OPERATING AND MAINTENANCE INSTRUCTIONS

SWB 300 / 600

Read this document prior to op-

erating the device.
This document contains all safe-
ty and warning notes.
Original operating instructions

0990014601-EN Rev. 4.0.0

 Coperion K-Tron Schweiz GmbH Tel. 0041 (0) 62 / 885 71 71
Lenzhardweg 43/45 Fax 0041 (0) 62 / 885 71 80
CH-5702 Niederlenz

Coperion K-Tron Pitman, Inc. Tel. 001 (0) 856 / 589 0500
590 Woodbury Glassboro Road Fax 001 (0) 856 / 589 81 13
Sewell, New Jersey 08080 USA

Coperion K-Tron Salina Tel. 001 (0) 785 / 825 16 11

606 N. Front St. Fax 001 (0) 785 / 825 8759
Salina, KS 67402-0017

Web: www.coperion.com

Before you call...

 Do you have alarm displays? Are you able to eliminate the causes?
 Have you modified part of the system, product or operating mode?
 Have you tried to remedy the fault in accordance with the operating
instructions?
 Note the project or order number You will find these on the machine
or in the system manual.
• Example: 0403214

Using the manual:

 This arrow identifies an individual action.
1. Numbers identify a sequence of actions which have to be executed
step-by-step.
▲ This symbol identifies a general safety note.

Reference to another manual.

Important information.

This symbol indicates that tools are required for the following task.

Specifies where information or a situation must be checked.

If an error or ommission is found, please contact:

documentation@coperionktron.com

Doc. No.: 0990014601-EN Coperion K-Tron assumes no responsibility for damages resulting from misuse of any equipment or neg-
ligence on the part of operating personnel. Further, you may kindly refer to the purchase order, confirma-
Date: 2020/Jun/02 tion or other document that contains the express Coperion K-Tron warranty disclaimer limiting or excluding
certain warranties with respect to the company's equipment. Except as otherwise expressly provided by
Coperion K-Tron in any such document, COPERION K-Tron MAKES NO WARRANTY OF MERCHANT-
Original: 0990014601-EN ABILITY OR FITNESS FOR A PARTICULAR PURPOSE, NOR ANY OTHER WARRANTY, EXPRESS
OR IMPLIED, WITH RESPECT TO THE EQUIPMENT.
 Contents

1 General information ................................................................................................................... 7

1.1 Target groups .............................................................................................................................. 7
1.2 Warnings ...................................................................................................................................... 7
1.3 Symbols ....................................................................................................................................... 8
1.3.1 General ........................................................................................................................................ 8
1.3.2 Warning sign ................................................................................................................................ 9
1.3.3 Directional signs ........................................................................................................................ 10

2 Safety ........................................................................................................................................ 11
2.1 Proper use ................................................................................................................................. 11
2.2 Special risks ............................................................................................................................... 12
2.2.1 Combination with prefeeder ....................................................................................................... 12
2.3 General safety instructions ........................................................................................................ 13
2.3.1 Responsibilities of the operating company ................................................................................ 13
2.3.2 Organizational measures ........................................................................................................... 13
2.3.3 Safety-conscious operation ....................................................................................................... 13
2.3.4 Safety devices ........................................................................................................................... 14
2.3.5 Electrical Hazard ........................................................................................................................ 14
2.3.6 Additional equipment ................................................................................................................. 14
2.3.7 Customer service and repairs .................................................................................................... 14
2.3.8 Shut-down procedure ................................................................................................................ 15

3 Assembly and function ........................................................................................................... 16

3.1 Application ................................................................................................................................. 16
3.2 Function ..................................................................................................................................... 16
3.3 Structure .................................................................................................................................... 17
3.4 Safety devices and warnings ..................................................................................................... 18
3.4.1 Safety devices ........................................................................................................................... 18
3.4.2 Warnings .................................................................................................................................... 19

4 Technical Data ......................................................................................................................... 20

5 Transport, storage and disposal ............................................................................................ 22

5.1 Transport ................................................................................................................................... 22
5.2 Unpacking .................................................................................................................................. 22
5.3 Lifting ......................................................................................................................................... 23
5.4 Storage ...................................................................................................................................... 24
5.4.1 Preliminary work after longer storage ........................................................................................ 24
5.5 Disposal ..................................................................................................................................... 24

6 Installation ................................................................................................................................ 25
6.1 Prepare the place of installation ................................................................................................ 25
6.2 Instructions for operation with prefeeder ................................................................................... 25

Docu. No.: 0990014601-EN Rev. 4.0.0 Page 3

6.3 Mounting the feeder .................................................................................................................. 26
6.4 Mounting the prefeeder .............................................................................................................. 27
6.5 Setting up the weigh belt feeder ............................................................................................... 28
6.6 Belt scraper ................................................................................................................................ 29
6.7 Adjusting the side skirts ............................................................................................................. 30
6.8 Electrical connection .................................................................................................................. 31
6.8.1 Combination with prefeeder ....................................................................................................... 31

7 Start-up ..................................................................................................................................... 32
7.1 Belt feeder adjustment ............................................................................................................... 34
7.1.1 Setting the inlet gate height ....................................................................................................... 34
7.1.2 Sealing Inlet ............................................................................................................................... 34
7.1.3 Adjusting the nominal belt speed ............................................................................................... 35
7.2 Setting belt loading with a prefeeder ......................................................................................... 35

8 Operation ................................................................................................................................. 36
8.1 Switching on/off ......................................................................................................................... 37

9 Inspection and cleaning .......................................................................................................... 38

9.1 Switching off for cleaning ........................................................................................................... 39
9.2 Cleaning advises ....................................................................................................................... 39
9.3 Prepare cleaning ....................................................................................................................... 39
9.4 Cleaning without parts removal ................................................................................................. 39
9.5 Cleaning with parts removal ...................................................................................................... 40
9.6 After cleaning ............................................................................................................................. 40
9.7 Prefeeder cleaning ..................................................................................................................... 41

