, continuation
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Automatic The automatic filling requires:

refilling
• A feeding controller with the following minimum functions:
- Monitoring of the hopper filling level
- Operation of the refill device
• A refill device with the following minimum features:
- Hopper volume for a sufficient product quantity
- Shut-off device between the outlet and the feeding device
that can be operated by the feeding controller.
Be sure to observe the following points for automatic refilling:

• The feeder and the refill device form a closed system.
• The system has to be aerated/vented sufficiently.
• Protective measures have to be installed to the refill
device before the introduction of foreign bodies,
smoulder spots etc.
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Manual filling With manual filling

• the cover has to be opened or removed.
• the product has to be filled in by the operating staff.
Protective measures are required:

• Before a dust contamination of the environment
• Before the introduction of foreign bodies
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Monitoring of the With automatic refilling the filling levels are monitored by the feeding
filling levels controller (Congrav®). I.e.,
• upon reaching the minimum filling level the feeding controller will
start the refill operation.
• upon reaching the maximum filling level the feeding controller will
stop the refill operation.
21
4
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With manual refilling the operator has to monitor the filling levels and
execute the refill operation.
The optional filling level monitoring permits:

• "optical aids" (signal lamp, etc.)
• integration into the on-site process control system
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Executions Examples for aeration methods:

aeration/venting
Figure Method
Filter bag
• Filtering by means of the bag cloth
• Regular cleaning intervals are required
• Use is not recommended if the contamination
is too big
Filter pipe
• Filtering by means of Vyon foam tissue
• Regular cleaning intervals are required
• Not suitable for very dusty products
JetFilter
• Be sure to observe the operating instructions
Vacuum system (varying executions)
• The setting of the vacuum system must not be
stronger than required
• Regular cleaning of the suction line
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Warning The device gets dusty due to the filter bag/ the filter pipe
» Zone diversion
• Regular cleaning (dust layer < 1mm).
• Employ admissible filter bags (conductive filter material).
22
4
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Aeration, If the hopper cover is closed tightly an aeration/venting system is

venting required for the pressure compensation of the hopper.
Attention! Pressure variations in the hopper

» Operational disturbances appear
• Installation of a aeration/venting system that is suitable for
- displaced air volume
- environmental conditions
- product characteristics
• The feeding operation is not troubled by the aeration/venting
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Inertising If a protective atmosphere is required (e.g. N2) due to the product

characteristics, the device has to be inertised during the feeding
process. The supply of the protective gas:
• is provided on site
• has a max. allowed operating pressure of 20 mbar
• permits a pressure compensation (de/aeration)
- by the control of the inertising or
- of an equal pressure compensation
Protective gas systems are closed systems:

The pressure compensation is a requirement for the
operation, as a traditional de/aeration.
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23
4
Drive motors
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Mounted Depending on the execution of the feeding device the following drive
drive motors motors can be mounted:
• Drive motor for the feeding screw
• Drive motor for the trough agitator
• Drive motor for the trough agitator (optional)
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Indications Indications for the drive motors

drive motor
Feeding screw Agitator
• Threephase current drive • Threephase current drive
(standard) (standard)
• Operation of frequency • Mains operation
converter • Indicated direction of rotation
• Indicated direction of rotation
The complete documentation of the feeding device includes a

motor data sheet for each drive motor.
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Direction The operation of the drive motor is only allowed in the specified
of rotation direction of rotation (arrow).
Attention! Wrong direction of rotation

» Compacting product in the spiral
» Loosening of screw or agitator
» Damage of the device
• Operation has to be stopped immediately
• Enable the device
• Change the direction of rotation
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Nominal operating The nominal operating speed results from the nominal speed of the
speed drive motor, the transmission ratio is possibly taken into account, if a
motor-gear-combination is employed. It is a part of the dimensioning
of the device!
A modification of the dimensioning is only allowed if it has

been released by the manufacturer, otherwise the reception
of the device ceases to be effective.
24
4
Drive motors, continuation
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Modes The mode of a drive motor is determined by its function. The

drive motor following assignment applies as a standard:
Drive motor for Mode
Feeding organ Frequency converter with speed default
The speed of the drive motor (= working point) is set via
the frequency converter by means of the speed default.
Agitators Mains connection
The drive motor functions constantly with the nominal
operating speed ("embossed" speed).
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25
4
Speed monitoring
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Executions Feeder executions with speed monitoring:

of the device
If Then
loss-in-weight feeder (DDW-..) with speed monitoring
ATEX execution with speed monitoring
volumetric feeder optional speed monitoring
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Design of the The illustration shows the

speed monitoring mechanical construction of the
speed monitoring. The speed
monitoring system senses the
teeth of a toothed wheel (1) by
means of an inductive proximity
switch (2). The proximity switch
generates electric pulses per
revolution as a function of the
number of teeth.
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Evaluation The evaluation of the speed pulses and the control system of the
of speed pulses speed monitoring requires a suitable electric component group:
If Then
loss-in-weight feeder (DDW-..) Congrav®
volumetric feeder external evaluation unit
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26
4
Agitators
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Danger Rotating agitator

» Cutting of limbs, fatal injuries
» Very severe damage of the machine
• No operational release for the feeding device if the agitator has
free access.
• Prevent the operating staff from reaching into the rotating agitator
- Closed hopper cover
- Appropriately mounted hopper
- Mounted safety grid
• Regular maintenance/cleaning
- Wear long gloves as a protection
- Eliminate deposits (risk of unbalance)
- Checking of the shaft bushings (damaged bearing,
overheating)
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Use of the agitator As a rule, agitators are employed if required due to the product
characteristics. They support and improve the product feeding. The
use of agitators permits to
• improve the filling ratio of the feeding screw.
• prevent "bridging" product.
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Agitator types Trough agitators

• rotate vertically in the screw trough.
• are adjusted to the screw trough as far as their design/size are
concerned.
Hopper agitators
• rotate vertically or horizontally in the hopper.
• various designs are available as they are adjusted to the shape
of the hopper and the product characteristics.
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Operation Specifications and definitions for the operation of an agitator

of an agitator
• Agitators must only be employed for products that are suitable for
an agitator operation.
• Agitators are started and stopped with the feeding operation.
Exception: Product characteristics require a continuous operation
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27
4
The transport catches
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Introduction Transport catches are employed to protect the load cell(s) during
weighing of the device.
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Function Transport catches permit to connect the device with the base plate
(downstream connection point) and thus relieve the load cell(s). They
protect the load cell(s) from unallowed loading and torsions during
• a change of the place of the installation (transport)
• mounting/maintenance work.
During the operation some weighing systems protect the load

cell(s) against overloading by means of an "overload
protection screw". This overload protection does not
substitute the function of a transport catch.
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Execution Transport catches are red sheets or angles that are screwed to the
base plate and the feeding device.
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Use Employ the transport catches as follows:

• to be installed before any work/change of the site.
• to be removed before commissioning
• remain on the device without changing the feeding operation
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28
4
Operation
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Definition: Component groups for

operation
• the command of the device operation and/or
• the visualisation of the device status.
Examples:
• Signal lamps
• Start/stop switches
• Emergency switch
• Complex feeding controller (Congrav®)
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Executions The execution depends on 2 factors:

(grav. or vol.)
• On-site requirements, for instance:
- signal lamp
- signals for processing systems
- emergency cut-out systems
• The execution of the DualTray determines the type of feeding
controller.
Execution Feeding control employed

gravimetric Congrav®, ISC-system
volumetric Drive controller + potentiometer
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Comparison: The feeding controllers for a volumetric or a gravimetric execution

feeding differ as far as the design and especially as far as the functions are
controllers concerned.
Function volumetric gravimetric
Adjustment of the feed rate Potentiometer Input
0 – 100% setpoint [kg/h]
Acquisition of the feed rate No Yes
Control of the feed rate No Yes
Level monitoring No3 Yes
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3
Requires an optional weighing system with an external evaluation unit
29
5
Optional component groups of the device
5 Optional component groups of the device
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Introduction This chapter describes optional component groups of the device.

These component groups
• modify the construction and the functions of the device
• are adjusted to the corresponding execution of the device
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Quality rating of As already included in the designation "optional", this chapter

the descriptions describes component groups that are not included in the standard
execution of the device. Therefore, the following applies to the quality
rating of the description in this chapter:
If the component group Then the description
is available has to be observed (requirement)
is not available can be read through (information)
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Content of the This chapter is divided into 2 parts that describe the component
chapter groups for the optional equipment of the device.
Subject Page
DE-STA-CO-locks 31
The hopper agitator 32
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30
5
DE-STA-CO locks
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Construction The illustration shows the construction

of a DE-STA-CO lock:
No Description
1 Clamping lever
2 Locking protection
3 Bracket
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Application If required, the DE-STA-CO locks are employed optionally. Possible

selection criteria, e.g.:
• higher sealing force
• patented one-hand operation
(when opening the clamping lever (1) the thumb pushes the
locking protection (2) downwards).
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Safety DE-STA-CO locks:

• Opening without additional tool
possible
• Risk potential with security
relevant components
Additional protection:
• Screwing (S)
• Contact switch that is integrated
into the interlocking chain for the
operating release of the device.
Attention! No additional protection according to customer’s requirements

» Disassembly of security relevant components during the
operation
• Install security/protection measures on site
• User’s manual for the safe handling of the device
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31
5
The hopper agitator
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Illustration The illustration shows the

hopper agitator construction of a hopper
agitator that is revolving in
vertical direction
No Meaning
1 Drive motor
2 Shaft seals
3 Agitator
4 Shaft seals
5 Flange bearing
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Construction The hopper agitator

• Shaft with offset "agitator blades"
• Rotatable mounting position inside the hopper.
• Bearing by 2 flange bearings on the hopper wall
• Drive motor is mounted outside the hopper.
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Function The function of the hopper agitator is the amelioration of the product
feeding with the following product characteristics:
• compacting,
• bridging or
• generally poor flowability
The agitator blades rotate in the product, they are driven by the drive
motor. Effects of the agitator operation:
• homogenizing of the product in the hopper
• improved flowability of the product
• homogeneous filling ratio of the feeding screw
• improvement of the product feeding
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32
5
The rotatable execution
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Introduction With a rotatable execution the feeding device is mounted on a

turntable.
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Feeding device The illustration shows a typical

with turntable application for the rotatable
execution of a feeding device:
A feeding device can have 2
different feeding positions.
No Description
1 Locking bolt
2a Locking position 1
2b Locking position 2
3 Turntable
4a Feeding position 1
4b Feeding position 2
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Requirements Additional requirements for a rotatable execution:

rotatable
execution Area Requirements
Cabling • Appropriate for the rotation
• Protected against ripping off or entangling
• No risk for the operator
Operation and • Only locked operating positions
activities • Work (maintenance etc.) on the device is
only allowed if it is locked.
Before a rotation of • Lock the transport catches.
the device • Loosen the connection of the outlet.
• Loosen the connection of the inlet.
Rotation of the • Rotation guided by the operator
device • Guiding at a downstream connection point
of the device (e.g. base plate, base frame
etc.)
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33
6
Safety instructions
6 Safety instructions
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Introduction This chapter indicates safety instructions concerning possible

hazards or for a safe operation of the DualTray.
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Validity The safety instructions are to be observed for the operation of the
device and for any work on the device, even if they are not mentioned
explicitly in the description of the steps to be taken.
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Definition: The term “disconnection” is employed for the following hazard notes
Disconnection and in the rest of this manual. “Disconnection” means:
• Disconnect the device from all supply media.
• Protect it against unauthorised reconnection.
• Discharge all kinds of energy stocks (manually or due to
sufficient dwell times)
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chapter
Subject Page
Marking of hazard notes 35
Hazard notes 36
Residual danger 40
Protective design measures 41
Safety instructions for weighing 43
Marking of the device 44
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34
6
Safety instructions
Marking of hazard notes
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Introduction In this chapter and in the following ones hazard notes mark situations
that are dangerous for the operating staff and/or the machine. The
composition of the hazard notes follows a determined structure and
quality rating. This chapter describes both, structure and quality
rating.
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Structure of the The scheme shows the composition of a hazard note:

hazard notes
Signal word Reason of danger
» Effect of danger
• Countermeasure
Additional explanation:
Element Meaning
Signal word Marks the quality rating and is described
below.
Symbol General: Attention symbol
Special: Electricity symbol etc.
Effect, Listings, several elements possible
countermeasure
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Quality rating The meaning of the signal word:

of the
hazard notes Signal word Meaning
Danger Imminent danger that may cause severe injuries or
death.
Warning Possibly dangerous situation that may cause severe
injuries or death.
Caution either
possibly dangerous situation that may cause
slight injuries
or
dangerous situations the potential hazard of
which is a function of unknown parameters e.g.
”product characteristics”.
Attention! Possibly dangerous situation that might cause
material damage to other equipment.
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35
6
Safety instructions
Hazard notes
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Danger Malpractice
Considerable hazard potential for the operating staff and the machine
• Be sure to comply with the intended purpose.
• Be sure to observe the instructions for mounting, operation and
maintenance.
• Be sure to observe the instructions for the execution of the
corresponding work.
• Do not carry out any arbitrary modification.
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Danger Voltages that are hazardous upon contact

