High Accuracy Feeders GDU 201 GDU 451
Operating manual 2008 edition High Accuracy Feeders GDU 201 GDU 451 Manufacturer: Gericke GmbH Max-Eyth-Straße 1 78239 Rielasingen Germany Phone +49 (0) 7731 929-0 Fax +49 (0) 7731 929-310 Website: http://www.gericke.net 18.38.5028.2.4 uk GDU 201/451 High Accuracy Feeders Contents 1 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 3 3.1 3.2 3.3 4 4.1 4.2 4.3 4.4 4.5 5 5.1 5.2 5.3 5.4 5.5 5.6 6 6.1 6.2 6.2.1 6.2.2 6.2.3 6.3 6.3.1 6.3.2 6.3.3 6.4 6.4.1 6.4.2 6.4.3 6.4.4 7 7.1 7.2 8 9 9.1 9.2 10 Introduction ....................................................................................................................................... 3 Safety.................................................................................................................................................. 4 Safety symbols .................................................................................................................................... 4 Intended use........................................................................................................................................ 4 Sources of danger ............................................................................................................................... 5 Other dangers ..................................................................................................................................... 5 Safety information for operator ............................................................................................................ 5 Noise emission .................................................................................................................................... 5 Workplaces ......................................................................................................................................... 5 Equipment of category II 1 D/G, 2 D/G and 3 D/G acc. to directive 94/9 ............................................ 5 Operation in explosive dust/air or gas/air atmosphere ........................................................................ 6 General safety instructions – erection, commissioning, cleaning, maintenance, troubleshooting ...... 6 Safety Instructions for feeder of category II 1D/G inside ..................................................................... 7 Design and function.......................................................................................................................... 8 Design ................................................................................................................................................. 8 Functional description ......................................................................................................................... 9 Operating conditions ........................................................................................................................... 9 Assembly.......................................................................................................................................... 10 General Points................................................................................................................................... 10 Storing of feeders .............................................................................................................................. 10 Inspection on delivery........................................................................................................................ 10 Installation of the machine ................................................................................................................ 11 Electrical connections........................................................................................................................ 11 Commissioning ............................................................................................................................... 12 General information ........................................................................................................................... 12 Checklist before trial run ................................................................................................................... 12 Trial run without product .................................................................................................................... 13 Trial run with product ......................................................................................................................... 13 Normal operation ............................................................................................................................... 13 Troubleshooting................................................................................................................................. 14 Repair and Maintenance ................................................................................................................. 15 General information ........................................................................................................................... 15 Disassembly of feeder ....................................................................................................................... 