ATEX - (DDW-) TSR XX - Operating Instructions (Rev.3.0 - April 2017)

ATEX execution
Supplementary information in the technical

description “The ATEX execution“ has to be
observed!
OPERATING INSTRUCTIONS
(DDW-) TSR XX
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Imprint
Device assignment
Device names: (DDW-) TSR xx
Device variant: ATEX
Document
Document status: Original
Type of document: Operating instructions
File designation: e2030057
Document ID: 057
Revision: 3.0
Date: 17-04-05
Editor: Brabender Technologie GmbH & Co. KG
Copyright: © 2017, Brabender Technologie GmbH & Co. KG
Copyright (according to DIN EN ISO 16016)

No part of this document may be reproduced, transmitted, sold or disclosed
without prior permission. In the event of contraventions, compensation for
damages will be claimed. All rights reserved with regard to patent claims or
submission of design or utility patent.
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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 future reference.
2 Safety ©Operating instructions (DDW-) TSR xx

Table of contents
Imprint ........................................................................................................ 2
1. Safety ................................................................................................... 5
Use of the device.......................................................................................... 6
Safety instructions........................................................................................ 8
Specifications for the operating licence of the device.......................... 8
Qualification of the operating personnel ............................................. 8
Dangerous contact voltages on the device ........................................... 8
Disconnection of the device ................................................................. 9
Discharge of residual energy storages .................................................. 9
Earthing of the device ........................................................................... 9
Sound level............................................................................................ 9
Sharp-edged components................................................................... 10
Specification for the operation of the screw feeder .......................... 10
Warnings on the device ...................................................................... 11
Residual dangers ........................................................................................ 12
2. The description of the device .............................................................. 14
Description of the construction of the device ........................................... 15
Component groups of the device............................................................... 16
The hopper.......................................................................................... 16
Feeding organ and feed drive ............................................................. 18
The weighing of the device ................................................................. 22
Technical data ............................................................................................ 24
3. Mounting ........................................................................................... 25
Mounting instructions................................................................................ 26
Place of the installation.............................................................................. 27
Mounting work........................................................................................... 28
Installation on site .............................................................................. 28
Connection inlet/outlet ...................................................................... 28
Connection ventilation/deaeration .................................................... 29
Electrical mounting work ........................................................................... 30
©Operating instructions (DDW-) TSR xx Safety 3

4. Commissioning ................................................................................... 38
Notes on commissioning ............................................................................ 39
Process of commissioning .......................................................................... 40
Step 1: Tests on the device ............................................................ 40
Step 2: Connection of supply media .............................................. 40
Step 3: Verification of the sense of rotation ................................. 40
Step 4: Verification and adjustment of the weighing ......................... 41
Step 5: Determination of the feed rate ......................................... 43
Product feeding .......................................................................................... 45
Step 6: Adaptation of the feed rate............................................... 47
5. Decommissioning................................................................................ 48
6. Alarm cut-outs .................................................................................... 49
Causes of malfunction ................................................................................ 50
7. Maintenance ...................................................................................... 52
Notes on carrying out maintenance .......................................................... 53
List of components ..................................................................................... 54
Care and inspection ................................................................................... 56
Cleaning of the device ................................................................................ 58
Specifications for cleaning .................................................................. 58
Description of the cleaning processes ................................................ 59
Assembly/disassembly of individual components ..................................... 61
Disassembly of drive motor ................................................................ 61
How to change the shaft sealing at the front bearing ........................ 61
How to change the shaft sealing of the rear bearing ......................... 62
How to change the shaft sealings on the agitator .............................. 63
Disassembly of the screw.................................................................... 64
Disassembly of the agitator ................................................................ 65
Assembly of the agitator ..................................................................... 65
Adjustment of speed monitoring ........................................................ 66
8. Storage and disposal ........................................................................... 67
Storage of the device, of individual assemblies ......................................... 68
Disposal of the device, of individual components ..................................... 69
Index ......................................................................................................... 70

1. Safety
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
Use of the device 6
Safety instructions 8
Residual danger 12

Use of the device
Intended purpose The “TSR xx“ is a metering feeder for the feeding of bulk solids that can be fed
by means of a screw (= feeding device) and a trough agitator.
The product is filled into the hopper, from there it is conveyed into the agitator
trough, where an agitator rotates vertically. The agitator permits an improved
and more even filling ratio of the screw. The rotating screw transports the
product to the outlet of the device from where it falls freely into the
downstream equipment. The screw is driven by a drive motor (= feed drive)
that is controlled by means of a suitable drive controller. The working point of
the device, the feed rate (= product quantity/unit of time) is adjusted by
means of the determination of the speed of the feed drive.
Appropriate products Bulk solids (no liquids) with the following product characteristics are
appropriate for being discharged/fed with the device:
• Suitable size of product particles
• Appropriate flowability
• Free from contamination, foreign bodies etc.
• No ignition capability due to friction or strokes
• No explosive characteristics
• No change of the product characteristics due to
- the feeding operation
- the operation of an agitator
• No inadmissibly high wear of the machine parts in contact with the
product
Specifications for use The standard dimensioning of the device requires the following environmental
and operating data for the field of application:
Temperature: 0°C to +45°C

Humidity: up to 85% without condensation
Medium: Air or inert gas
Wind/draught: < 0.3 m/s
max. negative/ positive pressure: 2 mbar (20mm water column)
Product temperature: 0°C to + 60°C
Voltage supply: AC 230/400V

Use of the device, continuation
Required component Electrical assemblies are required for the following control functions (minimum
groups for the operation requirement):
• Start/stop of the operation of the device
• Determination of the working point of the device (= speed setting)
Advanced demands during weighing

The weighing of the device 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-…”).
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 a component of the intended use of the device.
Modification of the field of application on site

If the field of application on site is changed, a new release of the operation by
the manufacturer is required.