» Electric stroke during work on electric component groups
Work on the device:

• Disconnect the device before the start of the work.
• To be carried out by a qualified electrician
• Please observe:
- the valid standards and regulations,
- the state of the art
- the acknowledged engineering rules
Maintenance of the device:
• Check electric component groups/installation.
• In case of damage:
- the device has to be stopped immediately.
- disconnect the device.
- eliminate the damage or exchange component groups.
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Warning No earthing or inappropriate earthing

» Discharge of static loads
• Connect the marked main earth connection point of the device to
the on-site equipotential bonding.
• Earth connections between the device and the mounted
component groups must not be interrupted or removed.
• Connections to earth have to be checked regularly and renewed
if required.
36
6
Safety instructions
Hazard notes, continuation
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Warning Residual energy storage

» Electric stroke, contusions, burns and other
• Disconnect the device.
• Sufficient waiting time before the start of work:
- Discharge of electric energy stocks
- Cooling of hot surfaces (thermic)
- Aeration of compressed-air lines (pneumatic)
• If available:
Positioning into the final position, so that the formation of elastic
or torsional forces can be prevented.
Examples for energy stocks:

Type Example
Electric Charged capacitors, coils
Mechanic Tensioned springs
Pneumatic Filled compressed-air storage
Thermic Hot surfaces, dissipators
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Danger Rotating agitator

» Cutting of limbs, fatal injuries
» Very severe damage of the machine
• No operational release for the feeding device if the agitator has
free access.
• Prevent the operating staff from reaching into the rotating agitator
- Closed hopper cover
- Appropriately mounted hopper
- Mounted safety grid
• Regular maintenance/cleaning
- Wear long gloves as a protection
- Eliminate deposits (risk of unbalance)
- Checking of the shaft bushings (damaged bearing,
overheating)
37
6
Safety instructions
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Caution Leakages
» As a function of the product characteristics leakages present are
hazardous for the operating staff and the machine
Immediate measures:
• Stop the device.
• Safety measures for the protection of the operating staff and the
machine have to be taken.
Elimination of the damage:

• Eliminate the leakage and its cause.
• Eliminate damage of the device.
• Clean the device and the environment.
• Correct disposal of residual product.
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Caution Residual product in the device

» Endangers persons because of hazardous product
characteristics
» Contamination of the environment during the disassembly
» Product blending during product change
• Safety measures for the protection of the operating staff and the
machine have to be taken.
• Correct disposal of residual product, contaminations.
• Thorough cleaning before a product change.
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Caution Inadmissible product temperatures

» Danger for the operating staff and the environment
» Drastic reduction of the average lifetime of the device
» “Hidden” damages the effects of which can only be seen later
• Be sure to respect the allowed range of product temperatures
• Mark hot surfaces
38
6
Safety instructions
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Attention! Foreign bodies on the device, in the product zone

» Damage of on-site equipment
» Operational failures
• Foreign bodies have to be removed before commissioning
• Closed product zone
• Protective measures have to be installed
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Attention! Improper transport of the device

» Endangering operating staff and the environment
• Prepare the device for the transport
• Employ suitable lifting equipment or similar
• Use transport equipment (transport eyelets etc.) that is mounted
to the device.
• Do not tie transport straps or similar to the component groups.
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39
6
Safety instructions
Residual risks caused by the device
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Introduction The device has been manufactured according to the state of the art
and under respect of the valid standards and regulations. However,
there are “residual dangers”.
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Caution Activity or operating situation causing the residual risk

• Activities:
- Be sure to observe the specifications.
- Take protective measures before carrying out the operations.
• Operating situations:
- Comply with the allowed working/operating range.
- Immediate cut-out in case of dangerous operating situations.
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Residual risk Source of Product jam

product jam danger:
• in the inlet/outlet of the device
• in the upstream/downstream equipment
Effect: • Operational failures
• Damage of the device
Measures: • The free product flow into the device and out of the
device has to be guaranteed.
• With upstream/downstream devices that stop the
operation of the device (interlocking chain).
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Residual risk Source of Missing pressure compensation because of

ventilation/deaerat danger:
ion • missing ventilation4
• inappropriate execution of the ventilation.
• external pressurisation.
Effect: • Operational failures
• Damage of the device
• Endangering the operating staff and the environment
Measures: • The device has to be aerated/vented sufficiently.
• Avoid pressurisation with overpressure/low pressure
caused by connected equipment.
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4
Ventilation = ventilation or deaeration of the device
40
6
Safety instructions
Protective equipment
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Introduction The device is equipped with protective equipment to protect the

operating staff and the machine. Please find below a description of
the protective equipment.
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In general, the type-approval of the device ceases to be

effective, if one protective measure has been mounted
correctly or has been deactivated.
Components with Different types of protective equipment may be mounted to a device.

protective The protective equipment may have different functions.
functions
1. Components with a pure protective function
These components (e.g. covers) have only been mounted due to
their protective function. As a rule, they have no effect on the function
of the device. But:
An operation of the device is only allowed with a properly
mounted protective equipment.
2. Components with combined functions

These components have an operative function and a protective
function. For instance:
• The hopper has the function to store product.
• The construction size of the hopper prevents the operating staff
from reaching into the rotating components.
3. Components with monitoring functions

These components are switches or detectors that monitor the
closing, the position or the status of a component. As a rule, they
deliver an electrical signal that is integrated into an interlocking chain.
If one or several monitoring devices report an error, an interlocking
chain will block the operational release of the device. I.e. it
• will prevent the start of a stopped device
• will cause an immediate stop of a started device
41
6
Safety instructions
Protective equipment, continuation
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Sealings Set screws or similar are adjusted and fixed in position in our works
by lacquer or a seal. The sealings must not be damaged. Otherwise
the type-approval of the device and the manufacturer’s liability cease
to be effective.
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Safety screwing As a rule, the protective equipment is tightly screwed, i.e. a tool is
required for disassembly and accidental loosening is thus prevented.
If components with protective functions are fixed by means of "quick
release" connections, at least one "quick release" connection is
protected by means of an additional safety screwing against
unintentional operation.
Safety screwing is a protective equipment. As an alternative

the component can also be monitored by means of the "quick
release" connection (switch, sensors).
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42
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Safety instructions
Safety instructions for weighing
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Introduction For feeders with a weighing system (level monitoring or gravimetric

feeding) further safety instructions have to be observed due to the
construction and due to the weight reading.
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Mounting, The mounting and the place of the installation have to comply with
place of the the high requirements concerning the protection against external
installation perturbations (vibrations, chocks, vibrations etc.) for a safe weighing.
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Allowed The allowed operating range of a weighed device is a function of the

operating range operating data:
• the load cell(s)
• the evaluation unit or the controller
• the feeding device (hopper contents, drive etc.) and
• the product employed (bulk density)
The allowed operating range takes into account all these

operating data and does not violate the limits.
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Operation During the weighing process the weight signal is evaluated via a
suitable evaluation unit (level monitoring) or a feeding controller
(gravimetric feeding).
Requirement for the an accurate operation:

Qualified specialist personnel adjusts the evaluation unit/the
feeding controller to the operating data of the load cell.
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Attention! Transport or work on the device

Damage of the weighing system
Before the start of the work/transport:
The transport catch(es) have to be mounted completely and properly.
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43
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Safety instructions
Marking of the device
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Warning labels Beware of dangerous electric voltages.

on the device Any work on the device/the component group required
• a qualified electrician
• and a secure, zero-potential state
Beware of high surface temperatures.

Any work on the device/the component group required
• protective equipment (gloves etc…)
• sufficient cooling down before the start
Beware of danger of bruising.

Any work on the device/the component group required
• appropriate protective equipment
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Instructions Disconnect the device from the power supply.

on the device Before the start of any work on the device
• it has to be disconnected from the power supply
• protect it against unauthorised reconnection
Connect the earth connection line.

Marked earth connection points
• have to be connected correctly to protective earth
Be sure to observe the specified direction of rotation.

During the commissioning
• check the direction of rotation of the drive motor
• change the wrong direction of rotation
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Prohibitions Sharp-edged agitator

on the device Considerable risk of injuries, therefore:
• Never put hands or arms into a rotating agitator.
• Put on long gloves during the work.
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44
7
Mounting of the device
7 Mounting of the device
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The aim The aim of mounting is to put the device in a state where it is ready
of mounting for the start of the operation.
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chapter
Subject Page
Instructions for mounting 46
Instructions for electrical mounting 48
Place of the installation, auxiliaries 49
Transport of the device 50
General mounting work 51
Electrical mounting 53
Electrical mounting of optional component groups 58
Connection of feeding controller (for a DDW-…) 59
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45
7
Instructions for mounting
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Mounting Prescriptions for appropriate mounting:

• The mounting has to be carried out by specialist personnel.
• Be sure to comply with the statutory provisions.
• Eliminate sources of danger for the operating staff and the
environment.
• Do not damage the device.
• Avoid disturbances of the mounting work.
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ATEX environment For mounting in an ATEX-environment:

• Check whether the device is appropriate (marking on the identi-
fication plate) for being employed in the actual ATEX-environment.
If the device is Then
appropriate mounting is allowed
not appropriate mounting has to be discontinued immediately.
• Do not cause any additional explosion hazard.
• Employ allowed tools, measuring instruments.
• Equipotential bonding at the inlet/outlet of the device via the
flexible connection
- flexible, conductive material
- earthing of the tightening straps (fastening), if they are
equipped with an earthing bolt.
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Instruction for Preliminary mounting work for sample measurements that permit to
commissioning determine/check the feed rate of the device:
• A collecting receptacle that is suitable for the product quantity
has to be available.
• If necessary, a bypass line to the collecting receptacle has to be
mounted.
46
7
Instructions for mounting, continuation
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Interruption of To be observed in case of an interruption of mounting:

mounting
• Protect the device against foreign bodies.
• Mark that the device is partly mounted and
• protect it against an unauthorised commissioning.
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Completing the Mounting ends with if the device is ready for operation. This includes:
mounting work
• Correct and complete mounting of the device.
• “Final cleaning” of the environment, remove all foreign bodies.
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47
7
Instructions for electrical mounting
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Danger Working with voltages that are hazardous upon contact

» Electric stroke during work on electric component groups
• Be sure to comply with the statutory provisions.
• Have the work done by a trained and authorised electrician.
• Disconnect the device (please see the page 34).
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Connection Prerequisite for the type approval of the device:

earthing
Provide an appropriate earth connection. This means:
• The earthing has to be carried out according to the standards.
• The mains earth connection point has to be connected to the
equipotential bonding on site.
• Continuous earthing
- of the complete device
- of the connections on site
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Cabling Cabling work has to be carried out appropriately. This means:

• Only employ the allowed cable types
• Do not exceed the max. allowed cable length
• Separate laying of high-voltage current and signal/control lines
• Implementation of all protective measures against
electromagnetic interfering fields
Danger Inappropriate cabling

» Danger for the operating personnel and the environment
» Operational disturbances and malfunctions
• Cabling work has to be carried out appropriately
• For off-size cable types/length you have to demand the approval
of the manufacturer
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Screwed cable The screenings are a function of the available screwed cable glands
glands, screening and they are connected as follows:
For What to do: provide screening

Metal acc. to the illustration
Plastic PE terminal, junction box
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48
7
Place of the installation, auxiliaries
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Place of the The place of the installation has to comply with the following
installation specifications:
General specifications:
• according to standards (ArbStättV, GefStoffV etc.).
• stable, dry, at level, free from vibrations
• suitable for the load/loading to be expected
• protected against the impact of climate
• allowed environmental temperature
• free from oils, fats, gases, vapours etc.
• no explosive atmosphere.
Instructions for the equipment:
• sufficient illumination
• sufficient dimensioning, so that a possible access to the device or
components that are mounted to the device are not blocked
• connections for necessary supply media (evacuation, supply
voltages, compressed-air, etc.) are available.
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Mounting tools Required for mounting:

Tools
• General locksmith’s tools
• General electrician's tools
• level
Auxiliary equipment
• Lining plates for the horizontal alignment
• Cover tarpaulin
• Cleaning rags, cleaning agent
Before use make sure to observe the “Cleaning of the
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device” (page 85).
49
7
Transport of the device
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Caution Inappropriate transport

» Risk of injury
» Damage of the device or the equipment
• Use suitable transport equipment
• Do not fasten transport equipment to mounted component
groups
• Use mounted transport equipment (transport eyelets etc.)
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Transport to the Suitable lifting equipment (fork lift truck, crane, etc.) permits to
place of the transport the following items to the place of the installation:
installation
• the device
• loosely supplied parts
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Be sure to observe the total weight of the device!