16 Metering nozzle ................................................................................................................................. 16 Metering tool...................................................................................................................................... 16 Intromitter .......................................................................................................................................... 17 Sealing between drive shaft and trough ............................................................................................ 18 Stuffing box seal (standard) .............................................................................................................. 18 Stuffing box seal by means of air purging (option) ............................................................................ 19 Shaft seal with air purging (option) .................................................................................................... 20 Servicing intervals ............................................................................................................................. 21 Tools.................................................................................................................................................. 21 Flat seals ........................................................................................................................................... 21 Shaft seals......................................................................................................................................... 21 Servicing intervals for accessories .................................................................................................... 21 Cleaning ........................................................................................................................................... 22 Cleaning the outside of the feeder .................................................................................................... 22 Cleaning the inside of the feeder....................................................................................................... 22 Troubleshooting .............................................................................................................................. 23 Spare parts....................................................................................................................................... 24 General information ........................................................................................................................... 24 List of spare parts .............................................................................................................................. 24 Disposal ........................................................................................................................................... 25 GmbH 18.38.5028.2.4 uk Page 2 GDU 201/451 High Accuracy Feeders 1 Introduction This operating manual has been written especially for personnel entrusted with the installation, dismantling, commissioning, operation, maintenance and repairing of the GDU High Accuracy Feeders. All information contained in this operating manual must be observed to ensure troublefree operation. Failure to comply with the recommendations, especially those in connection with safety, may result in personal injury to operation or maintenance staff or damage being done to the unit itself or associated equipment. This operating manual must always be within reach. The manufacturer is not liable for any damage or faults due to non-observance of the information in the manual. Gericke reserves the right to make technical modifications which serve the purpose of further developing or improving on the individual features of the feeders. This operating manual refers to the feeders described in the technical data sheet and includes information on various options. The conditions specified in this data sheet may not be exceeded. Moreover, separate documentation relating to options and accessories can be found in the appendix. GmbH 18.38.5028.2.4 uk Page 3 GDU 201/451 High Accuracy Feeders 2 Safety The operator must ensure that all employees entrusted with the installation, dismantling, commissioning, operation, maintenance, cleaning and repairing of the machine read and observe the instructions in the operating manual, in particular those in connection with safety. 2.1 Safety symbols This sign marks potentially dangerous parts of the feeders. It requests the user to be particularly careful. Please observe the relevant safety notes in the operating manual. Danger These danger signs indicate all particularly important safety information in this operating manual. This information has to be observed at all times. Non-observance can cause serious injury to the operator. Danger of explosion This warning sign indicates all particularly important safety information in this operating manual. This information has to be observed exactly in order to avoid damage being done to the device. Attention 2.2 Intended use These High Accuracy Feeders can cause serious damage if not put to proper use and if not used for the purpose intended. The feeders may only be used in product and operating conditions, e.g. temperature and installation position etc., as