Operating manual

Translation of the Original Manual

KBW

ODM - High capacity chain bucket elevator

KBW 250x19700AA /AF10 005ELV

Customer: Saint-Gobain Construction

Products Romania S.r.l.
1st District, One Unit Tower
165 Floreasca Road, 10th Floor
RO-014459 Bucharest

Delivery adress: SGCPRo S.R.L.

Fab. Placi
Trascaului 2
RO-401135 Turda
Romania

Technical contact: Mr. Chr. Werner

Christian.werner@dimatteo.de
Our Project no.: P9001156
Machine no. : P9001156.010
Year of manufacture: 2023
Your Project: Bucekt elevators for Turda Line 2, Romania

Your order: 4502801255 form 04.10.2022

DI MATTEO Förderanlagen GmbH & Co. KG

Address Römerstrasse 1-16
City 59269 Beckum, Germany
Telephone +49 2521 / 93 44 - 0
Fax +49 2521 / 93 44 - 222
Email info@dimatteo.de
Internet www.dimatteo.de
This document is to be regarded as information for use / operating manual and has
been prepared in accordance with the following standards and guidelines.

Standard / guideline Description

DIN EN IEC/IEEE Preparation of information for use (instructions for use) of
82079-1 products - Part 1: Principles and general requirements
DIN EN ISO 20607 Safety of machinery - instruction handbook
General design principles
DIN EN ISO 17100 Translation services
Requirements for translation services

The German language version is considered to be the lead document.

Edition of these operating manual

Incomplete ODM - High capacity chain bucket elevator KBW
machine:
Date 2023-03-06
Original language: Deutsch / German
Language Version: English / Romanian

All translations were made with great care by a certified technical translator.

Revision management:
Revision Date Description
Rev00 2023-03-06 Preparation of the operating manual

Person in Responsible:

Responsibilities
Title Surname Department / Area of responsibility
Mrs. Meyer - Technical documentation:
Erdt Operating instructions, technical data, technical
presentation, technical descriptions
Mr. Kleinedowe Technical documentation:
Operating instructions, technical data, technical
descriptions, standards and guidelines, safety instructions
risk assessments
 We reserve the right to make technical changes necessary to improve the machine
characteristics, which may result in deviations from the illustrations and information
contained in this manual.
All copyrights and property rights to this machine, as well as all associated
documentation remain the property of DI MATTEO Förderanlagen GmbH & Co.
KG.
This manual is intended for personnel entrusted with assembly, programming,
operating, and maintenance tasks. It contains guidelines and drawings of a
technical nature that must not be duplicated or disseminated, in whole or in part,
used for competitive purposes without authorization, or communicated to third
parties.
All rights reserved.
Copyright 2022 DI MATTEO Förderanlagen GmbH & Co. KG

3
Table of Contents
1 Declaration of Incorporation of Partly Completed Machinery ............................... 8
2 About this manual ..................................................................................................... 9
2.1 Gender-neutral formulation .................................................................................................. 9
2.2 Use and storage .................................................................................................................. 9
2.3 Liability and warranty for this operating manual .................................................................. 9
2.3.1 Exceptions to the warranty ................................................................................................10
2.4 Notification of revisions ......................................................................................................11
2.5 Scope of delivery ...............................................................................................................11
2.6 Service address .................................................................................................................11
2.7 Liability and warranty .........................................................................................................12
3 Safety ....................................................................................................................... 13
3.1 General information concerning safety ..............................................................................13
3.2 Compliance with instructions in the operating manual ......................................................14
3.3 Requirements for operation ...............................................................................................15
3.4 Obligations of the owner ....................................................................................................16
3.4.1 General requirements ........................................................................................................16
3.4.2 Operating manual ..............................................................................................................16
3.5 Other applicable documents ..............................................................................................16
3.6 Warning notices in the manual ..........................................................................................17
3.6.1 Local statutory regulations .................................................................................................18
3.7 Intended use ......................................................................................................................19
3.8 Non-intended use ..............................................................................................................19
3.9 Foreseeable misuse ..........................................................................................................20
3.10 Target groups ....................................................................................................................21
3.10.1 Restriction of groups of persons / target groups ...............................................................21
3.10.2 Personnel requirements.....................................................................................................21
3.11 Qualifications of personnel ................................................................................................22
3.11.1 Hazards posed by untrained personnel .............................................................................23
3.12 Instruction of the employees ..............................................................................................23
3.12.1 Instruction ..........................................................................................................................23
3.12.2 Instruction protocol ............................................................................................................24
3.13 Instruction log ....................................................................................................................24
3.14 Safety instructions for personnel .......................................................................................25
3.15 Personal protective equipment ..........................................................................................26
3.15.1 Personal protective equipment ..........................................................................................26
3.16 Safety notices and warning signs on the machine ............................................................28
3.16.1 Attachment of pictograms and information signs ..............................................................28
3.17 Safety tests ........................................................................................................................29
3.18 Safety devices ...................................................................................................................29
3.19 Safety tests ........................................................................................................................29
3.19.1 Hazards posed by inclement weather ...............................................................................30
3.19.2 Hazards posed by ambient conditions ...............................................................................30
3.19.3 Environmental hazards ......................................................................................................31
3.19.4 Hazards posed by moving parts ........................................................................................31
3.19.5 Hazards due to electrical energy .......................................................................................32
3.19.6 Danger due to a potentially explosive atmosphere ...........................................................32
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 3.19.7 Hazards due hydraulic and pneumatic energy ..................................................................33
3.19.8 Hazards due to hot spots ...................................................................................................33
3.19.9 Hazards associated with the handling of chemical substances ........................................34
3.19.10 Hazards posed by gases, fumes, and dusts......................................................................34
3.19.11 Hazards posed by gases, fumes, and dusts......................................................................34
3.19.12 Danger due to hazardous substances ...............................................................................35
3.20 Instructions concerning specific hazards and residual risks..............................................36
3.20.1 Operation and running of the system ................................................................................37
3.20.2 Inspection ..........................................................................................................................38
3.20.3 Conversions and unauthorized modifications ....................................................................38
3.21 Transport and assembly ....................................................................................................38
3.21.1 Cleaning, maintenance, and repair ....................................................................................39
3.22 Spare parts and wear parts ...............................................................................................39
3.23 Conduct in emergency situations ......................................................................................40
3.24 Foreseeable misuse ..........................................................................................................41
3.25 Conduct in the event of faults ............................................................................................42
4 Technical data sheet ............................................................................................... 43
4.1 Machine characteristics P9001156 ...................................................................................43
4.2 Bulk material characteristics ..............................................................................................44
4.3 Plant data ...........................................................................................................................44
4.4 Noise emission ..................................................................................................................45
5 Structure and function ............................................................................................ 46
5.1 Bucket elevator designs - overview ...................................................................................46
6 Structure ODM - High capacity chain bucket elevator KBW ............................... 47
6.1 Components description ....................................................................................................48
6.1.1 Bucket elevator head .........................................................................................................48
6.1.2 Drive...................................................................................................................................48
6.1.3 Frequency converter / soft start .........................................................................................48
6.1.4 Bucket elevator chimneys ..................................................................................................48
6.1.5 Bucket ................................................................................................................................48
6.1.6 Traction means for conveying ...........................................................................................49
6.1.7 Bucket elevator bottom ......................................................................................................49
6.1.8 Tensioning station ..............................................................................................................49
6.2 Sensors ..............................................................................................................................50
6.2.1 Speed monitor ...................................................................................................................50
6.2.2 Level control ......................................................................................................................50
6.2.3 Belt misalignment switch (optional) ...................................................................................50
6.2.4 Temperature monitoring (optional) ....................................................................................50
6.2.5 Compensators (optional) ...................................................................................................50
6.3 Function bucket elevator....................................................................................................51
7 Transport ................................................................................................................. 52
7.1 Safety .................................................................................................................................52
7.2 Checking the delivery ........................................................................................................53
7.3 Packaging ..........................................................................................................................53
8 Storage ..................................................................................................................... 54
8.1 Safety .................................................................................................................................54

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 8.2 Intermediate storage ..........................................................................................................54
9 Assembly ................................................................................................................. 55
9.1 Safety .................................................................................................................................55
9.2 Preparatory measures for set-up .......................................................................................57
9.3 Set-up and alignment.........................................................................................................57
9.4 Threaded fitting of the housing flanges .............................................................................57
9.5 Mechanical installation .......................................................................................................58
9.5.1 Installation of the chutes ....................................................................................................58
9.5.2 Aligning the bucket elevator ..............................................................................................59
9.5.3 Assembly the bucket head.................................................................................................59
9.5.4 Assembly of bucket elevators with a small center distance ..............................................59
9.5.5 Installation of lateral guides ...............................................................................................59
9.5.6 Installation of the chains and buckets ................................................................................60
9.5.7 Settings at the bucket elevator outlet ................................................................................61
9.5.8 Installation of drive group...................................................................................................62
9.5.9 Installation of the inspection drive .....................................................................................63
9.5.10 Installation of the central lubrication system ......................................................................63
9.6 Electrical installation ..........................................................................................................63
9.6.1 Electrical connection of the central lubrication pump ........................................................63
9.6.2 Electrical connection for speed monitoring ........................................................................64
9.6.3 Electrical connection of the drive unit ................................................................................64
9.7 Cleaning after assembly ....................................................................................................64
10 Commissioning ....................................................................................................... 65
10.1 Safety .................................................................................................................................65
10.2 Trial run ..............................................................................................................................66
10.3 Starting up after a scheduled shutdown ............................................................................66
11 Operation ................................................................................................................. 67
11.1 Safety .................................................................................................................................67
11.2 Prior to operation ...............................................................................................................68
11.3 Operation of the machine ..................................................................................................68
12 Faults ....................................................................................................................... 69
12.1 Safety .................................................................................................................................69
12.2 Preparation for fault rectification ........................................................................................71
12.3 Switching the machine on again after faults ......................................................................71
12.4 Faults and troubleshooting ................................................................................................72
13 Maintenance ............................................................................................................ 73
13.1 Safety .................................................................................................................................73
13.2 Prior to maintenance ..........................................................................................................75
13.3 Switching the machine on again after maintenance ..........................................................76
13.4 General information ...........................................................................................................76
13.5 Inspection/inspection schedules ........................................................................................77
13.6 Maintenance ......................................................................................................................77
13.6.1 Maintenance schedule .......................................................................................................78
13.6.2 Lubrication instructions ......................................................................................................80
13.6.3 Lubrication instructions -Overview.....................................................................................83
13.6.4 Lubrication - Elevator bottom .............................................................................................84

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 13.6.5 Lubrication -Elevator head .................................................................................................84
13.6.6 Lubrication list ....................................................................................................................86
14 Spare parts .............................................................................................................. 88
14.1 Ordering spare parts ..........................................................................................................88
14.2 Spare parts ........................................................................................................................89
15 Decommissioning ................................................................................................... 93
15.1 Safety .................................................................................................................................93
15.2 Decommissioning the machine ..........................................................................................94
16 Dismantling.............................................................................................................. 95
16.1 Safety .................................................................................................................................95
16.2 Prerequisites for dismantling .............................................................................................98
16.3 Electrical dismantling .........................................................................................................98
16.4 Mechanical dismantling .....................................................................................................98
17 Disposal ................................................................................................................... 99
17.1 Safety .................................................................................................................................99

KBW 7 / 101
Rev. 00 2023-03-06
1 Declaration of Incorporation of Partly Completed Machinery

EC Directive 2006/42/EC Annex II No. 1B

DI MATTEO Förderanlagen GmbH & Co. KG
Römerstraße 1-16
59269 Beckum
Germany
Mrs. Meyer-Erdt, employee of DI MATTEO Förderanlagen GmbH & Co KG, is
authorized to compile the technical documentation for the machine listed below:
Herewith the company DI MATTEO Förderanlagen GmbH & Co. KG,
that the following machine:

Designation and type of the ODM - High capacity chain bucket elevator
machine: KBW 250x19700AA /AF10 005ELV
Machine no.: P9001156.010
Issued for: Saint-Gobain Construction
Products Romania S.r.l.
1st District, One Unit Tower
165 Floreasca Road, 10th Floor
RO-014459 Bucharest

is an incomplete machine according to article 2g.

The company DI MATTEO Förderanlagen GmbH & Co. KG hereby declares that
the above-mentioned machine is exclusively intended for installation in or
assembly with another machine or equipment which complies with the legal
regulations and requirements according to EC Directive 2006/42/EC.
This incomplete machine has been constructed in accordance with the provisions
of the following EC Directives 2006/42/EC.
The following harmonized standards have been applied:
DIN EN ISO 12100 : 2010 DIN EN 14122-2 4.2.2
DIN EN ICE / IEEE 82079-1 DIN EN ISO 206007
DIN EN 60204-1 : 2019 – VDE DIN EN 618
VDI 2324 DIN 15233
DIN 15234 DIN 15234
The specific technical documentation referred to in Annex IIB has been
established and shall be made available in electronic form to the national
competent authority upon request.
Beckum, 2023-03-06

Dr. Luigi DI MATTEO

(Chief Executive Officer)

KBW 8 / 101
Rev. 00 2023-03-06
2 About this manual

2.1 Gender-neutral formulation

For better readability, the language forms male, female, and diverse (m/f/d) are not
used simultaneously.

2.2 Use and storage

This operating manual is required for the proper and safe start-up, operation, and
maintenance of the machine. This operating manual applies only to the machine
specified on the cover page and is not subject to notification of revisions made.
Information contained in this operating manual applies from the date of initial
commissioning and must be complied with until the date of ultimate disposal.
The owner has to ensure that the manual is read and has been understood by all
involved persons, prior to commencing tasks associated with the machine. The
chapter on safety provides an overview of all the important safety aspects for
ensuring optimum protection of personnel as well as safe and trouble-free
operation of the system.
The manufacturer is not liable for damage resulting from failure to comply with the
instructions provided in this operating manual.
This operating manual must be on hand in the vicinity of the machine for the
operator at all times.
If there are environmentally hazardous materials and/or substances hazardous to
health, they must be disposed of separately and properly.

2.3 Liability and warranty for this operating manual

The company DI MATTEO points out that despite all care taken in the preparation
of documentation, errors cannot be completely excluded.
For the services provided by us, we assume the legal warranty from the day of
acceptance.
Any errors detected must be reported to us immediately, at the latest within 10
days after final delivery, in writing and in a comprehensible form.
If it turns out during the processing of the complaint that it is not a warranty case,
we will invoice the costs incurred, travel expenses and working time.

Notice:
DI MATTEO expressly does NOT check the factual, content-related and technical
correctness of the technical documents and data provided - in particular in the case
of the suppliers or manufacturer documentation that is also applicable - and
therefore any liability is also excluded in these cases.

KBW 9 / 101
Rev. 00 2023-03-06
2.3.1 Exceptions to the warranty
Parts subject to wear and tear and operating materials are excluded from the
warranty, as their service life depends on the respective area of application and the
intensity of use.
Only in the case of production errors or verifiable defects can you make warranty
and guarantee claims.

Wear parts are components or assemblies of a product which may lose their
functionality during the service life of this product if used as intended.

As part of regular maintenance and servicing, wear parts on this machine must be
checked and replaced by qualified personnel.

Within the scope of a regularly performed cleaning of the machine with suitable
means, the service life of spare and wear parts can be extended. Cleaning
intervals of the machine are recommended at weekly intervals.
On the other hand, material residues that are not removed can shorten the service
life of spare and wear parts.