The total weight of the device is indicated on the spare parts
drawing.
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Caution Danger of tipping

» Risk of injury for the operating staff
• Be sure to observe the centre of gravity.
• Use an appropriate, allowed anti-tipping device.
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50
7
General mounting work
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Instructions for Make sure to observe the following points for mounting:
the execution
• Horizontal alignment
• Max. 2mm offset
for the connection of the device to the equipment on site
• Flexible connections to the product lines on site
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Installation Persons, tools

• 1-2 persons (lifting equipment, mounting)
• Lifting equipment (crane, fork lift truck etc.)
• General locksmith’s tools
• Lining sheets for horizontal alignment
Step What to do
1 If required, carrying straps or similar have to be fastened
without causing damage to the device
2 Transport the device to the place of the installation
3 Align the device at the place of the installation
4 Align the device horizontally (lining sheets)
5 Screw the base frame to the floor construction
51
7
General mounting work, continuation
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Connection To protect the product lines on site external disturbances they are
inlet/outlet connected to the inlet or outlet of the device by means of a flexible
connection. As a function of the section size, the inlet/outlet (QVA)
and the product line (QRL) three different executions are employed for
the flexible connection.
Section Execution
QVA < QRL 1. Graduated flexible connection sleeve
QVA = QRL 2. Step bellow (high flexibility)
3. Sleeve
(if less flexibility is sufficient)
Sleeve and the fixing material for the flexible connection are supplied
loosely with the device.
QVA > QRL is not supported!

There is a risk of product jam.
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Connection Standard execution of the venting system:

of venting
• Filter bag/pipe loosely supplied
Mounting of the venting system:

Venting Mounting work
Filter bag • Connection to the venting nozzles
• Suspend the filter bag in the retainer
Filter pipe • Connection to the venting nozzle
JetFilter • Be sure to observe the operating instructions
Suction • Downstream connection point provided on site
• Flexible connection to the venting nozzle or by
means of an annular gap ("china hat")
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52
7
Electrical mounting
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Information on Two different types of information are employed for the description of
electrical the electrical mounting: wiring plans and task descriptions. Both types
mounting of information are to be found in different chapters of this manual.
Type of information Chapter
Task descriptions in this chapter
Wiring plans in appendix A
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Order of the Due to the special application and the component groups employed 3
wiring plans different types of wiring plans may be included in the documentation
folder. The following order of rank has been defined for the wiring
plans.
Orde Wiring plan

r
1 Wiring plans that have been made specially for the order
• Take into account the special design of the application
• Independent documents in the documentation folder
2 Standard wiring plans
• Take into account the standard design of the device
• Included in appendix A
3 Documentation of component suppliers:
• Only for the standard design of the manufacturer
• Independent documents in the documentation folder
Feedback, enquiry
If the different wiring plans are contradictious, for instance
interchanged poles of a component group:
• contact the service department of the manufacturer
• solve the problem.
53
7
Electrical mounting, continuation
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Connection of the Prerequisite for the operation of the

earthing device is an appropriate and
continuous earthing of the device. The
on-site earthing of the device:
No Description
1 Connection
main earth connection
Earth connections that are provided

in our works:
• Connection base plate and
housing (2)
• Component groups the
mounting of which is not
appropriate for earthing.
Left figure:
Example for the earthing of a cover.
Important:
The length of the earthing cable on the cover is adapted to
the use to be expected (opening, depositing).
54
7
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ATEX Equipotential bonding of sleeves with a corresponding requirement

environment: due to the category of the device:
earthing sleeves,
clamping rings either or
Conductive material "Bridging" by means of a flexible earthing cable
If the tightening straps Measure to take

are equipped with ground the tightening straps have to be connected to
bolts earth.
Examples for the equipotential bonding of a sleeve:

with conductive material without conductive material
Sleeves made of conductive material are

marked with .
55
7
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Installation in an Installation of electrical component groups:

ATEX environment
If ATEX-category Installation
is sufficient in the ATEX environment is allowed
is not sufficient outside of the ATEX environment taking
into account the maximum cable lengths
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Junction boxes As a rule, the electrical connections of the individual component groups of
the device are cabled in junction boxes that are mounted to the base frame
of the device. The cabling is already provided in our works.
Listing of the terminal functions in the junction boxes:
• Wiring plans
• Terminal connections junction box -JBn (annex A)
The connections to the terminals of the junction boxes have to be
provided on site.
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Connection The following information only applies to weighed devices:

of the load cell
The connection of the load cell(s) and the evaluation of the signal is
made by means of an evaluation unit that is mounted to the device or
in a separate control cabinet. It has to comply with the following
requirements:
• supply voltage for the load cell(s)
• reading of the weight signal / the weight signals
• processing of the weight signal / the weight signals
• visualisation and/or signal relaying to an external visu-
alisation/processing (e.g.: Congrav®).
Be sure to observe the documentation of the manufacturer!
56
7
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Connection of the The feed drive is connected to a drive controller.

feeding device
Feed drive Drive controller
ac drive Frequency converter
dc drive Rectifier
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Connection The drive motor (ac drive) is connected to the mains.

agitator drive
• Operation of the agitator drive:
If Then
feeder starts agitator starts
feeder stops agitator stops
• Recommendation:
Install a separate main switch for the agitator drive:
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57
7
Electrical connection of optional component groups
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Requirement The listed operations require that the device is equipped with the
corresponding optional component group.
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Connection work The drive motor is connected directly to the mains. The constant
hopper agitator speed results from the rated speed of the drive motor and the
transmission ration of the gear.
Electrical connection work:
• Connection of the drive motor (threephase current)
• Install an "emergency" cut-out.
• In standard the drive motor is operated via the operating contact
of the feeding controller.
If the feeder The agitator will
starts start
stops stop
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58
7
Connection to a feeding controller
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Introduction A feeding controller is required for the operation of a loss-in-weight

feeder (DDW-…). The manufacturer offers 2 systems, namely
Congrav® or ISC-system.
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Congrav® A Congrav® system has the following features

• operating and control unit are one device
• the electric component groups of the feeding device are
connected to the Congrav®
The illustration shows a schematic Congrav® system.
Part Meaning
BF Refill valve
DA3 Refill request
M Feed drive
FU Drive controller for (M)
DA1 Operating release for (FU)
Stgr Speed input for (FC)
U Speed sensing
DE Speed reading
W Weight signal
WS Weight signal reading
S Interlocking chain protective switch
DE1 Digital input “interlocking“
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ISC-system An ISC-system has the following features:

• the operating and the control unit has interconnected via the ISC
field bus
• controller and drive regulator are mounted to the device
The illustration shows a

schematic ISC structure
Part Meaning
IDx Feeding device with ID number x
x= 1 … 16
A Display-/operating unit
here: Congrav® RC4
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59
8
Commissioning of the device
8 Commissioning of the device
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Aim of The commissioning has the following aim:

commissioning
• The check of the correct functioning and
• The computation of the operating parameters
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To be prepared ATEX:
on site
All product supply/discharge lines are
• discharged
• dust-proof/gas-proof
Bypass:
During the commissioning of a feeding station the discharge/feed rate has
to be computed. For this purpose, a complete feeding operation is
required. If the downstream equipment is not appropriate, it is required to
install a bypass line in a collecting receptacle.
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Content of the This chapter deals with the commissioning of the device. The chapter
chapter is divided in 5 parts.
Subject Page
Instructions for commissioning 61
Commissioning sequence 62
Commissioning of the feeding device 64
Commissioning of the weighing system 65
Determination of the discharge rate/feed rate 69
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60
8
Instructions for commissioning
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Free During commissioning the product feeding is started for the

product flow computation of the feed rate. For this purpose, the following
conditions have to be complied with:
• Sufficient product quantity available
• Free product flow into/out of the device
• Collect or process the product quantity that has been fed:
- Feeding into a collecting receptacle
- Feeding into downstream parts of the installation
• A bypass line to the collecting receptacle may possibly be required.
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How to prepare For commissioning

commissioning
with bypass line: without bypass line:
• Connect the bypass line • Prepare the downstream
• Provide a collecting receptacle parts of the installation.
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Danger Commissioning with dangerous products

Danger for the operating staff and the environment due to leakages
or functional failures of the device
• Employ a product substitute:
If you employ Then you have to observe
Product substitute Harmless but otherwise identical
product characteristics
No product substitute You have to take all necessary
measures for the protection of the
operating staff and the environment.
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Interruption of the The commissioning has to be interrupted, if:

commissioning
• there are problems during commissioning.
• the mounting of the device has to be corrected.
Before the start of corrections on electrical assemblies:

5
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• disconnect the device .
5
Definition Disconnection see page 34
61
8
Rundown of commissioning
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Protective The parameter setting of control/regulating units determines the

function: working range of the device /the component group and thus is a
setting protective function that permits to stay in the allowed working range.
of parameters
The setting of parameters
• has to be carried out before commissioning.
• select "safe parameters", if parameters have been
optimised during commissioning.
Feeding controller Congrav® for ATEX-applications:

Operational failures have to cause a shut down of the feeding
operation. This is obtained by the following parameter settings of the
software of Congrav®:
Parameter Setting
Alarm configuration "Switch off" all alarms
Speed monitoring The parameter "speed minimum" has to be
set in such a manner that the motion
monitoring is not skipped.
Filling ratio screw The level limits "underload" and "filling level
minimum" have to be so set in such a manner
that the screw cannot run empty.
Drive controller:
Rotating component groups in explosion-hazard areas
(screws, agitator etc.) must not exceed the allowed
circumferential speed in no operating situation (Smax = 1m/s).
Parameterisation of the drive controller assures the compliance:

• Drive controllers delivered with the device have already been
parameterised in our works, marked unambiguously and sealed.
• Drive controllers provided on site have to be parameterised,
marked unambiguously and sealed by the user.
62
8
Rundown of commissioning, continuation
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Before The user is engaged by law to have the following inspections

commissioning: carried through and documented by authorised specialist staff.
Proof of efficiency
• Complete earthing, equipotential bonding of the device
• Monitoring functions (e.g. evaluation of PTC-resistor)
• Operation of frequency converter: setting of parameters
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Commissioning The commissioning runs down as follows:

Step What to do
1 Connect all supply media
2 Warming-up of the electronics (approx. 30 min.)
3 Commissioning of the feeding device (page 64)
4 Commissioning of the weighing system (page 65)
5 Determination of the feed rate/discharge rate (see page 69)
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Termination of The commissioning ends with the determination of the feed

commissioning rate/discharge rate, then the device is ready for operation.
Examples for possibly required work:
actual status necessary work