described in the technical data sheet. The operating conditions according to chapter 3.3 and 2.11, or settings laid down by the manufacturer for the operation of the geared motor unit and the inverter (optional), must be kept to. Adherence to conditions for erection, dismantling, commissioning, operation, cleaning and maintenance forms a vital part of proper usage. GERICKE does not assume any liability for damage resulting from non-compliance with the indicated conditions. Unauthorised alterations and changes which impair safety and function of the device are prohibited. Written confirmation from GERICKE is required before carrying out any alterations. Only the use of original spare parts is allowed. We cannot guarantee that spare parts purchased elsewhere have been designed and manufactured in accordance with safety and load requirements. GmbH 18.38.5028.2.4 uk Page 4 GDU 201/451 High Accuracy Feeders 2.3 Sources of danger The High Accuracy Feeders and additionally required parts have been designed in accordance with the state of the art and equipped with the latest safety measures. Nevertheless, incorrect operation or use can be sources of danger. Before carrying out any work on the machine requiring safety devices, such as trough lid, metering pipe, sleeve connections, terminal box cover etc., to be put out of operation, it is essential that the device is switched off. Additionally, it must be protected against unintentional restart; e.g. lockable switch (not within the scope of delivery). Doors and flaps may only be opened after the machine has been switched off and secured against unintentional restart and once the drive of the machine has come to a complete standstill. Never remove safety devices or put them out of operation by modifying the system. 2.4 Other dangers The GDU High Accuracy Feeders are not ready for use when delivered by the manufacturer. They may only be operated once the user has connected all electrical devices to the mains professionally. Inputs and outputs as well as rotating parts (e.g. metering tool, intromitter) and any open flange couplings must be secured by safety devices against non-authorised action according to DIN EN 294. The operating company must also ensure that non-authorised persons neither work in any way on the machine nor put it into operation. A cloud of dust may emerge when opening the feeders for cleaning and maintenance purposes. Even if the safety instructions have been kept to, leakage or some sort of mechanical damage to the feeders can arise. A cloud of dust can escape through seals and screw connections. 2.5 Safety information for operator Any work to be carried out on or with the unit may only be done by specially trained or suitably instructed personnel. The operator must equip the machine with a suitable emergency switch-off mechanism. After the completion of electrical installation or repair work, protection measures (e.g. safety limit switches and grounding) must be inspected. In addition to this operating manual, the applicable legal or otherwise relevant accident prevention and environmental protection regulations must be observed and their observation by others be monitored. 2.6 Noise emission The A-rated equivalent permanent sound pressure level of these machines (without metering helix/with intromitter) is less than 70 dB(A), measured during idle running. The reading was carried out one metre from the outside of the trough and 1.6 metres above the base plate. 2.7 Workplaces As the machines are not ready for use on delivery, no specific workplace is indicated. The workplaces are determined once the unit has been integrated into the plant as a whole. If the unit is installed in a plant with an automatic filling device, the workplace during the metering process is not specified. 2.8 Equipment of category II 1 D/G, 2 D/G and 3 D/G acc. to directive 94/9 In potentially explosive areas, only feeders which are suitable for those conditions may be used (category II 1 D/G, 2 D/G and 3 D/G). GmbH 18.38.5028.2.4 uk Page 5 GDU 201/451 High Accuracy Feeders 2.9 Operation in explosive dust/air or gas/air atmosphere For the operation of the feeders in explosive dust/air and gas/air atmosphere, all relevant regulations have to be observed. These are in particular: 2.10 • Directive concerning the use of electrical equipment in explosive areas • Directive regarding non-electrical devices in areas prone to explosion (guideline 94/9/EC) • Directives governing machinery • Operational safety directive (national) • Explosion protection directive (Guideline 1999/92/EC) • Directive concerning hazardous materials • Accident Prevention Regulation (UVV) • Other DIN, VDE and EN guidelines General safety instructions – erection, commissioning, cleaning, maintenance, troubleshooting • Undertake prescribed tasks for maintenance and inspection at specified intervals. • Inform operating staff before commencing maintenance and servicing work. • Safeguard all the components and operating media connected upstream and downstream to the feeders against accidental starting. • Switch off the feeders when any maintenance-, inspection or repair work is being carried out. • Safeguard the main switch against an unexpected restart. • Close the main switch and take out the key (not in GERICKE’s scope of delivery). • Use warning