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ATEX execution
Supplementary information in
the technical description
“The ATEX execution“ has to be observed!
OPERATING INSTRUCTIONS
(DDW-) DVT XX
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Imprint
Device assignment
Device names: (DDW-) DVT xx
Device variant: ATEX
Document
Document status: Original document
Type of document: Operating instructions
File designation: e2113305
Document ID: 305
Revision: 1.3.1
Date: 16-06-22
Editor: Brabender Technologie GmbH&Co.KG
Copyright: © 2016, Brabender Technologie GmbH&Co.KG
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Table of contents
Imprint ........................................................................................................ 2
Table of contents ......................................................................................... 3
1. Safety ................................................................................................... 5
The use of the device ................................................................................... 6
Safety instructions........................................................................................ 8
Specifications for the type approval of the device ............................... 8
Qualification of the operating personnel ............................................. 8
Dangerous contact voltages on the device ........................................... 8
Disconnecting the device ...................................................................... 9
Discharging of storages of residual energy ........................................... 9
Earthing of the device ........................................................................... 9
Sound level............................................................................................ 9
Warnings on the device ...................................................................... 10
Residual dangers ........................................................................................ 11
2. The description of the device .............................................................. 13
Description of the design of the device ..................................................... 14
The component groups of the device ........................................................ 15
The hopper.......................................................................................... 15
Feeding organ and feed drive ............................................................. 17
The weighing of the device ................................................................. 20
Technical data ............................................................................................ 22
3. Mounting ........................................................................................... 23
Mounting instructions................................................................................ 24
The place of the installation ....................................................................... 25
Assembly work ........................................................................................... 26
Installation on site .............................................................................. 26
Connection inlet/outlet ...................................................................... 26
Connection ventilation/deaeration .................................................... 27
Electrical mounting work ........................................................................... 28
4. Commissioning ................................................................................... 34
Notes on commissioning ............................................................................ 35
Commissioning sequence........................................................................... 36
Step 1: Tests on the device ............................................................ 36
Step 2: Connection of supply media .............................................. 36
Step 3: Verification and adjustment of the weighing .................... 36
Step 4: Determination of the discharge rate ................................. 39
Product feeding .......................................................................................... 41
Step 5: Adaptation of the discharge rate ...................................... 43
5. Decommissioning................................................................................ 44
6. Fault shutdowns ................................................................................. 45
Causes of malfunction ................................................................................ 46
7. Maintenance ...................................................................................... 48
Information on maintenance ..................................................................... 49
Component list ........................................................................................... 50
Care and examination ................................................................................ 52
Assembly/disassembly of individual components ..................................... 53
Hopper disassembly ............................................................................ 53
Hopper assembly ................................................................................ 53
Disassembly of vibrating tray .............................................................. 54
Assembly of vibrating tray .................................................................. 54
8. Storage and disposal ........................................................................... 55
Storage of the device, of individual components ...................................... 56
Disposal of the device, of individual components ..................................... 57
9. Index .................................................................................................. 58
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1. Safety
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This chapter describes the use of the device and the safety instructions for the
use of the device.
Subject Page
The use of the device 6
Safety instructions 8
Residual danger 11
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Intended purpose The “DVT xx“ is a feeder for the feeding of bulk solids that can be fed by means
of a vibrating tray (= feeding unit).
The product is filled into the hopper from where it is conveyed on the vibrating
tray. The directional vibration of the vibrating tray conveys the product to the
outlet of the device where it falls freely out of the device. The directional
vibration is generated by a vibrating conveyor (= drive) that is mounted below
the vibrating tray. The working point of the device, the feed rate (= product
quantity/unit of time) is adjusted by means of the determination of the
vibration amplitude of the vibrating conveyor.
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Appropriate products For the discharge /feeding with the device bulk solids (no liquids) with the
following product characteristics are appropriate:
• Suitable size of product particles
• Appropriate flowability
• Free from contaminations, foreign bodies etc.