Bypass installed Disassemble bypass
Collecting receptacle has been Remove collecting receptacle
employed
Employ a product substitute Discharge the device completely
Cleaning is necessary Clean the device
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63
8
Commissioning of the feeding device
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Checking An arrow marks the direction of rotation of the motor ( ). For

the direction the check you have to start the feeder for a short period and examine
of rotation the direction of rotation. If the direction of rotation is incorrect:
Step What to do
1 Switch off the power supply.
2 Protect it against unauthorised reconnection.
3 Change the direction of rotation.
Motor type Then you have to observe
Threephase current Exchange two (e.g. U, V) of the three
drive connection lines (U,V,W).
dc drive Exchange the “armature” connections.
4 Reconnect the power supply.
This check has to be carried out for all drives of the feeding
device.
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Vent screw Depending on the design of the device the gears are equipped with
Gear or without vent screw.
Gear Then you have to observe
With vent screw 1 Vent screw is closed upon delivery.
2 Open the vent screw
Operational requirement for the device:

The vent screws of all gears have to be opened.
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Shut-off device Depending on the design the outlet of the device might be closed by
on the outlet a shut-off device (quick-closing valve, slide valve or similar).
Attention! Operation of the device with a closed outlet

» Operating failures, damage of the device
• Locking chain:
The device is only enabled if the outlet is opened
• During the commissioning
Check the correct functioning of the locking chain.
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64
8
Commissioning of the weighing system
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Introduction The following operations are only required, if the device is equipped
with a weighing system. Feeder types
• DDW-… (Loss-in-weight feeder)
• MS-… (Feeder with level monitoring)
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Transport catches Transport catches of the weighing

DDW-H3 system DDW-H3
No Description
A Locked transport catch
B Unlocked transport catch
1 Base frame
2 Red sheet
3 Adjusting screw
4 Weighing frame
Unlock the transport catch before commissioning:

Step What to do
1 Loosen the locknut from the adjusting screw.
2 Loosen the red sheet and screw it tight as illustrated (B).
3 Loosen the adjusting screws until there is an air gap of 3-5
mm.
4 Lock the adjusting screw by means of the locknut.
In case of an interruptions lock the transport catch:

Step What to do
1 Loosen the locknut from the adjusting screw.
2 Loosen the adjusting screws until there is an air gap of ~1
cm on the load cell.
3 Screw tight the red sheet as illustrated (A).
4 Lock the adjusting screw by means of the locknut.
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Transport catches Weighing systems DDW-MD, DDW-MS or MS-:

MDx, MSx
Loosen the screwing of the red metal sheets or angles and store the
detached transport catches for the next use.
65
8
Commissioning of the weighing system, continuation
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Transport catches Unlock the transport catch before commissioning:

DDW-H1x
Step What to do
1 Loosen the red sheets from the weighing frame.
2 Open both toggle-type fasteners at the force transmission
lever (above the two junction boxes).
In case of an interruptions lock the transport catch:

Step What to do
1 Close both toggle-type fasteners at the force transmission
lever and thus lock the force transmission lever.
2 Mount the red sheets to the weighing frame.
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DDW-MSx:
Check of overload
protection screw
A
B
After having loosened the transport catch you have to make a visual
inspection to check whether the distance d between the overload
protection screw(s) (3) and load cell(s) (2) is appropriate.
Number load cells Number overload Clearance
protection screws
1 1 (fig. A) d ~ 0,5 mm
3 2 (fig. B) d ~ 1 mm
66
8
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Load cell: Check the free motion:

Free motion
Step What to do
1 Read the actual weight value
2 Place on a test weight
3 Take off the test weight
4 Same weight value as for step 1?
Yes No
ready Find the reasons why the load cell cannot move freely:
• Has the transport catch been loosened correctly?
• Is the connection to the inlet flexible enough?
• Is the connection to the outlet flexible enough?
• Obstruction caused by foreign bodies, contamination?
• Has the overload protection screw been set correctly?
• Mechanical structures defective?
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Load cell: The lever factor (LF) is a parameter for the adaptation of the weight
Lever factor reading carried out by the evaluation unit.
Step What to do
1 Reset memorised tare values6
2 Note the actual weight value (W 0)
3 Place on a test known weight (W T). The load has to
act to the centre of the load cell(s).
4 Read the new weight value (W 1).
5 Compute the difference (W 1 - W 0).
6 Check the lever factor
If Then you have to observe
(W 01 - W 0) = (W T) Lever factor correct
(W 01 - W 0) ≠ (W T) Correct the lever factor
LFnew= LFold x (W T/(W 01 - W 0))
6
Tare: a function of the evaluation unit,
the empty weight of the hopper is not taken into consideration by the actual weight display
67
8
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Load cell: The function of the load cell has to be tested by means of several
Function load measurements over the complete weighing range.
Step What to do
1 Test1: Test weight ~10% of weighing range
These tests are idealised and thus cannot always be carried

through. If this is the case, the tests have to be possibly
carried out in such a manner that the functions of the device
are still available. Practical limits are due to :
• big weighing ranges
• the selection of the available test weights
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68
8
Determination of the discharge rate/feed rate
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Determination Determination of the discharge rate (= product/time unit):

of the
discharge rate Method Description
Gauging7 The gauging method is employed for volumetric
or gravimetric feeding.
Type of feeding Function “Gauging”
Volumetric Computation of a feed rate curve for
different working points.
Gravimetric Checking of the feeding accuracy
With big differences between the
“sampling quantity” and the gauging it
is recommended to check/correct the
“lever factor“.
Sampling quantity The feeding controller Congrav® permits to

(gravimetric) control the sampling quantity and thus the
feeding accuracy.
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Adjustment Adjustment as required:

as required
• Start the device.
• Change the working point of the drive until the required discharge
rate is reached.
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Rundown How to determine the feed rate by gauging:

of gauging
Step What to do
1 Refill the device.
2 Place the collecting receptacle below the device.
3 Adjust the setpoint (working point).
4 Start the feeding operation for a certain period (e.g. 2 min.)
5 Stop the feeding operation after this period has run down.
6 Weigh the product quantity that has been discharged.
7 Compute the discharge rate (kg/h).
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Gravimetric Feeding controller of the Congrav® series

discharge rate
Carry out the “Checking of the max. output”.
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Please refer to the software manual of the feeding controller!
7
Gauging = feeding into a collecting receptacle for a subsequent test weighing
69
9
The operation of the device
9 The operation of the device
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Introduction The chapter describes the “feeding operation” of the device.

Depending on the execution of the device there are 2 types:
Execution Feeding operation
Feeding device of a volumetric execution
Loss-in-weight feeder of a gravimetric execution
Both types differ as far as the

• functions and
• the required feeding controller are concerned
Both types are described in separate sections, so that the

section that is not applicable can be left out.
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Supplementary Be sure to observe the documentation of the feeding controller

documentation employed:
• Operating/monitoring functions for the feeding operation
• The manufacturer offers different systems
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Note: This chapter only takes into account the feeding controller of the
Feeding controller Congrav® series. If you use other systems:
• other systems have to be authorised by the manufacturer
• adjust the descriptions accordingly.
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chapter
Subject Side
The operation of a volumetric execution 71
The operation of a gravimetric execution 72
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70
9
The operation of a volumetric execution
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The task The device has the task to discharge product with a defined working
point of the feeding device. The discharge rate (= feed rate) is neither
sensed nor controlled.
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Functions of the The feeding controller for volumetric operation offers at the following
feeding controller functions:
• Starting/stopping of the discharge
As a rule the start/stop function is made by means of a switch
that permits to commute the operating release of the drive
controller.
• Command of the feed drive by means of a suitable drive
controller.
• Default value for the discharge rate (= setpoint)
Normally this is a rotary potentiometer or master signal.
The component groups of the feeding control must not

necessarily be integrated in a housing as “device”. They can
for instance also be integrated in a control cabinet.
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Description As a rule, the volumetric operation runs down as follows:

of the sequence
of operations Step Action
1 Adjust the working point (e.g. for a potentiometer = 50%)
2 Start the feeding operation (product discharge starts)
3 Adjust the discharge rate if required (reduce or increase the
potentiometer setting)
4 If the product quantity has been reached, stop the feeding
operation.
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Typical The filling of a weigh-feeder

application The feeding controller of the weigh-feeder permits to start/stop the
product discharge via the “refill signal” (relay contact or similar):
If the filling level of the hopper Then the refill contact has to be
is inferior /equal to minimum set (product discharge starts)
is superior/equal to maximum reset (product discharge stops)
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71
9
The operation of a gravimetric execution
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The task With gravimetric product discharge, also designated as gravimetric

8
feeding, the product is discharged with a fixed feed rate . For this
purpose the system measures the feed rate and controls it as a
function of the setpoint. Components employed:
• a feeding device with weighing system
• a feeding controller type Congrav®
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Functions of the A Congrav®-type feeding controller has the following main functions:
feeding controller
Congrav® • Reading in and processing of the weight value
• Computation of the actual feed rate
• Control algorithm for the difference between setpoint and actual
value
• Monitoring of the hopper filling level
• Monitoring of further feeding parameters
• Visualisation and operating functions
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Description Gravimetric feeding runs down as follows:

of the sequence
of operations No Action
1 Set the desired feed rate as setpoint in [kg/h].
2 Start the feeding operation with this setpoint and start the
feeding controller (= gravimetric feeding).
3 The Congrav® computes the loss in weight during one cycle
from the weight signal of the weighing system.
4 The actual feed rate (= act) is computed from the loss in weight.
5 The difference (set – act) is entered into the control algorithm.
6 The setpoint for the drive controller is changed as a function of
the result of the control algorithm.
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8
Feed rate = product quantity per time unit (e.g. 1000 kg/h)
72
10
Decommissioning of the device
10 Decommissioning of the device
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Introduction This chapter describes the different switch-off modes of the device.
The device can be switched off
• manually by the operator or
• automatically by the controller of the device/installation.
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Limitation The description in this chapter does not take into account any
product-specific influences on the switch-off.
If additional jobs result from the corresponding product

characteristics, they have to be integrated into the process, if
necessary.
Example:
With a product that is not allowed to remain in the feeder due
to its characteristics, e.g. precipitation hardening, the feeder
• has to be discharged completely before switch-off.
• has to be cleaned completely and thoroughly after the
switch-off.
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Content This chapter is divided into 2 switch-off groups, that are described
of the chapter separately.
Subject Page
Switch-off with untroubled operation 74
Alarm cut-outs 75
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73
10
Switch-off with untroubled operation
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Short-term Occurs, if the device has to be stopped for a short period due to
switch-off operational requirements
Execution How to continue the operation
Stop command Start command
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Maintenance, Switch off the device before maintenance/repair work

repair
Execution
Step What to do
1 Discharge the device
2 Stop the feeding operation
3 Disconnect the device (see page 34)
4 Protect the device against unauthorised switching on
5 The work has to be carried out correctly
How to continue the operation

No modification of the device 1 Connect the supply media
2 Check of functions
3 Start the operation
Modification of the device 1 Commissioning
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Decommissioning For a decommissioning or storage of the device a complete switch-off

has to be carried out
Execution
Step What to do
1 Switch-off as described in the chapter “Maintenance/repair“
2 Electrical disconnection of the device
3 Disconnect the device from all supply media
4 Disassemble the device
5 Storage or disposal according to the specifications
How to continue the operation

Step What to do
1 Assemble the device
2 Mounting of the device
3 Commissioning of the device
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74
10
Alarm cut-outs
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Description An alarm cut-out differs from a normal switch-off. Alarm cut-outs are
caused by operating conditions that prevent a further operation of the
feeder.
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Reasons for Alarm cut-outs are caused by

alarm cut-outs
• an emergency cut-out by the operator due to a hazardous
situation during the operation.
• monitoring equipment, if the monitored operating parameter is no
longer within the allowed limits.
• a cut-out due to a malfunction of the upstream/downstream parts
of the installation.
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How to continue Before the device is once again ready for operation it is required to
the operation eliminate the reasons for the alarm cut-out.
after an
alarm cut-out Step What to do
1 Find the causes for the malfunction
2 Eliminate the causes for the malfunction
3 Make sure that the device is ready for operation.
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Reasons for Malfunctions, their reasons and remedies are described in the
alarm cut-outs chapter “Malfunctions” (page 76).
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Ready for It is not possible to determine precisely what is required to make the
operation device ready for operation, as this is a function of the effects of
functions failures (e.g. damage of the device).
With an alarm cut-out the device is stopped immediately

without taking into account the sequence of operations. The
resulting effects on the device and the other parts of the
installation have to be taken into account for the readiness
for operation.
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75
11
Malfunctions of the device
11 Malfunctions of the device
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Attention! Malfunction of the device