sign to ensure restart is not activated. • Adhere to safety guidelines for the product to be metered. • Deduce the personal safety measures from the safety datasheet. • Dangers arising due to contact or inhalation of dangerous dust and gases are to be ruled out by using the relevant safety measures. • Fasten and secure bigger assemblies carefully on lifts during replacement. • Replace defective parts immediately. • Check whether all threaded joints are securely fastened. • After completion of maintenance work, test safety appliances for normal functioning. GmbH 18.38.5028.2.4 uk Page 6 GDU 201/451 High Accuracy Feeders 2.11 Safety Instructions for feeder of category II 1D/G inside • The volumetric feeders can only be used for dust with a MIT > 200 °C, a layer temperature > 210 °C and a MIE > 1 mJ. • In the case of inflammable gases or vapours, the following points have to be observed (see category of feeder): a) Category 1 (inside the feeder) The MIT of the gases or vapours has to be > 163 °C b) Category 2 (inside and outside of the feeder) The feeders have a max. surface temperature of 130 °C and fulfil the requirements of temperature class T4 (T3, T2, T1). • Teflon inserts inside the metering nozzles cannot be used. Only an insert of conductible material or material with a disruptive voltage of less than 4 kV can be used if plastic ones are to come into operation. • If the product to be metered has a tendency to self–ignite, the feeder has to be emptied and possibly cleaned if it is out of operation for any length of time. • Continuous earthing of all conductive parts of the feeder has to be guaranteed. • The device is to be earthed on site. • Up- and downstream equipment requires the same protection as the feeder (avoiding potential ignition sources). If up- and downstream equipment is protected by constructive explosion measures (e.g. explosion pressure proofed design), the feeder has to be isolated from that equipment by ex proofed protection systems according to RL 94/9. • The High Accuracy Feeders may only be used if the material they are made of is so resistant to corrosion or to mechanical, thermal and chemical influences caused by the product to be metered or by operating conditions that the ex protection of the feeder is not eliminated. • Attached parts have to be selected and installed appropriately to correspond with the required zones and processing conditions. If gases and vapours of explosion group IIC are involved, the thickness of the colour coat (< 0.2 mm) has to be observed. GmbH 18.38.5028.2.4 uk Page 7 GDU 201/451 High Accuracy Feeders 3 Design and function 3.1 Design Attention GmbH 1 Metering nozzle 3 Metering tool 4 Seal (front plate) 5 Trough 6 Shaft seal drive shaft of intromitter 7 Shaft seal drive shaft of metering tool 9 Intromitter 22 Geared motor unit for metering tool 23 Geared motor unit for intromitter The feeders can be equipped with different metering tools in various sizes depending on the bulk material to be metered. Benefit from our experience and contact us or our representatives. We do not assume any liability whatsoever in case of damage caused by metering unsuitable bulk material. 18.38.5028.2.4 uk Page 8 GDU 201/451 High Accuracy Feeders 3.2 Functional description The GDU High Accuracy Feeders are used for the metering of bulk material. The metering tool is driven by a geared motor unit. The output volume flow can be varied by adjusting the rpm of the drive for the geared motor unit. The intromitter is driven by a geared motor unit with constant rpm (inverter optional) and therefore ensures homogenisation as well as reliable transport of the bulk material to the metering tool. As a result of this, high accuracy is achieved even when metering products with poor flowing properties. 3.3 Operating conditions Ambient temperature: 0 to + 40 °C Place of installation: Indoors, dry, roofed over, no corrosive air pollution, protection against permanent humidity and UV rays. Height of assembly: Maximum 1000 m above NN Product temperature: 0 to + 80 °C Mode of operation: Zero pressure (please contact us or our representative for information in connection with pressure-superimposed devices). For other operating conditions, refer to the technical data sheet and to the enclosed documentation provided by the manufacturer of the geared motor unit and inverter. GmbH 18.38.5028.2.4 uk Page 9 GDU 201/451 High Accuracy Feeders 4 Assembly 4.1 General Points Danger of injury Personnel should be very careful when lifting, lowering and assembling the feeders and only use suitable lifting tools as well as protection wear. Danger Warning Electrical connections should only be dealt with by qualified personnel. Regulations stipulated by the manufacturer of the motor must be adhered to (find attached). Attention Danger of explosion 4.2 Danger of explosion During maintenance, assembly and service, any risk of an explosive atmosphere (dust clouds) must be eliminated. Before assembly, pay attention to the attached operating instructions concerning separate components. We recommend sending for our specialists for proficient assistance during assembly. GERICKE does not assume any liability in case of damage done on account of unqualified work carried out by staff not employed by Gericke. Storing of feeders If the feeders are not put to use straight away, they have to be stored in suitable conditions so that trouble free operation does not present difficulties later. They have to be protected against frost, damp, dirt and mechanical influences. The following storage conditions are recommended: • Vented storage room free of dust and shock proof • Relative humidity max. 80% • Temperature when storing between -20°C and +70°C • Direct heat (sun, radiator) to be avoided. Storage tips concerning the geared motor units and inverters can be found in the separate documentation supplied by the manufacturer. 