KBW 10 / 101
Rev. 00 2023-03-06
2.4 Notification of revisions

If there are any problems or difficulties the owner of the machine cannot resolve,
then the owner should contact the service department at DI MATTEO without
delay.
This operating manual is subject to technical modifications necessary for machine
improvement.
The manufacturer reserves all rights to this operating manual; this also applies to
the grant of a patent or the registration of a utility model or design. Without prior
written agreement, this operating manual may neither be copied nor made
accessible to third parties; or misused in any other way.

2.5 Scope of delivery

This operating manual only applies to the machine cited in the order confirmation
and on the cover sheet.

2.6 Service address

DI MATTEO Förderanlagen GmbH & Co. KG

Address Römerstrasse 1-16
City 59269 Beckum, Germany
Telephone +49 2521 / 93 44 - 0
Fax +49 2521 / 93 44 - 222
Email info@dimatteo.de
Internet www.dimatteo.de

KBW 11 / 101
Rev. 00 2023-03-06
2.7 Liability and warranty

The machine has been built in accordance with the recognized state of the
technology, accepted safety-related rules, and appropriate standards and
directives.
Nevertheless hazards to life and limb can occur for the user or third-parties, which
could also cause damage to the machine or other material assets.
Warranty claims and liability claims for personal injury or material damage are
excluded if they are attributed to one or more of the following causes:

• Non-intended, improper use of the machine

• Failure to comply with the operating manual and all associated parts and
appendices
• Unauthorized structural or technical changes of the machine
• Deployment of untrained personnel
• Inadequate instruction of personnel by the owner
• Operating errors and operator errors
• Operation of the machine with defective or improperly attached safety
devices and protective devices
• Faulty assembly or installation
• Set-up on an unsuitable substrate
• Use of unsuitable or untested operating equipment
• Faulty operation of required tools and auxiliary materials
• Failure to maintain and inspect machine parts and wear parts
• Failure to comply with the prescribed maintenance intervals
• Faults that are not rectified
• Use of non-approved spare parts
• Other misuse
• Catastrophic events through the effects of foreign objects and force majeure

The information in this manual describes the characteristics of the product without
assurance of these characteristics.
No claims can be made legally binding for previously delivered machines from the
information, illustrations, and descriptions in this manual. The information, data and
instructions specified in this manual were up to date at the time this manual went to
press.
Notify the manufacturer immediately after detecting the deficiency or the fault.

KBW 12 / 101
Rev. 00 2023-03-06
3 Safety

3.1 General information concerning safety

The chapter on safety provides an overview of all the important safety aspects for
ensuring optimum protection of personnel as well as safe and trouble-free
utilization of the machine, including its transport, operation, and disposal.
Failure to comply with instructions given in this operating manual and safety
information can result in significant hazards to persons and damage to the
machine.
The machine has been designed and built in accordance with the latest technology
and recognized safety-relevant directives and standards. The machine is
operationally reliable.
Nevertheless, there may be residual hazards associated with the machine under
the following circumstances:
• The machine is not used as intended.
• The machine is improperly operated by untrained or uninstructed personnel.
• The machine is improperly maintained or serviced.
• Failure to comply with information relevant to safety and warnings detailed in
this manual.
• The machine is improperly modified or converted.
• The prescribed maintenance tasks are not carried out according to schedule.

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Rev. 00 2023-03-06
3.2 Compliance with instructions in the operating manual

Note
Any person assigned to work on the machine must have read and understood
this manual, in particular the “Safety” chapter.

Knowledge of and compliance with instructions given is prerequisite for protecting

personnel from hazards and avoiding mistakes.
Therefore, compliance with all safety instructions is strictly required to ensure your
safety.
The operating manual is part of the machine and must be available at the machine
at all times. Personnel must read and understand the operating manual and
comply with information detailed therein during any task. Contact the manufacturer
immediately if there are any questions or ambiguities regarding this operating
manual (see contact details).
Apart from the safety information in this manual, compliance with the following
rules and regulations is also required:
• Intended use.
• Relevant accident prevention regulations (UVV).
• Occupational health and safety regulations.
• Generally recognized technical safety regulations.
• Country-specific regulations.
• Documentation for attachment parts.
• Documentation provided by third-party manufacturers accompanying the
machine.
• Manufacturers' specifications (material safety data sheets) for consumables,
auxiliary materials, and chemical substances.
These rules and regulations can also be supplemented with operating instructions
that account for factory-internal regulations or company-specific particularities.
In addition to information contained in this operating manual, persons should also
receive company-internal instruction based on their professional qualifications.
The safety regulations issued by the owner of the entire system take priority over
the product documentation provided by DI MATTEO.

KBW 14 / 101
Rev. 00 2023-03-06
3.3 Requirements for operation

The owner has to check the compatibility with other systems and equipment,
because such information is not assessable for us.
Moreover, the following prerequisites must be in place for ordinary operation of the
machine (unless these are part of our area of responsibility):
• The machine is correctly and completely assembled.
• A trial run was conducted with all of the required setting tasks completed.
• Instruction of operating personnel in the operation of the machine and relevant
safety regulations.
• If hot or cold machine parts cause hazards these parts must be protected
against contact by the customer.
• Exclusion of hazards posed by electrical energy (for details please see, e.g.
VDE regulations or utility company specifications).
• The machine must be easy to access.
• The primary responsibility for proper machine operation is assigned to one
person.

KBW 15 / 101
Rev. 00 2023-03-06
3.4 Obligations of the owner

3.4.1 General requirements

The machine most be used in such a manner that it safely suffices for the intended
use and the loads that can be reasonably expected. Prior to initial commissioning
of the machine and following maintenance or structural changes, a technical expert
should inspect the machine.

3.4.2 Operating manual

The operating manual is an important and integral part of the system. The owner
must ensure that the operating manual is read by everyone working on or with the
machine. The operating manual must kept at the installation site of the machine
where it is accessible at all times.
The owner should add applicable local regulations to the operating manual. Apart
from the regulations listed below this also includes specifications on supervisory
and reporting obligations. The aim is to include specific company features with
regard to work organization, operating procedures and personnel deployed.

Note
DI MATTEO is not liable for any damage resulting from failure to comply with
information provided in product-relevant documentation.

3.5 Other applicable documents

Compliance with information given in this operating manual as well as information

given in other applicable documents is mandatory. Other applicable documents
usually include:
• Supplier documentation
• Documentation concerning the electrical system
• Material safety data sheets
• Project diagrams

Note
The specifications of the order confirmation cite the specific documents that are
belong to the product-specific documentation.

KBW 16 / 101
Rev. 00 2023-03-06
3.6 Warning notices in the manual

In this manual warning notices are marked with a signal word panel. These signal
words are used to express the seriousness of the hazard.
Compliance with warning information is mandatory to prevent accidents and
damage to persons and property.
The following signal words and symbols are used in this manual:

WARNING
Indicates general hazards if the following measures are not complied with.

DANGER
Failure to take appropriate precautionary measures will result in death or severe
physical injury.

WARNING
Failure to take appropriate precautionary measures can result in death or severe
physical injury.

CAUTION
Indicates a potentially dangerous situation which can result in minor injury, if it is
not avoided.

ATTENTION

Indicates a potentially dangerous situation which can result in material damage, if it

is not avoided.

Note
This indicates advice on the application as well as other useful information.

KBW 17 / 101
Rev. 00 2023-03-06
3.6.1 Local statutory regulations
The owner is responsible for ensuring compliance with all binding laws,
regulations, ordinances and existing national provisions with respect to accident
prevention as well as any possibly applicable internal provisions regarding work,
operations, or safety at the relevant place of installation.

Applicable local regulations and laws include:

• Safety of personnel (accident prevention regulations)
• Safety of equipment (personal protective equipment and maintenance)
• Disposal of products and materials (Waste Management Act)
• Cleaning (cleaning agents and disposal)
• Environmental protection requirements

The owner has to ensure that the following inspections are carried out:
• Inspection of the machine for operational reliability
• Checking of safety devices for correct functioning
• Performance of all inspections according to the maintenance schedule

KBW 18 / 101
Rev. 00 2023-03-06
3.7 Intended use

All DI MATTEO products as well as all other components being part of DI

MATTEO's scope of delivery may be used only for their intended purpose. Their
usage is indicated in the product-specific documentation in conjunction with the
technical specification defined in the contract concluded with DI MATTEO. The
technical specifications are part of the order confirmation.
In this regard the technical specifications and information concerning the intended
use (assembly conditions, connection conditions, ambient conditions and operating
conditions) which are indicated on the rating plate and other applicable documents,
are authoritative.
Intended use also includes complying with information in the operating manual and
complying with the inspection and maintenance conditions. The product-specific
documentation applies only for the intended use of the machine as specified in the
order.
Should any situations arise due to special local conditions or in special individual
cases, which were not known to DI MATTEO, then such situations may not be
taken into account in the operating manual. In this case the system owner has to
ensure risk-free operation or shut down the machine until measures for safe
operation have been implemented in coordination with DI MATTEO or other
competent authorities.

Note
The machine is an incomplete machine and is designed for installation in a
system.

3.8 Non-intended use

Any use other than that specified in the chapter, “Intended use” and in this
operating manual, or any use extending beyond the specified intended use is
considered non-intended use. The manufacturer is not liable for damage resulting
from improper use. The user/owner alone bears the risk.
• It is prohibited to modify the machine in any way.
• It is not permitted to operate the machine with bypassed safety devices.
• It is prohibited to use the machine to transport persons.
• It is not permitted to use the machine for conveying any loads or materials
other than those specified in this manual.

KBW 19 / 101
Rev. 00 2023-03-06
3.9 Foreseeable misuse

The points below describe foreseeable misuse of the machine:

• Installation on unsuitable surfaces.
• Attachment of transport aids on machine parts.
• Failure to comply with operating data.
• Failure to comply with maintenance intervals.
• Wrong direction of rotation.
• Activation while running down the system.
• Exceeding or falling below speed limit values.
• Non-dosed feed of the material to be conveyed into the machine.
• Non-ensured further conveyance of the conveyed material at the material
discharge of the machine.
• Operation with or without damaged components, which are intended to
improve the safety of personnel and the machine.
• Operation without oil.
• Filling the system with oil quantities above the required quantities.

KBW 20 / 101
Rev. 00 2023-03-06
3.10 Target groups

3.10.1 Restriction of groups of persons / target groups

WARNING
Risk of injury
There is risk of injury:
• For persons with reduced, physical, sensory or mental capabilities.
• For personnel lacking experience or knowledge.
• For persons with a cardiac pacemaker.
(depending on the task and area of application))
• For persons, who are not yet at least 18 years of age.
• For persons with addictions.
The owner must ensure that the groups of persons cited above are not present in
the machine's area of activity, or are present in this area only if accompanied by
and under the supervision of an authorized and trained person.

3.10.2 Personnel requirements

The owner must ensure that the following requirements are met:
• Only assign trained personnel who are familiar with the basic accident
prevention regulations and who have been instructed in the proper handling of
the machine
• Compliance with the legal minimum age
• Only personnel assigned by the owner in writing are allowed to operate,
service, maintain, and repair the machine
• The owner must clearly define and regulate the areas of responsibility,
accountability, and supervision of personnel, so that unclear competencies
cannot occur
• No access for unauthorized persons in the machine area
• Comply with supervisory and reporting obligations and operational
particularities.
• Explain rules of conduct in emergency situations This also includes knowledge
of first-aid measures and of local rescue facilities.
• Explanation of correct handling of hazardous substances
Ultimately, the owner or personnel authorized by the owner is/are responsible for
ensuring accident-free operation. If personnel do not possess the required
knowledge, then they must receive training and instruction.

KBW 21 / 101
Rev. 00 2023-03-06
3.11 Qualifications of personnel

Tasks on the machine must only be executed by personnel qualified and who are
qualified and who have been instructed in this regard in accordance with prevailing
rules and legal regulations. The following requirements must be met:
• Personnel must possess special knowledge and experience in the relevant
technical field. This applies in particular to repair tasks involving electrical,
mechanical, hydraulic and pneumatic equipment of the machine.
• Personnel must have knowledge of relevant standards, provisions, accident
prevention regulations, and operating conditions.
• Personnel must be authorized by the safety officer to execute the required
tasks.
• Personnel must be capable of identifying possible hazards and avoiding these.
The qualifications required of personnel are subject to varying legal requirements,
depending on the place where the machine is being used. The owner has to
ensure that applicable laws are being complied with. Unless statutory provisions
have been made, the following listing shows the required minimum qualification for
personnel to be authorized to perform the stated tasks.

Personnel Task Qualification Lifecycle

Personnel skilled Lifting/setting down and Verifiable experience in the Transport,
in load-moving transporting the machine handling of suspended assembly,
tasks loads and load securement Dismantling
1)

Skilled personnel Mechanical tasks for: Installation, Completed training for Installation,
(mechanics) commissioning, fault rectification, industrial mechanic or commissioning,
maintenance tasks and similar equivalent fault rectification,
decommissioning qualification (company- maintenance
internal training and/or tasks,
external training) 1) decommissioning,
dismantling
Specialized Electrotechnical tasks Completed specialized Installation,
personnel training for electrotechnical commissioning,
(qualified engineering or similar fault rectification,
electrician) equivalent qualification maintenance
(company-internal training tasks,
and/or external training) 1) decommissioning,
dismantling
Skilled personnel Operation and setup of the Person instructed by the Start-up,
(operators and machine owner using the operating operation, fault
machine setters) manual elimination
Skilled personnel Proper disposal of the machine: Knowledge of the disposal Shutdown,
(disposer) regulations applicable at the dismantling and
place where the machine is disposal
used
Skilled personnel Implementation of applicable Knowledge of safety All
(safety officer) safety regulations regulations applicable at the
place where the machine is
used
Surveyor Walkabout inspection of the Person guided by skilled –
machine safety personnel
1) Minimum of 3 years of professional experience

KBW 22 / 101
Rev. 00 2023-03-06
3.11.1 Hazards posed by untrained personnel

WARNING
Inexperienced and unqualified members of personnel put themselves and other
persons at risk.
• Tasks must only be performed by persons who are experienced in carrying out
the assigned tasks and who have received instruction regarding the
associated hazards.
• Clearly define the responsibilities and duties of personnel for the relevant
lifecycle.
• Only deploy appropriately trained and authorized personnel who possess the
qualifications described under "Requirements of personnel".
• Personnel receiving training may only be active at the machine under the
constant supervision of an experienced specialist.

3.12 Instruction of the employees

3.12.1 Instruction
The ordering party and the owner of the system are obligated to provide
instruction.

DI MATTEO Förderanlagen GmbH & Co. KG offers the following

recommendations with regard to instruction:

The owner must protect personnel against health hazards and instruct personnel
prior to the first time personnel commence their activity on the machine. Thereafter
the instruction must be repeated at regular intervals, however at least once a year.

Personnel must have read the operating manual and received instruction.
Personnel must confirm their understanding of the content with their signatures.

KBW 23 / 101
Rev. 00 2023-03-06
Unterweis

3.12.2 Instruction protocol

3.13 Instruction log

The instruction log serves as verification and it must be copied in advance,

conscientiously filled out, and archived for the entire service life of the machine.

Topic / content of the instruction Instruction was Date Employee signature

executed by:

Verifications/logs concerning content and topics of the instruction, in hard copy

form and digital form must be kept and stored.