» Possible danger for the operating staff and the machine
• Switch off the device
• Eliminate the malfunction and its effects.
• Find and eliminate the cause.
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Contacting In case of difficulties that cannot be eliminated by the user of the

the service plant, it is required to contact the service department of the
manufacturer.
The address, phone and fax number of the manufacturer are
included in the appendix D.
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Content Subject Page

of the chapter Malfunctions and remedies 77
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76
11
Malfunction and remedy
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Discharge The device is switched on but does not start to feed.

operation does
not start Points to check Result What to do
Voltage supply Missing Connect voltage supply
Available Go on
Supply lines Interrupted Connect supply lines
Wrong cable type Employ correct cable type
Okay Go on
Drive controller Damaged Exchange drive controller
Fuse damaged Exchange fuse
Okay Go on
Interlocking chains for enable Available Fulfil enable conditions
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Wrong direction Wrong direction of rotation of the drive motors:

of rotation
If Then
Threephase current (ac) Change the connections "U" and "V".
Direct current (dc) Change the "armature" connections.
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Uneven filling The filling ratio of the screw is too uneven

ratio
Points to check Result What to do
Product activation Missing Switch on
Too small Increases
Okay Go on
Screw type Inappropriate Exchange
Okay Go on
Hopper filling level/content Too low Refill earlier
Bridging Product activation
Okay Go on
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Grinding noises Grinding noises in the screw pipe

9
Øscrew Too big Change the screw
Okay Go on
Product deposits Available Clean the screw pipe
in the screw pipe Okay Go on
Product jam between Available Øscrew smaller or
screw – pipe wall Øsccrew pipe bigger
Okay Go on
9
Øscrew = screw diameter
77
11
Malfunction and remedy, continuation
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Screw jammed The screw gets jammed during feeding.

Foreign bodies Available 1 Remove
2 Check for damages
3 Eliminate the cause
Not available Go on
ØScrew Too big Reduce Øscrew or
Increase Øscrew pipe
Okay Go on
Screw type Not appropriate Use screw that suits product.
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Feed rate The feeding quality deteriorates.

Screw/screw pipe Øscrew too small Change the screw
Okay Go on
Adaptation feeding organ
Product characteristics Changed
or feeding parameters
Okay Go on
Drive controller Parameter changed Carry out adaptation
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Feeding control The feeding controller does not function in a stable manner, A possible
reason might be the parameterisation of the feeding controller.
Filter limits Frequent violation 1 Eliminate external perturbation
Available 2 Adjust the setting
Control Too slow Adjust the parameter
Too aggressive
Manipulated variable
Wrong value Determine the "max. output" once again
of the start
78
11
Malfunction and remedy, continuation
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Weight values The weight values fluctuate strongly.

Foreign bodies Available Remove
Not available Go on
Transport catches Not loosened Loosen completely
Okay Go on
Flexible connections Tensile stress Unstrained mounting
Offset too big Max. 2mm offset
Okay Go on
Operating environment External perturbations Eliminate the reasons
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Automatic refilling The automatic refilling does not work.

Product storage Empty Refill
Available Go on
Shut-off device Does not open Eliminate the cause
Okay Go on
Product flow Jammed Eliminate the cause
Okay Go on
Flow rate Too small 1 Check the product line
2 Check the venting
3 Increase the flow rate
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79
12
Maintenance
12 Maintenance
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Introduction Maintenance means the regular inspection and cleaning. It is

necessary in order to maintain the device and to guarantee the safety
of operations.
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Danger Explosive gas mixtures or dust concentrations

» Severe or deadly injuries
• The formation of a dust layer on the device has to be avoided, as
the swirling dust particles could produce an explosive mixture.
- Dust layer has to be inferior to 1mm.
• No ignition sources must be produced from cleaning.
• Dimensioning of the cleaning intervals:
- The operability of the device is maintained.
- The allowed dust layer (< 1mm) is not exceeded.
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Content The chapter is divided in 3 parts.

of the chapter
Subject Page
Specifications 81
Maintenance jobs 83
Cleaning 85
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80
12
Maintenance
Maintenance instructions
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Warning Residual product in/on the device

» Product with hazardous characteristics
• Please observe the product data sheet
• Take safety precautions for the operating staff and the equipment.
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Before the start Measures for the protection of the operating staff and the
environment:
10
Start of maintenance 1 Disconnect the device
Dangerous product characterisitcs 1 Protect the operating staff as prescribed
2 Dispose product rests as prescribed
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During the Make sure to observe the following points during the maintenance:
maintenance
• Safety instructions
• Do not damage the device
Damaged components:
Expert repair is not possible Exchange
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ATEX environment If the works are carried out in an ATEX environment:

• Be sure to employ allowed tools.
• Avoid sparks.
• Do not cause zone distortions11
• Wear electrically conductive clothing.
• Always provide a good equipotential bonding.
• Inspection/monitoring of the works by the fire brigade or similar.
10
For definition Disconnection see page Fehler! Textmarke nicht definiert.
11
by leaking product rests, dust etc.
81
12
Maintenance
Maintenance instructions, continuation
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Cleaning of the Agitators need a lot of cleaning due to the deposits. For a simple
agitator check and cleaning of the agitator, the bigger component groups can
be equipped with a cleaning hole.
Be sure to observe the following points for any work on the cleaning
hole:
• Before the opening of the cleaning hole
- make sure that the residual product quantity in the trough is
below the cleaning hole,
- disconnect the device from the mains.
• After the cleaning work
- clean the cover and the frame of the cleaning hole,
- close the cover correctly.
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Warning Fixed, sharp-edged agitator

» Risk of injury
• Wear long gloves as a protection
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Termination of Termination of maintenance:

maintenance
• All foreign bodies inside and outside of the device have be
removed.
• Put the device in its correct state of operation:
- Completeness
- Safety status
• Test the safety equipment.
• Carry out a new commissioning.
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82
12
Maintenance
Maintenance jobs
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Intervals Marking of the intervals:

Abbr. Interval
W Weekly maintenance
2W Fortnightly maintenance
M Monthly maintenance
3M Maintenance every 3 month
H Maintenance twice a year
Y Maintenance once a year
Please refer to the indications in the documentation of the
-- manufacturer
The intervals indicated are based on experience, they are

no standard values. They are influenced by
• Operating conditions/Environment of the device
• Product characteristics
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Maintenance jobs Maintenance jobs to be carried out:

Interval What to do
W Check whether flexible sleeves show damage, wear or ruptures.
Replace damaged parts.
W Check the fastenings of the sleeves.
Tighten loose fastenings or replace if necessary.
2W Clean the device.
2W Check whether there are deposits (screw, agitator etc.)
Clean contaminated component groups.
W Clean filter bag/venting equipment
2W Check all mobile parts.
Remove contaminations by means of an industrial vacuum cleaner.
2W Tightness of the sealings (drive shafts, covers etc.).
Replace damaged sealings.
2W Checking of the clamping connection
2W Static inspection of the weighing system (please see commissioning)
M Check and renew, if required, all electrical connections including the
earth connections.
M Check whether all electrical screw connections are fastened.
-- Drive(s)
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Preventive 1Y Exchange all shaft sealing rings and packings.

exchange 3J Exchange sleeves, compensators and sealings.
5Y Replace all roller bearings and sliding bearings.
83
12
Maintenance
Maintenance jobs, continuation
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Tightness Drive shafts are sealed by means of

drive shafts packings. With untight drive shafts
product pours out in the area
between the sealing plate (1) and the
gland packings (2). In this case the
packings (4) have to be retightened
by means of the clamping nuts (3).
If retensioning is no longer possible
the packings have to be exchanged.
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84
12
Maintenance
Cleaning of the device
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Dust, Remove dust and contaminations:

contamination
Dust Industrial vacuum cleaner
Loose contaminations Industrial vacuum cleaner
Solid contaminations (Damp) cloth
Warning Discharge of static loads

• Synthetic materials must only be cleaned by means
of a damp cloth.
• Use an earthed industrial vacuum cleaner.
Attention! Disposal of product rests

» Contamination of the environment
• Please observe the product data sheet.
• Please observe the legal regulations.
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Cleaning agent Please observe the following points:

(wet cleaning)
• Do not employ combustible, aggressive or chlorous cleaning
agents or cleaning agents that contain solvents.
• The cleaning agent has to be authorised by the manufacturer.
• No wet cleaning of bearings and electrical component groups (if
required, component groups have to be protected!)
• Avoid any disturbance of the functioning due to the wet cleaning,
e.g. with mobile component groups.
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After the To be observed after the wet cleaning:

wet cleaning
• Dry the device in order to avoid effects of corrosion, degreasing
etc...
• Spilt cleaning liquid around the feeder has to be wiped away.
Stationary humidity around the feeder is not allowed during the
operation.
• Component groups that have been degreased despite all caution
have to be greased again.
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85
13
Setting-up and exchange
13 Setting-up and exchange
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Introduction This chapter describes work cycles that are required for the setting-
up of the device and for the exchange of component groups.
Technical term Meaning
Setting-up Modifications of the device that permit to adapt the
device to the operating area.
Exchange Modifications of the device that permit to exchange
a damaged component group.
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chapter
Subject Page
Safety and preparatory work 87
Assembly/disassembly of a trough agitator 89
Shaft sealing: Readjust the tension or renew 90
Adjustment of the speed measurement 91
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86
13
Safety and preparatory work
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Attention! Mounting work

» Risk of injury
• Be sure to observe the instructions for the mounting work (page 46).
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Caution Zone distortion by disassembly (residual product!)

» No operating licence
• Measures have to be taken against zone distortion and for the
protection of the operating staff and the machine (additional
suction or similar).
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Caution Disassembly of the device /individual assembly groups

» product in the device
» supply media connected
• Discharge the device
• Disconnect the device12
• Take safety measures for a product contact, if required by the
product characteristics.
• Before commissioning be sure make sure that the device is safe
to operate.
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Attention! Weight of the individual subassemblies

» Risk of injury
» Damage of the machine or peripheral equipment
• If required, employ a suitable lifting equipment.
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The manual does not include the use of lifting equipment.
Warning Fixed, sharp-edged agitator
» Risk of injury
• Wear long gloves as a protection
12
Definition of enable please see page Fehler! Textmarke nicht definiert.
87
13
Safety and preparatory work, continuation
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Caution Rotating screw with free access

» Risk of injury
• Do not operate the device, if the screw pipe or the vertical outlet
are disassembled.
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88
13
Assembly/disassembly of the agitator(s)
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Disassembly
two-piece
trough agitator
Disassembly of a two-piece trough agitator:

Step What to do
1 Loosen the nuts of the cleaning hole (1) by means of approx.
2 rotations.
2 Rotate the cover of the cleaning opening approx. 8° to the
left and remove it.
3 Loosen the fastening screws (2) of the agitator.
4 Pull the front part of the agitator (3) approx. 5mm to the front
and remove it to the top.
5 Pull the rear part of the agitator (4) approx. to the front and
remove it to the top.
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Assembly Assembly of a two-piece trough agitator:

two-piece
trough agitator Step What to do
1 Clean the components of the agitator and the cleaning hole
thoroughly.
2 The shaft, the agitator connection and the fastening screw
have to be greased well but not excessively.
3 Slide the rear part (4) onto the shaft.
4 Plug the front part (3) onto the connection.
5 Fix the agitator by means of the fastening screw (2).
6 Close the cover of the cleaning hole.
Attention! Excessive greasing of the components

» Contamination of the product zone
• Apply a quantity of grease that permits biting of the component
groups.
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89
13
Shaft seals: Readjust the tension or renew
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Packings The drive shafts of screw feeders and

agitators are sealed by means of a
packing. If the packings are leaking
they have to be retensioned or
exchanged.
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Exchange of If retensioning is not possible the packings have to be exchanged.

