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Bulk Solids Feeding ● Weighing ● Discharging ● Flow Metering

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ATEX execution
Supplementary information in
the technical description
“The ATEX execution“ has to be observed!

OPERATING INSTRUCTIONS
(DDW-) DVT XX

Save this document for future reference


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Bulk Solids Feeding ● Weighing ● Discharging ● Flow Metering

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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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Protection notice (refer to DIN EN ISO 16016)


The reproduction, distribution and utilization of this document as well as the
communication of its contents to others without express authorization is
prohibited. Offenders will be held liable for the payment of damages. All rights
reserved in the event of the grant of a patent, utility model or design.
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Save this document for future reference


The document is an integral part of the device stated above. It has to be saved
completely, ready to hand and close to the device for later usage.
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2 Imprint ©Operating instructions (DDW-) DVT xx


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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

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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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4 Table of contents ©Operating instructions (DDW-) DVT xx


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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.

Content of the chapter “safety”:

Subject Page
The use of the device 6
Safety instructions 8
Residual danger 11
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The use of the device

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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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The use of the device, continuation

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Advanced demands during weighing


The weighing of the feeder requires other or additional assemblies for its
operation:
• An additional evaluation unit is required, if the weighing is employed as
filling level monitoring.
• A feeding controller type Congrav® or a system with comparable functions
is required for the operation of a loss-in-weight feeder (“DDW-…”).

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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

Adaptations to the field of application on site are listed in the order


confirmation and are part of the intended use of the device.

Modification of the field of application on site


In case of a modification of the field of application on site a new release for the
operation of the device has to be emitted by the manufacturer.

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Safety instructions

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Specifications for the type approval of the device

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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Qualification of the operating personnel

The following qualifications are required for the operating personnel:


• Trained on the device and the corresponding activities
• Authorised to carry out the required activities
• Knowledge of the regulations concerning the operator protection
• Knowledge of the actual operating conditions as far as the device and its
environment are concerned

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Dangerous contact voltages on the device

Dangerous contact voltages are required for the operation of the device. The
following specifications have to be respected for the protection of the
operating personnel:
• The device must not be operated with freely accessible terminals.
• Before 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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Safety instructions, continuation

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Disconnecting the device

In the operating instructions below use the term "disconnection".


“Disconnection” means:
Definition • Disconnect the device from all supply media.
• Protection against unauthorised reconnection.
• Discharge all kinds of energy stocks (manually or due to sufficient dwell
times)

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Discharging of storages of residual energy

Depending on the execution different storages of residual energy may be


mounted to the device. The table lists measures for the discharge of energy
storages:
Type Component (example) Measure
Electric Condenser, coil Observe the discharge time
Mechanic Spring Relieving
Pneumatic Compressed air Deaeration
Thermic Dissipator, surface Observe the cooling time

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Earthing of the device

The device must only be operated with a correct earthing. The main earth
connection point is connected to the equipotential bonding on site in a
standard-compliant manner. Earth connections between the device and
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

The sound level of the device is < 70dB (acc. to DIN45635)

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Safety instructions, continuation

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Warnings on the device

Sources of danger are marked by the standardised warning symbols on the


device. Additionally the following warning symbols are employed:

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

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This paragraph describes the possible dangers that might occur in an


admissible field of application and that might be caused by external influences,
e.g. carelessness or connections to equipment on site.
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Product jam Danger No free product flow


Effects: • Operational failures
• Damage of the device
Measures: • The free product flow into the device and out of the
device has to be guaranteed.
• Stop the operation of the device if connected
equipment on site is troubled.
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Product change Danger Wrong equipment of the device


Effects: • Operational failures
• Damage of the device
Measures: • Operation only with approved products
• Management of product/device equipment
• Conversion has to be carried out completely/with
special care
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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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Product blends Danger: With a product blend a separation of the product


ingredients may occur due to vibration.
Effects: The following problems may occur due to a change of
the mixing ratio of the product ingredients:
• Processing problems in the downstream process
• Change of the product characteristics
Measures: • Employ homogeneous product
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Residual dangers, continuation

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Insufficient Danger: No pressure compensation in the product hopper


aeration/deaeration Effects: • The product discharge (feeding) causes a negative
pressure in the hopper
• Product refilling causes an overpressure in the
hopper
• Pressure loads may cause operational failures or
damage of the device
Measures: • The device must only be operated with an
adequate aeration
• Cleaning intervals of ventilation filter units have to
be adjusted to the degree of contamination
• Stop the operation of the device if connected
equipment on site (e.g. vacuum system) is troubled
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2. The description of the device

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This chapter describes the construction and the function of the device and of
individual component groups.

