Operating Instructions

Weigh-belt feeder

DBW-G1/ 350 a

Seriel number:

Order no. Customer:

Date:

Please preserve for future utilization!

Edition: 06.12.1994

Revision: 1.0

BRABENDER Technologie KG
Kulturstraße 55-73
D-47055 Duisburg

Telephone: 0203/9984-0
Telefax: 0203/9984-155

© BRABENDER Technologie KG, 1994 Copyright as per DIN 34 B1110083.doc

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Table of contents

Table of contents
Chapter Page
1. General remarks ............................................................................................................. 2
1.1 Symbols and abbreviations .............................................................................. 3
2. Technical data................................................................................................................. 4
2.1 Data sheet........................................................................................................ 4
2.2 Noise measurement......................................................................................... 4
3. Design and function ........................................................................................................ 4
3.1 Design .............................................................................................................. 4
3.1.1 Housing ......................................................................................................... 4
3.1.2 Support frame ............................................................................................... 5
3.1.3 Belt drive ....................................................................................................... 5
3.1.4 Belt tensioning system .................................................................................. 5
3.1.5 Belt guides .................................................................................................... 5
3.1.6 Inlet shaft ...................................................................................................... 5
3.1.7 Material guide plates ..................................................................................... 6
3.1.8 End scraper................................................................................................... 6
3.1.9 Weighing unit ................................................................................................ 6
3.2 Functioning....................................................................................................... 6
3.3 Manipulation..................................................................................................... 7
4. Safety.............................................................................................................................. 7
4.1 Use in accordance with the intended purpose ................................................. 7
4.2 Indication of dangers and danger zones.......................................................... 7
4.3 Dangers arising from non-observance of safety instructions........................... 7
4.4 Safety instructions for the user of the plant...................................................... 7
4.5 Safety instructions for operation and maintenance work ................................. 8
4.6 Remaining hazards .......................................................................................... 8
4.7 Consequences of arbitrary modifications......................................................... 8
5. Transport and storage .................................................................................................... 9
5.1 Checking of the scope of supply ...................................................................... 9
5.2 Transport.......................................................................................................... 9
5.3 Storage............................................................................................................. 9
5.4 Packing and marking ................................................................................................... 9
5.5 Degree of assembly ...................................................................................................... 9
6. Mounting ......................................................................................................................... 10
6.1 Instructions for mechanical and electrical installation................................................... 10
6.5 Installation conditions.................................................................................................... 11
6.6 Mounting tools............................................................................................................... 11
7. Start-up and operation ................................................................................................................. 12
7.1 Preliminary checks........................................................................................................ 12
7.1.1 Electrical checks ........................................................................................... 12
7.1.2 Mechanical checks........................................................................................ 12
7.2 Static inspection............................................................................................................ 13
7.2.1 Checking of the adjustable drives ................................................................. 13
7.2.2 Checking the weighing system ..................................................................... 13
7.3 Commissioning with product......................................................................................... 14
8. Maintenance and repair .................................................................................................. 15
8.1 Maintenance and inspection list ....................................................................... 15
8.2 Disassembly and reassembly .......................................................................... 16
8.2.1 Belt change ................................................................................................... 16
8.2.2 Exchange of the load cell.............................................................................. 17
8.2.3 Exchange of the bearing ............................................................................... 17
9. Trouble-shooting ............................................................................................................. 18
10. Spare parts ................................................................................................................... 18

1. General remarks

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Weigh-belt feeder

Only with the aid of this operating manual it is possible to install, set, operate and maintain
the DBW. The manufacturer recommends that the operating manual is read through
carefully, since he does not accept liability for damage resulting from non-observance of this
operating manual. The operating manual should always be kept ready to hand for the
operator.

If difficulties arise which cannot be corrected by the user of the weigh-belt feeder, he should
contact the service department of the manufacturer.

Changes in design and construction, for the purpose of improving the device, are reserved.

1.1 Symbols and abbreviations

Identification key DBW

-- --

Belt width in mm

Regulated belt drive

Feeding system DBW

Explanation of the abbreviations

DB Feeding belt
DBW Weigh-belt feeder
DDW Loss-in-weight feeder
M modular
R Agitator
BAV Bin activator

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2. Technical data

2.1 Data sheet

Dimensions (over all)

Type of feeder LxWxH

DBW-G1-150 1120 x 535 x 505
DBW-G1-350 1640 x 630 x 535
DBW-G1-600 1860 x 890 x 535

Please find further technical data of your weigh-belt feeder on the separate data sheet that is
loosely supplied.