At the close of the event, the participants must confirm with their signature that
they have understood the content.

KBW 24 / 101
Rev. 00 2023-03-06
3.14 Safety instructions for personnel

Refrain from any work practice that:

• Endangers the health and safety of the user or third parties.
• Involves impairments of the machine or other material values.
• That impairs the safety and function of the machine.
• Involves disregard of stated safety instructions.

Moreover:
• Do not perform tasks on machines/systems while they are in operation.
• Do not perform any tasks on energized machine parts.
• Always use personal protective equipment for tasks on the machine.

WARNING
There is a risk of injury if the safety devices are taken out of service. Never
remove safety devices, take these out of service, or modify these.
• Check the safety devices for correct functioning every day.
• Inform the owner immediately of any faults or defects concerning the safety
devices.
• Ensure that covers (e. g. panels, shields, housings) are closed during
operation.
• When using chemicals ensure compliance with the information provided in
relevant material safety data sheets and disposal instructions provided by the
respective manufacturers, as well as all local safety requirements.
• Wear protective clothing.
• Only perform tasks with which you are familiar, that you are authorized to do,
and which are part of your area of responsibility.
• When handling operating materials (e.g. oils, greases or other chemical
substances), comply with the manufacturer’s specifications and safety
instructions that apply to the relevant product.

WARNING
There is a risk of damage to material assets if the machine is incorrectly
operated.
• Comply with information given in the descriptions for attachment parts and
auxiliary equipment (if applicable). Compare suppliers' documentation and/or
separate documentation from third-party manufacturers.

KBW 25 / 101
Rev. 00 2023-03-06
3.15 Personal protective equipment

3.15.1 Personal protective equipment

WARNING
Risk of accident and injury
Failure to use personal protective equipment can result in severe or fatal injury

• Use the prescribed personal protective equipment for carrying out any tasks
associated with the machine, e.g. hearing protection, eye protection, protective
footwear, protective helmet, protective clothing, protective gloves, and
respiratory protection.
• The owner must provide suitable and faultless protective equipment for every
employee; likewise the owner must ensure that all employees wear or use this
equipment. Preventative measures as stipulated in the current valid accident
prevention regulations must be complied with in every case.
• The owner must ensure that unauthorized persons are not in the hazard zone.
Hazard zones must be marked so that they are clearly indicated for everyone.

Mandatory Definition and requirement

sign
Hearing protection
For protection against hearing loss in environments with
high or continuous noise exposure

Protective goggles
To protect the eyes from ejected parts, dust, and liquid
splashes

Hard hat
For protection against falling and ejected parts and
materials.

Safety footwear
For protection against heavy falling parts and slipping on
slippery substrates
Safety footwear requirements:
Safety footwear of quality class - S2 protects the entire
foot:
• from crush injuries in the toe area.
– from possible injury through slipping.
• from injuries in the heel area.
Protective work clothing
Protective work clothing is tight-fitting work clothing with low
resistance to tearing, with tight sleeves, and without
projecting parts.
It primarily serves as protection against entanglement
through moving machine parts, such as shafts, spindles,
couplings, etc.

KBW 26 / 101
Rev. 00 2023-03-06
 Mandatory Definition and requirement
sign
Do not wear rings, chains or other jewelry; hair must be
covered. There is a risk of entrapment, entanglement or
being caught and dragged along on moving parts.

Use hand protection

Protective gloves must be used in the areas, in which the
hands must be protected from injuries due to chemical or
electrical hazards.
Use a fall arrest harness
Personal protective equipment to prevent falling is one of
the individual protective measures. Personal fall protection
equipment prechimneys the user from falling, either by
preventing a fall (restraint system) or by arresting a free fall
(fall arrest system). Personal fall arrest equipment consists
of a combination of components that at least include a body
holding device (e.g. fall arrest harness) and a fastening
system, that can be combined with reliable anchoring.
Wear a warning vest
Wearing a safety vest or warning vest is mandatory,
wherever persons under some circumstances cannot be
seen or are hard to see, in particular in the area of
mechanical equipment, or when driving company vehicles
Use a mask / respiratory mask
In the area of aggressive chemical substances,
microorganisms, and particles that can damage the lungs,
employees must wear masks / respiratory masks.

WARNING
Increased risk of accident and injury, as well as long-term and significant
health impairment when handling hazardous substances
For tasks on the machine, for which personnel can come into contact with
hazardous substances, PPE must be used in accordance with the PPE Ordinance
(EU) 2016/425. The owner must adequately instruct personnel with regard to
hazardous substances and the associated warnings.
Failure to use personal protective equipment can result in severe or fatal injury.

KBW 27 / 101
Rev. 00 2023-03-06
3.16 Safety notices and warning signs on the machine

Instructions and symbols, such as safety stickers attached to the machine must
always be complied with. Stickers must not be removed and maintained in a
completely legible condition.

3.16.1 Attachment of pictograms and information signs

• To avoid damage, but also to prevent certain actions, owner-provided
prohibition signs, as well as warning and information signs must be affixed
directly on the hazardous area were they are clearly visible
• Hazardous substances, or products that contain hazardous substances must
be marked with warning symbols and warning notices

KBW 28 / 101
Rev. 00 2023-03-06
3.17 Safety tests

3.18 Safety devices

WARNING
An increased risk of injury exists if safety devices are damaged, have been
modified, removed, or taken out of service.
The machine must only be operated with all protective equipment and safety
devices (e.g. emergency stop buttons, safety valves, coupling guards, belt guards,
contact thermometers, contact circuits) enabled.
• Ensure that safety devices are correctly functioning.
• Never remove protective equipment or safety devices, take these out of
service, or modify these; not even during trial operation.
Skilled personnel are to check safety devices for correct functioning at regular
intervals. The owner must be informed immediately of any faults with the safety
devices.

Note
The safety devices must be checked particularly after maintenance, service and
repair tasks have been completed.

3.19 Safety tests

WARNING
There is an increased risk of injury for persons performing tasks for which they
are neither qualified, nor for which they have received appropriate instruction.
• The commissioning process for the machine may be carried out only by
persons who are familiar with this task, have been instructed with regard to the
associated hazards, and who have the necessary qualifications
• All technical safety conditions have to be satisfied prior to carrying out the
start-up process Additional information and requirements are provided in the
chapters "Installation" and "Commissioning", in this operating manual.
• Prior to commissioning, a risk assessment must be prepared by the owner of
the system, as specified by occupational health and safety legislation
Safety tests to be carried out during the commissioning procedure:
• Continuity of the protective circuit
• Function check (inspection of safety devices, such as the protective hoods)
• Insulation test
• Voltage test
• Protection against residual voltages
• Checking for correct function of electrical equipment and particularly
equipment associated with safety and protective measures

KBW 29 / 101
Rev. 00 2023-03-06
3.19.1 Hazards posed by inclement weather

WARNING
The following weather-related hazards exist for persons and property, dependent
on weather conditions.
• Lightning. Hazard posed by direct lightning strike or in the case of contact with
metal parts that are live due to lightning current.
• Ice and snow: Hazard posed by slippery surfaces and icicles breaking off.
• Strong wind: Hazard posed by components and loose objects overturning and
falling.
• Rain, dust, sand, and fog. Hazard posed by poor visibility and slippery
surfaces.

3.19.2 Hazards posed by ambient conditions

Inadequate lighting:
Poor visibility due to inadequate lighting increases the risk of an accident.
• Any given task must be performed under adequate lighting conditions.

Inadequate access:
An increased risk of an accident exists (e.g. risk of falling) due to inadequate or
insufficiently secured access to the work area.
• Use appropriate measures to secure access to hazard areas.

Noise irritation:
The noise level emanating from the machine in the work area can cause severe
hearing damage and can be harmful to the health of personnel.
• Always use effective ear protection for the performance of tasks.
• Do not stay in the hazard zone any longer than necessary.

Contamination:
Operation of the machine will result in soiling that can present a slip hazard and
lead to injury of personnel.
• Use personal protective equipment for the performance of any task and
specifically wear safety boots.
• Remove impurities without delay

KBW 30 / 101
Rev. 00 2023-03-06
3.19.3 Environmental hazards

WARNING
Consumables such as greases and oils contain toxic substances that can lead to
contamination of drinking water and the soil. Consumables must be properly
disposed of.
• Oils and greases must be properly disposed of.
• Comply with applicable local disposal regulations.
• A company specialized in waste disposal must be entrusted with the disposal
of waste material.
• Comply with the manufacturers' specifications and material safety data sheets
for the individual substances.
• Also comply with specifications given in the suppliers' documentation.

ATTENTION
For any tasks on rotating parts (adjustment tasks, function checks, cleaning the
machine in the area) there is an increased risk of accident. Severe injury, loss of
body parts and death can be the consequences.

• All rotating machine elements must be provided with a protective hood.

• The machine must not be operated without protective hoods or if the
housing is open.
• If the machine must be operated without protective hoods or when the
housing is open (for troubleshooting / fault elimination) reaching into
the machine is prohibited.
• The safety distance to rotating parts must be maintained.
• Operation must only take place under supervision.
• It must be ensured that the machine can be switched off at any time.

3.19.4 Hazards posed by moving parts

WARNING
Moving machine parts that are freely accessible can present hazardous areas
that could cause severe and even fatal injuries. There is a risk of entrapment,
entanglement or becoming caught and dragged along on moving parts.
If spatial separation is not possible between the hazardous area and the
workstation, then the following safety measures must be complied with.
• Maintain a safe distance to the moving parts.
• Wear close-fitting clothing.
• Do not wear rings, necklaces or any other jewelry.
• Wear a hair net if you have long hair.
• Secure the machine and system parts against inadvertent reactivation to
prevent unintended movement of the machine parts. Cordon off the work area
and put up a warning sign.
• Only perform maintenance tasks after the machine has come to a standstill.
Depressurize system parts, if necessary.

KBW 31 / 101
Rev. 00 2023-03-06
3.19.5 Hazards due to electrical energy

WARNING
There is life-threatening danger if contact is made with live components. This will
result in severe or fatal injuries. Uncontrolled movements are also possible due to
activated electrical components.
• Only have an electrician perform tasks on electrical machines and equipment
according in accordance with the standard electrical engineering practice.
Prior to commencing tasks on the electrical system:
– De-energize the machine
– Safeguard the machine from being switched on again
– Ensure that motors, drive units and moving system parts are at a standstill
– The work area must be cordoned-off with a red & white safety chain and a
warning sign
– Check to ensure de-energized status
– Ground and short-circuit
– Cover adjacent energized parts
• Onl use tools that are electrically insulated
• Check electrical equipment regularly for damage Danger due to loose cable
connections or scorched cables. Rectify any defects immediately.
• Keep control cabinets closed at all times. Permit access only to authorized
personnel.
• When performing tasks involving live parts, always bring in a second person
who can engage the EMERGENCY STOP button or de-energize the machine
via the main switch with voltage disconnect. Immediately shut off the machine
if there are faults with the energy supply.
• For tasks involving high-voltage assemblies: After isolating the voltage, the
supply cable must be connected to the ground and the components, e.g. the
capacitors, must be short-circuited with a grounding rod.

3.19.6 Danger due to a potentially explosive atmosphere

WARNING
A mixture of flammable gas or dust in the vicinity of the machine cause an
explosion and cause severe and even fatal injuries.
• It may be necessary for the owner to ensure that gas detectors are installed on
the machine to warn of potentially explosive atmospheres at all times.
• In the case of a potentially explosive atmosphere, stop operation immediately
and ensure that there is sufficient ventilation.
• Rectify the cause for the potentially explosive atmosphere and only then
resume operation.

KBW 32 / 101
Rev. 00 2023-03-06
3.19.7 Hazards due hydraulic and pneumatic energy

WARNING
Pressurized hydraulic components or pneumatic components can cause severe
and even fatal injuries.
• Only personnel with special knowledge and experience in hydraulics and
pneumatics may work on hydraulic equipment, and pneumatic equipment,
respectively.
• Depressurize system sections and pressure lines (hydraulic system,
compressed air) that must be opened prior to performing repair tasks. Do not
open any pressurized lubrication lines or oil control lines, or re-tighten any
threaded fittings that are under pressure. There is a risk of injury due to oil that
may leak.
• Ensure that hydraulic and compressed air lines are professionally installed and
fitted. Do not confuse (swap) connections. Fittings, length and quality of hose
assemblies must meet the requirements.
• Regularly check all lines, hoses and threaded joints for leaks and external
damage. Repair any damage immediately. There is a risk of injury and a fire
hazard exists due to leakage.
Replace the hose connections at the specified or appropriate intervals, even if
safety-relevant external damage is not visible.
• Check air lines and oil lines for leakage, loose connections, chafe marks and
damage after they have been cleaned. Immediately rectify any defects that are
found.

3.19.8 Hazards due to hot spots

WARNING
There is a risk of sustaining burns due to high surface temperatures on motors
and components of the machine.
For tasks on or in the vicinity of hot spots of the machine:
• Maintain a safe distance to hot components.
• Wear suitable protective clothing.
• Switch off machine if necessary.
• Allow components to cool down.
• The customer has to install a safeguard if hot material is to be conveyed.

KBW 33 / 101
Rev. 00 2023-03-06
3.19.9 Hazards associated with the handling of chemical substances

WARNING
Contact with oils, greases, and other auxiliary substances can cause chemical
reactions. There is a risk of scalding when handling hot consumables or auxiliary
substances.
• When handling chemical substances observe and comply with the applicable
regulations and material safety data sheets from the relevant manufacturers.
• Personal protective equipment made of suitable material must be worn when
working with corrosive substances (e.g. rubber gloves, protective face mask).
• If there is contact with skin or eyes, immediately rinse out the affected area
with plenty of water. Suitable facilities (e.g. eye wash bottle station) must be
available in the vicinity of the workstation.

3.19.10 Hazards posed by gases, fumes, and dusts

WARNING
Harmful gases, fumes or dusts can escape when covers are opened.

• Ensure that there is sufficient ventilation and extraction and monitor the
oxygen concentration.
• Wear respiratory protection when cleaning the system, if necessary.
• Comply with existing local regulations when working in confined spaces.

3.19.11 Hazards posed by gases, fumes, and dusts

ATTENTION

Harmful gases, fumes or dusts can escape when covers are opened

• Ensure that there is sufficient ventilation and extraction and monitor the
oxygen concentration.
• Wear respiratory protection when cleaning the system, if necessary.
• Defective or leaking machine parts must be replaced immediately and as
prescribed. Only qualified personnel are allowed to execute these tasks.
Comply with the instructions in the chapters, "Maintenance" and "Service" in
this operating manual.
• Comply with existing local regulations when working in confined spaces.