Content of the chapter “device descriptions”:

Subject Page
Construction of the device 14
The component groups of the device 15
Technical data 22
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©Operating instructions (DDW-) DVT xx The description of the device 13


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Description of the design of the device

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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 component groups of the device

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The hopper
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Freely accessible product zone (open hopper)


» Foreign objects might enter the product zone and cause damage to
the device.
Caution
» Damage of the device and the environment caused by dust or other
product characteristics.
The operation of the device is only allowed, if
- hopper and hopper cover have been mounted correctly,
- existing connections have been carried out correctly and are
operationally reliable.

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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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The component groups of the device, continuation

The hopper, continuation


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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).

Setting of the layer height adjustment gate:


• The layer height adjustment gate must not touch the vibrating tray.
• Product jams must not occur between the layer height adjustment gate
and the vibrating tray.

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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.

Principle for the mounting height of the discharge cone:


"As low as necessary and as high as possible!"

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The component groups of the device, continuation

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Feeding organ and feed drive


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The “DVTxx“ (xx = construction size) is equipped with a vibrating tray as


feeding device, the vibrating tray functions with a directional vibration. The
vibration is generated by a vibrating conveyor that is mounted below the
vibrating tray.

Modifications of the vibrating tray or the vibrating conveyor


» Malfunctions or non-operability of the device

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.

This connection permits to keep the vibration of


the vibrating tray (flexible) and the surrounding
is protected against soiling (tight).
No Description
1 Step bellow inlet
2 Cover (only tray)
3 Vibrating tray (here: trough shape)
4 Vibrating conveyor
5 Step bellow outlet
6 Downstream connection point

As a rule, the step bellows are fixed with


clamping fasteners that are not shown here.

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©Operating instructions (DDW-) DVT xx The description of the device 17


Bulk Solids Feeding ● Weighing ● Discharging ● Flow Metering

The component groups of the device, continuation

Feeding organ and feed drive, continuation


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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.

The illustration shows the design of a


cover.
No Description
1 Cover
2 Clamping fastener
3 Tray
4 Positioning pins
Possible modification:
Screw connection instead of clamping
fasteners

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Vibrating conveyor The illustration shows a vibrating


conveyor with a mounted vibrating
tray.
No Description
1 Vibrating tray
2 Vibrating solenoid
3 Spring elements
4 Tachometer
5 Directional vibration

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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18 The description of the device ©Operating instructions (DDW-) DVT xx


Bulk Solids Feeding ● Weighing ● Discharging ● Flow Metering

The component groups of the device, continuation

Feeding organ and feed drive, continuation


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The tachometer (4) permits to measure the


vibration amplitude of the vibrating tray. It
consists of a coil (A) and a permanent
magnet (B) that are mounted with a
distance of d = 4mm.
A step bellow protects the air gap against
soiling.
The vibrations induce an alternating
voltage in the coil, the alternating voltage is
evaluated with suitable electrical
equipment.

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©Operating instructions (DDW-) DVT xx The description of the device 19


Bulk Solids Feeding ● Weighing ● Discharging ● Flow Metering

The component groups of the device, continuation

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The weighing of the device


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Device with weighing


system

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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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20 The description of the device ©Operating instructions (DDW-) DVT xx


Bulk Solids Feeding ● Weighing ● Discharging ● Flow Metering

The component groups of the device, continuation

The weighing of the device, continuation


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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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Special execution of the transport catch


The illustration shows the special execution of the transport catch (rotatable
hook with star-grip screw). This execution is employed if required (e.g. quick
cleaning).