10 Maintenance ............................................................................................................................ 42
10.1 Switching off for maintenance .................................................................................................... 43
10.2 Maintenance intervals ................................................................................................................ 43
10.3 Preparation maintenance ........................................................................................................... 44
10.4 Belt tension adjustment and pre-seal check .............................................................................. 44
10.5 Disassembly and assembly of supporting frame ....................................................................... 45
10.5.1 Extracting the supporting frame for cleaning ............................................................................ 45
10.5.2 Removing the supporting frame for maintenance ...................................................................... 45
10.5.3 Installing the supporting frame ................................................................................................. 46
10.6 Changing belt ............................................................................................................................ 47
10.6.1 Removing the belt ...................................................................................................................... 47
10.6.2 Pre-adjustments for new belt .................................................................................................... 48
10.6.3 Installation of the conveyor belt ................................................................................................. 48
10.6.4 Completing conveyor belt installation ....................................................................................... 48
10.6.5 Setting belt tracking ................................................................................................................... 49
10.7 Adjusting the belt tension .......................................................................................................... 50
10.8 Replacing the weigh deck ......................................................................................................... 51

Page 4 Docu. No.: 0990014601-EN Rev. 4.0.0

10.8.1 Setting the weighing bar ........................................................................................................... 51
10.8.2 Aligning the weigh deck ............................................................................................................. 52
10.8.3 Setting the overload stop of the weigh deck ........................................................................... 53

11 Troubleshooting ...................................................................................................................... 54
11.1 Troubleshooting table ................................................................................................................ 55

Docu. No.: 0990014601-EN Rev. 4.0.0 Page 5

Page 6 Docu. No.: 0990014601-EN Rev. 4.0.0
 General information 1
Target groups 1.1

1 General information

1.1 Target groups

Target group Definition

Operator Instructed person
Technician Qualified technician with a special knowledge of the standards.
Electrician Qualified electrician with a special knowledge of the standards.

1.2 Warnings

Warning Risk stage Consequences of non-

adherence
Directly hazardous situation Death, serious injury
DANGER
Potentially risky situation Death, serious injury

Potentially risky situation Minor injuries

Potentially risky situation Property damage

Docu-No.: 0990014601-EN Rev. 4.0.0 Page 7

1 General information
1.3 Symbols

1.3 Symbols

1.3.1 General

Symbol Meaning
All instructions after this symbol must be adhered to.

▲ This symbol indicates a general safety note

 This arrow is used for indicating a single action.
1. , 2. The numbers indicate a sequence of activities.
Reference to another manual.

Important information.

This symbol indicates that a tool will be required for the following
task.

This symbol indicates that data or conditions must be checked.

Page 8 Docu-No.: 0990014601-EN Rev. 4.0.0

 General information 1
Symbols 1.3

1.3.2 Warning sign

Symbol Meaning
Electrical hazard
This sign indicates an electrical hazard.

Crushing hazard
Do not place hands or other body parts into moving parts or ma-
chine.

Hot surface
Warning regarding hot surface. Danger for burning.

Docu-No.: 0990014601-EN Rev. 4.0.0 Page 9

1 General information
1.3 Symbols

1.3.3 Directional signs

Symbol Meaning
Ground icon
Indicates that a ground/PE connection is required.

Power icon
Power off and disconnect air supply before working on the machine.

Disconnect the power

Disconnect the machine from the power.

Disconnect the compressed air source

Disconnect the machine from the compressed air source.

Entanglement hazard into rotating parts

Disconnect the device before removing of safety devices.

Page 10 Docu-No.: 0990014601-EN Rev. 4.0.0

 Safety 2
Proper use 2.1

2 Safety

2.1 Proper use

The equipment is used for continuous feeding of bulk materials.

▲ Use only as stationary equipment.
▲ Only operate in conjunction with the appropriate control and drive
equipment from Coperion K-Tron.
▲ Only operate according the technical data specified.
▲ When processing dangerous bulk material, the safety instructions
for handling this material must be adhered to as well.
▲ Any modifications and changes on safety devices are prohibited.
▲ Never use for purposes not intended by the manufacturer.
▲ Never transport bulk materials that could cause a chemical reac-
tion with the materials of the equipment.
▲ Operate only in an atmospheric environment.
▲ Do not feed hot bulk material (> 50°C / 122°F).

Docu-No.: 0990014601-EN Rev. 4.0.0 Page 11

2 Safety
2.2 Special risks

2.2 Special risks

DANGER
Mortal danger as a result of live wires
▲ The device may only be connected by qualified electricians.

2.2.1 Combination with prefeeder

Operation with a prefeeder creates additional hazards.

• Observe the additional information in the declaration of

incorporation.
• Observe the operating instructions of the prefeeder.

Page 12 Docu-No.: 0990014601-EN Rev. 4.0.0

 Safety 2
General safety instructions 2.3

2.3 General safety instructions

2.3.1 Responsibilities of the operating company

▲ Ensure that only qualified and trained personnel work with the de-
vice.
▲ Establish personnel responsibilities for operation and mainte-
nance.
▲ Ensure that the personnel have read and understood the operating
instructions for all the installed components, particularly these
safety notes.
▲ The operating company must have damaged or missing compo-
nents replaced immediately.
▲ The intake of foreign materials (metal parts, stones) must be pre-
vented by the operating company.
▲ The operating company is responsible for compliance with legally
prescribed accident prevention and safety regulations.

2.3.2 Organizational measures

▲ Always keep the operating instructions within easy reach of the de-
vice. Ensure that they are always complete and legible.
▲ Observe the safety notes for the connected devices.
▲ In addition to the operating instructions, always comply with gen-
erally prescribed safety regulations governing accident prevention
and environmental safety.

2.3.3 Safety-conscious operation

▲ Read the operating instructions, in particular these safety notes,

and follow these instructions.
▲ Ensure that only authorised personnel enter the operating and
danger area of the device.
▲ Any changes (including changes in the operational behavior)
which affect safety must be reported immediately to the responsi-
ble member of the staff.
▲ Always keep safety in mind while working.
▲ Before any intervention switch off the main switch and separate
the compressed air supply.