KBW 34 / 101
Rev. 00 2023-03-06
3.19.12 Danger due to hazardous substances

WARNING
For tasks on the machine, for which personnel can come into contact with
hazardous substances, PPE must be used in accordance with the PPE
Ordinance (EU) 2016/425 and in accordance with the provided safety data sheet.
Failure to wear the personal protective equipment can result in severe or fatal
injuries/adverse health effects.
• When handling hazardous substances, the regulations and instructions in the
safety data sheets of the manufacturers of the hazardous substances,
applicable in this regard, must be complied with
• When working with hazardous substances suitable personal protective
equipment made of suitable material must be worn
• Prior to starting tasks, the personal protective equipment must be checked for
apparent defects through visual inspection
• The personal protective clothing must only be worn in the direct work
environment and must then be stored separately
• Relevant work areas must be clearly safeguarded by the machine owner, for
example through light barriers or motion detectors
– In accordance with ordinance (EC)1907/2006 version 2.7 BE SDB-300 000
002 056 of 08/31/2018 the owner must provide the safety data sheet and
make it accessible for every employee In particular, supplier information
concerning occupational health and safety must be included in the safety data
sheet.
– If hazardous substances are transported, used or stored in the machine, then
the machine owner must instruct his employees concerning the hazards and
protective measures as part of the yearly hazardous substance instruction,
and provide suitable personalized occupational health and safety measures
• A conscientious and careful manner of working is required for tasks involving
hazardous substances; trained and instructed personnel must work in this area
with extreme attentiveness and with a high level of concentration
• The owner must ensure an adequate supply of fresh air or an extraction
system
• Eating, drinking or smoking are prohibited in the hazardous area
• The machine, as well as the machine environment, must be cleaned
depending on the actual characteristics of the bulk material (e.g. dust fraction)
as needed, however at least once a week The cause of the contamination
must be eliminated immediately.

KBW 35 / 101
Rev. 00 2023-03-06
3.20 Instructions concerning specific hazards and residual risks

The information provided here serves as basic safety instructions regarding certain
types of hazards. Comply with these basic safety instructions during all tasks
performed on the machine.
By doing so, health hazards and dangerous situations can be avoided. Specific
safety instructions and warning information are given in the relevant chapters and
must also be followed.
Residual risks are determined on the basis of a risk assessment. All personnel who
work on and with the machine must be aware of these residual risks. Persons
should receive company-internal instruction based on their professional
qualifications. The instructions are to be followed to prevent residual risks from
leading to accidents or damage.

KBW 36 / 101
Rev. 00 2023-03-06
3.20.1 Operation and running of the system
• Operate components only if they are in a technically perfect and ready-to-
operate condition and in compliance with their intended use.
• Refrain from any work practice that adversely affects the safety of the
machine.
• The operator has to ensure that unauthorized persons cannot work on the
machine.
• Do not open the inspection access points while the machine is in operation as
there is a risk of injury. Inspection access points may only be opened after the
machine has been switched off and system parts have come to a complete
standstill.
• The machine must not be used for the transport of persons.
• Prior to switching on the machine, the operator must ensure that nobody can
be put at risk by starting up the machine.
• All the while the machine is in operation, the entire hazard zone must be
monitored and/or secured so that nobody could enter it without being noticed.
• When the machine is in operation, it may only be accessed if the operator has
been notified and after the machine has come to a standstill. The operator
must not allow unauthorized persons to enter the machine.
• The machine must not be left unattended while it is in operation.
• The machine must only be operated if all protective equipment and safety
devices are available and functioning correctly.
• The operator must ensure that the workplace at the machine is kept clean and
orderly via appropriate instructions and checks.
• Operating personnel must be instructed in the location and operation of fire
extinguishers. Compliance with fire reporting procedures and firefighting
measures is essential.
• Pay attention to the control display for activation and deactivation processes.
• Do not deactivate or remove exhaust, ventilation or cooling devices when the
machine is in operation.

KBW 37 / 101
Rev. 00 2023-03-06
3.20.2 Inspection
The owner must only place the machine into service if a technical expert has
inspected it. This also applies to the initial start-up of the machine and following
servicing measures or structural changes.
The owner must have a technical expert inspect the machine for operational safety
at fixed intervals, according to self-determined or locally prescribed regulations.
The results must be recorded in an inspection report.

3.20.3 Conversions and unauthorized modifications

The owner must not make any conversion of or extension to the machine that
could adversely affect the safety of the machine, without prior approval from the
manufacturer. This also applies to the installation and settings of safety devices, as
well as for the welding of supporting parts.

Note
Any intervention in the device/machine that changes the delivery condition or that
occurs without the express consent of the original manufacturer is done at the
sole responsibility of the executing party or of the owner.

3.21 Transport and assembly

WARNING
There is an increased risk of injury for persons performing tasks for which they
are neither qualified nor have they received appropriate instruction.
Assign only experienced persons to fasten loads and guide crane operators.
Compliance with accident prevention regulations is mandatory.
• Inform the forwarding agent and the manufacturer, immediately in writing of
any damage detected at delivery. Postpone start-up, if necessary.
• Use only hoists, transport equipment, load suspension devices and slings with
sufficient load-bearing capacity for transport.
• Only lift the machine or individual parts of the machine via the attachment
points intended for this purpose.
• Before use, check all attachment points such as, lifting lugs. This particularly
applies for the later transport of the machine after it has been running for an
extended period. Attachment points that no longer correspond to the condition
they were in when the machine was delivered must not be used.
• The machine must not be provided with additional attachment points through
welding, cutting, or drilling. A risk of cracking exists due to the effects of
welding, cutting or drilling.
• Do not stand or work beneath suspended loads. There is a danger of death
due to falling loads.
• When replacing system parts or larger assemblies, attach them carefully on
hoisting equipment and secure them.
• The positioning guide must remain in view of the operator or be within earshot
of him/her.
• If system parts must be removed for transport, then carefully mount and
secure these before restarting the machine.

KBW 38 / 101
Rev. 00 2023-03-06
3.21.1 Cleaning, maintenance, and repair
The owner must ensure that the machine and its safety devices are kept in a
correctly functioning state. Control and safety-relevant devices must be checked
for effectiveness.
Maintenance tasks must be carried out only by personnel with technical training.
Maintenance is described in the operating manual.

3.22 Spare parts and wear parts

The owner must ensure that proper spare parts are used for any maintenance,
servicing and repair tasks and that these meet the technical requirements specified
by the manufacturer. This is guaranteed when using original spare parts.
Spare parts and wear parts not supplied by DI MATTEO have neither been tested
nor approved. The installation and/or use of these parts may adversely affect
prescribed structural design characteristics and thus impair the safety of the
machine.

Note
DI MATTEO assumes no liability for damage that occurs due to use of non-
original spare parts and accessories.
• Only use original spare parts and accessories delivered by DI MATTEO.
• We recommend keeping a sufficient quantity of the most important spare
parts and wear parts in stock.

KBW 39 / 101
Rev. 00 2023-03-06
3.23 Conduct in emergency situations

The machine or parts thereof can be brought to a stop by activating an

EMERGENCY STOP / EMERGENCY SHUTDOWN button, if there is danger to life
and limb.

The owner must provide the required safety measures, such as EMERGENCY
STOP / EMERGENCY SHUTDOWN buttons, motion detectors or light signals for
the machine.

Note
An EMERGENCY STOP / EMERGENCY SHUTDOWN button should only be
activated in situations where the safety of persons or the machine is jeopardized.
An EMERGENCY STOP / EMERGENCY SHUTDOWN button must not be used
for normal shut-down of the machine.
The activation of an EMERGENCY STOP button does not disconnect the
machine from the electrical, hydraulic or pneumatic supply.

After an emergency shutdown, authorized personnel must be brought in

immediately to determine and rectify the cause for the emergency.
The automatic process flow is interrupted as a result of the emergency stop of the
machine. The machine must not be switched on again unless the reason for the
emergency stop has been eliminated.
Proceed as follows to restart the affected system area:
• Eliminate the hazard or fault.
• Unlock the previously pressed EMERGENCY STOP / EMERGENCY
SHUTDOWN button.
• Acknowledge the fault message at the control system, if required.
• Start machine operation.

KBW 40 / 101
Rev. 00 2023-03-06
3.24 Foreseeable misuse

The points below describe foreseeable misuse of the machine:

• Installation on unsuitable surfaces.
• Attachment of transport aids on machine parts.
• Failure to comply with operating data.
• Failure to comply with maintenance intervals.
• Wrong direction of rotation.
• Activation while running down the system.
• Exceeding or falling below speed limit values.
• Non-dosed or uncontrolled feed of the material to be conveyed into the
machine.
• Non-ensured further conveyance of the conveyed material at the material
discharge of the machine.
• Operation with or without damaged components, which are intended to
improve the safety of personnel and the machine.
• Operation of the drive unit without sufficient oil being filled.
• Filling the gear unit with oil quantities above the required quantities.
• Remaining residual hazards – pictograms and descriptions

Behavior due to carelessness or lack of concentration:

• Faulty installation of the individual components
• Mix-up and improper use of machine components
• Mix-up or faulty operation of control elements and operating elements

KBW 41 / 101
Rev. 00 2023-03-06
3.25 Conduct in the event of faults

If there are faults on the machine, under some circumstances a simple error may
be present, which can be found and remedied with the aid of the advice provided in
the chapter, "Faults".
• In the case of imminent danger, press the EMERGENCY STOP button
immediately.
• Switch off the machine and safeguard it from being restarted.
Also switch off the machine if you notice abnormal operating behavior. These
include for example:
– Abnormal noises, vibration, odors
– Incorrect behavior, errors in indication
– Increased temperatures
• All fault rectification tasks must only be performed by trained specialists, and
only when the machine is in de-energized status.
• If you are unable to remedy a given fault, contact the service department of DI
MATTEO.

KBW 42 / 101
Rev. 00 2023-03-06
4 Technical data sheet

4.1 Machine characteristics P9001156

Machine designation: ODM - High capacity chain bucket elevator

KBW 250x19700AA /AF10 005ELV
Total weight (kg) app.6.250kg
Bucket width 250mm
Center distance: 19.850mm

Delivery capacity: up to app. 53 m³/h,

but not more than 42 t/h,

a continuously uniform and pre-dosed bulk

material feeding is mandatory

Bucket filling: app. 75 % - 83%

Inlets: 1 pc
Outlets: 1 pc

Control flap: 2 pcs

Level monitoring sensor: 2 pcs (Niethammer)
type: FMK 508 V

Rotation monitoring 2 pcs (IFM)

inductive sensor type: IG5937

Security sensor: 2 pcs (Schmersal)

Typ: BNS: 260-02/01Z-L

SEW bevel geared drive: 1 pc – bevel geared drive (7,5kW)

Make SEW; with thermistors suitable
for FC operation.
ATEX: No specifications
This machine has not been designed for
ATEX application.

KBW 43 / 101
Rev. 00 2023-03-06
4.2 Bulk material characteristics

Designation: Gypsum and additives

Bulk density: app. 780-1380 kg/m³
Particle size: max. 1 mm (2D)
If no other particle size distribution of the bulk
material is specified in the text, an equal
distribution over the entire specified range is
assumed

Moisture content: <4%

Temperature: +5°C bis 80°C
Characteristics: free flowing, not adhesive, not (time) consolidating,
not corrosive with mild steel, pourable, mechanical
and pneumatic conveyable with the offered
equipment

Remark: any foreign bodies, incl. inert material, can cause

higher wear, damages or problems in the further
handling and are not in responsibility of DI
MATTEO

Explosion characteristics No specifications

considered: This machine has not been designed for ATEX
application.

4.3 Plant data

Note
EN - For further plant data please refer to the consumer list

Operating voltage 400 V / 50 HZ

Control voltage: 24 V-DC
Signal voltage: 24 V-DC
Explosion prtected
No specifications
application:
Conveying capacity: 50,0m³/h – 40t/h

KBW 44 / 101
Rev. 00 2023-03-06
4.4 Noise emission

The continuous sound pressure level has been measured at comparable machines
running without load, with the measurement made at a point 1 m from the machine
surface and 1.60 m above the floor or access platform:

Measurement methods in accordance with DIN 45635

Sound-level measuring device BEHA (type: 93411)
Measurement uncertainty  2 dB(A)
Sound pressure level
< 78 dB(A)
determined

Note

Operation of motors on the frequency converter results in a noise increase. In

addition, improper assignment of frequency converter parameters
can negatively influence the acoustic behavior of the unit.
Sound specifications of the motor and frequency converter unit can
only be assessed or ensured as a complete package, i.e. in conjunction with
tuning tasks.

KBW 45 / 101
Rev. 00 2023-03-06
5 Structure and function

Description bucket elevator - general

Bucket elevators are continuous conveyors with a defined traction means.
Bucket elevators convey suitable bulk material vertically.
Bucket elevators consist of the bucket elevator base with inlet, bearing and
deflection drum; the bucket elevator chutes and the bucket elevator head with
outlet, drive, bearing and drive drum; the traction means with the bolted buckets.

5.1 Bucket elevator designs - overview

Designation Description
ODM - High capacity belt bucket elevator GBW
Bucket elevator; with an EP or steel cord belt as traction means

Examples of use & features

GBW • Special design for alternative fuels

• Used for powdery to granular bulk materials: cement, raw
meal, etc.
• Use in the food industry
• Use with abrasive bulk materials: quartz, sand, clinker, etc.
• quiet running
ODM - High capacity central chain bucket elevator ZBW
Bucket elevator; with a central chain as traction means

Examples of use & features

ZBW • Use with coarse-grained and abrasive bulk materials: for

silo and mill feeding, in clinker grinding plants, tire chips,
etc.
• High-strength central chain for increased load cases
• Suitable for higher material temperatures
• longer service life of the chain due to the special design
• High conveying speed
ODM - High capacity chain bucket elevator KBW
Bucket elevator; with a round link chain as traction means

Examples of use & features

KBW
• Use with coarse-grained and abrasive bulk materials: for
silo and mill feeding, in clinker grinding plants, tire chips,
etc.
• Suitable for higher material temperatures
• Round link chain available in a wide range of material alloys

KBW 46 / 101
Rev. 00 2023-03-06
6 Structure ODM - High capacity chain bucket elevator KBW
A chain bucket elevator essentially consists of the following components:

Abb. 1: ODM - High capacity chain bucket elevator KBW

No. Description
1 Bucket elevator head with drive unit and material outlet
2 Bucket elevator chimneys (bolted or welded)
3 Bucket elevator foot with clamping unit and material inlet
4 Bucket
5 Traction means for conveying: round link chain

Note
The illustrated model is only exemplary and may differ from the actual design.

KBW 47 / 101
Rev. 00 2023-03-06
6.1 Components description
6.1.1 Bucket elevator head
The bucket elevator head consists of the head housing with hood and the
drive unit.
The adjustable discharge tongue is located in the bucket elevator head. This
discharge tongue is an extension of the discharge chute. With this adjustable
discharge tongue, the gap between bucket and discharge can be minimized, thus
reducing the amount of bulk material that falls down the bucket elevator chute.
A blind flange is arranged on the hood above the discharge side in order to
be able to connect the exhaust system.
The hood can be removed from the bucket elevator head in order to
dismantle the tension member and/or the drive drum, or drive sprocket.
6.1.2 Drive
A geared motor is used as the bucket elevator drive.
The power transmission from the gearbox to the shaft is made by a coupling.

6.1.3 Frequency converter / soft start

Bucket elevators are usually started up to full drive power over a period of time
(soft start) and also shut down again. This reduces the forces acting on the tension
member and the drive system.
The soft start can be realized with a special soft start device or a frequency
converter.
A frequency converter can be used to implement inspection and repair operation of
the bucket elevator. In inspection and repair mode, the bucket elevator is operated
at reduced speed without bulk material.
A slight optimization of the speed for operation is also possible with the
frequency converter.