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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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©Operating instructions (DDW-) DVT xx The description of the device 21


Bulk Solids Feeding ● Weighing ● Discharging ● Flow Metering

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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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Feeding device Data for the execution of the device:


Sound level: < 70dB(A)
Feeding unit: Vibrating tray
Drive: Vibrating conveyor
Drive controller: Vibration amplitude controller
Vibration amplitude sensing: Tachometer
Air gap tachometer: d = 4 mm
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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

22 The description of the device ©Operating instructions (DDW-) DVT xx


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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.

Content of the chapter “mounting”:

Subject Page
Mounting instructions 24
The place of the installation 25
Mounting work 26
Electrical mounting work 28
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©Operating instructions (DDW-) DVT xx Mounting 23


Bulk Solids Feeding ● Weighing ● Discharging ● Flow Metering

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Mounting instructions

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Connection work with supply media being active


» Danger caused by dangerous life voltage
» Danger caused by uncontrolled actions during the connection of the
Attention
supply medium
Therefore
- Connections shall only be made to connection points that are
disconnected from the corresponding supply medium.

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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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Interruption of To be observed in case of an interruption of mounting:


mounting
• Protect the device against foreign bodies.
• Mark that the device is partly mounted.
• Protect the device against an unauthorised commissioning.

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Mounting tools The following auxiliaries are required for mounting:


Work equipment Auxiliary equipment
General locksmith’s tools Cover tarpaulin
General electrician's tools Lining sheets
Level Cleaning rag
Suitable detergents

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24 Mounting ©Operating instructions (DDW-) DVT xx


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The place of the installation

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Characteristics The place of the installation has the following characteristics:


• corresponds to the valid standards
• stable, dry, free from vibrations and sufficiently suitable to take weight
• protected against weather conditions
• permissible ambient temperature
• free from oils, fats, gases, vapours etc.
• no explosive atmosphere

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Equipment The place of the installation has to be equipped as follows:


• sufficient illumination
• sufficiently dimensioned for all necessary workflow paths
• possibilities for connecting the required supply media

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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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©Operating instructions (DDW-) DVT xx Mounting 25


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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

Assembly of the device at the place of the installation:


1. Transport the device to the place of the installation.
2. Align the device at the place of the installation.
3. Align the device in horizontal position.
4. Screw the device to the floor construction.

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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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26 Mounting ©Operating instructions (DDW-) DVT xx


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Assembly work, continuation

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1. Slide the step bellow over line1.


2. Fix the step bellow by means of fastening strap1.
3. Slide fastening strap2 over the step bellow.
4. Slide the step bellow over line2.
5. Fix the step bellow by means of fastening strap2.
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Connection ventilation/deaeration

As standard, a filter bag is supplied for the


ventilation/deaeration of the device. The filter bag is
pulled over the vent pipe and fixed by means of a
clamping fastener. Due to its design the filter bag can
stand upright without further auxiliaries. The
venting/deaeration is made via the fabric surface of
the filter bag.

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On-site vacuum system


As an alternative the aeration/deaeration can be provided by a vacuum system
on site. The connection of the vacuum system to the vent pipe is made in a
flexible manner (e.g. sleeve) or without contact (e.g. suction funnel).

The suction must not interfere with the feeding operation!


If the suction is too strong it might cause an operational failure. Therefore, the
following has to be observed for the adjustment of the suction:
As strong as necessary and as light as possible!

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©Operating instructions (DDW-) DVT xx Mounting 27


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Electrical mounting work

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Voltages that are hazardous upon contact


» Danger caused by dangerous life voltages
» Danger caused by improper execution of the work
Attention
Therefore
- Employ trained electrical personnel.
- After the connection work the junction boxes have to be closed
correctly.

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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.

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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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28 Mounting ©Operating instructions (DDW-) DVT xx


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Electrical mounting work, continuation

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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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Establishment of an An interlocking chain is an electrical cabling,


interlocking chain
• that takes into account additional start conditions for the start enable of
the feeding operation (e.g. closed circuit breaker or operational readiness
of the connected equipment).
• that stops the feeding operation immediately, if one operating condition is
not complied with (e.g. tripping of a circuit breaker).