Docu-No.: 0990014601-EN Rev. 4.0.0 Page 13

2 Safety
2.3 General safety instructions

2.3.4 Safety devices

▲ Operating the device without safety devices entails risk:

– is dangerous for the health and life of the operator or third
persons
– of damage to the device or of other material assets
▲ Never alter mechanical safety devices and electrical control of the
safety devices. High risk of accident!
▲ Only operate if all the safety devices are present and functional.
▲ Check the function of the safety devices on a daily basis.
▲ Do not open or remove any lids and covers during operation.
▲ Do not change the finger protection plate on the rolls. Fingers may
otherwise become trapped.
▲ Belt scale never operate without belt when the belt scraper is in-
stalled.
▲ Do not change the electrical safety devices, e.g. fuses. High risk
of accident!
▲ Only use the specified fuse types when replacing fuses.
▲ Replace damaged cable joints and connections immediately.

2.3.5 Electrical Hazard

▲ Only qualified electricians may work on the electrical equipment.

▲ Protect electrical parts against humidity.

2.3.6 Additional equipment

▲ Modifications of the device are prohibited.

▲ The operating company is responsible for complying with all safety
regulations related to interoperation with any additional equip-
ment.

2.3.7 Customer service and repairs

Customer service address is found in the project manual.

▲ Repairs of the feeder may only be performed

– by the responsible Coperion K-Tron customer service.
– - by specialized staff trained by Coperion K-Tron.
▲ Only use original Coperion K-Tron parts.

Page 14 Docu-No.: 0990014601-EN Rev. 4.0.0

 Safety 2
General safety instructions 2.3

2.3.8 Shut-down procedure

▲ The operating company is responsible for the proper removal of

the equipment from service.

Docu-No.: 0990014601-EN Rev. 4.0.0 Page 15

3 Assembly and function
3.1 Application

3 Assembly and function

3.1 Application
The Weight Belt Feeder is used for continuous controlled gravimetric
or volumetric feeding of bulk materials.

3.2 Function
The weigh belt feeder is part of a feeding system. This system
consists of the feeder controller, the motor control unit and the weigh
belt feeder.
The feed material is transported from the storage bin onto the belt and
conveyed while in measurement to the process. The Load cell in the
weigh deck measures the belt load (weight of product per length of
belt) and sends this value to the controller. The required feed rate
(actual value) results from the multiplication of belt load and belt
speed. Motor speed controls the bulk material flow.

Option
• A second weigh deck is used for continuous belt taring and can
compensate for the build-up of material on the conveyor belt.
• A prefeeder (screw or vibratory feeder), located at the material inlet
on the weigh-belt feeder, conveys the material on to the belt.
• Connection for Dust exhausting
• Inlet shutoff gate
• Flexible connections
• Sampling valve
• Vibrating inlet
• Inlet hoppers

Page 16 Docu-No.: 0990014601-EN Rev. 4.0.0

 Assembly and function 3
Structure 3.3

3.3 Structure
(1) Housing
(2) Weigh deck 1 2 3
Optional: Second weigh
deck
(3) Inlet
(4) Supporting frame
(5) Outlet

4
Fig. 3.1 Structure of the SWB weigh belt feeder

Docu-No.: 0990014601-EN Rev. 4.0.0 Page 17

3 Assembly and function
3.4 Safety devices and warnings

3.4 Safety devices and warnings

3.4.1 Safety devices

• Following devices are compellingly defined as safety
devices
• Finger protection plate (1)
• Dust protection sleeve between SWB and prefeeder (3)

Fig. 3.2 Safety devices

Page 18 Docu-No.: 0990014601-EN Rev. 4.0.0

 Assembly and function 3
Safety devices and warnings 3.4

3.4.2 Warnings

The warning shown in is applied to the following positions

at the feeder:
• at the supporting frame Fig. 3.2/2

The warning shown in is applied to the following positions

at the feeder:
• at the supporting frame Fig. 3.2/2

Docu-No.: 0990014601-EN Rev. 4.0.0 Page 19

4 Technical Data
3.4 Safety devices and warnings

4 Technical Data

Specifications Limitations and remarks

Manufacturer Coperion K-Tron
Name with housing SWB-300-N
SWB-600-N
Name without housing SWB-300-O
SWB-600-O
Marking
or declaration of incorporation
Fusing see wiring diagram
Motor conveyor belt See name plate, machine data sheet, operating instructions
Gear drive conveyor belt See name plate, operating instruction gearbox
Lubrication as specified on name plate
Noise <70 dB (A)
Materials of constructions Housing and weighing frame: Rust-and acid-proof steel
Material contact surfaces DIN W.- No. 1.4404 / 1.4435, AISI 316L
Scale: powder coated aluminium casting
Belt: Silicon, PU
Seals, bellows, filter see spare part list in the project manual
Feeding capacity see machine data sheet
Weight with housing
SWB-300-N: 140 kg (308 lb)
SWB-600-N: 180 kg (396 lb)
without housing
SWB-300-O: 125 kg (275 lb)
SWB-600-O: 160 kg (352 lb)
or as specified on dimensional drawing
Operating temperature range with housing
0°C to +40°C [+32°F to +104°F]
without housing
0°C to +50°C [+32°F to +122°F]
Temperature of the bulk material 0°C to +40.5°C [+32°F to +105°F]
Temperature change: < ± 5°C (± 9°F) per hour
Table page 1 of 2

Page 20 Docu-No.: 0990014601-EN Rev. 4.0.0

 Technical Data 4
Safety devices and warnings 3.4

Specifications Limitations and remarks

Air stream for dust collector SWB 300: 22 m3 per hour
SWB 600: 44 m3 per hour
Label
Country of Origin: Switzerland
(1) Description Ursprungsland: Schweiz

(2) Serial number Typ / Type 1

(3) Gear Reduction
Ident.-No 2
(4) Scale
Getriebe / Reduction 3
(5) Ambient temperature /
Product temperature Waage / Scale 4
(6) Manufacturing year Tamb / Tprod
5
Jahr / Year
6
Kenzeichnung /
Marking

Coperion K-Tron (Schweiz) GmbH

CH-5702 Niederlenz
Patents pending

Table page 2 of 2

Docu-No.: 0990014601-EN Rev. 4.0.0 Page 21

5 Transport, storage and disposal
5.1 Transport

5 Transport, storage and disposal

5.1 Transport

Information about the weight see shipping note or drawing.