6.1.4 Bucket elevator chimneys

Bucket elevator chimneys are made of folded plates by welding or bolting.
They have a rectangular cross section.
Bucket elevator chimneys are connected, at defined intervals, with a vent
connector.
At a suitable place (accessibility) there is a slot door in the bucket elevator chute to
be able to mount/dismount the buckets.
A number of standard chimneys and a fitting vent are installed in a bucket elevator.
The
bucket elevator chimneys are statically load-bearing components.

6.1.5 Bucket
The buckets are attached to the traction means and transport the bulk material

KBW 48 / 101
Rev. 00 2023-03-06
6.1.6 Traction means for conveying

The means of traction are determined in advance.

Bucket elevators can be equipped with the following traction means.

Designation Description
GBW EP or steel cord belt
ZBW Central chain
KBW Round link chain

The respective version is listed in the technical data. Observe the applicable
technical documents for the machine.
6.1.7 Bucket elevator bottom
The bucket elevator bottom accommodates the deflection shaft with the bearing
and clamping device.
Likewise, on the bucket elevator base, the inlet chute is located on the side
of the ascending buckets.
The bucket elevator bottom must be able to support the entire load of the bucket
elevator.

6.1.8 Tensioning station

A chain bucket elevator is equipped with a weight tensioning device

Note
For information on the tensioning station, please refer to the enclosed
documents.
.

KBW 49 / 101
Rev. 00 2023-03-06
6.2 Sensors
The sensors are determined in advance.
Bucket elevators can be equipped with the following sensors.
The respective versions are listed in the electrics consumer list and in the technical
data, machine drawings.
Observe the applicable technical documents for the machine.
For retrofitting, please contact the service technicians of DI MATTEO company.

DI MATTEO Förderanlagen GmbH & Co. KG

Telephone +49 2521 / 93 44 - 0
Fax +49 2521 / 93 44 - 222
Email info@dimatteo.de

6.2.1 Speed monitor

The speed monitoring with inductive proximity switch is located on the deflection
shaft.
If this sensor does not give any feedback, even though the bucket elevator is
switched on, this means that the tension member does not rotate the deflection
shaft.
This can have various causes:
• Sensor defective
• Frictional connection between tension member and drive drum/sprocket not
sufficient Tension member cracked

6.2.2 Level control

The level indicator is mounted on the bucket elevator foot and prechimneys
overfilling of the bucket elevator foot.

6.2.3 Belt misalignment switch (optional)

Misalignment switch signals an impermissible misalignment of the traction means.

6.2.4 Temperature monitoring (optional)

Temperature sensors can be used to monitor bearing and stuffing box

temperatures.
Temperature sensors are also installed in the drive motors (TF).

6.2.5 Compensators (optional)

At the outlet chute of the bucket elevator, the bucket elevator must be able to
compensate for length. A compensator must be provided for this purpose.
Depending on the installation situation, this measure may also be required for the
inlet.
The compensators are coordinated in advance after consultation with the project
managers.

KBW 50 / 101
Rev. 00 2023-03-06
6.3 Function bucket elevator

Bucket elevators are used for vertical transport of powdery, granular to small-sized
bulk materials.
The buckets, which hold the bulk material, are attached to an endless tension
beam. The tension member can be a chain or a conveyor belt.

The tension beam is driven at the top bucket elevator head by a drive system.

The bulk material is filled into the buckets and the bucket elevator foot via a chute
at the bucket elevator foot located at the bottom, in which the deflection chain
wheel or the deflection drum is located, and is picked up by the passing bucket.
Most of the fed material falls into the bucket elevator foot and is scooped from the
bucket.

Bulk materials, the inlet chute can also be located in the first bucket elevator chute
above the bucket elevator foot.

To prevent the tension member, in particular a bucket elevator belt, from skewing
or being loaded on one side, the bulk material must be filled into the buckets as
centrally as possible.

In the ascending chute, the filled bucket is conveyed to the bucket elevator head
where it is discharged by centrifugal force, gravity, or a mixture of both, with the
bulk material passing through the discharge chute at the bucket elevator head into
the downstream production process.

In order for the bucket emptying to work, the bucket elevator must be run at
the predefined speed.

KBW 51 / 101
Rev. 00 2023-03-06
7 Transport

7.1 Safety

All tasks must only be performed by verifiably qualified specialists with due
consideration:
• This manual.
• All other manuals accompanying this machine (supplier documentation, etc.).
• Applicable local regulations and laws

There is an increased risk of injury and material damage if unqualified personnel

are deployed, and unsuitable or damaged hoisting equipment, slings, or means of
transport are used. Persons entrusted with the transportation of the machine thus
need to be trained at regular intervals.
For transport, follow the safety instructions specified in the chapter, "Safety".

Note
The transportation of the machine is carried out by the owner or by personnel
entrusted by him/her with this task. The applicable local regulations and laws
must always be complied with when transporting the machine to its destination.

DANGER
Suspended loads
Tipping or falling loads can lead to severe and even fatal injuries.
– Never step beneath suspended loads.
– Only use approved hoisting equipment and slings designed for and capable of
supporting the total weight of the attached load.
– Pay attention to the attachment points and the center of gravity of the load.
– Only use slings and load suspension devices that are in a technically perfect
condition.
– Secure loads with suitable devices.
– If transport safety devices are used, these should be removed only after the
conclusion of the assembly process.
– Secure loading and unloading areas against unauthorized entry.
– Ensure adequate lighting of loading and unloading areas.
– Move loads only under supervision of another person.
– Lower the load if you intend to leave the workplace.

KBW 52 / 101
Rev. 00 2023-03-06
 WARNING
Crushing of limbs between components
Moving components can crush limbs and cause severe injury.
– Maintain a safe distance to the components.
– Comply with the warning signs posted in the work area.
– Use personal protective equipment.

ATTENTION

Material damage due to incorrect handling of loads

The incorrect handling of loads during loading and unloading processes can lead to
material damage.
– Pay attention to the attachment points and the center of gravity of the load.
– The side walls or attachment parts of components must not be pushed
together by misaligned ropes or chains.
– Do not place the system on top of the protective hoods for the drive units.
– Secure the system parts against tipping over and shifting if you intend to
transport these on loading platforms.
– Avoid hard impact when lowering the load.
– Only set down loads on level ground of the required load-bearing capacity.

7.2 Checking the delivery

1. Remove transport packaging from individual machine parts.

2. Examine machine parts for transport damage.
• Inform the forwarding agent and DI MATTEO immediately in writing of any
detected damage.
• Protect machine parts from further damage.
3. Compare the shipment with the delivery note to verify completeness.

7.3 Packaging

1. Remove packaging material, prior to assembly.

2. Properly dispose of packaging material.

ATTENTION

Danger of environmental damage

Incorrect disposal of waste adversely affects the environment.
– Comply with local regulations and legal requirements when disposing of
waste.

KBW 53 / 101
Rev. 00 2023-03-06
8 Storage

8.1 Safety

All tasks must only be performed by verifiably qualified specialists with due
consideration:
• This manual.
• All other manuals accompanying this machine (supplier documentation, etc.).
• Applicable local regulations and laws

ATTENTION

Material damage due to incorrect storage

Incorrect storage of materials can lead to material damage.
– Comply with the storage requirements listed below.

8.2 Intermediate storage

Intermediate storage may be required between transport and assembly. The

following storage requirements apply:
1. To the extent possible, store the machine in dry, clean, dust-free, vibration-free
and frost-free ambient conditions until final assembly.
2. Only set down the machine on level substrates with sufficient load-bearing
capacity.
3. Do not place the machine on top of the protective hoods of the drive units.
4. Safeguard the machine against tipping over.
5. Protect the machine against the effect of ground moisture.
6. Prevent condensation; if possible adjust the storage temperature accordingly.
– If the system is stored outdoors, cover it with tarps and ensure that these are
open at the bottom, so that the condensate can run off.
7. Always store electrical equipment in closed, dry and frost-free facilities.
• Fit all free cable ends with shrink protection.
8. If the system was packaged for maritime transport, do not damage the
packaging and remove it only when the system can be assembled.
9. Leave system parts that will be stored in the supplied condition until they can
be assembled.
10. Remove transport safety devices only after the conclusion of the assembly
process.

Note
Comply with information listed in the technical specifications. Likewise,
instructions concerning preservation of supplier parts can be found in the
separate supplier documentation. Contact the manufacturer if there are any
questions concerning storage.

KBW 54 / 101
Rev. 00 2023-03-06
9 Assembly

9.1 Safety

All tasks must only be performed by verifiably qualified specialists with due
consideration:
• This manual.
• All other manuals accompanying this machine (supplier documentation, etc.).
• Applicable local regulations and laws

WARNING
There is an imminent risk of injury or material damage if the owner improperly
and incorrectly assembles the machine.

Note
Only service personnel from DI MATTEO or service personnel trained and
authorized by DI MATTEO are permitted to install the machine.

DANGER
Danger of death due to potentially explosive atmosphere
A mixture of flammable gas or dust in the vicinity of the system can cause
explosions and cause severe and even fatal injuries.
– The owner has to ensure that gas detectors are installed at the machine to
warn of potentially explosive atmospheres at all times.
– In the case of a potentially explosive atmosphere, stop operation immediately
and ensure that there is sufficient ventilation.
– Eliminate the cause of the potentially explosive atmosphere.

DANGER
Danger of death due to electric shock
There is life-threatening danger if contact is made with live components.
Uncontrolled movements are also possible due to activated electrical components.
This will result in severe or fatal injuries.
– Only qualified electricians are permitted to perform tasks on the electrical
system.
– Before commencing tasks on the electrical system, switch off the power supply
and safeguard it from being switched on again.
– Ensure correct grounding within the ATEX zone.

KBW 55 / 101
Rev. 00 2023-03-06
 DANGER
Suspended loads
Tipping or falling loads can lead to severe and even fatal injuries.
– Never step beneath suspended loads.
– Only use approved hoisting equipment and slings designed for and capable of
supporting the total weight of the attached load.
– Pay attention to the attachment points and the center of gravity of the load.
– Only use slings and load suspension devices that are in a technically perfect
condition.
– Secure loads with suitable devices.
– If transport safety devices are used, these should be removed only after the
conclusion of the assembly process.
– Secure loading and unloading areas against unauthorized entry.
– Ensure adequate lighting of loading and unloading areas.
– Move loads only under supervision of another person.
– Lower the load if you intend to leave the workplace.

WARNING
Crushing of limbs between components
Moving components can crush limbs and cause severe injury.
– Maintain a safe distance to the components.
– Comply with the warning signs posted in the work area.
– Use personal protective equipment.

WARNING
Danger of falling when working at height
The performance of work at height can lead to slipping and falling causing severe
injuries.
– Use personal protective equipment.
– Make sure that work conditions exist that enable the safe performance of work
at height.
– Use fall protection if there is no safe footing.
– Use a work platform, scaffolding, a passenger elevator, or an aerial
bucket/basket, for example.
– Protect the assembly area against falling objects.
– Never work alone.

KBW 56 / 101
Rev. 00 2023-03-06
 CAUTION
Sharp edges
Sharp edges may lead to cuts.
– Use personal protective equipment.
– Handle with care.

Note
The manufacturer is not liable for damage resulting from improper installation.

9.2 Preparatory measures for set-up

The following measures must be taken prior to set-up:

• The place of installation should be level and have the required load-bearing
capacity.
• The machine must be installed according to the specifications given in the
project diagrams (assembly diagram, foundation plan).
• Supply lines of sufficient capacities must be available.
• Suitable hoists must be provided.
• Operating materials must be available in the required quality and quantity.

9.3 Set-up and alignment

Perform the following steps, making reference to the assembly diagram and the
installation plan:
1. Mount the modules of the machine, according to the dimensions and
specifications.
2. Ensure sufficient free space for assembly for later maintenance measures.
3. Place the machine appropriately on the prepared base.
4. Align the machine.
5. Fasten the machine with the prescribed components and tools.
6. Remove the transport and assembly safeguards devices and keep them on
hand for later reuse for dismantling purposes.

9.4 Threaded fitting of the housing flanges

1. Housing flanges must be cleaned to remove adhering contamination (greases,

oils, dusts, rust, etc.)
2. Fit housing flanges with suitable sealing material and bolt them, if needed the
threaded fittings must be fitted with suitable securing measures (spring lock
washers, serrated lock washers, self-locking nuts, etc.).

Reference
Ensure that the housing flanges are not damaged and/or deformed, otherwise
proper operation cannot be guaranteed.

KBW 57 / 101
Rev. 00 2023-03-06
9.5 Mechanical installation

1. For proper assembly of the drive unit, the documentation provided by the
supplier, e.g. for couplings, gear unit, and motors must be complied with.
2. If a central lubrication pump has been provided for the purpose of supplying
grease to the bearings and possibly the glands, it must be installed with due
consideration of the supplier documentation.

9.5.1 Installation of the chutes

Connect the chutes to each other by means of chute connectors every 6 meters.
In addition, it should be noted that two chutes are equipped with belt monitors.
These chutes are to be installed in such a way that a pair of guards are located
directly above the foot, the second pair immediately below the head.
When tightening the connecting screws at the joints, ensure that the chutes are
exactly one above the other in order to avoid possible twisting of the entire bucket
shaft.
The installation of the chutes can be carried out in several ways:
1. Place chute for chute.
2. Hang a chute with special suspension on a crane. All further chutes are
subsequently built and placed under the chutes as a complete trough on the
foot.
3. If possible, take up the head with a tested lifting device from a crane, which
can pick up the load and reach the mounting height and distance. Now the
chutes (up and down chute) can be underbuilt. Once all chutes have been
installed, mount the entire unit on the base.
4. Install subsequently the bucket elevator bracing, but do not screw them tightly.
For the stability of the bucket elevator, the flaps are required at regular intervals
(indications on the overview drawing). Take care to ensure that a thermal change
in length is nevertheless possible. This also applies to all ceiling breaks when they
are installed in buildings. If the local conditions do not permit the attachment of
lateral guides intercept the bucket at least at head height to prevent external
influences, e.g. wind pressure, do not endanger stability. The screwing has to be
done after aligning the bucket.

KBW 58 / 101
Rev. 00 2023-03-06
9.5.2 Aligning the bucket elevator
The bucket base must be placed, aligned and fastened on the prepared
substructure in accordance with the dimensions of the assembly drawing or the
installation plan.
1. Place the solder in the middle of the ascending and descending trough and
measure it in the foot.
2. To balance it, attach the filler plates under the bucket elevator.
3. If the bucket elevator is aligned, the bracing can be tightened and the foot can
be anchored with anchor bolts.

9.5.3 Assembly the bucket head

The bucket elevator head must be placed, aligned and fixed on the assembled
bucket elevator shaft – consisting of a box or a double chute.

9.5.4 Assembly of bucket elevators with a small center distance

Depending on the local conditions and possibilities, bucket elevators with a small
center distance can be installed suspended.
1. Screw the chimneys under the bucket elevator head suspended from the
crane
2. Continue step 1 by gradually lifting the assembled section.
3. Place the entire unit consisting of head and chimneys on the base of the
bucket elevator and secure

9.5.5 Installation of lateral guides

For the stability of the bucket elevator, lateral guides of the chimneys are
necessary at regular intervals (information in the general arrangement drawing)

Advice
It must be ensured that a thermal change in length is nevertheless guaranteed.
This also applies to ceiling openings when installed in buildings.

If the local conditions do not permit the installation of lateral guides, the bucket
elevator must be supported at least at head height so that external influences, e.g.
wind pressure, do not endanger the stability.