The implementation of an interlocking chain is a function of the hardware used


on site (programmable logic controller, relay etc.) and has to comply with the
applicable regulations concerning the safety of man and machine. When using
a feeding controller type Congrav® the feeding is operated via the feeding
controller. Depending on the hardware execution of the Congrav® different
possibilities are available for the establishment of an interlocking chain.

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©Operating instructions (DDW-) DVT xx Mounting 29


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Electrical mounting work, continuation

Pos : 161 /Dosi ergeräte/Montage/E-Montagearbeiten - Kopfz eile Anschl uss plan ISC pl us @ 1\mod_1337581312955_41.docm @ 48601 @ @ 1

Pos : 162 /Steuer ung en/ISC pl us - Sys tem/Montage/Elektr. Anschl uss - Ansc hlus spl an CM + VC @ 6\mod_1373528976023_41.docm @ 102084 @ @ 1

Wiring plan plan


Connection The connection plan shows the connections for the ISC-VC plus and the ISC-CM
ISC plus plus, please note that the on-site connections of the load cell and the speed
monitoring to the ISC-CM plus are not illustrated.

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30 Mounting ©Operating instructions (DDW-) DVT xx


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Electrical mounting work, continuation

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Connection plan
CB plus

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Electrical mounting work, continuation

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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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Components of the feeding device:


Marking Meaning
JB1 Junction box: connection of the load cell
JB2 Junction box: connection of assemblies, supply
M1 Drive motor of the feeding device
B2 Load cell
B5 Speed monitoring
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Components for the operation:


Marking Meaning
OP1 T Operating unit Congrav® OP1 T
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Electrical mounting work, continuation

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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.

Content of the chapter “commissioning”:

Subject Page
Notes on commissioning 35
Commissioning sequence 36
Product feeding 41
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34 Commissioning ©Operating instructions (DDW-) DVT xx


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Notes on commissioning

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Product with hazardous characteristics


» Danger due to leakages or malfunctions of the device

Danger Therefore
- Employ a replacement product with non-hazardous, otherwise
identical product characteristics.
- Take all necessary security measures, if no replacement product is
available.

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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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Interruption of Commissioning is interrupted, if


commissioning
• there are problems during commissioning.
• it is required to correct the assembly of the device or other connected
equipment.

Corrections of the assembly


In case of corrections of the assembly make sure to observe the specifications
and notes on the mounting of the device.
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Commissioning sequence

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Step 1: Tests on the device


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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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Step 2: Connection of supply media


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1. Connect all supply media.


2. Warm up of approx. 30 min.
3. Continue the commissioning.

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Step 3: Verification and adjustment of the weighing


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Observe the execution!


Leave out this step your feeder is not equipped with a weighing system.

Known control weights


For testing the weighing system you need three known test weights (ideally,
10%, 50% and 90% of the weighing range of the load cell).

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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36 Commissioning ©Operating instructions (DDW-) DVT xx


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Commissioning sequence, continuation

Step 3: Verification and adjustment of the weighing,


continuation
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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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Free motion Check the free motion of the weighing system:


1. Read the weight loading of the weighing system.
2. Place an additional weight on the weighing system.
3. Take off the additional weight.
4. Read the weight loading of the weighing system.

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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©Operating instructions (DDW-) DVT xx Commissioning 37


Bulk Solids Feeding ● Weighing ● Discharging ● Flow Metering

Commissioning sequence, continuation

Step 3: Verification and adjustment of the weighing,


continuation
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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).

The lever factor has to be corrected, if (W1 - W0)  (WT):


5. Read the actual lever factor (LFact)
6. Compute the new lever factor (LFnew).
LFnew = LFact x (WT / (W1 - W0))
7. Enter and memorise the new lever factor.

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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Commissioning sequence, continuation

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Step 4: Determination of the discharge rate


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Refilling of the hopper Automatic refilling


The automatic refilling requires a feeding controller that permits to control the
product supply and to monitor the hopper filling level. The operating
personnel activates the refilling on the feeding controller which will then
enable the product supply until the hopper filling level has reached the
determined maximum filling level.