Safety instructions
Specifications for the operating licence 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 repairs original spare parts of the manufacturer or spare
parts with identical technical characteristics have to be employed (has to
be enabled by the manufacturer).
Qualification of the operating personnel

The following qualifications are required for the operating personnel:
• Trained on the device and its operation
• Authorised to carry out the required operations
• Knowledge of the regulations concerning the operator protection
• Knowledge of the actual operating conditions as far as the device and its
environment are concerned
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.

Safety instructions, continuation
Disconnection of the device

Below you will find the term "disconnection". "Disconnection" means:
• Disconnect the device from all supply media.
Definition! • Protection against unauthorised reconnection.
• Discharge all kinds of energy stocks (manually or due to sufficient dwell
times).
Discharge of residual energy storages

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 line Deaeration
Thermic Dissipator, surface Observe the cooling time
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.
Sound level
The sound level of the device is < 70dB (acc. to DIN45635)

Sharp-edged components
The device has sharp-edged components that present a danger of injury (cuts)
even if the drive is not on:
• the vertically rotating agitator
• the screw
Specification for the operation of the screw feeder

• The screw must only be operated with a protection against unauthorised
reaching into the device (e.g. mounted cover of screw trough). A freely
rotating screw has a considerable potential for injury.
• A screw must only be operated with a screw trough with appropriate
dimensions. In case of an inadmissible combination screw/screw trough,
operational failures and damage to the device may occur.
• The combination screw/screw trough must only be employed for a
suitable product. In case of an inappropriate product, operational failures
and damage to the device may occur.

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
Marks the allowed sense of rotation for the drive motor.

Allowed sense of In case of non-respect the rotating component groups risk to be torn out of
rotation their fastening during the operation.
Do not put arms/fingers into the rotating agitator and use long-shafted gloves
during work on the agitator at standstill.
In case of non-respect there is a considerable danger of injuries caused by the
sharp-edged agitator.
from the mains

Residual dangers
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.
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
Product jam Danger: No free product flow

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
Product change Danger: Wrong equipment of the device

Measures: • Operation only with approved products
• Management of product/device equipment
• Conversion has to be carried out completely/with
special care

Residual dangers, continuation
Insufficient Danger: No pressure compensation in the product vessel

aeration/deaeration Effects: • The product discharge (feeding) causes a negative
pressure in the vessel.
• Product refilling causes an overpressure in the vessel.
• 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 aeration 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 systems) is troubled.

2. The description of the device
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 15
Component groups of the device 16
Technical data 24
14 The description of the device ©Operating instructions (DDW-) TSR xx

Description of the construction of the device
Legend The illustration shows the construction of the device (without hopper):
No Meaning
1 Agitator drive motor
2 Screw drive motor
3 Rear cover for screw trough
4 Mounting plate
5 Screw
6 Screw trough
7 Outlet
8 Front bearing of screw
9 Front cover for screw trough
10 Cover cleaning opening
11 Agitator
12 Agitator trough
©Operating instructions (DDW-) TSR xx The description of the device 15

Component groups of the device
The hopper
The hopper stores the product to be fed, in a next step the product is
conveyed to the feeding unit.
Safety equipment The hopper is a protective device. It prevents the operator from putting
hands/fingers into the rotating component groups of the device. The protective
function is obtained by different measures (combinations are possible):
• the size of the hopper
• a mounted safety grid
• a safe screwing of the hopper or the hopper cover.
Freely accessible product zone (open hopper)

» The operating personnel risks to get injured by rotating components
when reaching into the product zone.
Attention
» Foreign objects might enter the product zone and cause damage to
the device.
» 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.
Protective grid The hopper is equipped with a protective grid, if

• the hopper cover is not screwed tightly (e.g. loose and/or flap function)
and
• the construction size of the hopper cannot prevent from reaching into
rotating components.
The protective grid does not replace a hopper cover

The operation of the device is only allowed if the hopper cover is closed. The
protective grid does not offer sufficient protection against foreign objects and
soiling.

Component groups of the device, continuation
Fastening Hopper
As a rule, the hopper is fixed by a screw connection to the screw/agitator
trough. A sealing material is employed between both components, if the
tightening force of the screw connection is sufficient the connection is tight.
Hopper cover
The hopper cover is screwed tightly to the hopper. A sealing material is
employed between both components, if the tightening force of the screw
connection is sufficient the connection is tight.
Exception :
Hopper cover fits loosely
Safety: With the use of a quick-release clamping fastener or a corresponding

Position monitoring application the correct mounting position will be monitored (e.g. magnetic
switch). During the electrical assembly of the device the position monitoring
signal is integrated into an electrical interlocking chain for the operating
release of the device.
Safety: A quick-release clamping connection may also be equipped with a mechanical

Mechanical locking lock. This lock permits to fix the clamping connection after closing and thus
prevents inadvertent opening of the clamping connection. The execution and
the use of a mechanical lock is a function of the corresponding type of
clamping connection and may be combined as a function of the corresponding
type of clamping connection with an electrical position monitoring.