KBW 59 / 101
Rev. 00 2023-03-06
9.5.6 Installation of the chains and buckets
After carrying out the assembly work described above, the chains can be pulled in
and the buckets screwed on.

ATTENTION

• Observe chain quality (embossing punch and wire marking) according to

the note on the assembly drawing.
• The chain ends are delivered bundled in pairs and must be mounted in
pairs!

1. Before attaching the buckets to the chain brackets, push the spacers onto the
pins of the chain brackets.
2. After pushing on the buckets, carefully tighten the fastening nuts with the
spring washers inside the buckets (see illustration).

Note
The weld seams of the chain links must face outward during assembly!
The weld seams of the chain links must not be pulled over the sprockets!

3. The nuts must be tightened a few days after commissioning.

Note
When closing the two chain ends endlessly, ensure that the deflection axis is in
the highest possible position.

KBW 60 / 101
Rev. 00 2023-03-06
9.5.7 Settings at the bucket elevator outlet
In order to achieve the highest possible degree of conveying of the bucket elevator,
the adjustable tongue must be pushed close and be fixed to the outer line of
movement of the buckets. In order to discharge the conveyed material at the outlet
of the bucket elevator head (see illustration). The distance to the line of movement
of the

KBW 61 / 101
Rev. 00 2023-03-06
9.5.8 Installation of drive group
The drive group usually consists of up to 7,5 kW power requirement, of a geared
motor with elastic coupling.
For larger drive powers than 7,5 kW, the drive group consists of the following
components:
• Elastic coupling between machine and gearbox or geared motor (the coupling
does not apply to plug-in gearboxes)
• Reduction gearbox with mounted backstop
• Starting and overload protection coupling between gearbox and motor
• Electric motor

If this is the case, the installation must be carried out as follows:

1. Pull the coupling halves onto the shaft journal and secure.
2. Set down, align and secure the gear unit on the substructure. Pay attention to
the coupling play!
For a slip-on version: Pull the gear unit onto the shaft journal, secure the
counter-torque support and, if necessary, fit the shrink disk according to
special instructions.
3. Set up, align and secure the electric motor. The direction of rotation must first
be adjusted to the running direction of the bucket elevator.

Note
The incorrect direction of rotation of the electric motor will destroy the backstop.
Adjust the direction of rotation to the running direction of the bucket elevator
beforehand.

4. Fill the gear unit with the prescribed quality and quantity of gear oil (see
manufacturer’s instructions).
5. Fill the hydraulic coupling with hydraulic oil in the prescribed quality and
quantity (see manufacturer’s instructions). The required quantity can be taken
from the assembly drawing and must be not be exceeded.
6. Connect the electric motor to the terminals taking into account the direction of
rotation indicated by an arrow.
For the electrical connection of drive, the manufacturer’s instructions listed in the
section „System – Machine elements“ must be considered.

KBW 62 / 101
Rev. 00 2023-03-06
9.5.9 Installation of the inspection drive
If the drive group is equipped with an additional inspection drive, this is used for
maintenance and inspection of the chain and buckets.
The speed of additional drive is dimensioned so that an inspection speed of
approx. 0.1 – 0.15 m/s is achieved. A freewheel clutch is used to transmit the
torque.
9.5.10 Installation of the central lubrication system
If a central lubrication pump is provided for supplying grease to the bearing points
and, if necessary, to the stuffing boxes, this must be installed in accordance with
the manufacturer’s special instructions.

9.6 Electrical installation

1. When making the electrical connections for the motor, the central lubrication
pump, as well as the sensor system, comply with the manufacturer's
instructions in the supplier documentation.
2. Regarding the electrical installation of the drive motor, it is essential to pay
attention to the direction of rotation of the gear output shaft, which is indicated
by an arrow. (Rotation in opposite directions can result in damage or
destruction)
3. Consult the manufacturer if the direction of rotation is not evident.
4. Check that all protective devices have been correctly installed.
5. Close all inspection access points.

9.6.1 Electrical connection of the central lubrication pump

If available, the electric motor of the central lubrication pump must be connected
electrically and the reservoir filled with plain bearing grease (see manufacturer’s
instructions in section „System – Machine elements“) and the reservoir filled with
plain bearings grease.

KBW 63 / 101
Rev. 00 2023-03-06
9.6.2 Electrical connection for speed monitoring
If available, the manufacturer’s notes on the switch housing or the notes listed in
the „Supplier Documentation“ section must be observed for the electrical
connection of the speed monitoring.

9.6.3 Electrical connection of the drive unit

If not provided by the customer, the manufacturer’s instructions on the motor
housing or those listed in the „System – Machine elements“ section must be
observed for the electrical connection of the motor.

ATTENTION
Opposing rotation of the gear drive pin can damage or destroy the sealing strips
(see special notes on the terminal box of the electric motor).
During the electrical installation of the drive motor, it is essential to pay attention to
the direction of rotation of the gear drive pin marked by the directional arrow!

9.7 Cleaning after assembly

1. Remove any (assembly) tools or foreign objects that may have been left lying
about after assembling the machine.
2. Clean the machine of moisture and contamination.

KBW 64 / 101
Rev. 00 2023-03-06
10 Commissioning

10.1 Safety

All tasks must only be performed by verifiably qualified specialists with due
consideration:
• This manual.
• All other manuals accompanying this machine (supplier documentation, etc.).
• Applicable local regulations and laws

Note
Only service personnel from DI MATTEO or service personnel trained and
authorized by DI MATTEO are permitted to commission the machine.

DANGER
Danger of death due to electric shock
There is life-threatening danger if contact is made with live components.
Uncontrolled movements are also possible due to activated electrical components.
This will result in severe or fatal injuries.
– Only qualified electricians are permitted to perform tasks on the electrical
system.
– Before commencing tasks on the electrical system, switch off the power supply
and safeguard it from being switched on again.
– Ensure correct grounding within the ATEX zone.

WARNING
Danger due to rotating and moving parts
Rotating and moving components can lead to the crushing and severing of limbs
which can cause severe injury.
– Maintain a safe distance to the components.
– Comply with the warning signs posted in the work area.
– Use personal protective equipment.
– Wear tight-fitting clothing

Note
The manufacturer is not liable for damage resulting from an incorrectly executed
start-up process.

KBW 65 / 101
Rev. 00 2023-03-06
10.2 Trial run
1.

1. Execute trial run without material to be conveyed.

2. Check periodically the chain run.
3. Operate chain bucket elevator with material.
4. Check again the chain run.

Note
New chains elongate more significantly in the initial operating time, if necessary
the chain must be retensioned. New chains are mounted tight.

10.3 Starting up after a scheduled shutdown

If the machine will be placed in service after it has been shut down for an extended
period, then the commissioning procedure must be re-executed.

KBW 66 / 101
Rev. 00 2023-03-06
11 Operation

11.1 Safety

All tasks must only be performed by verifiably qualified specialists with due
consideration:
• This manual.
• All other manuals accompanying this machine (supplier documentation, etc.).
• Applicable local regulations and laws

DANGER
Danger of death due to electric shock
There is life-threatening danger if contact is made with live components.
Uncontrolled movements are also possible due to activated electrical components.
This will result in severe or fatal injuries.
– Only qualified electricians are permitted to perform tasks on the electrical
system.
– Before commencing tasks on the electrical system, switch off the power supply
and safeguard it from being switched on again.
– Ensure correct grounding within the ATEX zone.

WARNING
Danger due to rotating and moving parts
Rotating and moving components can lead to the crushing and severing of limbs
which can cause severe injury.
– Maintain a safe distance to the components.
– Comply with the warning signs posted in the work area.
– Use personal protective equipment.
– Wear tight-fitting clothing

Note
Always comply with regulations on accident prevention, occupational safety and
health, operation, and safety.

KBW 67 / 101
Rev. 00 2023-03-06
11.2 Prior to operation

WARNING
Improper use and misconduct can lead to fatal injuries and material damage.

Each time before operation of the machine, note and comply with the instructions
in the Safety chapter and comply with the following instructions:
• Read the operating manual carefully and understand it.
• Through training and qualifications, check whether authorization to operate the
system is present.
• Check whether authorization to use the machine has been issued by the
owner.
• Familiarize yourself with the overall system and the applicable regulations.
• Coordinate workflows with all persons involved.
• Check the machine for damage before commencing operations.
• Negligent use of personal protective equipment can lead to severe physical
injury.

11.3 Operation of the machine

This machine is part of an overall system. The whole system is centrally controlled
via the master control panel.
Information on operation and the control system can be found in the operating
manual for the whole system.

Note
The manufacturer accepts no liability for damage that occurs through operation of
the machine with bulk goods that corrode the machine.

KBW 68 / 101
Rev. 00 2023-03-06
12 Faults

12.1 Safety

All tasks must only be performed by verifiably qualified specialists with due
consideration:
• This manual.
• All other manuals accompanying this machine (supplier documentation, etc.).
• Applicable local regulations and laws

DANGER
Danger of death due to potentially explosive atmosphere
A mixture of flammable gas or dust in the vicinity of the system can cause
explosions and cause severe and even fatal injuries.
– The owner has to ensure that gas detectors are installed at the machine to
warn of potentially explosive atmospheres at all times.
– In the case of a potentially explosive atmosphere, stop operation immediately
and ensure that there is sufficient ventilation.
– Eliminate the cause of the potentially explosive atmosphere.

DANGER
Danger of death due to electric shock
There is life-threatening danger if contact is made with live components.
Uncontrolled movements are also possible due to activated electrical components.
This will result in severe or fatal injuries.
– Only qualified electricians are permitted to perform tasks on the electrical
system.
– Before commencing tasks on the electrical system, switch off the power supply
and safeguard it from being switched on again.
– Ensure correct grounding within the ATEX zone.

DANGER
Danger of death due to damaged or exposed energized parts
Contact with live components will result in severe or fatal injuries.
– Only qualified electricians are permitted to perform tasks on the electrical
system.
– System parts, which must undergo inspection, maintenance and/or repair must
be de-energized.
– Secure the system parts against reactivation.
– Cordon off the work area and put up a warning sign.

KBW 69 / 101
Rev. 00 2023-03-06
 WARNING
Danger of falling when working at height
The performance of work at height can lead to slipping and falling causing severe
injuries.
– Use personal protective equipment.
– Make sure that work conditions exist that enable the safe performance of work
at height.
– Use fall protection if there is no safe footing.
– Use a work platform, scaffolding, a passenger elevator, or an aerial
bucket/basket, for example.
– Protect the assembly area against falling objects.
– Never work alone.

CAUTION
Sharp edges
Sharp edges may lead to cuts.
– Use personal protective equipment.
– Handle with care.

It is important to remember that:

1. If there are faults that pose imminent danger to persons or material assets, the
system must be shut-off immediately.
The owner is responsible for integrating the machine in the safety system of
the overall system.
2. Determine the cause for the fault.
3. Shut off the machine and safeguard it from being restarted if fault remedy
measures require tasks in the hazard zone.
4. Immediately inform the persons in charge of the fault
5. Have authorized, skilled personnel rectify the fault, dependent on the type of
fault.
6. If components have been replaced, ensure that they have been correctly
mounted.
– Comply with all screw/bolt tightening torque specifications.
– Comply with screw lock specifications.

KBW 70 / 101
Rev. 00 2023-03-06
12.2 Preparation for fault rectification

Comply with the following instructions before performing tasks:

1. All tasks must be performed when the machine is at a standstill.
– Execute a load-dependent disconnect the system.
2. Shut off the machine or the affected machine part for execution of tasks and
safeguard it from being switched on again unexpectedly.
– Lock the main switch with a personally assigned padlock.
– Attach a warning sign.
– Cordon off a large area around the work area.
– If there are indications of residual voltages, have a specialist execute
grounding measures.

12.3 Switching the machine on again after faults

The system must not be operated if there are defects that could adversely affect its
safe operation.
1. Ensure that no tools or objects have been left lying around from the
assembly or installation tasks.
2. Clean the machine of moisture and contamination.
3. Attach all protective devices.
4. Close all inspection openings.
5. Ensure that power supply in ensured from the owner's side.
6. Switch on the machine via the main switch.
7. Check all safety devices for electrical functionality.
Through an appropriate teste the functionality of the warning devices to warn
of a possible hazard, must be ensured. Repeat test for all safety elements:
– Emergency stop button
– Emergency off button
– Safety doors
– Light barriers, etc.
8. Check the direction of rotation of the drive motor again.
Note
Comply with information and specifications given in the suppliers' documentation.

KBW 71 / 101
Rev. 00 2023-03-06
12.4 Faults and troubleshooting

Note
• All tasks must only be performed when the machine is at a standstill. For this
execute a load dependent disconnect of the machine.
• Prior to commencing these tasks, ensure that the machine cannot be
restarted, either inadvertently or by unauthorized persons.

Malfunctions in the form of unsatisfactory conveyor behavior and/or abnormal

noise can be rectified using the following troubleshooting guide.

Fault Remedy
Power supply or power feed is Have a specialist check the power supply
faulty

Machine parts worn Replace (see „spare parts“ chapter) as part of

maintenance and in compliance with the safety
instructions
Lateral run of the chain See notes below

Damage to the welded Immediately consult the manufacturer and shut

structure down the machine by disconnecting it from the
power network
Supply or discharge devices Stop machine and after it has come to a standstill,
for bulk material are defective remove the obstruction

Bulk material is jammed Stop machine and after it has come to a standstill,
remove the obstructions

Properties of bulk material Consult the manufacturer

have changed

Caking of the bulk material Clean machine tasks after the machine has come
due to heat to a standstill

The following causes can be responsible for the lateral entry of the drive or
deflection pulleys, which must be corrected if necessary:
• Uneven chain stretching
• Inclined of the bucket elevator
• Inclination of the drive wheels or deflection wheels
• One-sided conveyor feed

KBW 72 / 101
Rev. 00 2023-03-06
13 Maintenance

13.1 Safety

All tasks must only be performed by verifiably qualified specialists with due
consideration:
• This manual.
• All other manuals accompanying this machine (supplier documentation, etc.).
• Applicable local regulations and laws

DANGER
Suspended loads
Tipping or falling loads can lead to severe and even fatal injuries.
– Never step beneath suspended loads.
– Only use approved hoisting equipment and slings designed for and capable of
supporting the total weight of the attached load.
– Pay attention to the attachment points and the center of gravity of the load.
– Only use slings and load suspension devices that are in a technically perfect
condition.
– Secure loads with suitable devices.
– If transport safety devices are used, these should be removed only after the
conclusion of the assembly process.
– Secure loading and unloading areas against unauthorized entry.
– Ensure adequate lighting of loading and unloading areas.
– Move loads only under supervision of another person.
– Lower the load if you intend to leave the workplace.

DANGER
Danger of death due to potentially explosive atmosphere
A mixture of flammable gas or dust in the vicinity of the system can cause
explosions and cause severe and even fatal injuries.
– The owner has to ensure that gas detectors are installed at the machine to
warn of potentially explosive atmospheres at all times.
– In the case of a potentially explosive atmosphere, stop operation immediately
and ensure that there is sufficient ventilation.
– Eliminate the cause of the potentially explosive atmosphere.

KBW 73 / 101
Rev. 00 2023-03-06
 DANGER
Danger of death due to electric shock
There is life-threatening danger if contact is made with live components.
Uncontrolled movements are also possible due to activated electrical components.
This will result in severe or fatal injuries.
– Only qualified electricians are permitted to perform tasks on the electrical
system.
– Before commencing tasks on the electrical system, switch off the power supply
and safeguard it from being switched on again.
– Ensure correct grounding within the ATEX zone.