• There is no ignition capability due to friction or strokes
• No explosive characteristics
• No change of the product characteristics due to the feeding operation
• No inadmissibly high wear of the machine parts in contact with the product
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Specifications for the The standard dimensioning of the device requires the following environmental
use and operating data for the field of application:
Temperature: 0°C to +40°C
Humidity: up to 85% without condensation
Medium: Air or inert gas
Wind/draught: < 0.3 m/s
Max. underpressure/overpressure: 2 mbar (20mm water column)
Product temperature: 0°C to +40°C
Voltage supply: AC 230/400V
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Required component The following electrical groups are required for the following control functions
groups for the operation (minimum requirement):
• Start/stop of the operation of the device
• Determination of the working point of the device (= vibration amplitude
setting)
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Adaptation to the The device is dimensioned according to the application conditions known
application on site when awarding the contract. They result from the customer’s indications
concerning
• the products employed and their characteristics,
• the environmental and operating conditions,
• the desired feed rate range
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Safety instructions
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Any operation shall be permitted only if the following specifications have been
complied with:
• The indications on the operating instruction have been complied with.
• Mounting, commissioning have been carried out correctly.
• The device must only be used for its intended purpose.
• The device is maintained regularly.
• For necessary repair work be sure to employ original spare parts of the
manufacturer or spare parts with identical technical characteristics (to be
approved by the manufacturer).
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Dangerous contact voltages are required for the operation of the device. The
following specifications have to be respected for the protection of the
operating personnel:
• The device must not be operated with freely accessible terminals.
• Before commencing any work on the electrical connections, you must first
disconnect the device from the mains.
• The device must not be operated with damaged electrical components.
Damaged component groups have to be repaired or exchanged
immediately.
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The device must only be operated with a correct earthing. The main earth
connection point is connected to the equipotential bonding on site in a
standard-compliant manner. Earth connections between the device and
Marking of the main earth assembled components that have been mounted in our works must not be
connection point interrupted or removed on site.
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Sound level
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Before the start of any work the device has to be disconnected from the mains
and protected against unauthorised reconnection.
In case of non-respect there is a considerable danger of injuries caused by
Disconnect the device dangerous voltages.
from the mains
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Residual dangers
Foreign bodies Danger Foreign bodies in the product area of the device
Effects: • Operational failures
• Damage of the device
Measures: • Employ clean product
• Circumspection/special care must be taken when
working on the device
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This chapter describes the construction and the function of the device and of
individual component groups.
Subject Page
Construction of the device 14
The component groups of the device 15
Technical data 22
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Legend No Meaning
1 Hopper cover (fixed execution)
a Connecting branch of product supply
b Connecting branch to the venting nozzle
2 Hopper
a Hopper fastening
3 Mounting frame (mounting frame + base)
4 Vibrating conveyor (drive)
5 Vibration isolation mounting pads
6 Vertical outlet (downstream connection point)
a Optional fastening with star-grip screws
7 Flexible step bellow
8 Vibrating tray
9 Cover of vibrating tray
10 Clamping fastener (fastening of cover)
11 Flexible step bellow (flexible connection of the vibrating tray with the
hopper outlet)
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The hopper
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The hopper stores the product to be fed and then the product is conveyed to
the feeding unit.
No Description:
1 Hopper
2 Flexible step bellow
3 Hopper outlet
4 Vibrating tray
5 Layer height adjustment gate
6 Clamping ring
7 Product flow
The hopper outlet protrudes into the vibrating tray and conveys the free-
flowing product in the conveying direction on the vibrating tray, where it is
transported to the outlet by the directional vibrations of the vibrating tray, the
product falls freely out of the outlet.
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Layer height adjustment As an option the hopper outlet is equipped with a layer height adjustment gate
gate (5). The distance between the layer height adjustment gate and the vibrating
tray permits to adjust the maximum height of the product layer on the
vibrating tray. The layer height adjustment gate is shifted along the hopper
outlet and fixed by means of the clamping ring (6).
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Discharge cone A product jam at the hopper outlet can be caused if the static product pressure
in the hopper is too high. Thus the free flow of the product into the vibrating
tray can be disturbed or prevented. In this case the hopper is equipped with a
discharge cone to relieve the pressure. The following illustration shows the
principle schematically.
No. Description:
1 Hopper
2 Discharge cone
3 Product flow
h Mounting height
d Gap width
The mounting height (h) of the discharge cone determines the gap width (d).