packings
Step What to do
1 Loosen the clamping nuts (3).
2 Pull the tensioning element (2) completely to the rear side.
3 Remove the old packing completely.
4 Clean the seat of the packing thoroughly.
5 Insert the new packings.
6 The clamping element has to be put on and tightened in an
even manner.
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Readjusting the How to readjust the tension of the packings:

tension of
packings Step What to do
1 The tensioning element (2) has to be retensioned evenly by
means of the 3 clamping nuts (3).
Attention! Packings have been retensioned too much

» Frictional heat between packing and shaft
• Loosen the tension of the packing
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90
13
Adjustment of speed monitoring
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Introduction The adjustment of digital speed monitoring:

Step What to do
1 Adjust the scanning distance (= signal detection)
2 Parameterisation of the evaluation unit (= signal evaluation)
according to the documentation of the device.
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Attention! Incorrect setting of the distance d

» Damage of the device (d too small)
» Incorrect speed measurement (d too big)
• If you hear a grinding noise the operation has to be stopped
immediately.
• Adjustment as per description.
• Safeguard the adjustment by means of the locknut.
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Set the distance d
Scanning distance d = 1mm
Step What to do
1 Loosen the screwing of the cover of the coupling.
2 Remove the cover.
3 Undo the locknut of the proximity switch.
4 Set the distance by means of a feeler gauge.
5 Lock the proximity switch by means of the counternut.
6 Place on the cover and fix it.
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91
14
Storage and close-down
14 Storage and close-down
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Introduction This chapter gives the instructions for the storage of the device or its
waste disposal.
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Content The chapter is divided in 3 parts.

of the chapter
Subject Page
Specifications 93
Storage 94
Disposal 95
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92
14
Instructions for storage/disposal
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Before the Storage or disposal of the device:

storage, disposal
• The device has to be discharged completely.
• Clean the device.
• Electrical, electronic and electromechanical component groups
have to be disassembled.
• Check the protective coating of the painted parts and, if
necessary, touch up or renew the painting.
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Storage place Specifications for the storage place:

Hall:
• weather resistant
• protected against intruding of unauthorised persons
Floor:
• paved
• with water drain
• free from vibration
• suitable for transport and lifting equipment
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Storage room Specifications for the storage room:

• suitably ventilated
• dry
• possibly free from dust
• free from ozone
• no storage room for solvents, lubricants and chemicals
• humidity of the air max. 40% to 70%
• temperature -20°C to +50°C
93
14
Storage
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Attention! Improper storage or handling

Device/component can no longer be used
• Be sure to observe the storage conditions
• Be sure to observe the conditions for the storage place/room
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Storage of Storage of the complete device, for instance due to mounting delays.
the device
Step What to do
1 Pack the device in a packaging box.
2 Position spacers under the cover of the packaging box to
permit circulation of the air.
3 However, it is also possible to stock the device outside under
a roofing.
For other packagings you have to proceed in the same way.

Permit air circulation in the packaging box.
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Storage of Instead of storing the complete device, it is possible to store the

individual individual component groups after disassembly. The components
components have to be stored in suitable storage rooms. Please refer to the table
for complementary storage conditions or limitations for special
component groups.
Components groups Storage conditions
Electrical, electronic • dry
equipment • clean
• +10°C to +40°C
• as per manufacturer’s indications
Sleeves, compensators, • dry
sealings • clean
• protected against incident light
• free from ozone
• pressure-relieved
94
14
Disposal
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Attention! Disposal of product rests

Contamination of the environment
• Please observe the product data sheet.
• Please observe the legal regulations.
• If necessary:
Components in contact with the product have to be disposed
separately.
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Before To be observed before the disposal:

the disposal
Step What to do
1 Disconnect the device (see page 34)
2 Disassemble all connections from the device
3 The device has to be disassembled completely.
4 The component groups have to be cleaned from product
rests.
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Disposal The individual component groups of the device have to be disposed

separately.
Component group Disposal
Drive, gear See manufacturer's indications
Electrical cables Cable scrap
Sleeves, compensator etc. PU, EPDM, silicone or similar
Hopper, pipes, sheets Metal scrap
Insulations According to material specifications
Electronical component group Disposal

Boards Special waste
Accumulators, batteries Special waste
Housing, synthetic materials Disposal of plastics
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95
15
Spare parts lists
15 Spare parts lists
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External Spare parts lists and drawings are made specially for each order and
documents are to be found in the documentation folder of the feeder. In the
spare parts list of the device the spare parts are marked by item
numbers. They permit to identify the spare parts in the spare parts
lists.
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96
16
Technical data
16 Technical data
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Introduction This chapter lists the technical data of the device.
In general, the listing gives the data for the standard

execution. Dimensionings that are not standard are marked
specially on the device.
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Content In this chapter the further technical data are divided into 3 parts.
of the chapter
Subject Page
General data 98
Product data 99
Identification key, nameplate 100
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97
16
Technical data
General data
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General General technical data

Data Indication
Dimensions Indicated on the device drawings
Voltage supply Standard: 230/400 VAC, 24VDC (control voltage)
Sound pressure level < 70dB (as per DIN 45635)
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Control voltage The 24Vdc control voltage has the following data:
Data Indication
Voltage range: 20 – 32 Vdc
Residual ripple: < 200 mVss
Voltage peaks: < 300 mVss
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Environment To be observed for the environment of the device:

of the device
Data Indication
Temperature: -20°C to +45°C
Humidity 40% to 70%. No stationary humidity
Medium Air or inert gas
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Feeding device Technical data of the feeding device:

Data Indication
Feeding organ Combination screw/screw pipe
Drive Threephase current drive (Special execution: dc drive)
Drive controller Frequency converter (Special execution: dc rectifier)
Speed monitoring Pulse scanning
Scanning distance d = 1 mm
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Nominal speed The nominal speed (Smax) and the nominal diameter (Ø) of the
screws, screw feeder and the agitator are dimensioned in our works.
agitators
Type ØScrew Smax,s ØAgitator Smax,r
TSR 105 105 mm 140 rpm 492 mm 20 rpm.
TSR 120 120 mm 140 rpm 492 mm 20 rpm.
TSR 150 150 mm 140 rpm 492 mm 20 rpm.
The type approval of the device ceases to be effective in

case of a modification of the parameters on site without
release by the manufacturer.
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98
16
Technical data
Product data
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Introduction This map lists the data of products that

• are allowed to be employed in the device (= appropriate).
• are not allowed to be employed in the device (= inappropriate).
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Product list Appropriate/inappropriate products for the feeding device:

Appropriate Inappropriate
• Granules • Inappropriate for screw feeding
• Fibres - Change of the product characteristic
• Powder - Unduly high frictional heat
- Product jams etc.
• Liquids
Appropriate product temperature range:

Appropriate temperature Inappropriate temperature
-20°C to +60°C Beyond the limits
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Hazardous Products with hazardous characteristics are inappropriate:

products
• explosive materials,
• shock-sensitive materials,
• materials that are sensitive to friction,
• disintegrating materials
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99
16
Technical data
Identification key, nameplate
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Definition The identification key identifies the device on the nameplate.

identification key
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Identification DDW - WS DG/L - B - ISC - ATEX

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Explanation The meaning of the abbreviations in the identification key:

identification key
Ident. Meaning
DDW Loss-in-weight feeder
WS Weighing system (DDW or filling level monitoring)
H3_ = hybrid weighing system
MD_ = digital platform load cell
MS_ = analogue platform load cell
DGxx Type and size
xx without trough agitator
xxR with trough agitator
B Hopper volume in litres

Hopper volume in litres
"R" behind the hopper volume: Hopper with agitator
ISC ISC execution

ATEX ATEX execution
100
16
Technical data
Identification key, nameplate, continuation
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Design of the The approved field of application is designated on the nameplate of

device marking the device.
Without type examination With type examination
Marking Meaning
Conformity mark according to appendix X of directive 94/9/EC
Explosion protection identification mark
II Equipment group (II = above-ground use)
2D/3G Category (inside/outside the device)
(here: inside 2D / outside 3G)
c Type of ignition protection “constructional safety“, EN 13463-5
IIA Explosion subgroup (with gas) classified according to the
minimum ignition energy
T135°C Max. allowed surface temperature of the device
(with dust: possible values 135°….250°C; here: 135°C)
T4 Temperature class (possible values: 2…4)
TA Allowed environmental temperature
(is only indicated, if it differs from the standard indication
-20°…+40°C)
A1 “0158“ marks the “notified body”
A2 Nr of ATEX certificate (combination of letters and numbers)
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101
Appendix A: Wiring plans
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Introduction The annex includes examplary wiring plans for various executions of
the device.
Execution Wiring plan
Loss-in-weight feeder Congrav® CB
Loss-in-weight feeder ISC ISC-system
Volumetric feeder Drive controller
Be sure to observe the following:

• The wiring plans show the standard connection.
Variations are possible.
• As a function of the execution of the feeding device
different electric component groups (drive controller, etc.)
are required.
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chapter
Subject Page
Connection to a Congrav® CB 103
Connection to an ISC-system 105
Terminal functions -JB2 107
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102
Connection to a Congrav® CB
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Wiring plan The illustration shows the connection of a Congrav® CB to a DDW:

CB with DDW Grey shade = components mounted to the DDW
103
Connection to a Congrav® CB, continuation
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Legend Explanation of the marking of the components in the wiring plan

CB with DDW
Marking Description
A1 1 Connection host computer (RS422) or
2 Connection ISC field bus (RS485)
A2 Connection operating unit OP1
A3 Congrav® CB
A4 Optional extension module “Digital”
A5 Optional extension module “Analogue”
B5.1 Proximity switch motion monitoring
B5.2 Vibration amplitude sensing
JB1 Junction box “Weighing” on the device
JB2 Junction box “Component groups” on the device
K1-4 Relay Congrav® CB
M ac: Motor dc: Motor (armature and field)
N1(AC) 1 Frequency converter FC-V1.x (ac motor) or
2 Vibration amplitude controller DRS 2 or
N1(DC) 3 dc rectifier 806273E (dc motor)
PTC PTC resistor (optional)
R Tray drive (vibration generator)
T Analogue tachometer (speed return)
12K1 Relay “operation” for the release of the drive controller
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Junction box Connection of the weighing system of DDW

JB1
DDW type Load cell + electronics Signal VCC
DDW-H3x13 IDL/F + BT1094 RS422 230Vac
DDW-MSx EMS + AED RS422 24Vdc
DDW-MDx MD + BR200; MD + BR202 RS422 24Vdc
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Drive controller The wiring plan illustrates the connection of three drive controller
types offered by the manufacturer.
The connection of drive controllers of other manufacturers is

provided by means of analogue control signals (see –N1(dc))
and requires at least one optional extension module
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“analogue”.
13
x = figure for the identification of the size
104
Connection of ISC execution
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Wiring plan With an ISC execution the connection of the devices to the ISC field
ISC field bus bus is provided via the feeding controller ISC-CM. The wiring plan
gives an exemplary illustration for 3 feeding devices (W01 – W03)
Legend Explanation of the marking of the components in the wiring plan:

wiring plan
Marking Description
A1.x Feeding controller ISC-CM (mounted to the device)
A2.x Drive controller ISC-FC or ISC-VC (mounted to the
device)
A3 Operating unit Congrav® RC4
D2 DIP switch setting (ISC-CM) for the termination
F1 Mains protection to be provided on site
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105
Connection of a volumetric feeding device
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Introduction Connection of a volumetric feeding device:

• Connection of drive controller
• Setting of working point14 via potentiometer or control signal
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Volumetric control Volumetric controls are complete units:

• Electric components are mounted and cabled in the housing
• Integrated operating elements (start, stop etc.)
• Separate documentation (manual etc.)
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Separate parts As an alternative the electric component groups for mounting on site
can be supplied loosely with the device.
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Connection Examplary connection of a feeding

FC-V1.x device with an ac drive:
Ident. Description
Vss Mains supply,
ac180-260V 45-60Hz
Q1 Maintenance switch
S1 Switch operating release
P1 Setpoint potentiometer
F1 Fuse provided on site
A2 Frequency converter FC-
V_._
A2.1 I/O module standard
B3 PTC resistor, PTC (option)
M1 Drive motor
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14
Setting of working point = default setting for speed or vibration amplitude (depending on the type of
drive)
106
Terminal function junction box -JBn (n=2, 3,…)
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Introduction Junction boxes mounted to the device (no ISC execution):