Feeding organ and feed drive
Feed drive A threephase motor (1) is employed as feed drive. The threephase motor is
operated by means of a suitable drive controller (frequency converter). The
adjustment of the motor to the drive controller and the field of application is
made by means of the parameterisation of the drive controller. Thus, the
parameterisation is part of the dimensioning of the device.
The working point of the device is adjusted by means of the determination of
the operating speed (=speed specification) of the feed drive. The speed
specification is a function of the execution of the drive controller and is made
by means of an analogue or serial control signal.
Speed monitoring The speed monitoring is provided by an inductive proximity switch (2) the
pulses of which are evaluated by a suitable electrical unit. The speed
monitoring has the function to monitor the specified limit values, minimum
and maximum speed.
Observe the execution!

• Standard for a loss-in-weight feeder (“DDW-“)
• Optional for all other executions

Feeding organ and feed drive, continuation

Screw The product is conveyed by means of a screw (3) that is driven by the feed
(feeding device) drive. The rotating movement of the screw generates a product feed that
conveys the product out of the agitator trough (6) to the end of the screw
trough (4). The dimensioning of the screw (type, pitch, diameter etc.) in
combination with the dimensioning of the screw trough determines the field of
application and work of the metering feeder.
Trough cover The cover (5) of the screw trough is protective equipment. It protects the
product area against the entry of foreign bodies and prevents from reaching into
the rotating screw. The protective function is obtained by different measures:
• The trough cover is screwed tightly.
• When using quick release fastenings (instead of screwing) the parts of the
trough cover that have not been screwed down are equipped with a
position monitoring (e.g. magnetic field sensor).
Operating requirement: evaluation of the position monitoring

The electrical assembly of the device takes into account the position
monitoring (if available) with the following functions:
• The device cannot be started, if the trough cover has not been closed properly.
• The device is stopped immediately, if the trough cover is opened during
the operation.


Trough agitator A vertically rotating agitator (7) that permits to improve the filling ratio of the
feeding device rotates in the agitator trough. The agitator is driven by a
separate drive motor (8) and rotates with a constant speed.
Special design
As a special design the drive motor is speed controlled via a drive controller.
The adjustment of the motor to the drive controller and the field of application
is made by means of the parameterisation of the drive controller. Thus, the
parameterisation is part of the dimensioning of the device.
Vertical outlet The vertical outlet (4.1) as a termination of the screw trough contains the front
bearing of the screw shaft. Here the connection is made to the downstream
equipment.
Bearing of the drive The illustration shows the construction of the

shaft bearing.
agitator No Description
1 Rear wall of agitator trough
2 Agitator drive shaft
3, 6 Nilos ring
4, 5 LSTO ring Sealing of drive shaft
7 Prelon sealing
8 Retaining plate
9 Spacer
10 Sealing plate
In case of a leaking sealing product flows via the

drive shaft behind the shaft sealing and drops down
(A). In this case all sealing elements have to be
exchanged.


Bearing of the screw
drive shaft
The markings in the illustration have the following meaning:

No Description
1 Rear wall of the screw trough (motor support)
2 Sealing
3 Sealing disk
4 Opening for product that might leak out
5 Flange bearing
6 Toothed coupling
7 Screw drive shaft
8 Ball bearing (component of the flange bearing (5))
9 Prelon sealing
10, 13 Nilos ring Sealing of drive shaft
11, 12 LSTO ring
A Product deposit in case of a leaking sealing
In case of a leaking sealing product will leak out along the drive shaft and to
the opening for product and form a deposit in the zone (A). In this case all
sealing elements have to be exchanged.

The weighing of the device

Device with weighing
system
Construction and For weighing, the feeding device is mounted on a weighing system with 4 load
function cells (2). 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-…)
Weighing system types The type of the weighing system is determined by the load cell employed.
Type Load cell(s)
MS x analogue load cell (x = construction size, weighing range)
Weighing systems type “H1x“ or “H3x“

These weighing systems are described separately. The description is a
component of the total documentation of the device.

The weighing of the device, continuation

Protective equipment: The transport catch connects the weighed subassembly to a fixed point of the
Transport catch construction (e.g. mounting plate) and thus relieves the weighing system. It
protects the load cell against inadmissible loads and torsions during a transport
and/or during the execution of mounting/maintenance work.
Transport catches
Execution - are red metal elements the number and shape of which
are a function of the construction of the device.
Use - are always completely fastened and loosened.
- 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.
Recommended Recommended tightening torques for the transport catch:

tightening torques
Screw M6: 8 Nm Screw M8: 20 Nm
Combination transport catch + transport eyelets

For these combinations the tightening torques have to be strictly complied with.