WARNING
Danger of falling when working at height
The performance of work at height can lead to slipping and falling causing severe
injuries.
– Use personal protective equipment.
– Make sure that work conditions exist that enable the safe performance of work
at height.
– Use fall protection if there is no safe footing.
– Use a work platform, scaffolding, a passenger elevator, or an aerial
bucket/basket, for example.
– Protect the assembly area against falling objects.
– Never work alone.

CAUTION
Sharp edges
Sharp edges may lead to cuts.
– Use personal protective equipment.
– Handle with care.

ATTENTION
Environmental damage due to oils and greases
The soil and drinking water can become contaminated due to carelessness when
performing installation, repair or maintenance tasks.
– Remove any excess grease from lubrication points that were greased
manually.
– Collect waste oil in suitable containers.
– Oils and greases must be properly disposed of.
Comply with applicable local disposal regulations.

KBW 74 / 101
Rev. 00 2023-03-06
 Note
The manufacturer is not liable for damage resulting from incorrectly performed
repair, service or maintenance tasks.

13.2 Prior to maintenance

Comply with the following instructions, prior to performing maintenance tasks on

the machine:
1. Inform the operating personnel about the tasks to be performed beforehand.
A supervising person should be appointed.
2. Adhere to the maintenance intervals specified in the maintenance schedule.
3. All tasks must be performed when the machine is at a standstill.
4. Shut off the machine for execution of tasks and safeguard it from being
switched on again unexpectedly.
– Lock the main switch with a personally assigned padlock.
– Attach a warning sign.
– Cordon off a large area around the work area.
– If there are indications of residual voltages, have a specialist execute
grounding measures.
5. If the removal of safety devices or protective equipment is required then these
should be refitted immediately following the completion of work and checked
for correct functioning.
6. When replacing individual parts or larger assemblies, convey them carefully
with tested sling gear. Only use suitable and technically perfect hoisting
equipment and load suspension devices with adequate load-bearing capacity.
7. For overhead installation tasks use safe climbing aids and work platforms. Do
not use system parts as climbing aids.
8. Wear fall protection gear for tasks performed at great heights.

KBW 75 / 101
Rev. 00 2023-03-06
13.3 Switching the machine on again after maintenance

1. Ensure that no tools or objects have been left lying around from the
preceding tasks.
2. Clean the machine of moisture and contamination.
3. Attach all protective devices.
4. Close all inspection openings.
5. Ensure that power supply in ensured from the owner's side.
6. Switch on the machine via the main switch.
7. Check all safety devices for electrical functionality.
Through an appropriate teste the functionality of the warning devices to warn
of a possible hazard, must be ensured. Repeat test for all safety elements:
– Emergency stop button
– Emergency off button
– Safety doors
– Light barriers, etc.
8. Check the direction of rotation of the drive motor again.
Note
Comply with information and specifications given in the suppliers' documentation.

13.4 General information

The purpose of servicing measures is to ensure that the correctly functioning

condition of the machine is maintained or can be re-established in the event of a
failure.
The machine requires must be maintained on a regular basis. Incorrectly
performed maintenance tasks can lead to faults or damage which, in turn, can
result in downtimes and costs for repair.

If the there are problems, or if there are questions, contact the manufacturer
immediately.
Please provide the following information in case of questions:
• Order number and consignment number.
• Describe the faults or malfunctions that have occurred as precisely as
possible.
• Measures taken so far to rectify the fault.

The following measures must be executed if the machine is sent to DI MATTEO:

1. Drain oil; otherwise, the shipment is considered as shipment of hazardous
goods.
2. Treat exposed parts with a preservative.
3. Attach dummy covers to flanges.
4. Comply with information given in the chapters on "Shutdown", "Dismantling"
and "Transport".

KBW 76 / 101
Rev. 00 2023-03-06
13.5 Inspection/inspection schedules

• We recommend having the manufacturer perform a general inspection once a

year or after 4000 operating hours.
• In this process, spare parts and wear parts, such as bearings and seals, are
replaced.
• The manufacturer recommends keeping a sufficient quantity of spare parts
and wear parts in stock, according to the parts list, to avoid or minimize waiting
times and downtimes in the event of a fault.

Contact the manufacturer at the following address for questions or scheduling with
regard to maintenance, repair or inspection:

DI MATTEO Förderanlagen GmbH & Co. KG

Address Römerstrasse 1-16
City 59269 Beckum, Germany
Telephone +49 2521 / 93 44 - 0
Fax +49 2521 / 93 44 - 222
Email info@dimatteo.de
Internet www.dimatteo.de

13.6 Maintenance

Carry out maintenance tasks in accordance with the points listed and the following
maintenance schedule.
• Comply with lubrication instructions for re-lubrication tasks involving the
machine as part of maintenance.
• Maintain drive unit, coupling, etc. as specified by the manufacturer, see
chapter "Supplier documentation".
• Replace damaged fastening elements and securing elements and other
damaged components with structurally identical parts (see the "Spare parts"
chapter).
• Check the machine for damage on the welded construction.
• If there is damage of any kind, consult with the manufacturer immediately.

Note
The machine will be damaged if operated with worn-out wear parts!

KBW 77 / 101
Rev. 00 2023-03-06
13.6.1 Maintenance schedule

commissioning

or once a year
After 4000 oh

After 8000 oh
or every six
Maintenance

Monthly

months
Weekly
After
intervals

Visual inspection and noise check

■ ■
Initiate repair, if necessary

Fastening screws or threaded fittings

■ ■
Re-tighten, if necessary

Weld seams
■ ■
Consultation with DI MATTEO

Bucket elevator head

Visual and noise control
Check for damage and wear
■ ■
Check fastenings / screw connections
Functional check
Cleaning recommended at regular weekly intervals

Drive shaft including bearing, bucket

elevator head
Check for damage and wear
■ ■ ■
Functional check
Lubricate bearings according to instructions
Replace defective parts immediately

Drive sprockets
Check for damage and wear
Functional check ■ ■ ■
Replace defective parts immediately
degrease if necessary

Drive bracket with coupling guard

Check for damage and wear ■ ■
Functional check

Bucket as a whole
Check fastening and correct alignment
readjust and tighten if necessary
■ ■
Check filling and filling quantities
readjust if necessary
Check for damage and wear

Bucket elevator foot

Visual and noise control
Check for damage and wear
Check fastenings / screw connections ■ ■
Functional check
Cleaning recommended at regular weekly
intervals

Bearing bucket elevator foot

Check for damage and wear
Functional check ■ ■
Lubricate bearings according to instructions
Replace defective parts immediately

KBW 78 / 101
Rev. 00 2023-03-06
 commissioning

or once a year
After 4000 oh

After 8000 oh
or every six
Maintenance

Monthly

months
Weekly
After
intervals

Chain
Chain bracket
Chain rollers (hub and segments)
Maintenance of the chains according to the
manufacturer's instructions ■ ■
Check for damage and wear recommended at
weekly intervals
Check fastening and correct alignment
readjust and tighten if necessary

Inlet with wear protection

Cleaning recommended at regular weekly
■ ■
intervals
Check for damage and wear

Tensioning device
Function check
■ ■
Check settings
Replace defective parts immediately

Speed monitoring
Fill level monitoring
Misalignment switch ■ ■ ■
Check function
Check settings
Replace defective parts immediately

Main inspection / Maintenance

Inspection / replacement of spare and wearing parts ■ ■
Check the complete machine / system

Lubrication
Check lubricant quantities at regular weekly
intervals. See lubrication instructions
Replace lubricant at least at annual intervals.
Clean lubrication points if necessary

Coupling
Perform maintenance, maintain lubrication intervals, See supplier documentation
change oil

For version: Hydro coupling

Check clutch play, replace clutch packings if See supplier documentation
necessary, change oil

Motor and gearbox

Perform maintenance tasks,
Check lubricant quantities at regular weekly See supplier documentation
intervals.
Replace lubricant at least at annual intervals.
Clean lubrication points if necessary

We recommend servicing the machine at the specified intervals. The listed maintenance
intervals and operating hours (oh) refer on average conditions. Depending on the ambient
conditions and operating conditions, other maintenance intervals may arise, which the
customer if necessary must adjust. Consult with the manufacturer in this case.

KBW 79 / 101
Rev. 00 2023-03-06
13.6.2 Lubrication instructions
General instructions:

Note
DI MATTEO expressly informs the system owner that proper and professionally
executed lubrication and maintenance of the system / machine at regular
intervals are an important component of operation of this machine.
• The correct application of the most suitable lubricants plays a significant part
in ensuring that the best operating performances are achieved and
malfunctions are avoided.
• The manufacturer only provides a warranty for the machine if lubricants with
the specified technical characteristics are used.

ATTENTION

– The system must be cleaned before each maintenance, highly flammable

substances / dusts, etc. must be removed. (Fire protection)
– Do not use any highly flammable solvents to clean the system! (Fire
protection)
– Before replacement, the lubricant must cool down.
Check the temperature with suitable measuring equipment.
(Accident prevention regulation / fire protection)
– When handling oils (hydraulic oils, thermal oils), in particular larger amounts,
the owner must initiate professional measures / safety precautions that
prevent oils from penetrating into the soil or ground water if there are leaks.
Comply with local regulations. (Environmental protection)
– Never mix different types of oil or grease together!
– It must be possible for the old lubricating grease to escape without obstruction.
– Mineral gear oils and greases allow lubricant change intervals of up to 10,000
operating hours. With synthetic lubricants the intervals can be increased 2.5x.
Obtain more detailed information in this regard from the respective lubricant
manufacturer.
– On the owner side, supplier information, supplier documentation, as well as
rating plate information must be complied with.
– Only use the specified makes to grease or lubricate the system. In this regard
ensure safe storage and eco-friendly disposal of the lubricants.

KBW 80 / 101
Rev. 00 2023-03-06
 Moving / rotating parts

Note
The following principle applies: All moving parts of the system or of a system
section must be serviced/maintained.
This maintenance includes cleaning the entire system, visual inspection of parts
that can loosen, the function tests of the safety devices and lubrication of all
moving parts.

Supplier parts

Note
For the supplier parts (such as motors, gear motor, bearings and couplings) DI
MATTEO only provides a maintenance recommendation.
On the owner side, supplier information, supplier documentation, as well as rating
plate information must be complied with.
1. Drive units are filled with lubricant in the factory, comply with the supplier
documentation in this regard.
2. The drive units are filled with lubricant in the factory, see the supplier
documentation in this regard.
3. The rolling bearings of the machine are pre-lubricated with the
appropriate amount of grease and are automatically relubricated by the
attached lubricator.
Attention:
• It must be possible for the old lubricating grease to emerge without
hindrance.
• The rolling bearings can be damaged by relubricating at high pressure.
DI MATTEO recommends SKF LAGD 125/WA2 as lubricator.

KBW 81 / 101
Rev. 00 2023-03-06
 The manufacture provides a warranty for the machine only if lubricants with the
specified technical characteristics are used. The drive units are filled with lubricant
in the factory, see the supplier documentation in this regard.

Basis of the lubricating Consistency DIN 51818 Lubricating grease in

grease NLGI class accordance with
DIN 51825
Lithium-soap II KP2P-30

The machine's housing bearing units are prefilled with the appropriate quantity of
grease and do not require relubrication under normal implementation conditions.
Under difficult conditions, such as continuous operation at high speeds, high
temperatures, heavy loads or a very wet or dirty environment, regular relubrication
is necessary. The re-lubrication should be executed during operation.
Attention:
• The old lubricating grease must be able to escape without obstruction.
• The roller bearings can be damaged through relubrication at high pressure.

Open and clean housing bearings every 8000 operating hours or once a year and
fill with a new grease filling.

Bearing Fill quantity

Pedestal bearing 630g

Flange bearing 60g

DI MATTEO recommends AVIA Lithoplex 2 EP as lubricant.

Note
The proper application of the most suitable lubricants plays a significant part in
ensuring that the best operating performances are achieved and malfunctions are
avoided.

KBW 82 / 101
Rev. 00 2023-03-06
13.6.3 Lubrication instructions -Overview

KBW 83 / 101
Rev. 00 2023-03-06
13.6.4 Lubrication - Elevator bottom

13.6.5 Lubrication -Elevator head

KBW 84 / 101
Rev. 00 2023-03-06
KBW 85 / 101
Rev. 00 2023-03-06
13.6.6 Lubrication list

Pos. Piece Initial fill Lubricant Lubricant Comments

quantity
(DIN 51517 part 3;
Lubricating DIN 51502; DIN ISO Lubricating
point VG class) interval

1 2 960 g KP 2 P-30 Avia Lithoplex Open the bearing housing

pedestal 2 EP Remove the spent grease
bearing from the bearing and
bearing housing.
Fill the cavities in the
Lubrication bearing with new grease.
line for Fill the bearing housing
bearing with the specified quantity
(gearbox of grease.
side)

2 2 560 g KP 2 P-30 Avia Lithoplex Open the bearing housing

2 EP Remove the spent grease
from the bearing and
pedestal bearing housing.
bearing
Fill the cavities in the
bearing with new grease.
Fill the bearing housing
with the specified quantity
of grease.
3 2 40 g Teadid 2200 Every 4.000 operating
hours a maximum of
every 6 months,
the stuffing boxes must
be cleaned and
repackaged.
4 2 20 g Teadid 2200 Every 4.000 operating
hours a maximum of
every 6 months, the
stuffing boxes
must be cleaned and
repackaged.

KBW 86 / 101
Rev. 00 2023-03-06
Pos. Piece Initial fill Lubricant Lubricant Comments
quantity
(DIN 51517 part 3;
Lubricating DIN 51502; DIN ISO Lubricating
point VG class) interval

5 1 7l CLP HC 220 Mobilgear 630 At an oil temperature of

70 °C: Oil change after
Gear
17000 h or after 5 years
motor at the latest.
(Oil change depends on
the oil temperature.)
Comply with the operating
manual of the gear motor

Comply with the operating

manual of the gear motor

Check the oil level after

3000 h, or after six
months at the latest.

See supplier
documentation
6 1 CLP HC 220 Mobilgear 630 See supplier
Coupling documentation
N Eupex

KBW 87 / 101
Rev. 00 2023-03-06
14 Spare parts

14.1 Ordering spare parts

Note
The manufacturer is not liable for damage resulting from the use of non-original
parts.

WARNING
If replacement is necessary, only use original parts. The use of non-original parts
can lead to damage.
• Please contact the service department to order spare parts. Order information
can be received via email, fax or telephone.
• For ordering spare parts it is essential that the information on the cover page
or the spare parts list is stated:
– Machine number / Consignment number:
– Spare parts list number (if available)
– Item number (if available)
– Item description
– Quantity

Send orders for spare parts to:

DI MATTEO Förderanlagen GmbH & Co. KG
Telephone +49 2521 / 93 44 - 0
Fax +49 2521 / 93 44 - 222
Email info@dimatteo.de

• DI MATTEO recommends keeping a sufficient quantity of spare parts and

wear parts in stock, according to the parts list, so as to avoid or minimize
waiting times and downtimes in the event of a fault.
• Please place your order in good time, so that the required parts are at hand for
the next scheduled maintenance. The delivery time for spare parts can vary.
Consequently a comprehensive spare parts order based on the longest
delivery time is recommended.