The gap width is adjusted in such a manner that it is possible to obtain an
adequate pressure relief at the hopper outlet and a safe product feeding into
the vibrating tray, if the product characteristics are complied with.
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Attention Therefore
- The combination vibrating tray/vibrating conveyor must not be
changed without approval of the manufacturer.
- The modification must only be carried out by duly qualified specialist
staff.
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Connection of the The illustration shows the assembly of an adequate connection at the inlet and
vibrating tray outlet of the vibrating tray.
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Cover of the vibrating The vibrating tray is equipped with a cover to protect it against foreign bodies
tray and to keep the surrounding clean.
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The horizontal vibrations of the oscillating magnet (2) are transmitted to the
mounted vibrating tray (1) by means of spring elements (3). There, a
directional vibration (5) is generated, that permits to transport the product on
the vibrating tray from the inlet towards the outlet.
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Construction and For weighing, the feeding device is mounted on a weighing system. The outlet
function of the device (2) is connected to the downstream connection point (4) via a
flexible connection (3). This downstream connection point permits to connect
the feeder to the on-site equipment. If an on-site equipment is connected to
the hopper inlet (e.g. for refilling), this connection also has to be done in a
flexible manner.
The weighing system permits to sense the product weight, it is then available
as electrical weighing signal for further evaluation. The product weight is
computed from the difference (actual weight – empty weight of the device).
The most important fields of application for weighing are
• the execution as loss-in-weight feeder (DDW-….)
• the monitoring of hopper filling level (MS-…)
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Weighing system types The type of the weighing system is determined by the load cell employed.
Type Load cell (7)
MDx Digital load cell (x = construction size, weighing range)
MS x Analogue load cell (x = construction size, weighing range)
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Protective equipment: The transport catch (6) connects the base plate (8) with the mounting plate (9)
Transport catch and thus relieves the weighing system (7). It protects the weighing system
against inadmissible loads and torsions during a transport and/or during
mounting/maintenance work.
Transport catches
Execution - are red metal elements, their number and shape are a
function of the construction of the device
Use - are always fastened and loosened completely
- are kept within reach of the place of use of the device
Fastening - are fastened before the start of any work on the device
or a transport of the device
Loosening - are loosened before the start of the operation
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Protective equipment: Vibration isolation mounting pads (5) are mounted below the base plate (8),
Vibration isolation they permit to absorb disturbing influences at the place of the installation.
mounting pads If this measure is not sufficient, the device has to be mounted on a mass plate.
The absorption effect of the combination of vibration isolation and heavy load
is considerably higher.
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Technical data
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Specifications for the The standard dimensioning of the device requires the following environmental
use and operating data for the field of application:
Temperature: 0°C to +40°C
Humidity: up to 85% without condensation
Medium: Air or inert gas
Wind/draught: < 0.3 m/s
Max. underpressure/overpressure: 2 mbar (20mm water column)
Product temperature: 0°C to +40°C
Voltage supply: AC 230/400V
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Nameplate The nameplate indicates the type of device, the machine number and the year
of construction of the device.
Clear marking of the device:
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Machine number
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3. Mounting
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This chapter describes the mounting work required to make the system ready
for operation.
The descriptions were formulated in a very general manner and only take into
account the standard assemblies of the manufacturer.
Subject Page
Mounting instructions 24
The place of the installation 25
Mounting work 26
Electrical mounting work 28
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Mounting instructions
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Assembly execution Make sure to observe the following points for mounting:
• Horizontal alignment
• Max. 2mm offset for the connection of the device to equipment on site
• Connection of the device to an equipment on site via a flexible connection
The following connections are allowed (direction of view is the direction of the
product flow):
• From a smaller cross-section to a larger cross-section
• Both product lines have the same cross-section.
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Transport to the place of Suitable lifting equipment (fork lift truck, crane, etc.) permits to transport the
the installation following items to the place of the installation.
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Assembly work
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Flexible connection
The connection of solid/rigid product/media lines must not cause any
disturbances of operation. Therefore the connection to equipment on site has
to be carried out in a flexible manner between a downstream connection point
on the device and a fixed point on site. The description of the connection of
the inlet/outlet shows the principle of the flexible connection.