Technical data
Specifications for use The standard dimensioning of the device requires the following environmental
and operating data for the field of application:
Temperature: 0°C to +45°C

Humidity: up to 85% without condensation
Medium: Air or inert gas
Wind/draught: < 0.3 m/s
max. negative/ positive pressure: 2 mbar (20mm water column)
Product temperature: 0°C to + 60°C
Voltage supply: AC 230/400V
Metering feeder Data for the execution of the device:
Sound level: < 70dB(A)

Feeding organ: Screw
Drive: ac drive
Drive controller: Frequency converter
Operating range: 2% - 99% x nominal speed
Speed monitoring: Pulse scanning via proximity switch
Scanning distance: d = 1 mm
Nameplate The nameplate indicates the type of device, the machine number and the year
of construction of the device.
Clear marking of the device: Machine number

3. Mounting
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 26
Place of the installation 27
Mounting work 28
Electrical mounting work 30
©Operating instructions (DDW-) TSR xx Mounting 25

Mounting instructions
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.
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.
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.
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
26 Mounting ©Operating instructions (DDW-) TSR xx

Place of the installation
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
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
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.

Mounting work
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.
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.
Connection inlet/outlet
The connection of the inlet/outlet of the device to 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 to a step bellow:
No Meaning
1 Line 1
2 Clamping ring 1
3 Step bellow
4 Clamping ring 2
5 Line 2

Mounting work, continuation
Connection inlet/outlet, continuation

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.
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.
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!

Electrical mounting work
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.
Junction boxes The connection of the electrical assemblies in junction boxes is provided in our
works in order to facilitate the connection on site. The junction boxes are
marked “-JB n” (n= 1, 2, 3,…). The following assignments apply to the junction
boxes
• The marking ”-JB 1“is reserved for the junction box of the weighing system
and is only employed, if the device is mounted on a weighing system.
• The electrical assemblies of the device are connected in the junction boxes
“-JB 2,3,4,…“. The number is adapted to demand.
• In case of a standard execution the terminals are connected according to
the determined terminal assignment of the junction boxes.
• Executions that deviate from the standard are described in the specific
wiring plans related to the order. Due to the specific execution a deviation
from the standard terminal assignments is possible. The wiring plans are a
separate document and complement the operating instructions.
Junction boxes With an ISC execution of the device the junction boxes also include the control
ISC plus electronics of the device (feeding controller, drive controller) for the operation
of the device. The ISC-components are described in the separate manual of the
ISC system.

Electrical mounting work, continuation
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.
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.

Wiring plan and Please find below the different wiring plans for the electrical connection of the
execution of the device device. Each wiring plan is designed for a specific execution of the device.
Connection plan Execution of the device

ISC plus Type: Loss-in-weight feeder (DDW-…)
Operation: ISC plus system
Characteristic: ISC-CM plus mounted to the device
Congrav® Type: Loss-in-weight feeder (DDW-…)
Operation: Feeding controller Congrav® (e.g. CB plus)
Characteristic: Congrav® in control cabinet
Volumetric Type: Standard device
Operation: Start/stop + WP-specification1
Characteristic: WP-specification via potentiometer or
control signal (e.g. 0-10VDC)
1
WP = “working point“ (operating speed, vibration amplitude etc.)

Wiring plan
ISC plus

Wiring plan CB plus

Wiring plan In the wiring plans the connection possibilities are identified by the numbers
legend (1, 2, etc.). The identifications (“ident.“) have the following meaning:
Ident. Meaning
1 Connection to mains supply on site
2 Connection of the digital inputs (“DI2“ – “DI4“)
3 Connection of BT fieldbus interface
The arrows mark the signal direction of the line.
4 Connection of the ProfiBus DP interface
The arrows mark the signal direction of the line.
5 Connection of Ethernet, ProfiNet interface
The connection requires an appropriate plug.
6 Connection of the digital outputs (“DO2“ – “DO4“)
7 Connection of the operating unit OP1 T
The connection is provided by means of a ready-made cable.
Wiring plan CBplus Identifications (“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
Components of the metering feeder:

Ident. 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

Components for the operation:

Marking Meaning
OP1 T Operating unit Congrav® OP1 T
Cable colours Abbreviations (Abbr.) used for the cable colours 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
Connection of separate The separate agitator motor (-M2) is

agitator motor connected via a motor protection relay (-
Q1) to the voltage supply. The electrical
cabling of the contactor coil (-K1M) permits
to actuate the agitator motor. The cabling
is executed in such a manner that
- the agitator drive starts, if the feeding
operation is started and all conditions
for an existent interlocking chain (e.g.
circuit breaker) have been complied
with.
- the agitator motor stops, if the feeding
operation is stopped.