5.2 Unpacking

Damaging as a result of careless unpacking!

▲ To avoid damaging the feeder or weighing system unpack careful-
ly.

1. Carefully remove the packing from the feeder.

2. Check that the delivery is complete. Also check all parts for
transport damage.
3. Report any damage immediately to Coperion K-Tron.

Page 22 Docu-No.: 0990014601-EN Rev. 4.0.0

 Transport, storage and disposal 5
Lifting 5.3

5.3 Lifting

DANGER
Risk caused by falling transport goods!
▲ Only transport the device by authorized and qualified personnel.
▲ Select the hoisting equipment in accordance with the total weight
to be transported.
▲ Fasten the hoisting equipment as indicated on the diagram.
▲ Do not stand under suspended loads.

 Fasten only belts at the weigh belt feeder.

Fig. 5.1 Transportation

Docu-No.: 0990014601-EN Rev. 4.0.0 Page 23

5 Transport, storage and disposal
5.4 Storage

5.4 Storage

Damage to property caused by improper storage!

▲ The device must be properly stored.

1. Empty and clean the device prior to shipment or storage. Attach

the material safety data sheet (MSDS) with all specifications of the
last fed bulk material.
2. If the device cannot stored in vertical position ensure that the oil
ventilation screw does not leak.
3. Seal all openings with blank flanges, blank stoppers or plastic
covers.
4. The store-room must fulfil the following requirements:
– Dry
– Frost-free

5.4.1 Preliminary work after longer storage

• Shafts, flange surfaces, feeding tools and all surfaces with contact
of bulk material must be completely free of corrosions inhibitors, dirt
or other pollutants.
• The lifetime of the lubricant will be reduced it the device is stored
longer than one year.

5.5 Disposal

Risk of injury and poisoning by the bulk material!

▲ Personal protective clothing is to be worn for all work on the de-
vice.
▲ The safety instructions for handling of dangerous materials must
be adhered to.

 Dispose of the device in accordance with the local regulations.

Page 24 Docu-No.: 0990014601-EN Rev. 4.0.0

 Installation 6
Prepare the place of installation 6.1

6 Installation

6.1 Prepare the place of installation

The place of installation must fulfil following conditions:

• Even and vibration-free (max. incline: 0.5 % or 0.3°).
• Clean (no oil, dust or other pollutants).
• The surface must be able to carry the inherent weight of the device
and all operating forces.
• The stability of the device must be ensured.
• The device must be freely accessible from all sides.
• Sufficient room must be available for installation / removing of
tubes, access to the connections and for maintenance and repair
work.

For dimensions see the dimensional drawing in the project manual.

6.2 Instructions for operation with prefeeder

There must be sufficient space to connect and disconnect the weigh

feeder and the prefeeder.

Docu-No.: 0990014601-EN Rev. 4.0.0 Page 25

6 Installation
6.3 Mounting the feeder

6.3 Mounting the feeder

• Leave sufficient space for maintenance and inspection work

SWB300: 1200 mm (47.2 in)

SWB600: 1500 mm (59 in)

• When mounting the weigh belt feeder ensure that the housing is not
distorted or twisted.
• Slide a piece of carton or a thin metal plate between the belt and the
inlet in order to protect the belt while a hopper or bin is being
installed.

• Mount an inlet slide gate above the feeder inlet so that the storage
bin can be shut off during inspection work or for a belt change.
• Install a sample valve under the outlet in order to take weight
samples more easily during calibration.

1. Mount the feeder.

2. Drill the mounting holes (for drill dimensions see dimensional
drawing).
3. Secure the weigh belt feeder with the four vibration/shock
absorbers (1).
1
68

Fig. 6.1 Vibration absorber

Page 26 Docu-No.: 0990014601-EN Rev. 4.0.0

 Installation 6
Mounting the prefeeder 6.4

6.4 Mounting the prefeeder

Leave sufficient space for maintenance and inspection work.

• Observe the operating instructions of the prefeeder.

• See dimension diagram in project manual.

1. Position the belt weigher and prefeeder.

2. Attach the dust protection sleeve to the inlet of the belt weigher.
3. Position the belt weigher and prefeeder according to the
dimensioned drawing.
4. Screw both devices into place.
5. Fasten the dust protection sleeve to the screw tube of the
prefeeder.

Docu-No.: 0990014601-EN Rev. 4.0.0 Page 27

6 Installation
6.5 Setting up the weigh belt feeder

6.5 Setting up the weigh belt feeder

1. Check whether the belt tracker (1) can be swiveled easily and the
rollers turned.

Fig. 6.2 Belt guide mechanism

2. Mount the belt (see chapter 10.6.2).

3. Check the following points:
– The belt tracker (2) lies correctly on the belt. The belt is not turned
inside out at the tracker contact point.
– The belt scrapers (1) are latched in and contacting the belt across
its entire width.
1 2

Fig. 6.3 Belt guide and scrapers

Page 28 Docu-No.: 0990014601-EN Rev. 4.0.0

 Installation 6
Belt scraper 6.6

6.6 Belt scraper

• The weigh belt feeder SWB300 has one scraper.

• The weigh belt feeder SWB600 has three scrapers; the longest
scraper is in the middle.