4.3 Inspection on delivery The machine is supplied fully assembled. Before installation of the machine, the delivery must be inspected with regard to the following: • check that all parts have been supplied (refer to the order confirmation) • transport damage • model designation (refer to the technical data sheet/order confirmation) • supply voltage of the electrical system GmbH 18.38.5028.2.4 uk Page 10 GDU 201/451 High Accuracy Feeders 4.4 Installation of the machine The feeders must be positioned horizontally on a stable, torsion-resistant base construction and installed free of tension. Flanges must be rectangular, plane and crack- and crevice-free. The four through borings (Ø 13 mm) are intended for screwing the feeder to the base construction. The product feeding device (e.g. feeding silo, filling tank) must be screwed to the upper trough flange of the hopper. Rotating parts, such as metering tool and intromitter must be covered by an appropriate safety device in line with the DIN EN 294 standard. Danger 4.5 Electrical connections The feeders can be equipped with various drive motors. This means that the electrical connections also vary. The drive motors used with this device are specified in the technical data sheet. The connection value can be seen on the type plate fixed to the drive motor. For connecting purposes, either the appropriate VDE regulations are valid or other rules and regulations in force in the country where the feeder is assembled. Any safety limit switches must be integrated in the start-up control of the drive motors in accordance with the regulations valid in the country where the feeder is assembled. The additional documentation for the electrical accessories is to be kept to. GmbH 18.38.5028.2.4 uk Page 11 GDU 201/451 High Accuracy Feeders 5 Commissioning 5.1 General information Commissioning of the feeders cannot be carried out in the countries of the EU until such time when it has been established that the machine conforms to the regulations of EU-directives for machines, the common norms, European norms or the relevant national norms. A trial run without the product is essential before the feeder can be put into operation. A trial run must also be carried out: • after a breakdown • after a prolonged holdup • after any repair work or maintenance work has been carried out • if the feeder has been reinstalled, for instance, after having been in storage Before the trial run, it is essential to check that the metering tool and intromitters are screwed tight. It may be necessary to tighten the screws manually. Tighten loose screws on the front panel. Attention Attention: The metering tool and the intromitter are screwed on with left-handed thread. Before commissioning, the operating manual must be read thoroughly. Danger 5.2 We recommend consulting our specialists for professional assistance when commissioning and when training operators and staff, hereby guaranteeing a thorough training. This will in turn result in shortening of time required for commissioning. Checklist before trial run Tick off each point when found to be satisfactory. Eliminate defects before you put the feeder into operation. • Ensure that there are no tools or other items (screws etc) in the feeder. • The motor power supply cables must be connected so that they comply with the local specifications and are fuse-protected. • The arrow indicating the direction of rotation must be attached to the feeder. • The feeder must be earthed. • The level of gear oil must be in accordance with the gear manufacturer’s operating instructions. • Check the connections of inter-connecting lines for tight enough fit and impermeability. • Check whether earthing of the device has been carried out as specified. GmbH 18.38.5028.2.4 uk Page 12 GDU 201/451 High Accuracy Feeders 5.3 Trial run without product Clothes can get stuck in the rotating metering tool and intromitter and the person concerned may be seriously injured. Only operate the feeder when all protection devices have been placed in position. Danger Pay attention to the following points when carrying out a trial run without product: 5.4 • Smooth, vibration-free working of the screw and intromitter • There should be no abnormal sounds, e.g. grinding noises, coming from the bearing. • Compare power input of the motors with the information given in the operating instructions provided by the motor manufacturer. • Check for any noise and overheating coming from the driving units. • Direction of rotation of metering tool and intromitter should conform to the arrow on the device. • Leakages in connection with the geared motor units • Dust emission from the sealings Trial run with product Make sure that there are no foreign substances in the product, especially