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.

Maximum filling level


The indication “80%“ is an indicatory value. The actual fixing of the maximum
filling level has to take into account the corresponding product characteristics
(e.g. bulk density) and has to be adjusted to the operating conditions.
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©Operating instructions (DDW-) DVT xx Commissioning 39


Bulk Solids Feeding ● Weighing ● Discharging ● Flow Metering

Commissioning sequence, continuation

Step 4: Determination of the discharge rate, continuation


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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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Determine the characteristic curve


“Gauging” permits to find the discharge rate for the corresponding vibration
amplitude. If different discharge rates are required, a characteristic curve is
necessary (vibration amplitude/discharge rate). For the determination of the
characteristic curve we recommend to perform measurements for the
following vibration amplitudes: “10%”, “50%” and “90%”. If required, the
characteristic curve can be improved by integrating further measurement
points.

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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.

Observe the software description


The “checking of max. output” is described in the software description of the
feeding controller.

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Product feeding

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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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Volumetric feeding As a rule, volumetric product feeding runs down as follows:


sequence
1. Adjust the working point (e.g. potentiometer = 50%)2. Start the
feeding operation.
3. If required, adjust the discharge rate by a corresponding modification of
the default value (here: potentiometer). 4. Stop the feeding operation, if
the required product quantity has been fed out.
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Product feeding, continuation

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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.

Be sure to observe the documentation of the feeding controller!


A safe feeding operation is only possible if the software parameters of the
feeding controller are permissible and adjusted to the operating conditions. An
expert parameterisation according to the documentation is absolutely required
for a use of the device according to the intended purpose.

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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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Product feeding, continuation

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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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Step 5: Adaptation of the discharge rate


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The discharge rate is changed by a modification of the vibration amplitude of


the vibrating tray within the allowed working range. If this measure does not
permit to achieve the desired discharge rate, it is required to modify the
device. Please find below the measures that allow a permissible modification
of the device.

Usage not according to the intended purpose


All other modifications to the execution and the electrical assemblies of the
device are not allowed without approval of the manufacturer and are thus not
according to the intended purpose.

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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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Brief disconnection The device is stopped for operational reasons.


Activation: Stop command on the operating unit
How to continue Start command on the operating unit
the operation

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Maintenance, Switch off the device for maintenance work.


repair
Activation: 1. Discharge the device.
2. Stop the operation.
3. Disconnect the device (see page 9)
4. Carry out the necessary work.
How to continue Commissioning has to be carried out
the operation

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Decommissioning Disconnect the device for storage or disposal.


Activation: 1. Switch off the device as described in “maintenance,
repair”.
2. Disconnect the device from all supply media,
connections, etc.
3. Disassemble the device.
4. As described in “storage and disposal”
How to continue 1. Reassemble the device.
the operation 2. Mount the device.
3. Commission the device.
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6. Fault shutdowns

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Fault shutdowns protect the device and the environment


Fault shutdowns occur in operational situations that do not permit to continue
the operation of the device. They are either triggered manually by the
operating personnel (“emergency stop”) or automatically by a monitoring
function or an interlocking chain.

Immediate stop
The fault shutdown of the device may have an effect on
upstream/downstream production processes. Further measures are possibly
required.

Operational readiness requires the elimination of causes


Before renewed commissioning be sure to find and eliminate the reason for
the fault shutdown.

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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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Discharge Voltage supply is missing


does not start » Connect the voltage supply.
» Replace defective fuses if required.
Execution of connection lines is incorrect
» Eliminate errors in the connections.
» Eliminate interruptions/damage.
» Replace wrong cable types.
Drive components damaged (motor, drive controller etc.)
» Replace damaged components.