Marking Description
-JB1 Junction box for the connection of the load cell
-JBn Junction box for the connection of the other electrical
n=2, 3… component groups of the device
The junction boxes -JBn:

• Number of terminals as required
• Fixed assignment of terminal no<->group of electrical components
• With an ISC execution only if required due to additional electrical
component groups.
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Terminals 01 - 19 Terminal functions for terminals (Kl) 01 - 19:

Te Connected devices B1 B2 Note
1 1. Feed drive U A B1= ac drive
2 2. Swivel drive MB V B B2= dc drive
3 W I
4 K
PE Protective earth
S Screening
5 1. Paddle drive U L B1= ac drive
6 2. Agitator drive V N B2 = separate fan
7 3. Separate fan W
PE
S
15
8 1. MM feed drive + +Ub B1 = 2 wire
9 2. MM idle roller DBW GND B2 = 3 wire
10 Out Out
S
11 1. ac 230V L For weighing amplifier (-JB1)
12 2. dc 24N N
PE
13 1. Tachometer feed drive + +Ub B1 = analogue T-signal
14 2. Speed monitoring DBW - GND digital T-signal
15 Out
S
16 1. PTC resistor feed drive 1 Numbered cable
17 2
S
18 1. PTC resistor paddle drive 1
19 2. PTC resistor agitator 2
S
15
MM = motion monitoring
107
Terminal function junction box -JBn (n=2, 3,…), continuation
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Terminals 20 - 49 Terminal functions for terminals (Te) 20 - 49:

20 1. Mech. safety switch 1 Diaphragm breakage etc.
21 2. Magnet. safety switch 2
S
22 1. Mech. safety switch 1 Pressure switch etc.
23 2. Magnet. safety switch 2
S
24 1. Position switch outlet OPEN + +Ub B1 = 2 wire
25 GND B2 = 3 wire
26 Out Out
S
27 1. Position switch outlet CLOSED + +Ub
28 GND
29 Out Out
S
30 1. Position switch inlet OPEN + +Ub
31 GND
32 Out Out
S
33 1. Position switch inlet CLOSED + +Ub
34 GND
35 Out Out
S
36 Solenoid valve outlet + L B1 = dc 24V
37 - N B2 = ac 230V
PE PE
38 Solenoid valve inlet + L
39 - N
PE PE
40 1. Feed drive pre-feeder U A B1= ac drive
41 V B B2= dc drive
42 W I
43 K
PE
S
44 1. Paddle drive pre-feeder U
45 2. Agitator pre-feeder V
46 3. Agitator feeding device (2.agi) W
PE
S
16
47 1. MM pre-feeder + +Ub B1 = 2 wire
48 GND B2 = 3 wire
49 Out Out
S
PE == protective earth; S == screening

16
StÜW = Stillstandsüberwachung
108
Terminal function junction box -JBn (n=2, 3,…), continuation
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Terminals 50 - 85 Terminal functions for terminals (Te) 50 -79:

50 1. Tachometer pre-feeder + +Ub B1 = 2 wire
51 GND B2 = 3 wire
52 Out Out
S
53 1. PTC resistor drive pre-feeder 1 Numbered cable
54 2
S
55 1. PTC resistor paddle pre-feeder 1
56 2. PTC resistor agitator pre-feeder 2
S 3. PTC resistor agitator feeder
57 1. Safety switch pre-feeder 1
58 2
S
59 1. Safety switch pre-feeder 3
60 4
S
61 1. Speed drive roller DBW + +Ub B1 = 2 wire
62 GND B2 = 3 wire
63 Out Out
S
64 1. Position switch MB + +Ub
65 GND
66 Out Out
S
67 1. Temperature sensor product
68
S
69 1. Auxiliary switch
70 2. Repair switch
S
71 1. Fan 1+2 (FW../2) L
72 N
PE PE
73 1. Safety switches + +Ub B1 = 2 wire
74 GND B2 = 3 wire
75 Out Out
S
76 1. Solenoid valve JetFilter + L B1 = dc 24V
77 - N B2 = ac 230V
PE PE
78 Safety switch trough - hopper +
79 -
80 Safety switch trough - hopper +
81 -
82 Safety switch hopper cover +
83 -
84 Safety switch hopper cover +
85 -
PE == protective earth; S == screening
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109
Annex B Indications concerning the manual
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Supplementary The operating instructions are supplemented by the following

documentation documents:
• Supplementary descriptions of mounted component groups,
special executions etc.
• Documentations of suppliers
• Spare parts drawings and lists
• Certificates, written confirmations etc.
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Documentation Together, all documents form the documentation of the device

of the device
• It is a part of the device.
• It has to be made available to the operating staff that operates
the device.
• It has to be kept in stock for the lifetime of the device.
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Further indications Further indications concerning the designations and the revisions are
described in the following chapters.
Subject Page
Marking in the operating instructions 111
Documentation revisions 112
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110
Marking
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Safety instructions Danger The safety instruction designates an immediate danger

that might lead to severe injuries or even to death.
Danger The safety instruction designates an immediate danger

caused by an electrical equipment that might lead to
severe injuries or even to death.
Warning The safety instruction designates a situation that might

be hazardous and that would lead to severe injuries or
even to death.
Caution The safety instruction designates a situation that might

be hazardous and that might lead to slight injuries.
Moreover this sign marks dangerous situations the risk
of which is a function of unknown parameters such as
“product characteristics”.
Attention! The safety instruction designates a situation that might

be hazardous and that might cause material damage
to other equipment.
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General Pictogram for pointing out important notes.

instructions
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111
Revisions
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During During the project phase some documents might possibly be revised.
the project phase If the documentation has already been delivered, the revised
documents will be sent to the customer, as he will have to update his
documentation.
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After the Documentations, especially operating manuals have to be revised

termination continuously. After the termination of the project the customer is not
of the project entitled to automatic updates of the documentation due to the current
revisions.
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Revision index The revision index of the device documentation and the operating
instructions is marked on the corresponding cover sheet.
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The user has The user might have different revisions of the operating instructions.
different revisions
• If different revisions of the documentation exist for a device
delivered, the documentation with the highest revision index is
the actual version and substitutes all previous revisions.
• If different revisions of the documentation exist for the same
device out of different deliveries, the documentations of the
corresponding delivery remain valid. As due to a possible
modification of the machine or device, both documentations are
required for the description of the corresponding execution of the
device.
It is generally recommended to observe the instructions given

in the latest revision for work on the older device, if they are
aimed at increasing the safety for the operating staff and the
safety of operations.
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112
Annex C Forms
Annex C Forms
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Certificate of In a feeding device you will always find residual product, with which
Nonobjection the persons that carry out maintenance or inspection might get in
contact. To be able to protect his staff the manufacturer requires the
Certificate of Nonobjection as specified below:
• Filled in completely by a qualified, authorised specialist staff.
• If available, it has to be complemented by a product data sheet of
the product supplier.
• It has to be handed in with the repair order.
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Content Appendix C includes the following forms:

appendix C
Subject Page
Certificate of Nonobjection 114
Spare parts order 115
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113
Annex C Forms
Certificate of nonobjection
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Machine data The machine data of the device:

Type:
Machine no.:
Date of delivery:
Shipping note no.:
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Indications Please answer the following questions:

on the
DualTray Question Yes No
Has the device been completely discharged before
shipment/preparation and cleaned on the outside and
inside?
Do we have to observe special safety precautions
regarding products that are damaging to health or
causing water pollution for further manipulation?
Did the device get in contact with:
• Hazardous materials?
• Pollutants?
• Other pollution loads or materials with obligation
to label.
If you answer the last question by “yes”, be sure to enclose a
product data sheet.
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Further safety Concerning flushing media, residual liquid ingredients and disposal
measures
1.
2.
3.
4.
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Statement We herewith confirm that the indications above are correct and
complete. The shipment is executed according to the legal
regulations.
Name:
Position:
Phone:
E-mail:
Date, signature:
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114
Annex C Forms
Spare parts order
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Address
for shipment
Address Please fill in if this address differs from the address for shipment
for account
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Technical data Indications on the device in the spare parts order:

Machine number:
Designation of the device:
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Order Binding purchase order for the following spare parts:

Part no.: Designation Number
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Confirmation Confirmation of the order:
Date: Signature:
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115
Annex D Addresses and index
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Content Appendix D contains the address and index directory.

appendix D
Subject Page
Addresses 117
Index directory 119
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116
Addresses
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Germany and Head office Service

international Brabender-Technologie KG Brabender-Technologie KG
Kulturstrasse 55-73 Kulturstrasse 55-73
D-47055 Duisburg D-47055 Duisburg
PO box:
Postfach 350138 D-47032 Duisburg
Tel.: ++49-(0)203-9984-0 Tel.: ++49-(0)203-9984-299

FAX: ++49-(0)203-9984-155 FAX: ++49-(0)203-9984-166
[email protected] [email protected]
http://www.brabender-technologie.com
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North America Head office Service

Brabender-Technologie Inc Brabender-Technologie Inc
6500 Kestrel Road 6500 Kestrel Road
Mississauga, Ontario Mississauga, Ontario
Canada L5T 1Z6 Canada L5T 1Z6
Tel.: (905)-670-2933 Tel.: (905)-670-2933

FAX: (905)-670-2557 FAX: (905)-670-2557
TOLL: (888)-284-4574
[email protected] [email protected]
http://www.brabenderti.com
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Great Britain Sales, Service

Genesis Process Solutions
Unit 5 Springvale Business Centre
Millbuck Way
Sandbach
Cheshire.
CW11 3HY
Tel.: ++44-(0)1270 766300

FAX: ++44-(0)1270 766302
[email protected]
117
Addresses, continuation
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China Sales, service

Brabender Technology (Beijing) Co. Ltd.
rd
3 F, B Section, No.3 Workshop,
nd
2 project of Guanglian Industrial Park,
No.2. Kechuang East 5th Rd., Opto-Mechatronics Industrial Park,
Tongzhou, Beijing # P.C:101111
Tel.: 0086-10-81504121，81504087
Fax: 0086-10-81504301
Email: [email protected]
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Russia Sales, service

Brabender Moscow
1-j Schipkovsky per. 20
Office 711
115093 Moscow
Tel.: ++7-495-235-73-95
FAX: ++7-495-959-74-16
[email protected]
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Middle East Sales, service

Brabender Technologie Middle East
PO Box 18139
Tel.: ++971-(0)4-288 7835

FAX: ++971-(0)-4-288 1035
[email protected]
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118
Index
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Compliance with the zone allocation........................ 12