Connection plan In “volumetric” operation the

volumetric feed drive (M) is controlled via a
frequency converter (A2) that
permits to adjust the operating
speed via a potentiometer (P1).
The device will feed with this
operating speed as soon as it is
enabled (switch S1). The
frequency converter is no
component of the device but is
mounted in a control cabinet or
similar and connected on the
device to the feed drive via the
junction box (JB2).
Legend Explanation of the markings employed (“ident.“):

Ident. Meaning
Q1 Main switch, maintenance switch
F1 Fuse
S1 Switch “operating release”
P1 Potentiometer “speed specification“
A2 Frequency converter type “FC-Vx“
A2.1 Frequency converter I/O module “standard“
JB2 Junction box on the device
M Feed drive
B3 PTC thermistor (if available)

4. Commissioning
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 39
Commissioning sequence 40
Product feeding 45
38 Commissioning ©Operating instructions (DDW-) TSR xx

Notes on commissioning
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.
Product feeding During commissioning the product feeding is started for the computation of
the feed 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)
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.
©Operating instructions (DDW-) TSR xx Commissioning 39

Process of commissioning
Step 1: Tests on the device

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.
Step 2: Connection of supply media

1. Connect all supply media.
2. Warm up of approx. 30 min.
3. Continue the commissioning.
Step 3: Verification of the sense of rotation

A direction arrow marks the prescribed sense of rotation on each drive motor.
During this step the sense of rotation is checked by means of a visual check.
1. Enter a small speed (~10%).
2. Start the device and check the sense of rotation.
3. Stop the device.
In case of a wrong sense of rotation the sense of rotation has to be changed.

4. Switch off the power supply.
5. Protection against unauthorised reconnection.
6. Exchange two of the connection lines (U, V, W), (e.g. U, V).
7. Switch on the voltage supply.

Process of commissioning, continuation
Step 4: Verification and adjustment of the weighing
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.
Loosen the transport Loosen the transport catch completely according to the description (see page
catch 22).
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.

Step 4: Verification and adjustment of the weighing,

continuation
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 (W).
2. Place on a known test 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 - W)  (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.
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

Step 5: Determination of the feed rate

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.

Step 5: Determination of the feed rate, continuation

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 feed 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 speed (setpoint).
4. Start the feeding operation for the duration of measuring (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. Calculate the feed rate [kg/h] (here: product weight x 60/2)
Determination of the characteristic curve

“Gauging” permits to find the feed rate for the corresponding speed. If several
feed rates are required a characteristic curve is needed (speed – feed rate). For
the determination of the characteristic curve we recommend measurements with
the following speeds: “10%”, “40%” and “75%”. If necessary, the characteristic
curve can be improved by integrating further measurement points.
Determination type The feed 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 feed rate (= “output”) for different
speed 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.

Product feeding
Preparations The commissioning is terminated by making the system ready for operation. In
order to make the system ready for operation the following preparations are
required:
• Remove auxiliary equipment (collecting receptacle etc.).
• Possibly reconnect separated connections (e.g. outlet).
• Possibly undo conversions (e.g. bypass).
• Discharge the device completely, if a replacement product has been
employed.
• If required, clean the device and the environment.
• Refill the device.
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 feed rate is not
sensed and not controlled. I.e. feed rate variations e.g. caused by a variating
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.
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 feed 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.
Operation of the screw without product

» Damage of the device by radial deflections of the screw in the screw
pipe (screws are not turning true).
Attention
Therefore
- Be sure to monitor the filling level in the hopper and refill the hopper
before reaching of the minimum allowed filling level.
- Increased attention during a feeding operation with a high speed.

Product feeding, continuation
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.
Gravimetric product During gravimetric product feeding the feeding operation is started with a
feeding determined discharge rate (product quantity /time unit). During feeding the
feed 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.
Gravimetric feeding As a rule, the feeding controller is used to operate the gravimetric product
sequence feeding and it runs down as follows:
1. Set the desired feed rate as setpoint.
2. Start the feeding operation.
The start command starts the automatical 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.

Product feeding, continuation
Step 6: Adaptation of the feed rate

The feed rate is changed by a modification of the operating speed of the drive
motor in the allowed working range. If this measure does not permit to
achieve the desired feed rate, it is required to modify the device. Please find
below the measures for an admissible 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.
Exchange of the screw The device is equipped with another screw execution.

5. Decommissioning
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.
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
Maintenance, Switch off the device for maintenance work.

repair
Activation: 1. Discharge the device.
2. Stop the operation.
3. Disconnect the device. (see (see page 9)
4. Carry out the necessary work.
How to continue Commissioning has to be carried out.
the operation:
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. Assemble the device.
the operation: 2. Mount the device.
3. Commission the device.
48 Decommissioning ©Operating instructions (DDW-) TSR xx

6. Alarm cut-outs
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.
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.
©Operating instructions (DDW-) TSR xx Alarm cut-outs 49

Causes of malfunction
Discharge operation 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.
Required releases are missing
» Comply with demands of interlocking chains and other operating
requirements.
Grinding noises Product deposits in the screw pipe

» Clean the screw pipe.
Product jam between screw and pipe wall
» Employ a screw with a different screw diameter.
Uneven filling ratio Screw type not suitable

» Employ other screw type
Product quantity not sufficient
» Refill the hopper.
» Provide agitator function.
» Replace damaged agitator.
» Take measures against product bridges in the hopper.
50 Alarm cut-outs ©Operating instructions (DDW-) TSR xx

Causes of malfunction, continuation
Screw jammed Foreign bodies in the product zone