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Uneven vibration Missing vibration


amplitude control » Damaged vibration elements on the vibrating conveyor have to be
exchanged.
» Rigid connections at the inlet and/or outlet have to be eliminated.
- Incorrect assembly of the flexible connection has to be corrected.
- Be sure to employ materials with sufficient flexibility for the
connections.
Incorrect vibration amplitude measurement (tachometer)
» Check the air gap between the coil and the permanent magnet.
- The distance is d = 4mm.
- Remove dirt particles from the air gap.
- An incorrect fit of the flexible cover has to be corrected.
- Exchange a damaged cover.
» In case of reverse poling of the connections, the connections have to
be swapped.
Incorrect controller configuration on the feeding controller
» Correct the controller settings.

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Discharge rate Vibration amplitude too small


too low » Increase the setpoint for the vibration amplitude.
» Increase the vibration amplitude range (decade switch).
Changed product characteristics
» Adjust the vibration amplitude setting.
» Adjust operating parameters.

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Causes of malfunction, continuation

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No product feeding Vibrating tray does not vibrate


» Check the function of the vibrating conveyor, exchange the damaged
vibrating conveyor.
» Check the vibration of the vibrating tray (vibration elements, flexible
connections) and reproduce the vibration, if required.
Product jam in the product supply
» Eliminate foreign bodies that impede the product flow.
» Correct the height of the layer height adjustment gate.
» Reduce the static product pressure from the hopper outlet (discharge
cone).
» Product is not suitable for feeding.
Product moves not enough on the vibrating tray
» Increase the vibration amplitude.
» Increase the vibration amplitude range (decade switch).
» Check the vibration of the vibrating tray (vibration elements, flexible
connections) and reproduce the vibration, if required.

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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.

Content of the chapter “maintenance”:

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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48 Maintenance ©Operating instructions (DDW-) DVT xx


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Information on maintenance

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Before the disconnection – discharge the device


For carrying out the disassembly work of components in contact with the
product, the feeder has to be discharged by means of a “cleaning operation”
Disconnection before the start of work. The "cleaning operation" permits to discharge the
from the mains feeding device as far as possible by means of the feeding organ.
Disconnect the device
Before the start of any work on the device or on individual components of the
device it has to be disconnected from all supply media and stocks of possibly
present residual energy have to be discharged.

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Residual product in/on the device


» During the disassembly of the device/of individual assemblies the
operating personnel might come into contact with the product.
Caution
» Reactions with the cleaning agent might occur.
Therefore
- Be sure to observe the indications of the product data sheet.
- Possibly necessary measures before the start of work
- Safety measures
- Measures for correct disposal

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Damp cleaning Be sure to observe for damp cleaning:


• You must only employ detergents authorised by the manufacturer and not
detergents that contain solvents that are combustible, aggressive or
chlorinated.
• No damp cleaning of bearings and electrical components.
• In case of damp cleaning be sure to protect bearings and electrical
components from moisture.
• After the cleaning the device has to be dried thoroughly, standing
moisture has to be removed and components that have possibly been
degreased have to be re-greased.

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Component list

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50 Maintenance ©Operating instructions (DDW-) DVT xx


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Component list, continuation

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Component list No Component


1 Hopper cover
a Vent pipe b Inlet pipe
2 Clamping ring
3 Hopper
4 O-ring sealing (layer height adjustment gate)
5 Clamping ring (layer height adjustment gate)
6 Layer height adjustment gate (optional)
7 Step bellow (connection hopper/vibrating tray)
8 Hopper fastening (here: star-grip screws)
9 Mounting frame for the hopper
10 Mounting plate
11 Vibration isolation mounting pads
12 Transport catch (here: quick-release execution)
13 Vertical outlet
14 Step bellow (connection to the outlet of the vibrating tray)
15 Vibrating conveyor
16 Tachometer
a Coil b Step bellow c Permanent magnet
17 Fastening vibrating tray (here: star-grip screw)
18 Mounting bracket vibrating tray + coil (tachometer)
19 Vibrating tray
20 Cover of the vibrating tray (2 pieces)
21 Attachment rubber for the cover
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Care and examination

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Intervals Marking of the intervals:


W weekly 2W fortnightly
M monthly 3M three-monthly
Y annually H biannually

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Care Care works (T = time interval):