A Components with protective functions ..................... 41
Additional component groups ...................................17 Confirmation.............................................................. 115
Address for account ................................................115 Congrav®.................................................................... 59
Address for shipment ..............................................115 Connection agitator drive.......................................... 57
Addresses .................................................................117 Connection FC-V1.x ............................................... 106
Adjustment of speed monitoring ...............................91 Connection inlet/outlet............................................... 52
Aeration, venting .........................................................23 Connection of the load cell ....................................... 56
After the termination of the project .........................112 Connection of venting ............................................... 52
After the wet cleaning .................................................85 Connection earthing................................................... 48
Agitator types...............................................................27 Connection of a volumetric feeding device ........... 106
Agitators .......................................................................27 Connection of ISC execution .................................. 105
Aim of commissioning................................................60 Connection of the earthing ........................................ 54
Alarm cut-outs .............................................................75 Connection of the feeding device ............................. 57
Allowed operating range ...........................................43 Connection to a Congrav® CB............................... 103
Ambient temperature .................................................12 Connection to a feeding controller............................ 59
Annex B Indications concerning the manual .........110 Connection work hopper agitator ............................. 58
Annex C Forms ........................................................113 Construction..........................................................31, 32
Annex D Addresses and index ...............................116 Construction of the weighing system ....................... 17
Appendix A Contacting the service .............................................. 76
Wiring plans..........................................................102 Content of the declaration of incorporation.............. 14
Application ...................................................................31 Content of the EC declaration of conformity ........... 13
Appropriate products .................................................... 6 Control voltage............................................................ 98
Assembly two-piece trough agitator .........................89
Assembly/disassembly of the agitator(s) .................89 D
ATEX environment.............................................. 46, 81 Data provided by the manufacturer....................13, 14
earthing sleeves, clamping rings..........................55 DDW-MSx
Automatic refilling.......................................................21 Check of overload protection screw.................... 66
Automatic refilling........................................................79 Decommissioning ...................................................... 74
Decommissioning of the device ............................... 73
B Definition...................................................................... 10
Before the disposal....................................................95 Disconnection ........................................................ 34
Before commissioning operation................................................................. 29
Proof of efficiency...................................................63 weighing.................................................................. 17
Before the storage, disposal.....................................93 Degree of cleaning ....................................................... 9
Before the start............................................................81 Description .................................................................. 75
C Description of the sequence of operations ......71, 72
Cabling .........................................................................48 Description of the component groups of the device19
Certificate of nonobjection .......................................114 Description of the device .....................................15, 16
Certificate of Nonobjection.......................................113 Design of the device marking .............................8, 101
Checking the direction of rotation............................64 Design of the speed monitoring................................ 26
China ..........................................................................118 Designation ...........................................................13, 14
Circumferential speed of rotating component groups DE-STA-CO locks...................................................... 31
........................................................................................ 9 Determination of the discharge rate/feed rate......... 69
Cleaning agent (wet cleaning)...................................85 Dimensioning of the device ......................................... 6
Cleaning of the agitator ..............................................82 Direction of rotation ................................................... 24
Cleaning of the device................................................85 Disassembly two-piece trough agitator.................... 89
Commissioning ...........................................................63 Discharge operation does not start .......................... 77
Commissioning of the device ....................................60 Disconnection ............................................................. 34
Commissioning of the feeding device ......................64 Disposal....................................................................... 95
Commissioning of the weighing system ..................65 Documentation of the device ................................. 110
Comparison Drive controller .......................................................... 104
feeding controllers..................................................29 Drive motors................................................................ 24
Completing the mounting work .................................47 During the project phase ........................................ 112
119
During the maintenance ............................................ 81 Installation in an ATEX environment .......................56

Dust, contamination .................................................. 85 Instruction for commissioning....................................46
Instructions for commissioning..................................61
E Instructions for electrical mounting ...........................48
Effects.......................................................................... 10 Instructions for mounting............................................46
Electrical connection of optional component groups Instructions for storage/disposal ...............................93
...................................................................................... 58 Instructions for the execution.....................................51
Electrical mounting..................................................... 53 Instructions on the device ..........................................44
Environment of the device ....................................... 98 Intended purpose......................................................5, 6
Evaluation of speed pulses ...................................... 26 Interruption of mounting .............................................47
Exchange of packings ............................................... 90 Interruption of the commissioning.............................61
Execution .................................................................... 28 Intervals........................................................................83
Executions (grav. or vol.).......................................... 29 Introduction ..............................................................5, 41
Executions of the device .......................................... 26 ISC-system ..................................................................59
Executions aeration/venting...................................... 22
Explanation identification key.................................. 100 J
Extended obligations for ATEX ................................ 12 Junction box JB1 ......................................................104
External documents.................................................. 96 Junction boxes ............................................................56
F L
Fastening, sealing ...................................................... 20 Legend CB with DDW .............................................104
Feed rate..................................................................... 78 Legend wiring plan....................................................105
Feeding control........................................................... 78 Load cell
Feeding device ........................................................... 98 Free motion ............................................................67
Feeding device with turntable .................................. 33 Function ..................................................................68
Field of application.........................................................8 Lever factor .............................................................67
Free product flow ...................................................... 61 Load cell types ............................................................17
Function................................................................. 28, 32
Functions of the feeding controller ........................... 71 M
Functions of the feeding controller Congrav® ........ 72 Machine data.............................................................114
Further safety measures ......................................... 114 Maintenance................................................................80
Maintenance instructions ...........................................81
G Maintenance jobs .......................................................83
Gauging....................................................................... 69 Maintenance, repair...................................................74
General........................................................................ 98 Malfunction and remedy ............................................77
General data ............................................................... 98 Malfunctions of the device .........................................76
General instructions ................................................. 111 Manifest abuse............................................................10
General mounting work ............................................. 51 Manual filling................................................................21
Germany and international...................................... 117 Marking ......................................................................111
Gravimetric discharge rate........................................ 69 Marking of hazard notes ............................................35
Great Britain .............................................................. 117 Marking of the device .................................................44
Grinding noises .......................................................... 77 Middle East................................................................118
Modes drive motor.....................................................25
H Monitoring of the filling levels .....................................21
Hazard notes .............................................................. 36 Mounted drive motors ................................................24
Hazardous products .........................................99, 100 Mounting ......................................................................46
Hopper cover .............................................................. 20 Mounting of the device ...............................................45
How to continue the operation after an alarm cut- Mounting tools .............................................................49
out ................................................................................ 75 Mounting, place of the installation ............................43
How to prepare commissioning ............................... 61
N
I Nominal operating speed...........................................24
Identification key, nameplate .................................. 100 Nominal speed screws, agitators..............................98
Illustration hopper agitator ......................................... 32 North America ...........................................................117
Improper use .............................................................. 10 Note
Index .......................................................................... 119 Feeding controller ..................................................70
Indications on the DualTray .................................. 114
Indications drive motor............................................... 24 O
Inertising ...................................................................... 23 Obligations of the user ...............................................11
Information on electrical mounting .......................... 53 Operation .............................................................. 29, 43
Installation ................................................................... 51 Operation of an agitator ............................................27
120
Optional component groups of the device...............30 Statutory provisions ................................................... 11

Order ..........................................................................115 Storage ........................................................................ 94
Order of the wiring plans ...........................................53 Storage and close-down ........................................... 92
Storage of individual components ........................... 94
P Storage of the device ................................................ 94
Packings ......................................................................90 Storage place.............................................................. 93
Place of the installation...............................................49 Storage room .............................................................. 93
Place of the installation, auxiliaries............................49 Structure of the hazard notes.................................... 35
Prerequisite for the type-approval ............................... 5 Supplementary documentation ........................70, 110
Preventive exchange..................................................83 Switch-off with untroubled operation ........................ 74
Product data ................................................................99
Product list ...................................................................99 T
Prohibitions on the device.................................. 44, 45 Technical data ....................................................97, 115
Protective equipment .................................................41 Terminal function junction box -JBn (n=2, 3,…) ... 107
Protective function Terminals 01 - 19 ..................................................... 107
setting of parameters............................................62 Terminals 20 - 49 ..................................................... 108
Terminals 50 - 85 ..................................................... 109
Q Termination of commissioning ................................. 63
Qualification of the operating staff.............................11 Termination of maintenance ..................................... 82
Quality rating of the hazard notes ...........................35 The construction......................................................... 16
Quality rating of the descriptions ..............................30 The hopper.................................................................. 20
R The hopper agitator.................................................... 32
Readjusting the tension of packings.........................90 The operation of a gravimetric execution ................ 72
Ready for operation ...................................................75 The operation of a volumetric execution.................. 71
Reasons for alarm cut-outs ......................................75 The operation of the device....................................... 70
Requirements rotatable execution............................33 The rotatable execution ............................................. 33
Requirements, conditions ............................................ 7 The task.................................................................71, 72
Residual risk product jam ..........................................40 The transport catches ................................................ 28
Residual risk ventilation/deaeration ..........................40 The use of the device ........................................... 6, 11
Residual risks caused by the device ........................40 The user has different revisions.............................. 112
Revision index...........................................................112 The weighed execution ............................................. 17
Revisions ...................................................................112 Tightness drive shafts ................................................ 84
Rundown of gauging .................................................69 Transport catches DDW-H1x ................................... 66
Rundown of commissioning......................................62 Transport catches DDW-H3..................................... 65
Russia ........................................................................118 Transport catches MDx, MSx ................................... 65
Transport of the device .............................................. 50
S Transport to the place of the installation .................. 50
Safety ...........................................................................31 Typical application ..................................................... 71
Safety and preparatory work .....................................87
Safety equipment........................................................20 U
Safety instructions.............................................. 34, 111 Uneven filling ratio ...................................................... 77
Safety instructions for weighing.................................43 Use............................................................................... 28
Safety screwing...........................................................42 Use in ATEX environment .......................................... 7
Screw jammed............................................................78 Use of the agitator ...................................................... 27
Screwed cable glands, screening.............................48 V
Sealings .......................................................................42 Validity.......................................................................... 34
Separate parts...........................................................106 Vent screw Gear ....................................................... 64
Set the distance d .......................................................91 Volumetric control..................................................... 106
Setting-up and exchange...........................................86
Shaft seals W
Readjust the tension or renew..............................90 Warning labels on the device................................... 44
Short-term switch-off .................................................74 Weighing system H3x ............................................... 18
Shut-off device on the outlet ......................................64 Weighing system MSx (4 load cells)........................ 18
Spare parts lists ..........................................................96 Weight values ............................................................. 79
Spare parts order......................................................115 Wiring plan CB with DDW ....................................... 103
Speed monitoring .......................................................26 Wiring plan ISC field bus ......................................... 105
Statement ..................................................................114 Wrong direction of rotation ....................................... 77
=== Ende der Liste für Textmarke Inhalt ===
121

ATEX - TSR XX - Operating Instructions (Rev.2.1 - April 2016)

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ATEX - TSR XX - Operating Instructions (Rev.2.1 - April 2016)

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387 - TSR - ATEX E2121387 TSR xx - ATEX 2.

Original operating instructions

Document status: Original operating instructions

Pos: 1.5 /Information Mapping/Betriebsanleitungen/Kap 00 - Impressum und Inhalt/Inhaltsverzeichnis @ 8\mod_1172133710285_3.doc @ 123025 @ @ 1

Determination of the discharge rate/feed rate ............................................................. 69

Prerequisite for Prerequisite for the type approuval of the device:

Any disrespect of the intended purpose has the following effect:

Content of the The chapter is divided into 7 parts.

Appropriate Products that are appropriate for being discharged/fed by means of

Dimensioning of The device is dimensioned according to the known operating

After any modification of the operating conditions a renewed

Use in ATEX environment

Warning Modification of the ATEX zone in the production periphery

Requirements, If the device is used in an ATEX environment the following

To be observed additionally for the application in areas with gas

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------------ Continuation: next page ---->

Use in ATEX environment, continuation

Field of The field of application of the device is determined by the marking of

Attention Operation outside the determined field of application

Design of the The approved field of application is designated on the nameplate of

Without type examination With type examination

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------------ Continuation: next page ---->

Use in ATEX environment, continuation

Circumferential Rotating component groups in explosion-hazard areas must

Degree of cleaning Manufacturer’s instructions concerning the degree of cleaning of the

Improper use The use is to be considered as improper in case of non-compliance

Examples for an improper use:

Effects Any abuse of the device

Obligations of the user

Statutory During the operation the following national and international

Qualification of Required qualification of the operating staff:

Simple cleaning and maintenance work:

Extended obligations for ATEX

Danger Potentially explosive gas mixtures or dust concentrations

Ambient The allowed ambient temperature according to EN13463 has to be

Compliance with Be sure to comply with the determined zone allocation:

Content of the EC declaration of conformity

Introduction If the execution of the device corresponds to the terms of

Moreover this declaration includes further indications concerning the

Data provided by The declaration includes the following information:

Designation Indications given in the declaration that serve to designate the

Content of the declaration of incorporation

Introduction If the device is executed as a partly completed machine in the terms

Data provided by The declaration includes the following information:

Designation Designation of the partly completed machine:

2 Description of the device

The type designation indicates the construction size and the

Content The chapter is divided in 2 sections.

3 Description of the device

The illustration shows the

The weighed execution

Definition: The technical term “weighing” designates the computation of the

Construction of For this purpose, the feeding device is mounted on a weighing

Additional The weighing requires additional electrical component groups:

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The weighed execution, continuation

Weighing system The weighing system DDW-H3x:

Weighing system The weighing system DDW-MSx:

4 Description of the component groups of the device

Introduction This chapter describes the component groups of the device.