» Remove foreign bodies and replace damaged components.
» Eliminate the reason for the penetration of the foreign body.
Screw diameter too big
» Change the combination screw/screw pipe.
Screw type not suitable
» Employ other screw type.
Discharge rate Activation of the drive

too low » Increase the speed of the drive.
Wrong screw execution
» Employ a screw with a suitable execution.
Changed product characteristics
» Employ a screw with a suitable execution.
» Adjust operating parameters.
©Operating instructions (DDW-) TSR xx Alarm cut-outs 51

7. Maintenance
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
Notes on maintenance 53
Component list 54
Care and examination 56
Cleaning 58
Description for the disassembly of individual components 61
52 Maintenance ©Operating instructions (DDW-) TSR xx

Notes on carrying out maintenance
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.
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.
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
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.
» Danger of cuts caused by the agitator and the screws.
Caution Therefore
- Use gloves when working on these components.
©Operating instructions (DDW-) TSR xx Maintenance 53

List of components

List of components, continuation
Component list No Component

1 Agitator drive motor
2 Agitator trough
3 Agitator drive shaft
4 Retaining plate (shaft sealing)
5 Cover of clutch coupling
6 Shaft sealing, agitator
(Nilos, LSTO, LSTO, Nilos, spacer, Prelon)
7 Screw drive motor
8 Spur gear
Speed monitoring
9 Inductive proximity switch
10 Clutch coupling
11 Rear flange bearing, screw
12 Spacer (product outlet opening)
13 Rear shaft sealing, screw
14 Sealing disk
15 Sealing
16 Motor support (= rear wall of trough)
17 Screw
18 Mounting plate
19 Sealing
20 Rear trough cover
21 Sealing
22 Screw trough
23 Front trough cover
24 Front shaft sealing, screw
25 Front flange bearing, screw
26 Cover of front screw bearing
27 Cover of cleaning hole (agitator trough)
28 Front agitator element
29 Rear agitator element

Care and inspection
Intervals Marking of the intervals:
W weekly 2W fortnightly
M monthly 3M three-monthly
Y yearly H biannually
Care Care works (T = time interval):

T Activities
W Filter bag/clean ventilation (if available)
2W Clean the device.
- Dust and loose contaminations have to be removed by means of
an industrial vacuum cleaner.
- Solid contaminations have to be removed with a (damp) cloth.
Examination Examination of the device (T = time interval)

T Component Examination
W Flexible connections Damages
W Fastenings Tight fit
2W Screw Wear, tear
2W Agitator Wear, tear
2W Mobile parts Functionality
2W Sealings Tightness
2W Shaft sealings Tightness
2W Locks Attraction force, tight fit
M Electrical connections Tight fit
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.

Care and inspection, continuation
Damaged shaft sealing Screw drive shaft

In case of a leaking sealing on the rear bearing
(= bearing on the drive)
• product flows via the drive shaft to the
product outlet opening (arrow)
• the product forms a deposit in the zone
(A) below the bearing.
Drive shaft, agitator

In case of a leaking sealing of the agitator drive shaft, product flows over the
drive shaft and behind the shaft sealing and then drops down. The product
forms a deposit on the screw bearing and laterally in the motor support.
Measure
In general, all sealing elements have to be exchanged In case of a leaking shaft
sealing.

Cleaning of the device
Specifications for cleaning
Design of the cleaning process

The dimensioning of the cleaning process by the operator helps to prevent any
danger to persons, the environment and the machine
• because appropriate/allowed cleaning tools are employed.
• the cleaning personnel works with the necessary protective equipment.
• no cross contaminations (feeding products, cleaning agents etc.) will be
produced.
Cleaning place The cleaning place must be suitable for

• the safe execution of the cleaning of the device.
• the correct neutralization and disposal of the resulting wastewaters.
Specifications for Permitted cleaning agents for the cleaning of components in contact with the
cleaning agents product have to comply with the following specifications:
• Not combustible
• Do not form any explosive or flammable vapours
• No scouring additives
• Temperature of use/working temperature ~ 20°C
• PH value between 4 - 10pH
• Comply with the requirements for the field of application of the device (e.g.
conformity to food processing regulations acc. to “NSF White Book™“)
Cleaning quality
For a consistent cleaning quality during the cleaning sequence be sure to observe
the “Sinner’s circle“. The cleaning quality is defined as the total sum from the
relation of the parameters temperature, time, chemistry and mechanics.

Cleaning of the device, continuation
Description of the cleaning processes

Matrix cleaning The following matrix lists possible cleaning procedures as a function of the
procedures application of the device.
Plastics/Global industries ATEX Hygienic, FOOD/Pharma

Dry cleaning X X* X
Controlled wet
X X
cleaning
Wet (COP) X X X
* only with an industrial vacuum cleaner that is approved for the ATEX zone.
Dry cleaning During dry cleaning, contaminations will be eliminated without use of a liquid
cleaning agent.
• Remove loose contaminations by means of an appropriate auxiliary (e.g.
industrial vacuum cleaner).
• Remove adhesive contaminations by means of a cloth.
Friction between different materials

Avoid static loading!
Controlled wet cleaning During a “controlled wet cleaning“ only components in product contact are
wet cleaned. The following specifications apply to a “controlled wet cleaning“:
• The following components have to be cleaned by means of a cloth, if required
the cloth can be moistened with water or a suitable cleaning agent.
- Bearings and electrical components
- Components that are not in contact with the product
- Lacquered components
• During wet cleaning of components in product contact, the components
stated above have to be protected from humidity.
• After cleaning
- the device/the component has to be dried thoroughly,
- remove standing moisture,
- possibly grease degreased components.