T Activity
W Clean the filter bag/the deaeration equipment (if existing)
2W Clean the device.
- Dust and loose contaminations have to be removed by means of
an industrial vacuum cleaner.
- Solid impurities have to be removed with a (damp) cloth.
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Examination Examination of the device (T = time interval)


T Component Examination
W Flexible connections Damages
W Fastenings Tight seat
2W Mobile parts Functionality
2W Sealings Tightness
2W Locks Attraction force, tight seat
M Electrical connections Tight seat
Electric cables Damages

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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Assembly/disassembly of individual components

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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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Procedure for the disassembly of the


hopper:
1. The device has to be discharged
completely and it has to be
disconnected from the mains.
2. Undo the step bellow at the
hopper outlet.
3. If available: loosen the
connections of the hopper cover.
4. Loosen the fastening of the
hopper.
5. Lift the hopper, place it down at a
suitable place.

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Hopper assembly
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Procedure for the disassembly of the hopper:


1. Lift the hopper and transport it to the device.
2. Align the hopper (outlet chute points in the direction of the vibrating tray)
and place the hopper on the mounting frame.
3. Fasten the hopper.
4. If available: check the position of the layer height adjustment gate and
correct it, if necessary.
5. Mount the step bellow at the hopper outlet and at the inlet of the
vibrating tray.
6. If available: make the connections at the hopper cover (venting, inlet).
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Assembly/disassembly of individual components, continuation

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Disassembly of vibrating tray


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Procedure for the disassembly of the vibrating tray:


1. Disassemble the hopper.
2. Loosen the connection at the
outlet of the vibrating tray.
3. Take off the fastening of the
cover and the covers (2 pieces).

4. Loosen the fastening of the vibrating tray.


5. Take the vibrating tray from the mounting frame.

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Assembly of vibrating tray


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Procedure for the assembly of the vibrating tray:


1. Insert the vibrating tray into the mounting frame.
2. Fasten the vibrating tray.
3. Mount the cover of the vibrating tray.
4. Mount the flexible connection at the outlet of the vibrating tray.
5. Mount the hopper.
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8. Storage and disposal

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This chapter describes the conditions for the storage and the disposal of the
device or of its individual components.

Content of the chapter “storage and disposal”:

Subject Page
Storage of the device, of individual assemblies 56
Disposal of the device, of individual assemblies 57
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Storage of the device, of individual components

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Execution of the device Execution of the device for storage:


• The device is completely discharged and thoroughly cleaned.
• The protective coating of the painted parts is okay or has been
renewed/touched up.
• The following components have to be disassembled:
- In general all sleeves and compensators have to be disassembled and
have to be stored together with the device under appropriate storage
conditions.
- Components with special storage conditions

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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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Disposal of the device, of individual components

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Residual product in/on the device


» During the disassembly of the device/of individual assemblies the
operating personnel might come into contact with the product.
Caution
» Reactions with the cleaning agent might occur.
Therefore
- Be sure to observe the indications of the product data sheet.
- Possibly necessary measures before the start of work
- Safety measures
- Measures for correct disposal

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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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Disposal The individual components of the device have to be disposed separately.


Component Disposal
Drive, gear see manufacturer's indications
Electrical cables Cable scrap
Sleeves, compensator etc. PU, EPDM, silicone or similar
Hopper, pipes, sheets Metal scrap
Insulations according to material specifications
boards Special waste
accumulators, batteries Special waste
Plastic Disposal of plastics
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9. Index

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Assembly, execution 24 Product, characteristics 44


Disconnection, warning symbol 10 Tachometer 18, 22, 51
Drive 32 Use in accordance with the
Environment, data 6, 22 intended purpose 6
Intended purpose 8, 42, 43 Vibrating conveyor 14, 17, 18, 22,
Mounting, tools 24 51
Operating personnel, qualification Vibrating tray 14, 15, 17, 18, 22,
8 47, 51
Operation, allowed 15 Vibration amplitude 22, 46
Product, appropriate 6 Wiring plan, CBplus 32
=== Ende der Liste für T extmar ke Inhalt ===

58 Index ©Operating instructions (DDW-) DVT xx

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