(1) Belt scraper SWB300/

Belt scraper SWB600
middle
(2) Belt scraper SWB600
outside
(3) SWB600 arrangement Belt
scraper 1 2

Fig. 6.4 Overview Belt scraper

Docu-No.: 0990014601-EN Rev. 4.0.0 Page 29

6 Installation
6.7 Adjusting the side skirts

6.7 Adjusting the side skirts

Property damage caused by side skirts

– Be sure that the side skirts never come in contact with the
conveyor belt as weighing errors will occur.

Side skirts are mounted near the belt edges to minimize the loss of
bulk material spilling laterally from the conveyor belt.
The side skirts are adjusted when:
• Operating the feeder for the first time
• Change in feed material, e.g. from powder to pellets.
• conveyor belt change

Set the distance of the side skirts (1) to the belt (2) as follows:

Granular material
1. Set 3.0 mm (0.1 inch) or half the size of the smallest feed material
part (Dimension A) at the end of the inlet, whichever is smallest.
2. Set the full size of the smallest feed material part (Dimension B) at
the outlet.

Powder
 Let the side skirt rise slightly toward the outlet.

Fig. 6.5 Setting of the side guide

panels for granulates

Page 30 Docu-No.: 0990014601-EN Rev. 4.0.0

 Installation 6
Electrical connection 6.8

6.8 Electrical connection

DANGER
Mortal danger as a result of live wires
▲ The device may only be connected by qualified electricians.
▲ Observe the local regulations.

Connect the ground connection to a low-impedance equipotential

bonding ( 0.1 ). See grounding information at the device.

Provide a lockable main switch to disconnect the main power supply.

Information concerning the electrical connection is provided in the

wiring diagram in the project manual and the controller operating
instructions.

1. Connect the device in accordance with the total connection

diagram.
2. Ground the device carefully.

6.8.1 Combination with prefeeder

Risk of injury from combined machine

▲ Emergency stop absolutely necessary.
▲ Equip each machine with a separate maintenance switch.

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7 Start-up
6.8 Electrical connection

7 Start-up

Risk of injury and poisoning by the bulk material!

▲ Personal protective clothing is to be worn for all work on the de-
vice.
▲ The safety instructions for handling these materials must be ad-
hered to.

Risk of damage to goods by the bulk material

▲ Never feed materials which may cause a chemical reaction with
the materials of the device, for example bulk material containing
the following substances:
– Acid
– Iodine
– Chromium
– Bromium

Risk of damage to property caused by foreign bodies

▲ Before the first activation ensure that the device is free of objects
such as screws, packaging rests, etc.

Risk of damage to property caused by wrong direction of rotation

▲ In the case of wrong direction of rotation the device can get dam-
aged. Do not fill bulk material into the device before the correct di-
rection of rotation has been confirmed.

For more information see controller operating and programming

instructions.

1. Switch on the feeder with the connected controls (see operating

instructions).

When the feeder is running the belt moves towards the outlet.

2. Check the running direction of the belt.

Page 32 Docu-No.: 0990014601-EN Rev. 4.0.0

 Start-up 7
Electrical connection 6.8

3. If the running direction is wrong, change the direction of rotation of

the motor.

Perform the further initial operation according to the controller operat-

ing instructions.

Docu-No.: 0990014601-EN Rev. 4.0.0 Page 33

7 Start-up
7.1 Belt feeder adjustment

7.1 Belt feeder adjustment

If product spills laterally from the conveyor belt, check the following:
I • Inlet gate opening set too high.
• Side skirts set incorrectly.
• Seal from inlet damaged.

7.1.1 Setting the inlet gate height

The feed material may not contact the side skirts (B) (see Fig. 7.2).

 Use a small inlet, so that the feed material does not contact the
side skirts.
 Ensure that the maximum and minimum inlet heights are observed
during operation.
 If necessary, adjust the inlet height by opening or closing the
vertical inlet gate until the desired inlet opening is achieved.

Fig. 7.1 Inlet

Max. inlet height (A):

B B • At a wide inlet range maximum inlet height A  10 cm
• At a narrow inlet range maximum inlet height A  5 cm
A
Min. inlet height (A):
Fig. 7.2 Height of the inlet area • Three times the particle diameter of the feed material

7.1.2 Sealing Inlet

• Seal (Fig. 7.3/1) wrong mounted or worn out. The seal lip have to
point towards the belt center.

Fig. 7.3 Inlet seal

Page 34 Docu-No.: 0990014601-EN Rev. 4.0.0

 Start-up 7
Setting belt loading with a prefeeder 7.2

7.1.3 Adjusting the nominal belt speed

 Ensure that the maximum belt speed is not exceeded (for
information on the max. belt speed see machine data sheet).
1. Adjust the inlet gate opening (A) in order to achieve a
belt load [kg/m] bigger than 1 kg/m.
2. Set min. setpoint [kg/h] and run the feeder.
Check for drive command (bigger than 5%).
3. Set max. setpoint [kg/h] and run the feeder.
Check for drive command (smaller than 90%))

7.2 Setting belt loading with a prefeeder

 Set the conveying speed of the feed material from the prefeeder
slightly higher than the belt speed.
For information on setting the prefeeder see operating and
programming instructions of the prefeeder and belt feeder.

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8 Operation
7.2 Setting belt loading with a prefeeder

8 Operation

It is not allowed to change Digital output function, polarity and map if

the feeder is running.

Risk of injury and poisoning by the bulk material!

▲ Personal protective clothing is to be worn for all work on the de-
vice.
▲ The safety instructions for handling these materials must be ad-
hered to.

Crushing hazard
Danger of injuries from the moving belt. Therefore observe the
following points:
▲ Only operate the weigh belt feeder with hoppers and outlets in or-
der to prevent access to the moving belt.
▲ Do not reach into the feeder hopper during the feeding process.
▲ Ensure that hair, clothing and tools do not come into contact with
the weigh belt feeder.
▲ Only operate the weigh belt feeder if the belt is installed and all the
covers are closed.

Property damage caused by bulk material!

▲ Never feed materials which may cause a chemical reaction with
the materials of the device, for example bulk material containing
the following substances:
– Acid
– Iodine
– Chromium
– Bromium

Property damage
The weigh belt feeder can be damaged during operation without belt.
▲ Only operate the weigh belt feeder with the conveyor belt.