Cleaning of the device, continuation
Description of the cleaning processes, continuation

Wet cleaning (COP) All components to be cleaned are disassembled and cleaned at the provided
cleaning place (COP = clean out of place). The following example shows the
process of cleaning that meets very high standards:
• Precleaning with water
• Cleaning with a lye solution
• Periodic cleaning with water
• Neutralisation (possibly disinfection)/acid cleaning
• Final cleaning with low-germ (distilled) water
• The correct neutralization and disposal of the resulting wastewaters.

Assembly/disassembly of individual components
Disassembly of drive motor

1. Enable the drive motor.
2. Disconnect the electric connection of the drive motor.
3. Support the drive motor by means of a suitable carrying aid (carrying strap
and lifting equipment).
4. Disassemble the cover of the clutch coupling.
5. If available, disassemble the proximity switch of the speed monitoring.
6. Undo the fastening screws of the drive motor.
7. Loosen the drive motor cautiously out of the coupling by means of the
lifting equipment and transport the motor to a suitable storage location.
How to change the shaft sealing at the front bearing
Disassembly of shaft
sealings
1. Take off the fastening of the cover and the cover.

2. Loosen the fastening of the flange bearing and remove the bearing.
3. Pull off the sealing plate with the Prelon sealing.
4. Remove the sealing from the shaft.
Assembly of shaft 1. Loosen the Prelon sealing from the sealing plate.
sealings 2. Clean all elements.
3. Insert a new Prelon sealing.
(Alignment of the sealing lips → see detail drawing!)
4. Slide a new sealing onto the shaft.
5. Slide on the sealing plate with the Prelon sealing.
6. Slide on and fasten the flange bearing.
7. Assemble the cover.

Assembly/disassembly of individual components, continuation
How to change the shaft sealing of the rear bearing

Disassembly of shaft The drive motor and the speed monitoring have to be demounted. Steps for
sealings disassembly:
1. Pull off the clutch coupling.

2. Loosen the fastening of the hub and pull off the hub.
3. Loosen the fastening of the flange bearing and remove the flange bearing.
4. Remove the spacer.
5. Pull off the sealing plate with the shaft sealings.
6. Pull off the sealing that seals the bearing to the trough wall.
Assembly of shaft
sealings
1. Loosen the shaft sealings from the sealing plate.

2. Clean all elements.
3. Insert new shaft sealings into the sealing plate (B).
4. Slide on the new sealing that seals the bearing to the trough wall.
5. Slide on the sealing plate with the shaft sealings.
6. Insert the spacer.
7. Mount the flange bearing.
8. Mount the hub with the clutch coupling.

How to change the shaft sealings on the agitator

Disassembly of shaft For the disassembly it is necessary to demount the drive motor. Steps for
sealings disassembly:
1. Loosen the fastening of the retaining plate and remove the retaining plate.
2. Pull off the spacer with the Prelon sealing.
3. Remove the sealings from the shaft.
Assembly of shaft 1. Loosen the Prelon sealing from the spacer.

sealings 2. Clean all elements.
3. Insert a new Prelon sealing.
(Observe the alignment of the sealing lips!)
4. Slide the new sealings onto the shaft acc. to the order and alignment
shown in the illustration.
5. Slide on the spacer with the Prelon sealing.
6. Mount the retaining plate.

Disassembly of the screw
The following activity requires two people and a suitable carrying aid (lifting
equipment + 2 crane lugs).
1. Disassemble the drive motor.

2. Disassemble the trough cover.
3. Loosen the flange bearing from the front end of the screw shaft.
4. Disassemble the cover of the clutch coupling.
5. Pull off the clutch coupling.
6. Disassemble the rear shaft bearing.
7. Loosen the fastening of the drive console (forms the rear wall of the
trough) and cautiously remove the drive console.
8. Support the rear end of the screw shaft by means of a carrying aid
(carrying strap + lifting equipment).
9. An operator supports the front screw shaft.
10. The second operator cautiously removes the troughed screw conveyor out
of the trough by means of the carrying aid.
11. If the front screw shaft reaches the last cross brace of the screw trough, a
second carrying aid is fastened in the front part of the screw. Be sure to
observe an even weight distribution between two carrying aids.
12. Cautiously lift the troughed screw conveyor out of the screw trough and
store it in a suitable storage location.
13. Immobilise the troughed screw conveyor by means of the wooden
wedges, to secure it against rolling away.

Disassembly of the agitator
1. Remove the cover (1) of the cleaning hole (figure A).

2. Remove the locking screw (2) of the agitator by means of a hexagon box
spanner. Hold the front piece with your free hand.
3. Take the agitator out of the agitator trough and place it down in an
appropriate place (figure B; here: execution in two parts).
Assembly of the agitator

1. Clean all parts of the agitator thoroughly.
2. Slightly grease the agitator shaft.
3. Slide the agitator on the agitator shaft.
4. Secure the agitator with the screw.
5. Place on the cover of the cleaning hole and tighten all screwings.