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Installation on site
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Connection inlet/outlet
The connection of the inlet/outlet of the device to the equipment on site has
to be executed in a flexible manner. The materials for a flexible connection are
delivered with the device.
The illustration shows the construction principle of a flexible connection of two
product line ends with a step bellow:
No Meaning
1 Line 1
2 Clamping fastener 1
3 Step bellow
4 Clamping fastener 2
5 Line 2
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Connection ventilation/deaeration
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Junction boxes The connection of the electrical assemblies in junction boxes is provided in our
works in order to facilitate the connection on site. The junction boxes are
marked “-JB n” (n= 1, 2, 3,…). The following assignments apply to the junction
boxes
• The marking ”-JB 1“is reserved for the junction box of the weighing system
and is only employed, if the device is mounted on a weighing system.
• The electrical assemblies of the device are connected in the junction boxes
“-JB 2,3,4,…“. The number is adapted to demand.
• In case of a standard execution the terminals are connected according to
the determined terminal assignment of the junction boxes.
• Executions that deviate from the standard are described in the specific
wiring plans related to the order. Due to the specific execution a deviation
from the standard terminal assignments is possible. The wiring plans are a
separate document and complement the operating instructions.
Junction boxes With an ISC execution of the device the junction boxes also include the control
ISC plus electronics of the device (feeding controller, drive controller) for the operation
of the device. The ISC-components are described in the separate manual of the
ISC system.
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Cable screwings The following illustration shows the correct use of the metallic cable screwings.
The cable is isolated according to the illustration and inserted into the cable
screwing. The screening (A) is pushed over the metal cap (M), then the
screwing is tightened.
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Connection plan
CB plus
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Legend for wiring plans Markings (“ident”) used in the wiring plans:
Ident. Meaning
ISC-CM plus Feeding controller
ISC-FC plus Frequency converter
DO1 Digital output 1 (operating release)
M1 Drive motor
B1 Weight signal amplifier/load cell
B5 Speed monitoring
In ISC field bus "IN"
Out ISC field bus “OUT”
Impulse Impulse signal
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Wiring plan CBplus Markings (“ident”) used in the connection plan “CBplus“ :
legend
Components in the control cabinet/box:
Ident. Meaning
F Protection
FC Frequency converter
CB plus Feeding controller CB plus
DI Digital inputs (DI1-4)
DO Digital outputs (DO1-4)
K2,3,4 External relay in the control cabinet
GND Ground potential
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Cable colours The following abbreviations (Abbr.) for the cable colours are employed in the
wiring plans:
Abbr. Colour Abbr. Colour Abbr. Colour
BN Brown GN Green BU/WH Blue/White
BK Black GY Grey WH/BU White/Blue
BU Blue PK Rose GNYE Green/Yellow
WH White RD Red
VT Violet YE Yellow
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4. Commissioning
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This chapter describes the activities required for the commissioning of the
device.
The descriptions were formulated in a very general manner and only take into
account the standard assemblies of the manufacturer.
Subject Page
Notes on commissioning 35
Commissioning sequence 36
Product feeding 41
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Notes on commissioning
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Danger Therefore
- Employ a replacement product with non-hazardous, otherwise
identical product characteristics.
- Take all necessary security measures, if no replacement product is
available.
Product feeding During commissioning the product feeding is started for the computation of
the discharge rate of the device. An active product feeding requires
• a sufficient product quantity,
• free product flow into/out of the device,
• a receptacle for collecting the product quantity that has been fed. For this
purpose two possibilities are available
1. Feeding into downstream parts of the installation
2. Feeding into a collecting receptacle (possibly requires an additional
bypass line)
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Commissioning sequence
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Commissioning must only be carried out, if the following specifications are duly
fulfilled.
1. Has all mounting work been finished?
2. Have all supply media been connected?
3. Are all supply media available as required?
4. Sufficient product quantities are available.
5. All foreign bodies and contaminations have been removed.
6. All necessary measures to ensure the safety of operations have been
taken.
7. The device and the other equipment required are ready for operation.
8. Sample measurements can be carried out.
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Evaluation unit
A suitable evaluation unit is required for weighing. The evaluation unit is
connected to the weighing system and processes the weight signal e.g. for a
weight display.