nothing metallic. If necessary, sieve the product before feeding. Danger This trial run may not be carried out until the one without product has been completed and all the defects have been eliminated. The minimum filling level must be 100 mm above the trough flange. Pay attention to the following points when carrying out a trial run with product: • Smooth running of metering tool and intromitter with minimum amount of vibration • There should be no abnormal sounds, e.g. grinding noises coming from the bearing. • Compare power input of the motors with the information given in the operating instructions provided by the motor manufacturer. • Noise and heating development coming from the driving units • Direction of rotation of metering tools and intromitter should conform to the arrow on the device. • Leakages in connection with the geared motors • Dust-escaping through the seals The feeding rate required can be set by measuring change in weight of the product at 1-minute intervals and by varying the rpm. 5.5 Normal operation The feeder is constructed for continuous operation. The operator must ensure that problems do not arise on account of insufficient cleaning or product sticking to the sides. GmbH 18.38.5028.2.4 uk Page 13 GDU 201/451 High Accuracy Feeders 5.6 Troubleshooting Before starting the feeder, familiarise yourself with the instructions concerning problem-solving. If problems do occur, you will then be able to deal with them quickly and effectively. Please contact us or our representatives if you require assistance. Should problems arise, stop the feeder and any components connected to it immediately. Attention GmbH 18.38.5028.2.4 uk Page 14 GDU 201/451 High Accuracy Feeders 6 Repair and Maintenance 6.1 General information When carrying out maintenance, cleaning and servicing, the general safety instructions in this operating manual should be kept to. Operational safety and service life of the feeders depend on proper maintenance and servicing along with several other factors. Maintenance specifications in the appendix of this manual are to be adhered to, along with the instructions below. We recommend appointing Gericke personnel to undertake repair work on the feeders when it first becomes necessary. Your maintenance personnel can then be trained at the same time. The following should be observed when carrying out repair work. We recommend you maintain a stock of spare parts. Spare parts that have become unusable after disassembly need to be replaced. During the warranty period, the feeder may only be disassembled with the approval of the manufacturer. The conveying system must be shut down and secured against accidental starting when any maintenance and inspection work on the feeder or its accessories is being carried out. Danger Electrical connections are to be dealt with exclusively by qualified technicians! Specifications of motor manufacturer to be adhered to. Attention During maintenance, assembly and servicing, ensure that the atmosphere is not explosive (e.g. dust clouds). Maintenance specifications in the appendix of this manual and the instructions below are to be kept to. Danger of explosion GmbH 18.38.5028.2.4 uk Page 15 GDU 201/451 High Accuracy Feeders 6.2 Disassembly of feeder 6.2.1 Metering nozzle Loosen the cap nut and the 6 hexagonal bolts M6 or M10 (wrench size 13 or 17) with a suitable tool and remove. Then the front plate of the metering nozzle can be taken off. Always make sure that no pressure is put on the metering tools from the side. Check flat-seal when re-assembling and replace it, if necessary. 6.2.2 Metering tool The metering tool is fixed to the drive shaft of the motor for the metering tool by means of a M20 left-handed thread.. All the metering tools are equipped with a hexagon at their rear (wrench size: 30) by means of which they can be loosened with a fork wrench when turned in a clockwise direction. Additionally, all metering tools have a hexagon trunnion in their centre by which all the metering helixes can be loosened with a corresponding socket wrench and the full flight screw with a fork wrench. If the drive shaft for coarse feeding also rotates, this can be locked behind the stuffing box by means of a SW 22 fork wrench. Beforehand, remove the protective plate on the side and fix it in place again immediately afterwards. GmbH 18.38.5028.2.4 uk Page 16 GDU 201/451 High Accuracy Feeders 6.2.3 Intromitter The metering tool is fixed to the drive shaft of the applicable drive motor by means of a left-handed M 16 or M 30 thread. The intromitter can be loosened by turning the hexagon at its far end in a clockwise direction using a SW 24 or SW 46 fork wrench. Additionally, there is a hexagon trunnion at the front end of the intromitter by means of which it can be unscrewed when turning in clockwise The intromitter is fixed to the drive shaft of the applicable drive motor by means of a left-handed M direction. If the drive shaft also rotates, this can be locked behind the stuffing box by means of a SW 22 fork wrench. Before doing this, remove the protective plate on the side and fix it in place again immediately afterwards. GmbH 18.38.5028.2.4 uk Page 17 GDU 201/451 High Accuracy Feeders 6.3 Sealing between drive shaft and trough There are various ways of sealing drive shafts, metering tool /intromitter in connection with the wall of the trough (see below). Please consult the technical data sheet for information on the sealing used here. 6.3.1 Stuffing box seal (standard) On delivery of the device, the sealing rings (item 6.4) of the stuffing box are already pre-tensioned. They can be tightened by approx. 