Adjustment of speed monitoring

Depending on how the proximity switch has been mounted, the scanning
distance is visible or not visible. Therefore, the adjustment is carried out with
or without sight.
1. Pull the plug of the proximity switch.
2. Undo the locknut of the proximity switch.
3. Adjustment without sight
a. Slightly rotate the proximity switch against the toothed wheel.
b. 1-2 rotations counterclockwise.
If available: Observe the position of the angular plug.
Adjustment with sight
a. Set the distance to 1 mm.
4. Lock the proximity switch by means of the counternut.

8. Storage and disposal
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 68
Disposal of the device, of individual assemblies 69
©Operating instructions (DDW-) TSR xx Storage and disposal 67

Storage of the device, of individual assemblies
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
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)
68 Storage and disposal ©Operating instructions (DDW-) TSR xx

Disposal of the device, of individual components
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
» Danger of cuts caused by the agitator and the screws.
Caution Therefore
- Use gloves when working on these components.
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.
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
Vessel, pipes, sheets Metal scrap
Insulations According to material specifications
Boards Special waste
Accumulators, batteries Special waste
Plastic Disposal of plastics
©Operating instructions (DDW-) TSR xx Storage and disposal 69

Index
A O
Aeration 13, 29 Operating personnel, protection 8
Aeration, filter bag 29, 56 Operating personnel, qualification8
Agitator 6, 10, 11, 15, 17, 19, 20, Operation, allowed 16
36, 50, 53, 55, 56, 57, 63, 65, 69 Operation, no start 50
Agitator, trough 6, 15, 17, 19, 20, P
55, 65 Product outlet opening 55, 57
Assembly, execution 26 Product, appropriate 6
C Product, characteristics 6, 16, 39,
Connection, sleeve 29 43, 48, 51
Connection, step bellow 28, 29 R
D Residual energy storage 9
Disconnection, warning symbol 8, S
11 Safety grid 16
Drive 6, 11, 15, 20, 35, 40, 47, 55, Screw 6, 10, 15, 17, 19, 20, 21, 23,
61, 62, 63, 64 24, 28, 41, 45, 47, 50, 51, 55, 56,
Drive shaft 20, 21, 55, 57 57, 64, 65
Drive shaft, agitator 65 Shaft sealing 20, 55, 56, 57, 61, 62,
Drive shaft, screw 20, 64 63
E Speed monitoring 18, 24, 35, 55,
Earthing, correct 9 61, 62, 66
Environment, data 6, 24 U
G Use in accordance with the
Gear 55, 69 intended purpose 6
I V
Intended purpose 8, 46, 47 Ventilation 29, 56
L Ventilation, filter bag 29, 56
Load cell, free movement 41, 42 Ventilation, vacuum system 13, 29
Load cell, lever factor 42 Vertical outlet 20
M W
Mounting, tools 26 Wiring plan, CBplus 35
70 Storage and disposal ©Operating instructions (DDW-) TSR xx

ATEX - (DDW-) TSR XX - Operating Instructions (Rev.3.0 - April 2017)

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2 Safety ©Operating instructions (DDW-) TSR xx

©Operating instructions (DDW-) TSR xx Safety 3

4 Safety ©Operating instructions (DDW-) TSR xx

Content of the chapter “safety”:

©Operating instructions (DDW-) TSR xx Safety 5

Temperature: 0°C to +45°C

6 Safety ©Operating instructions (DDW-) TSR xx

Advanced demands during weighing

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

Modification of the field of application on site

©Operating instructions (DDW-) TSR xx Safety 7

Specifications for the operating licence of the device

Qualification of the operating personnel

Dangerous contact voltages on the device

8 Safety ©Operating instructions (DDW-) TSR xx

Disconnection of the device

Discharge of residual energy storages

Earthing of the device

©Operating instructions (DDW-) TSR xx Safety 9

Specification for the operation of the screw feeder

10 Safety ©Operating instructions (DDW-) TSR xx

Warnings on the device

Marks the allowed sense of rotation for the drive motor.

©Operating instructions (DDW-) TSR xx Safety 11

This paragraph describes the possible dangers that might occur in an

Product jam Danger: No free product flow

Product change Danger: Wrong equipment of the device

12 Safety ©Operating instructions (DDW-) TSR xx

Insufficient Danger: No pressure compensation in the product vessel

©Operating instructions (DDW-) TSR xx Safety 13

Content of the chapter “device descriptions”:

14 The description of the device ©Operating instructions (DDW-) TSR xx

©Operating instructions (DDW-) TSR xx The description of the device 15

Freely accessible product zone (open hopper)

Protective grid The hopper is equipped with a protective grid, if

The protective grid does not replace a hopper cover

16 The description of the device ©Operating instructions (DDW-) TSR xx

Safety: With the use of a quick-release clamping fastener or a corresponding

Safety: A quick-release clamping connection may also be equipped with a mechanical

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

Feeding organ and feed drive

Observe the execution!

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

Feeding organ and feed drive, continuation

Operating requirement: evaluation of the position monitoring

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

Feeding organ and feed drive, continuation

Bearing of the drive The illustration shows the construction of the

In case of a leaking sealing product flows via the

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

Feeding organ and feed drive, continuation

The markings in the illustration have the following meaning:

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