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 Operation 8
Switching on/off 8.1

• Avoid shock and vibration at the weigh belt feeder during operation.

8.1 Switching on/off

 Switch the device on/off with the connected controller.

For more information see controller operating and programming

instructions.

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9 Inspection and cleaning
8.1 Switching on/off

9 Inspection and cleaning

DANGER
Risk of injury caused by unintentional switching on!
▲ Switch off the device before maintenance work and secure it
against unintentional restarting (see Chapter 9.1).

Damage to property caused by corrosive and toxic detergents.

▲ Follow the safety regulations for dealing with cleaning agents. Af-
ter use dispose properly the cleaning agents.
▲ Use only cleaning agents with 5.0 <pH <8.5.
▲ Clean with non-toxic cleaning agents and disinfectants.
▲ Only use cleaning agents that not affect the used seal and filter
materials (silicone / PTFE / Teflon / polyester fabric).
▲ Any residues of cleaning agent on parts with product contact are
not allowed.
▲ Do not clean with high pressure cleaners, steam cleaner or com-
pressed air.
▲ Not remove product adhesion with force.
▲ There must no moisture on electrical components.
▲ All parts must be dry cleaned before assembly.

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 Inspection and cleaning 9
Switching off for cleaning 9.1

9.1 Switching off for cleaning

• Condition: The device must be completely empty.

1. Switch off the device at the controller (see operating instructions
of the controller).
2. Turn off the power supply by switching off the main switch.
The power supply of the device is switched off.
3. Disconnect the media supply (pneumatic supply, hydraulic supply
etc.) and discharge the residual energy that may be stored.
4. Place a lock at the main switch to avoid unintentional reconnection
of the power supply.
Lock-out switch to be provided by customer if not supplied.
5. Place a warning sign on the main switch reading: “Do not switch
on!”
The device is switched off.

In combination with a prefeeder, switch off and secure the prefeeder

using the same procedure.

9.2 Cleaning advises

• Clean only with light air stream.

• In case of external soiling, clean all the components of the
equipment with a damp cloth and use normal industrial cleaners.
• Clean with a vacuum cleaner or with a smooth brush.
• Eliminate dust accumulation > 5 mm through cleaning.

9.3 Prepare cleaning

1. Empty the belt feeder for cleaning
2. Ensure that no bulk material can continue flowing unintentionally.
3. Switch off the feeder (see chapter 9.1).

9.4 Cleaning without parts removal

1. In case of external soiling, clean all the components of the feeder
with a damp cloth and use normal industrial cleaners.
2. Pull out the supporting frame (see chapter 10.5).
3. Clean the inlet and the supporting frame completely.

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9 Inspection and cleaning
9.5 Cleaning with parts removal

9.5 Cleaning with parts removal

1. Remove the conveyor belt (see chapter 10.6.1).
2. If necessary, remove and clean the inner belt scraper (plow) (1).
3. Clean the bulk material residue and other dirt from the housing,
weighing unit and support frame.
4. Check the conveyor belt for wear and damage. Replace worn or
damaged belt.
1
5. Check the belt tensioning unit for smooth operation.
6. Check the belt guide rollers for smooth operation.

Fig. 9.1 Inner belt scraper

9.6 After cleaning

1. Ensure that the adjusting link (2) is right-angled and that the bolt
1 2 (1) is horizontal.
2. Mount the belt again and ensure that the inner belt scraper is
positioned correctly (see chapter 10.6.2).
3. Start up the belt feeder and tare the belt.

Fig. 9.2 Connecting piece and bolt

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 Inspection and cleaning 9
Prefeeder cleaning 9.7

9.7 Prefeeder cleaning

For cleaning the prefeeder see operating instructions of the prefeeder.

To clean the prefeeder, it must be separated from the belt weigher.

1. Loosen the dust protection sleeve on the screw tube of the

prefeeder.
2. Loosen the fastening screws on the belt scale or prefeeder.
3. Disconnect the machines.
4. Clean the prefeeder.
5. Check the dust protection sleeve for wear and damage. Replace
worn or damaged dust protection sleeve.
6. Reassembly is carried out in the reverse order.

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10 Maintenance
9.7 Prefeeder cleaning

10 Maintenance

Risk of injury caused by unintentional switching on.

▲ Switch off the device before every intervention and secure it
against unintentional restarting (see Chapter 9.1).

Risk of injury caused by spring tensioning

When carrying out maintenance work on the switched-off feeder there
is a danger of injury through unintentional switching-on.
▲ Switch off the feeding system before carrying out maintenance
work on the feeder and secure it against unintentional restarting
(see chapter 9.1).
▲ Never remove spring of the tensioning mechanism. The spring has
a strong pretension. (see Fig. 10.1)

Fig. 10.1 Spring tensioning

• Only qualified and trained personnel may carry out maintenance

work on the feeding equipment.
• Only qualified electricians may work on the electrical equipment.

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 Maintenance 10
Switching off for maintenance 10.1

10.1 Switching off for maintenance

• Condition: The device must be completely empty.

1. Switch off the device at the controller (see operating instructions
of the controller).
2. Turn off the power supply by switching off the main switch.
The power supply of the device is switched off.
3. Disconnect the media supply (pneumatic supply, hydraulic supply
etc.) and discharge the residual energy that may be stored.
4. Place a lock at the main switch to avoid unintentional reconnection
of the power supply.
Lock-out switch to be provided by customer if not supplied.
5. Place a warning sign on the main switch reading: “Do not switch
on!”
The device is switched off.

In combination with a prefeeder, switch off and secure the prefeeder

using the same procedure.