10 mm. Retightening of the sealing rings is necessary if product escapes from the trough between driving shaft and sealing rings. The stuffing box lid, pos. 6.2, is then pressed into the stuffing box package by means of the corresponding M6 hexagonal bolts. If the sealing rings have been tightened as much as is possible, then the sealing rings, pos.6.4, as well as the pressure disk, pos. 6.3, can be replaced. A slit has been made in the sealing rings for easier fitting. Attention When tightening the sealing rings, pos.6.4, make sure that the surface of the rotary shaft is not damaged by the increased friction between sealing rings and shaft surface. The drive motor should not be overcharged, since it could otherwise be damaged or suffer from excessive wear. Make sure you take note of any temporary increase in the temperature of the stuffing box seal following modification or re-tightening. This may occur in particular when being used in explosive areas. Maximum surface temperature should not exceed that indicated in the technical data sheet. Danger of explosion GmbH 18.38.5028.2.4 uk Page 18 GDU 201/451 High Accuracy Feeders 6.3.2 Stuffing box seal by means of air purging (option) This special type of stuffing box seal allows pressing of sealing gas into the air chamber between sealing rings, pos 6.4 and the rotary shaft lip seal, pos. 6.10. The hose with the purge air passing through it (outer diameter of 8 mm) is connected to the ring angled plug. The pressure of the air on the sealing is set at 0.2 to 0.5 bar by means of a pressurereducing station (optional). Air consumption is about 0.01 m³/min. On delivery of the device, the sealing rings, pos. 6.4 of the stuffing box package, have already been pre-tensioned. They can be tightened by approx. 10 mm. It is necessary to tighten the sealing rings if too much sealing gas penetrates into the interior of the trough between sealing rings and driving shaft or if product escapes between driving shaft and sealing rings. The stuffing box seal lid, pos. 6.2, is then pressed into the stuffing box seal package by means of the corresponding M6 hexagonal bolts. If the sealing rings have been tightened on several occasions, it is quite likely that any further increase of tension is not possible. If this is the case, the sealing rings, pos. 6.4, and the pressure disk 6.3 as well as the rotary shaft lip seal, pos. 6.10, can be replaced. A slit has been made in the sealing rings for easier fitting. Attention When tightening the sealing rings, pos. 6.4, make sure that the surface of the rotary shaft is not damaged by the increased friction between sealing rings and rotary shaft surface. The drive motor must not be overcharged either as it could otherwise be damaged or suffer from excessive wear. Make sure you take note of any temporary increase in the temperature of the stuffing box following modification or re-tightening. This may occur in particular when being used in explosive areas. Maximum surface temperature should not exceed that indicated in the technical data sheet. Danger of explosion GmbH 18.38.5028.2.4 uk Page 19 GDU 201/451 High Accuracy Feeders 6.3.3 Shaft seal with air purging (option) This special type of shaft seal with air purging allows pressing of sealing gas into the air chamber between the packing rings pos. 5.3. The hose with the purge air passing through it (outer diameter of 8 mm) is connected to the ring angled plug. The pressure of the air on the sealing is set at 0.2 to 0.5 bar by means of a pressurereducer station (optional). Air consumption is about 0.01 m³/min. Remove the circlip (5.9) with a special gripper. After this, remove the first shaft seal (5.8), the first PTFE-disk (5.3), the second shaft seal (5.8), the bush (5.2), the third shaft seal (5.8) and the second PTFE-disk (5.3). Check all shaft seals, PTFE disks and flat seal (5.4) and replace them, if necessary. Assembly takes place in reverse order. GmbH 18.38.5028.2.4 uk Page 20 GDU 201/451 High Accuracy Feeders 6.4 Servicing intervals The servicing intervals indicated are average values based on experience. As we cannot provide information on every possible bulk material, we recommend deciding on the servicing intervals in accordance with your own experience with the product to be metered. They can also be adapted to in-house schedules, e.g. cleaning routines. Servicing intervals indicated here should however never be exceeded. In general, we recommend daily visual inspection with particular attention being paid to the following: 6.4.1 • degree of contamination (refer to Chapter 7 for cleaning) • noises • damage • function • secure fastening of protection devices • Check electric connections and ground cable for damage, secure fastening and strain relief. Tools Metering nozzle, metering tool and intromitter must be checked for wear every three months. If abrasive products are being metered, parts must be checked once a month. 