2.2 Noise measurement

The emission value of 80 dB(A) (working place) is not exceeded.

3. Design and function

3.1 Design
The weigh-belt feeder is essentially made up of the following elements:

Fig. 1: Design of the weigh-belt feeder

Legend:
1. Housing 4. Belt tensioning system
2. Support frame 5. Belt drive
3. Belt drive 6. Inlet shaft

3.1.1 Housing

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The housing is a steel plate construction. The base of the housing is bolted on.

Four bore holes in the lower flange of the housing are provided for mounting the housing on
a frame or base. Removable covers are fitted to the front, back and top. The lateral covers
can be fitted or removed with quick release fastenings. The top covers are loosely put on.
The housing is equipped to take the conveyor belt with the weighing unit. For DBW-G1/350
and DBW-G1/600 the chain drive is mounted at the rear of the housing.

3.1.2 Support frame

The support frame is a robust, high quality steel construction. It is the base on which the
drive roller, guide roller, weighing unit, belt guides and several scrapers are located and it
enables the complete conveyor belt to be assembled in the housing.

3.1.3 Belt drive

A dc gear motor is used as belt drive. The speed is monitored by a tachometer fitted on the
dc gear motor. The drive transmission to the belt is done by means of appropriate sprocket
wheels and chains. The complete drive unit is variably fitted to the housing in order to allow
tensioning of the chain.

In case of special designs the belt frame can be detached. Here, the belt frame is provided
with a plug connection in order to allow an easy disconnection.

Belt slippage is prevented by the rubber coated drive roller in connection with the weight-
loaded tensioning system. The scraper mounted on the inside of the drive roller prevents the
roller from becoming dirty.

3.1.4 Belt tensioning system

The guide roller located at the discharge side of the belt is equally designed to function as a
belt tensioner. Tensioning of the belt is done by means of a weight acting on the guide roller
via a lever.

3.1.5 Belt guides

The automatic belt guidance system is fitted at the lower part of the belt. It consists of a roller
with a frame, which has the function of both, a plough-shaped scraper and a belt guide. The
whole assembly is able to swivel around a central fixing bolt. When the belt runs towards the
side, the frame swivels in such a way that the guiding roll runs at a slight angle to the belt
and corrects its direction.

3.1.6 Inlet shaft

The product inlet shaft with its adjustable slide valve is firmly bolted to the housing. The slide
valve serves to adjust the desired cross sections of the outlet, and thus determines the belt
load. In no case it must be used as a shut-off valve. The product inlet shaft is only suitable
for flowable materials. A special prefeeder is required for poorly flowing materials.

The product inlet shaft is only suitable for flowable materials. A special prefeeder is
required for poorly flowing materials.

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3.1.7 Material guide plates

Two material guide plates with adjustable height limit the sides of the belt. The guide plates
are mounted to the housing.

3.1.8 End scraper

The weight-loaded end scraper located below the guide roller keeps the belt free from
adhering product material.

3.1.9 Weighing unit

The weighing unit consists of a weighing bridge, below which a load cell with protection class
IP 65 is installed. Adjustable stops are fitted to provide protection against mechanical
overload.

3.2 Functioning
The product is fed onto the belt from a slide valve which is manually set, and then flows over
the weighing plate. The belt is driven by a shunt-wound dc motor with speed control.

The product flow (the actual value of the weigh-belt feeder) is a product of two parameters:

Belt speed x belt load

The actual value is compared with the setpoint signal, and any difference between the two
causes the belt speed to be corrected. If the correction is not effective, an alarm system
triggers. The parameters setpoint, belt speed, actual value and belt load can be called up
on the display any time the necessary information is entered via the keyboard.

The following formula is used to calculate the rated output:

VN x Q x 60
PN =
fQ x lw

PN = rated output in kg/h

VN = rated belt speed in m/min.
Q = belt load in kg
fQ = load factor (0,5 = constant)
lw = length of weighing bridge in m

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3.3 Manipulation
a. Avoid foreign bodies from penetrating into the housing.
b. Dust, dirt and other particles should not accumulate in such a way as to transfer a part of
the measuring force to the housing and thus to falsify the measuring value.
c. The load cell is a precision measuring instrument and must be handled with care. Special
attention should be given to this during transport and installation. Impacts and even
simply dropping them, can permanently damage the transducers.