10.2 Maintenance intervals

Element Checkpoints when in operation Interval

Belt feeder Eliminate dust accumulation > 5 mm Weekly
through cleaning
Belt feeder Cleaning interior: As required (feed product dependent)
Belt, drive- and idler rollers, scale belt
tracking, belt tension and scraper
Belt feeder Belt tension 1000 h
Belt feeder Pre seals bearings 1000 h
Belt feeder Rollers and bearings 10000 h or 2 Years
Belt feeder Weighing bar As required (feed product dependent)
Gear drive Check oil and oil level 3000 h
Gear drive Oil change See gear drive operating instructions
in the project manual.
Motor Motor brushes As required (see motor data sheet)

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10 Maintenance
10.3 Preparation maintenance

10.3 Preparation maintenance

1. Empty the feeder.
2. Ensure that no bulk material can continue flowing unintentionally.
3. Switch off the feeder (see chapter 9.1).

10.4 Belt tension adjustment and pre-seal check

1. Check Distance A with the conveyor belt tensioned.
A A: 74 ±1 mm
2. If the distance is greater than 76 mm, reset the distance
(see chapter 10.7).
3. Check the pre-seals of the bearings on drive and idler rollers and
check for leaks.

Fig. 10.2 Belt tension adjustment

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 Maintenance 10
Disassembly and assembly of supporting frame 10.5

10.5 Disassembly and assembly of supporting

frame

The system is equipped with two telescopic rails and mechanical

stops so that the supporting frame can be extracted to a set distance.

10.5.1 Extracting the supporting frame for cleaning

1. Remove the covers of the weigh belt feeder.
2. Loosen the knurled knob (3) and push the two brackets upwards.

Fig. 10.3 Loosening the knurled

screws

3. Slide out the supporting frame slowly until the stop (1).
4. Clean the unit while extracted on the rails.

Fig. 10.4 Pulling out the supporting

frame

10.5.2 Removing the supporting frame for maintenance

1. Carry out step 1 to 5 in chapter 10.5.1.
2. Remove the connections from the load cell and the speed sensor.
3. Pull up the stop pins (Fig. 10.4/1).
4. Using two people, one on each end of the supporting frame,
remove the frame completely.

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10 Maintenance
10.5 Disassembly and assembly of supporting frame

10.5.3 Installing the supporting frame

Crushing hazard
▲ When slide back there is a risk of trap of fingers.

Only carry out step 1 and 2 in case of complete dismantling of the

supporting frame (dismantling for maintenance). If the supporting
frame was only pulled out for cleaning, begin installation at step 3.

1. Use two people to carefully slide the supporting frame into the
housing until the supporting frame rests again on the telescopic
1
rails. Ensure that the telescopic rails slide in correctly.
2. Latch the stop pin.
3. Slide the supporting frame slowly completely into the housing.
Turn the drive roller (3) so that the coupling (2) of the drive roller
locks into the coupling of the worm drive gear.
4. Pull down the two hangar brackets and tighten the
knurled knobs (1).
5. Close the front door and upper cover.
2 3

Fig. 10.5 Installing the supporting

frame

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 Maintenance 10
Changing belt 10.6

10.6 Changing belt

• Open-end wrench 13 mm (2)
• Caliper to 200 mm.

10.6.1 Removing the belt

1. Slide out the supporting frame (see chapter 10.5.1).
2. Loosen the knurled knob (1), but do not remove it. Swivel the
bracket (2) sideways and fasten it in this position with the knurled
knob.
3. Lift the scraper (3) slightly and pull it out forward.

Fig. 10.6 Belt scraper

4. Open the tensioning mechanism (2).

1
2

Fig. 10.7 Opening (2) and closing (1)

the tensioning mechanism

5. Mark the running direction on the belt for proper re-installation.

6. Pull the belt out the front of the feeder.
7. Pull out the stop pin (5) and remove the belt tracker (6).
8. Remove and clean the inner belt scraper (see Fig. 10.12/1).
9. Clean the supporting frame.

Fig. 10.8 Belt guide

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10 Maintenance
10.6 Changing belt

10.6.2 Pre-adjustments for new belt

Before installing the belt ensure that the tension is correct by checking
the specified distances.

1. Check distance B (setpoint value: 146 ±0.2 mm).

B 2. If necessary, set distance B at the turnbuckle to 146 ±0.2 mm.

Fig. 10.9 Belt guide

10.6.3 Installation of the conveyor belt

1. Mount the inner belt scraper (1).
2. Mount the cleaned belt tracker (2) and check that the rollers runs
free and independently.
3. Slide the cleaned or new belt onto the rollers. Ensure that the
running direction is correct.
4. Slide in the scraper (3) in and let it latch in.
1 5. Latch the bracket (4) in again and tighten the knurled knob.
6. Close the tensioning lever.
7. Check that the belt tracker rollers and belt scraper are positioned
4 correctly.

3 2

Fig. 10.10 Mounting

10.6.4 Completing conveyor belt installation

1. Check distance A (setpoint value: 74 ±1 mm).
A 2. If distance A > 76 mm, reset the distance (see chapter 10.7).

Fig. 10.11 Belt guide

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 Maintenance 10
Changing belt 10.6

3. Check the position of the inner belt scraper (1).

The inner belt scraper should lie loosely on the belt.
4. Slide the supporting frame into the frame (see chapter 10.5.3).

Fig. 10.12 Inner belt scraper

10.6.5 Setting belt tracking

Open-end wrench 13 mm (2)

1. Switch on the motor, set it to the maximum belt speed and check
how the belt tracks on the machine.
1 2
2. If the belt goes off line in one direction, loosen the lock nut (2) at
the turnbuckle and carry out corrections at the adjusting nut (1) as
follows:
Note:
It is important for proper weighing that the belt runs laterally centered
on the weigh deck.
Fig. 10.13 Turnbuckle adjustment

Only loosen or tighten the adjusting nut (1) in 90 degree steps.

Belt runs towards the  Tighten the adjusting nut, turn to

adjusting turnbuckle (left) the right.
Belt runs away from the  Loosen the adjusting nut, turn to
adjusting turnbuckle (right). the left.