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Loosen the transport The screwings of all red metal elements of the transport catch have to be
catch loosened completely and all parts of the transport catch have to be stored for
later use.
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The test is completed, if the weight values (1) and (4) are identical. If the two
values differ from each other make sure to find and eliminate the cause for the
missing motion. Possible causes:
• The transport catch has not been loosened completely.
• The flexible connection of the inlet/outlet is not sufficient.
• The weighing system is impeded by foreign bodies/contamination.
• The cabling of the assemblies of the device, the adjustment of the
overload protection screw or other executions of the device are
inaccurate.
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Lever factor The lever factor (LF) permits to adjust the weight display of the evaluation unit
to the actual weight loading. The adjustment runs down as follows:
1. Read the actual weight value (W0).
2. Place on a test known weight (WT).
The force shall be applied centrically on the weighing system.
3. Read the new weight value (W1).
4. Compute the difference (W1 - W0).
Check the new lever factor by a new test measurement and adjust it once
again, if required.
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Functional testing The function of the weighing system is tested by means of three load
measurements over the complete weighing range. The free motion and the
lever factor are checked with each test measurement. The following test
weights are recommended:
1. Test weight ~10% of weighing range
2. Test weight ~50% of weighing range
3. Test weight ~90% of weighing range
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Manual filling
The device is refilled manually by the operating personnel. The operator will fill
in the product into the hopper using a suitable aid. Please observe the
following points:
• Take care when filling in the product. A possibly available protective grid
impedes the product flow into the hopper.
• It is not allowed to remove the protective grid to simplify refilling (safety
equipment!).
• Terminate refilling if the hopper is approx. 80 % filled. The monitoring of
the filling level is made optically or via the evaluation unit if the system is
weighed.
Determination mode "Gauging" means that the feeding is started for a fixed duration of
“gauging” measurement and the product quantity fed during this time will be weighed.
The discharge rate [kg/h] is computed from both values – measuring time and
product quantity. “Gauging” runs down as follows:
1. Choose a suitable collecting receptacle with a known empty weight.
2. Place the collecting receptacle under the outlet.
3. Adjust the vibration amplitude (setpoint).
4. Start the feeding operation for the measuring time (e.g. 2 min.).
5. Stop the feeding operation after expiry of the measuring time.
6. Weigh the collecting receptacle and compute the product weight
(weight/empty weight).
7. Compute the discharge rate [kg/h] (here: product weight x 60/2)
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Determination type The discharge rate can also be determined in some other way, if the device is
“checking of max. operated with a feeding controller type Congrav®. A feeding controller type
output” Congrav® offers the function “checking of max. output". This function
computes and automatically memorises the discharge rate (= “feed rate”) for
different vibration amplitude values. The characteristic curve that has thus
been computed is employed by the feeding controller for the control of the
feeding operation.
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Product feeding
Preparations The commissioning is terminated by making the system ready for operation. In
order to make the system ready for operation the following preparations are
required:
• Remove auxiliary equipment (collecting receptacle etc.).
• Possibly reconnect separated connections (e.g. outlet).
• Possibly undo conversions (e.g. bypass).
• Discharge the device completely, if a replacement product has been
employed.
• If required, clean the device and the environment.
• Refill the device.
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Volumetric product In case of volumetric product feeding the feeding operation functions with a
feeding constant control of the feed drive (fixed working point). The discharge rate is
not measured and not controlled. I.e. discharge rate fluctuations e.g. caused by
a fluctuating filling degree of the feeding organ will not be detected and
corrected. Volumetric product feeding is mostly used, if the downstream
processing equipment does not require an even discharge rate or if it is not
affected by discharge rate fluctuations.
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Required conditions for For gravimetric product feeding the equipment and the control of the device
gravimetric product have to comply with the following required conditions:
feeding
• The device is a loss-in-weight feeder (“DDW - …”) and is thus equipped
with a weighing system.
• A feeding controller type Congrav® or with comparable functions has to be
employed.
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Gravimetric product During gravimetric product feeding the feeding operation is started with a
feeding determined discharge rate (product quantity /time unit). During feeding the
discharge rate will be measured and controlled via a control circuit. The control
circuit modifies the control of the feed drive and thus tries to correct
variations– e.g. due to a fluctuating filling degree of the feeding organ -
promptly.