4. Safety

4.1 Use in accordance with the intended purpose

Field of application of your weigh-belt feeder is the gravimetric feeding of dry powders
(granules and powders).

Feed rate, design and dimensioning of the weigh-belt feeder will be fashioned to the
particular application by Brabender Technologie KG. For this, the special product data and
the operational requirements will be taken into account.

The weigh-belt must only be used for the products specified in your order, because it has
been dimensioned to this particular application.

4.2 Indication of dangers and danger zones

You will find the following sign on your weigh-belt feeder:

Fig. 2: Danger sign

4.3 Dangers arising from non-observance of safety instructions

þ Stand-still of feeder if it is employed for unsuitable product.
þ Construction elements of the weigh-belt feeder risk to be destroyed.
þ In case of explosion-proof design: installation is no longer explosion-proof if you modify
the construction elements relevant for the explosion protection.
þ Risk of personal injury if you do not disconnect the feeder from the mains before
conversion, cleaning or service operations.

4.4 Safety instructions for the user of the plant

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Only skilled staff is allowed to mount, operate, maintain and service the weigh-belt feeder.
The responsibility for the manipulation of the weigh-belt feeder has to be clearly defined, the
user of the plant has to see that only authorised persons work with the feeder.

The user of the plant has to train the operating staff regularly about the contents of the
operating instructions and the safety regulations. The operating instructions have to be kept
at hand for the operator.

By means of special instructions and checks the user of the plant has to ensure that the
working place at the feeders has to be clean and clearly arranged.

4.5 Safety instructions for operation and maintenance work

Before cleaning, service or maintenance work the complete installation has to be switched
off and disconnected from the mains. The main switch has to be protected against
unauthorised switching on.

Protectional equipment must only be opened by means of suitable tools.

The product inlet shaft is only suitable for flowable materials. A special prefeeder is required
for poorly flowing materials.

4.6 Remaining hazards

Source of danger Danger How to prevent the danger

Support frame, belt drive Personal injury caused by the All covers, whether loosely
rotation of the belt and the on the feeder or bolted, have
rolls. to be in their proper position.
Foreign bodies on the belt. Damage or destruction of The upper cover has to be
downstream equipment. kept closed during the
feeding operation.

4.7 Consequences of arbitrary modifications

Arbitrary modifications of the weigh-belt feeder by the customer risk to cause functional
failures. In case of such modifications the feeder is no longer guaranteed by Brabender
Technologie KG.

Safety equipment must not be demounted or put out of function.

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5. Transport and storage

5.1 Checking of the scope of supply

The scope of supply has to correspond to our order confirmation. Transport damages have
to be confirmed by the forwarding company directly after receipt of the goods and announced
to the deliverer.

5.2 Transport
For a safe transport you should use transport equipment such as a base scaffolding or
transport eyelets in which the load hooks can catch. Hooking at other parts of the feeder is
not permissible, this might lead to considerable deterioration.
Before the transport of the weigh-belt feeder the transport catches have to be mounted again
(see chap. 7).
As measuring instruments are sensitive to shock and vibrations they have to be handled with
care (do not mount on the frame construction!). Interconnection cables on the modules must
not be used as transport grips.

5.3 Storage
If it is necessary to stock the weigh-belt feeder over a longer period on the construction site,
the following has to be observed: put back the feeder in its original package material. In
order to permit air circulation in the packaging box, the cover of the box should be bolstered
with distant pieces. Ideally, the boxes should be stored in a closed hall. However, it is also
possible to stock them outside under a roofing.
The following is required of the storage place for packed and unpacked equipment:

Hall - weather resistant

- protected against intruding of unauthorised persons
Floor - paved, with water drain
- free from vibration
- passable for transport and lifting equipment

Environmental conditions - suitably ventilated

- dry
- free from dust
- humidity of the air 50 % - 60 %
- temperature app. - 20 °C to + 50 °C

5.4 Packing and marking

If the weigh-belt feeder is delivered to the construction site it is packed in a box.

5.5 Degree of assembly

The weigh-belt feeder is mainly completely mounted. Loosely supplied construction groups
and accessories are to be found on the packing list.

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6. Mounting

6.1 Instructions for mechanical and electrical installation

Mechanical installation
The weigh-belt feeder is mounted horizontally on a pedestal or stand, the supplied vibration
isolating mounting pads are fitted in between. On installation it should be ensured that the
unit is not subject to torsional stress.