3. Tighten the lock nut (2) and continue to monitor belt tracking. If
necessary, redo the belt tracking adjustment.
4. Adjust the side skirts (see chapter 6.7).
5. Switch on the motor, set it to the maximum speed and carry out a
final check of the belt tracking.

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10 Maintenance
10.7 Adjusting the belt tension

10.7 Adjusting the belt tension

The belt tension is only adjusted during maintenance.

• Open-end wrench 13 and 18 mm

• Caliper 100 mm

1. Check distance A at the tensioned belt.

(Setpoint value A: 74 ±1 mm).
A 2. Set length C so that the distance A = 74 ±1 mm by loosening the
lock nut (1) and turning the adjusting link (3).

Note:
One rotation of the adjusting link (3) results in a distance reduction of
12 3 1.25 mm.
The connecting piece (3) has to be positioned vertically and the bolt
(2) horizontally.

C 3. After the tensioning system has been adjusted, check again

distance A while the belt is tensioned.
Fig. 10.14 Setting the belt tension

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 Maintenance 10
Replacing the weigh deck 10.8

10.8 Replacing the weigh deck

• Open-end wrench 17 mm
• Allen key 4 and 5 mm
• Torque wrench 6 Nm

1. Remove terminal cover (1) from the load cell by loosening the two
Allen screws.
2. Disconnect wires from the terminals.
3. Loosen the Allen screws (2) at position (A/B/C) and remove the
weigh deck.
4. Install the new weigh deck.
5. Tighten the Allen screws with a torque of 6 Nm.
6. Connect the load cell. Be sure that the load cell cable clears the
supporting frame and any moving parts when fully engaged.
7. Mount the terminal cover (1).
8. Adjust the weighing bar (see chapter 10.8.1).

Fig. 10.15 Replacing the weigh deck

10.8.1 Setting the weighing bar

Damage to property
▲ While working on the weighing bar the load cell has to be protected
against mechanical damage by securing it.
▲ High torque on the weighing bar screws can damage the load cell.

 Check the alignment of the weighing bar. All bars have to form one
level (0/0/0 mm +/- 0.03).

Fig. 10.16 Weighing bar alignment

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10 Maintenance
10.8 Replacing the weigh deck

If the weighing bar is not adjusted:

1. Remove the weigh deck.
2. Lay down the weigh deck on the bars (Choose level surface)
3. Adjust the 3 bearing surfaces (ABC) 31mm +/-0.05 mm to the
reference surface.
4. Lock the height setting by:
– tighten the screws alternatively
– increasing the torque step by step to 6 Nm.

Fig. 10.17 Weighing bar reference

10.8.2 Aligning the weigh deck

1. Check the surface D (see Fig. 10.18). If the surface D does not lie
within the tolerance of 0.2 mm, set it to the highest point.

Fig. 10.18 Aligning the weighing unit in the supporting frame

2. Adjust the distance between the weighing bar, the rollers and the
inlet platform to 0,4 to 0,7 mm by adjusting the screws A,B and C
(see Fig. 10.19).
– Loosen the Allen screws (1).
– Loosen the lock nut (2).
– Adjust the alignment with screw (3).

3. Check the gap between the weighing bar and overload stops and
adjust if necessary (see chapter 6.8).

Fig. 10.19 Weigh deck adjusting

screws

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 Maintenance 10
Replacing the weigh deck 10.8

10.8.3 Setting the overload stop of the weigh deck

• In order to protect the load cell against overloading the overload

stop (A) is set to 0.15 mm. This corresponds to a load of 7.5 kg.

• Allen key 3 mm
• Open-end wrench 10 mm

 Use the Allen screws (1) to set gap (A) between the weighing
beam and overload stop to 0.15 mm maximum clearance.

A
0.15 mm

Fig. 10.20 Gap setting at weighing unit

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11 Troubleshooting
10.8 Replacing the weigh deck

11 Troubleshooting

Risk of injury caused by unintentional switching on.

▲ Switch off the device before every intervention and secure it
against unintentional restarting.
▲ Depressurize the system.

 Always switch off before carrying out repairs.

 Check the device.
 Please observe the error messages displayed on the connected
control device or host computer.
 Document errors and call the local service center (customer
service see project manual).

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11.1 Troubleshooting table
Error Possible cause
Belt goes off line. • Belt guide rollers do not have any
contact with the belt.
• The belt guide rollers do not rotate.
• Idler roller is dirty.
Product sticks to the • Scraper is dirty or jammed.
belt.
Bulk materials spills • Side skirts not set correctly.
laterally from the belt • Inlet opening too high.
• Sealing lips from inlet are damaged.
Drive roller slips. • Belt tensioner not functional.
• Drive roller and or the inside of the
belt is dirty.
Belt runs at the • Speed sensor defective.
maximum speed. • Wiring between the Speed sensor
and controller broken.
• Insufficient product on the belt.
• Inlet blocked.
Motor does not turn. • No power to the motor.
• Motor brushes are worn.
Poor accuracy. • Weigh deck not well adjusted.
Weighing failure. • Load cell has failed.
Machine does not run • No voltage
Docu-No.: 0990014601-EN Rev. 4.0.0
Troubleshooting 11
Troubleshooting table 11.1
Remedy
 Check whether the belt guides
run smoothly and are clean.
 Check and clean the rollers.
 Clean the roller, correct it if
necessary (see chapter 10.6).
 Clean and make it run smoothly.
 Set side skirts per section 6.7.
 Adjust inlet opening per section
7.1.
 Replace seal.
 Check the tensioning device.
 Clean the roller and belt.
 Check the setting.
 Check the line and connections.
 Check the inlet slider. If
necessary, adjust.
 Remove the foreign bodies.
 Check the input voltage and
fuses at the motor drive.
 Read and respond to alarm
messages.
 Replace motor brushes or
motor.
 Check adjustments per section
10.8.
 Replace weigh deck.
 Replace weigh deck.
 Check the input voltage and
fuses.
Page 55
11 Troubleshooting
11.1 Troubleshooting table

Page 56 Docu-No.: 0990014601-EN Rev. 4.0.0