6.4.2 Flat seals The flat seal of the front plate, stuffing box and possibly trough flange seal must be checked during cleaning or if leaking occurs. They must be replaced, if necessary. 6.4.3 Shaft seals If the metering system is constantly in operation, tightness of the shaft seal must be checked every three months. If abrasive products are being metered, then this should take place once a month. If the stuffing box needs tightening on account of leakage of product, proceed as described in chapters 6.3.1 and 6.3.2 above. Attention When tightening the sealing rings, pos.6.4 (7.4) make sure that the surface of the rotary shaft is not damaged by the increased friction between sealing rings and rotary shaft surface. The driving motor must also not be overcharged, since it could otherwise suffer damage, or excessive wear could be the result. Make sure you take note of any temporary increase in the temperature of the stuffing box after modification or retightening of the packing. This may occur in particular when being used in explosive areas. This temperature should not exceed the maximum surface temperature specified in the technical data sheet. Danger of explosion 6.4.4 Servicing intervals for accessories Information on servicing intervals for geared motor units, level indicator, solenoid valves etc. can be found in the corresponding manuals (part of the documentation). GmbH 18.38.5028.2.4 uk Page 21 GDU 201/451 High Accuracy Feeders 7 Cleaning The feeders must be disconnected from the power supply and secured against accidental starting before cleaning can begin. Danger Dust layers on the feeders can form an explosive cloud as a result of a draught or pressurised air. Dust layers have to be removed for this reason. Danger Cleaning intervals depend on the amount of dust and have to be decided on by the operator. Clean by wiping, brushing and vacuuming (never by means of pressurised air). Danger of explosion 7.1 Cleaning the outside of the feeder Depending on the type and degree of product residue: 7.2 • Clean the device with a vacuum cleaner. • Clean with water max. 80°C (add mild cleaning agent, if necessary). Do not use water jets. Observe the protection class of the drive motor. Cleaning the inside of the feeder Make sure that no material can flow into the trough. Depending upon the degree of soiling, the unit can be dismantled in several stages (see chapter 6). The trough can be flushed with water or vacuumed with a suitable device. Ensure that the temperature does not exceed 80°C so as not to damage the sealing parts. Do not use aggressive cleaning detergents. Check sealings for damage and replace them, if necessary. GmbH 18.38.5028.2.4 uk Page 22 GDU 201/451 High Accuracy Feeders 8 Troubleshooting Before performing the work described below, the high accuracy feeder must be isolated from the power supply and secured against accidental starting. Danger Type of fault/malfunction Possible reason Remedy Metering helix or intromitter does not rotate. No voltage to the corresponding geared motor. Check main switch, protective motor switch, emergency-off system and power supply lead. Loud noises in the trough. Distorted intromitter or metering Replace defect parts, clean tools due to foreign substances in trough and sieve bulk material the bulk material. before it reaches the trough. Direction of rotation of drive motor is incorrect. Check direction of rotation and change it, if necessary. Device is leaking. Corresponding sealing fitted incorrectly or defect. Fit sealing properly or replace it. Device does not meet with performance characteristics indicated in the order confirmation. Incorrect tools chosen or characteristics of the bulk material have changed. Please contact us or our representative. Bulk density differs from the bulk density specified in the order confirmation. Use the appropriate metering tool. Please contact us or our representative. GmbH 18.38.5028.2.4 uk Page 23 GDU 201/451 High Accuracy Feeders 9 Spare parts 9.1 General information It is very important to stock the most important spare and wear parts on site to ensure continuous operation of the feeder. GERICKE GmbH is not liable for any damage arising from the use of spare parts purchased elsewhere. When ordering spare parts, please indicate the type and serial number of your feeder, length and size of the metering nozzle and metering tools as well as the seal variation for the metering tool and intromitter (in accordance with the technical data sheet). 9.2 List of spare parts A list of spare parts is an integral part of the documentation. GmbH 18.38.5028.2.4 uk Page 24 GDU 201/451 High Accuracy Feeders 10 Disposal The delivered machine is a robust construction and a long life product. Should it nevertheless be necessary to dispose of it one day, then there are various ways of doing this: • Send the machine back to the producer with no product in it. GERICKE will then dispose of it appropriately. The customer will be charged with costs for proper environmentalfriendly disposal. • The customer disposes of the machine himself. The system consists of electric and electronic parts (separate disposal) as well as plastic and metal ones. The machine has to be disassembled completely and the different materials separated. Disposal will then be carried out by local disposal companies or municipal authorities. GmbH 18.38.5028.2.4 uk Page 25
© Copyright 2024