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Gravimetric feeding As a rule, the feeding controller is used to operate the gravimetric product
sequence feeding and it runs down as follows:
1. Enter the desired discharge rate as setpoint.
2. Start the feeding operation.
The start command starts the automatic control of the feeding operation by
the feeding controller. The further sequence of control and monitoring of the
feeding operation depends on the functions of the feeding controller and is
described in its documentation.
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Adaptation of the If the device is equipped with a layer height adjustment gate, the setting of the
product layer in the tray layer height adjustment gate permits to adjust the layer height on the vibrating
tray and thus the range of the discharge rate.
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Adaptation of the As a standard feature the vibration amplitude controllers of the manufacturer
decade switch are equipped with a decade switch (step 0 - 9). The decade switch permits to
select 10 different vibration amplitude ranges (decades), in which the
characteristic curve of the vibration amplitude is shifted parallel to the higher
(increase the decade) or the smaller (decrease decade) values.
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5. Decommissioning
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The following process descriptions do not take into account influences that
occur due to product characteristics or the operation in a production plant. If
additional activities result from these influences they have to be integrated
into the corresponding processes.
Example: Product characteristics
In cases of a product that is not allowed to stay in the device, the device has to be
• discharged completely before shutdown and cleaned thoroughly after
shutdown.
• discharged by means of suitable measures after a fault shutdown, if the
elimination of the cause of the malfunction takes too long.
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6. Fault shutdowns
Immediate stop
The fault shutdown of the device may have an effect on
upstream/downstream production processes. Further measures are possibly
required.
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How to continue the Steps to be taken in order to continue the operation after a fault shutdown:
operation after a fault
1. Find the cause for the malfunction.
shutdown
2. Eliminate the cause for the malfunction.
3. Make sure that the device is ready for operation.
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Causes of malfunction
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Noise level too high Layer height adjustment gate too low
» Increase the height of the layer height adjustment gate so that
- the layer height adjustment gate does not touch the vibrating
tray.
- product jams must not occur between the layer height
adjustment gate and the vibrating tray.
Overamplified vibration amplitude
» Adjust the vibration amplitude setting.
» Check the tachometer
- Air gap = 4mm
- No contaminations in the air gap
- The electrical connection has reverse polarity
» Adjust the vibration amplitude controller.
No sufficient flexibility
» Check the connections at the inlet and outlet of the vibrating tray and
correct, if necessary.
» Impediment of the vibrating tray caused by external sources of
interference has to be eliminated.
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7. Maintenance
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This chapter describes the activities required for the maintenance of the
device. These activities include the general maintenance and the
disassembly/assembly of components that are subject to wear or require an
increased cleaning effort.
Subject Page
Information on maintenance 49
Component list 50
Care and examination 52
Description for the disassembly of individual components 53
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Information on maintenance
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Component list
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Removal of defects
Allowed possibilities for the removal of identified defects:
1. Damaged component is professionally repaired.
2. Damaged component is replaced by a new component.
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Hopper disassembly
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Be sure to observe the construction size and the execution of the hopper!
» Heavy load
» Danger of tipping over when lifting
Attention
Therefore
- employ a suitable lifting tool
- observe the centre of gravity and employ a suitable anti-tilt stand
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Hopper assembly
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This chapter describes the conditions for the storage and the disposal of the
device or of its individual components.
Subject Page
Storage of the device, of individual assemblies 56
Disposal of the device, of individual assemblies 57
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Storage conditions Storage conditions for the storage of the device/individual assemblies:
Temperature: +10°C to +40°C
Humidity: 40% to 70% No standing moisture
Medium: Air (well ventilated and free from ozone, chemicals,
solvents)
Storage room Weather-proof, enclosed building
Clean, possibly free from dust
Packaging: suitable packaging box, provide spacers under the
cover (air circulation)
Miscellaneous: For sleeves, compensators:
protected against incident light
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Before the disposal Before the disposal the following procedures have to be carried out:
1. Disconnect the device from all supply media.
2. Disassemble all connections from the device.
3. The device has to be disassembled completely.
4. The component groups have to be cleaned from product rests and
lubricant residues.
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9. Index