KBW 88 / 101
Rev. 00 2023-03-06
14.2 Spare parts

KBW 89 / 101
Rev. 00 2023-03-06
 RO:Suport de lanț cu 2 piulițe și
placă de distanțare

EN: Chain brackets

with 2 nuts and spacer plate

KBW 90 / 101
Rev. 00 2023-03-06
 ODM - High capacity chain bucket elevator KBW 250x19700AA /AF10 005ELV
Saint-Gobain Construction
Products Romania S.r.l.
Company: 1st District, One Unit Tower Machine-No: P9001156.010
165 Floreasca Road, 10th Floor
RO-014459 Bucharest
Pieces Designation Inspection
Pos. V/E Quantitiy
Built-in finished
1 V 1 Set of Chain ends; complete ☐
1.1 V 4 Chain ends; short; bundled in pairs ☐
1.2 V 180 Chain ends; long; bundled in pairs ☐
2 V 92 Buckets SSH 250 ☐
2.1 V 184 Chain brackets with 2 nuts and spacer plate ☐
2.2 V 184 Spacer link ☐
3 V 1 Drive shaft; complete ☐
3.1 V 1 Drive shaft ☐
3.2 V 2 Chain wheel; complete ☐
Set of segments for chain wheel
3.2.1 V 2 ☐
1 set = 8 pieces
4 E 2 Gland; driving side; complete ☐
4.1 E 2 Gland housing; 2-parts; driving side ☐
4.2 E 2 Set of packings for gland; 1 set = 3 pieces ☐
5 E 2 Pedestal bearing; complete; driving side ☐
5.1 E 2 Pedestal bearing Housing; with clamping sleeve ☐
5.2 E 2 Roller bearing insert ☐
6 E 1 Elastic coupling; complete ☐
coupling buffer for flexible coupling
6.1 V 8 ☐
requirement = 8 pieces per coupling
7 E 1 Tensioning station complete; KBW ☐
7.1 E 2 Guide rode ☐
7.2 E 2 Gland; tensioning side; complete ☐
7.2.1 V 2 Gland housing; 2-part; tensioning side ☐
7.2.3 V 2 Set of packings for gland; 1 set = 3 pieces ☐
8 E 2 Link bearing complete, BW ☐
8.1 E 2 Rolling bearing insert with labyrinth sealing ☐
8.2 E 2 Radial-sealing ring ☐
8.3 E 2 Lubrication hose ☐
8.4 E 1 Automatic lubricator (Perma) ☐

KBW 91 / 101
Rev. 00 2023-03-06
 ODM - High capacity chain bucket elevator KBW 250x19700AA /AF10 005ELV
Saint-Gobain Construction
Products Romania S.r.l.
Company: 1st District, One Unit Tower Machine-No: P9001156.010
165 Floreasca Road, 10th Floor
RO-014459 Bucharest
Pieces Designation Inspection
Pos. V/E Quantitiy
Built-in finished
9 V 1 Deflection shaft; complete ☐
9.1 E 1 Deflection shaft ☐
9.2 V 2 Chain wheel complete ☐
Set of segments for chain wheel
9.2.1 V 2 ☐
1 set = 8 pieces
9.2.2 E - Flange disc ☐
10 E 1 SEW bevel geared drive ☐
Rotation sensor
16 E 2 rotation monitoring - bottom ☐
rotation monitoring - head (control)
17 E 2 Level monitoring sensor ☐
Security sensor
18 E 2 ☐
2 pieces for maintanance door
In case of spare part orders necessarily
V Wear part
specify the machine/ order number and item
E Spare part
number!
*if profided

__________________ ________________________
Date Signature

KBW 92 / 101
Rev. 00 2023-03-06
15 Decommissioning

15.1 Safety

All tasks must only be performed by verifiably qualified specialists with due
consideration:
• This manual.
• All other manuals accompanying this machine (supplier documentation, etc.).
• Applicable local regulations and laws

WARNING
There is an imminent risk of injury or material damage unless the owner correctly
shuts down the system and takes it out of service.

Note
The owner or a person authorized by him/her to do so is to shut down the
machine and take it out of service.
The system is to be taken out of service in compliance with applicable local
regulations and laws.

DANGER
Danger of death due to electric shock
There is life-threatening danger if contact is made with live components.
Uncontrolled movements are also possible due to activated electrical components.
This will result in severe or fatal injuries.
– Only qualified electricians are permitted to perform tasks on the electrical
system.
– Before commencing tasks on the electrical system, switch off the power supply
and safeguard it from being switched on again.
– Ensure correct grounding within the ATEX zone.

WARNING
Danger due to rotating and moving parts
Rotating and moving components can lead to the crushing and severing of limbs
which can cause severe injury.
– Maintain a safe distance to the components.
– Comply with the warning signs posted in the work area.
– Use personal protective equipment.
– Wear tight-fitting clothing

KBW 93 / 101
Rev. 00 2023-03-06
15.2 Decommissioning the machine

The following instructions must be complied with if the machine will be at a

standstill for more than three days:
1. Empty the machine with the last operation process.
2. Bring down the system and comply with the shut-down procedures, if
necessary.
2. Switch off the machine via the main switch.
2. Ensure that power supply services are deactivated at the owner's site.
3. Check to ensure the de-energized state of the machine.
3. Disconnect the machine from the power supply.
4. Then clean the machine with water and remove coarse contamination and
dust accumulations.
5. Treat exposed metal parts with a suitable preservative (corrosion protection).
6. If the machine is placed outdoors, cover it, see chapter "Storage".
7. Handle, drive unit, sensor systems, and if present central lubrication pump as
specified by the manufacturer, see chapter "Supplier documentation".

KBW 94 / 101
Rev. 00 2023-03-06
16 Dismantling

16.1 Safety

All tasks must only be performed by verifiably qualified specialists with due
consideration:
• This manual.
• All other manuals accompanying this machine (supplier documentation, etc.).
• Applicable local regulations and laws

WARNING
There is an imminent risk of injury or material damage if the owner improperly
and incorrectly dismantles the machine.

Note
The owner or a person authorized by him/her to do so is to dismantle the
machine.
The system must be dismantled in compliance with applicable local regulations
and laws.

DANGER
Danger of death due to electric shock
There is life-threatening danger if contact is made with live components.
Uncontrolled movements are also possible due to activated electrical components.
This will result in severe or fatal injuries.
– Only qualified electricians are permitted to perform tasks on the electrical
system.
– Before commencing tasks on the electrical system, switch off the power supply
and safeguard it from being switched on again.
– Ensure correct grounding within the ATEX zone.

DANGER
Danger of death due to damaged or exposed energized parts
Contact with live components will result in severe or fatal injuries.
– Only qualified electricians are permitted to perform tasks on the electrical
system.
– System parts, which must undergo inspection, maintenance and/or repair must
be de-energized.
– Secure the system parts against reactivation.
– Cordon off the work area and put up a warning sign.

KBW 95 / 101
Rev. 00 2023-03-06
 DANGER
Suspended loads
Tipping or falling loads can lead to severe and even fatal injuries.
– Never step beneath suspended loads.
– Only use approved hoisting equipment and slings designed for and capable of
supporting the total weight of the attached load.
– Pay attention to the attachment points and the center of gravity of the load.
– Only use slings and load suspension devices that are in a technically perfect
condition.
– Secure loads with suitable devices.
– If transport safety devices are used, these should be removed only after the
conclusion of the assembly process.
– Secure loading and unloading areas against unauthorized entry.
– Ensure adequate lighting of loading and unloading areas.
– Move loads only under supervision of another person.
– Lower the load if you intend to leave the workplace.

WARNING
Danger of falling when working at height
The performance of work at height can lead to slipping and falling causing severe
injuries.
– Use personal protective equipment.
– Make sure that work conditions exist that enable the safe performance of work
at height.
– Use fall protection if there is no safe footing.
– Use a work platform, scaffolding, a passenger elevator, or an aerial
bucket/basket, for example.
– Protect the assembly area against falling objects.
– Never work alone.

WARNING
Danger due to rotating and moving parts
Rotating and moving components can lead to the crushing and severing of limbs
which can cause severe injury.
– Maintain a safe distance to the components.
– Comply with the warning signs posted in the work area.
– Use personal protective equipment.
– Wear tight-fitting clothing

KBW 96 / 101
Rev. 00 2023-03-06
 WARNING
Crushing of limbs between components
Moving components can crush limbs and cause severe injury.
– Maintain a safe distance to the components.
– Comply with the warning signs posted in the work area.
– Use personal protective equipment.

CAUTION
Sharp edges
Sharp edges may lead to cuts.
– Use personal protective equipment.
– Handle with care.

ATTENTION

Material damage due to incorrect handling of loads

The incorrect handling of loads during loading and unloading processes can lead to
material damage.
– Pay attention to the attachment points and the center of gravity of the load.
– The side walls or attachment parts of components must not be pushed
together by misaligned ropes or chains.
– Do not place the system on top of the protective hoods for the drive units.
– Secure the system parts against tipping over and shifting if you intend to
transport these on loading platforms.
– Avoid hard impact when lowering the load.
– Only set down loads on level ground of the required load-bearing capacity.

ATTENTION

Danger of environmental damage

Human carelessness can adversely affect the environment. Substances that are
harmful to the soil and drinking water must not enter the soil or the sewer system.
– Clean contaminated components before dismantling them.
– Collect substances such as lubricating greases and oils as well as other
chemical substances in suitable containers and properly dispose of these.
– Comply with local regulations and legal requirements when disposing of
waste.

KBW 97 / 101
Rev. 00 2023-03-06
 Note
The manufacturer is not liable for damage resulting from improper dismantling.

16.2 Prerequisites for dismantling

1. Execute decommissioning, chapter "Decommisioning" and comply with the

following instructions.
2. Depressurize components and lines that are pressurized.
3. If necessary, disconnect, such as pipelines.
4. Collect consumables and hazardous materials.
5. Close off exposed connection points of piping, if applicable.

ATTENTION

Environmental damage due to escaping operating materials.

Clean contaminated components before dismantling them. Collect harmful
substances in suitable containers and properly dispose of these.

16.3 Electrical dismantling

When dismounting the motor, and possibly the central lubrication pump, as well as
the sensor system, comply with the manufacturer's instructions in the supplier
documentation.

16.4 Mechanical dismantling

1. Attach the transport safety devices.

2. Unscrew the fastenings of the machine with the prescribed components and
tools.
3. Dismantle the modules of the machine, according to the dimensions and
specifications.

KBW 98 / 101
Rev. 00 2023-03-06
17 Disposal

17.1 Safety

All tasks must only be performed by verifiably qualified specialists with due
consideration:
• This manual.
• All other manuals accompanying this machine (supplier documentation, etc.).
• Applicable local regulations and laws

WARNING
The intentional or unintentional further use of used components, such as roller
bearings, timing belts, etc., can harm persons, the environment, and the system.
Comply with the following instructions:
• The owner is responsible for proper disposal of waste.
• Only skilled personnel may dispose of waste.
• Drain and collect consumables in suitable containers and properly dispose of
these
• At the end of its service life, dismantle the system, separate its parts according
to the material they are made of and have a company specialized in recycling
pick up the scrap.

ATTENTION

Danger of environmental damage

Incorrect disposal of waste adversely affects the environment.
– Comply with local regulations and legal requirements when disposing of
waste.

KBW 99 / 101
Rev. 00 2023-03-06
Index

A F
About this manual 9 Faults 42, 69
Aligning the bucket elevator 59 Faults and troubleshooting 72
Ambient conditions 30 Foreseeable misuse 20, 41
Assembly 55 Frequency converter / soft start 48
Assembly of bucket elevators with a small center fumes 34
distance 59 Fumes 34
Assembly the bucket head 59 Function bucket elevator 51

B G
Belt misalignment switch (optional) 50 Gases 34
Betrieb der Maschine/Anlage 68 Gender-neutral formulation 9
Bucket 48 General information 76
Bucket elevator bottom 49 General information concerning safety 13
Bucket elevator chimneys 48 General requirements 16
Bucket elevator designs - overview 46
Bucket elevator head 48 H
Bulk material characteristics 44
Hot spots 33
C Hydraulic energy 33

Checking the delivery 53 I

Chemical substances 34
Cleaning 39 Inclement weather 30
Cleaning after assembly 64 Inspection 38
Commissioning 65 Inspection/ inspection schedules 77
Compensators (optional) 50 Installation
Components description 48 Pictograms 28
Conduct in emergency situations 40 Installation of drive group 62
Conversions 38 Installation of lateral guides 59
Installation of the central lubrication system 63
D Installation of the chains and buckets 60
Installation of the chutes 58
Danger due to hazardous substances 35 Installation of the inspection drive 63
Declaration of incorporation 8 Instruction 23
Decommissioning 93 Instruction log 24
Decommissioning the machine 94 Instruction of the employees 23
Dismantling 95 Instruction protocol 24
Disposal 99 Intended use 19
Drive 48 Intermediate storage 54
Dusts 34
L
E
Legal regulations 18
Edition of these operating manual 2 Level control 50
Electrical connection for speed monitoring 64 Liability and warranty 12
Electrical connection of the central lubrication Liability and warranty for this operating manual 9
pump 63 Local regulations 18
Electrical connection of the drive unit 64 Lubrication instructions 80
Electrical energy 32
Electrical installation 63 M
Elektrische Demontage 98
Environmental hazards 31 Machine characteristics 43
Explosive atmosphere 32 Maintenance 39, 73, 77
Maintenance schedule 78
Mechanical installation 58
KBW 100 / 101
Rev. 00 2023-03-06
Mechanische Demontage 98 S
Modifications 38
Safety 13, 52, 54, 55, 65, 67, 69, 73, 93, 95, 99
Moving parts 31
Safety devices 29
Safety instructions / personnel 25
N
Safety notices and warning signs on the machine
Noise emission 45 28
Non-intended use 19 Safety tests 29
Notification of revisions 11 Scope of delivery 11
Sensors 50
O Service address 11
Settings at the bucket elevator outlet 61
Obligations of the owner 16 Set-up and alignment 57
Operating manual 14, 16 Spare parts 88, 89
Operation 67 Spare Parts 39
Operation of the system 37 Specific hazards 36
Ordering spare parts 88 Speed monitor 50
Other applicable documents 16 Starting up 66
Storage 54
P Structure and function 46
Packaging 53 Structure ODM - High capacity chain bucket
Person in Responsible: 2 elevator KBW 47
Personal protective equipment 26 Switching the machine on again after faults 71
Personnel requirements 21 Switching the machine on again after
Pictograms and auxiliary signs 28 maintenance 76
Plant data 44
Pneumatic energy 33 T
Preparation for fault rectification 71 Technical data sheet 43
Preparatory measures for set-up 57 Temperature monitoring (optional) 50
Prerequisites for dismantling 98 Tensioning station 49
Prior to maintenance 75 Threaded fitting of the housing flanges 57
Prior to operation 68 Traction means for conveying 49
Transport 52
Q Transport and assembly 38
Qualifications of personnel 22 Trial run 66

R U
Repair 39 Untrained personnel 23
Requirements for operation 15 Use and storage 9
Residual risks 36
Restriction of groups of persons 21 W
Revision management: 2 Warning notices 17
Running of the system 37 Wear Parts 39

KBW 101 / 101

Rev. 00 2023-03-06