The red transport protection plate above the weighing bridge may not yet be removed
because it relieves the strain on the weighing bridge (required for taring).

The inlet and outlet are to be connected to the appropriate equipment using flexible
connections. At least 750 mm clearance are to be left at the front, back and motor side of the
unit for checking and maintenance operations.

For belt change of DBW/G1-600 a clearance of app. 1000 mm has to be left at the side that
is opposite to the belt drive.

It is recommended to mount a slide valve over the inlet so that the product feed can be shut
off during maintenance or checking work (e.g. taring, belt changes).

To facilitate commissioning a calibration valve (standard accessory) should be fitted to the

outlet.

When installing units you have to pay attention that possible machine displacements will not
be blocked or that servicing works, e.g. module exchange, or servicing of downstream
equipment are still possible.

Electrical installation
Control cabinets have to be installed in an environment corresponding to their type of
enclosure.

Wiring of movable and/or vibrating components of the installation has to be carried out with a
flexible cable that is mounted to a stationary component.

When laying the measuring cables you have to go round interference fields, that are for
example emitted by transformers and their supply lines.

Make sure that cable entries in junction boxes or ducts are well closed up and insulated.
Cabling has to be effected as per the enclosed scheme with the cable specified by
Brabender or similar. Signal and pilot wires have to be laid in separate ducts and separated
from the power cable. The same goes for cabling in the control cabinet.

The weighing signal is transmitted by special cables. These must not be re-
placed by other cables. Conductor sections in installations are recommen-
dations, they are not binding and to be checked by the customer!

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For the electrical connection of the weigh-belt feeder the reglementations for earthing,
connection to neutral and protective switches specified by the power supply station in charge
have to be observed.

6.5 Installation conditions

Customer's assistance
Before the start of the installation the following points have to be prepared by the customer
or the person he put in charge in order to guarantee that the installation can be carried
through without any problem and without delay:

• Transport and lifting devices that are required for the transport of the parts to the place
where the feeder is to be put in place and for the installation itself, have to be available.
• Electrical energy (local voltage) and water have to be available in sufficient quantities.
• The place where the feeder is to be installed has to be protected against possible
negative impacts of the climate. With temperatures below 0°C at the place of the
installation, continuation of the mounting work cannot be guaranteed. The place of the
installation has to be sufficiently illuminated.
• The tools required for mounting have to be available.
• Auxiliary materials (product, cleaning agent - not combustible and non aggressive,
cleaning rag, cover tarpaulin etc.) have to be available in sufficient quantities.
• Works at or over the place of installation, that might impede considerably the mounting of
the feeder.

6.6 Mounting tools

- General locksmith's tools
- Torque wrench

Lifting equipment
- Fork truck

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7. Start-up and operation

The commissioning of a weigh-belt feeder is described for component 1, as an example.

7.1 Preliminary checks

Commissioning your weigh-belt feeder should generally be started with a check whether the
feeder is in working order. For this, you proceed as follows:

7.1.1 Electrical checks

• Check correct execution of cabling as per electrical plans.
• In case, control cabinets are part of the scope of supply it is important that you stick to the
security instructions attached on the inner side of the control cabinet door.

7.1.2 Mechanical checks

• Have you removed all packing material and stoppers?
• Is it possible to move the belt guide mechanism easily to and fro?
• Can the guide roller be easily rotated?
• Transport catches (painted red) have to be taken off the tensioning weight (fig. 3).

TRANSPORT CATCH

BELT SCRAPER
Belt guides

Fig. 3: Transport catches of the weigh-belt feeder

• Is it possible to lift the weight easily, is the belt tensioned correctly?

• Insert the belt scraper (loosely supplied) into the retaining device (fig. 3). Is it in touch with
the belt on its whole width?
• Put the belt into the belt guide of the guide roller (fig. 3). Is the belt correctly positioned on
the belt guide?
• Are the material guide plates properly set so that they do not touch the belt? The gap
between the guide plates and the belt can be adjusted by releasing the hexagonal-head
screws. Gap for powder app. 1 mm on the inlet side and app. 2-3 mm on the discharge
side. For granules, the gaps are to be increased accordingly to avoid jamming. The
material guide plates should never touch the belt otherwise it would be destroyed.

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7.2 Static inspection

7.2.1 Checking of the adjustable drives

♦ Switch on the voltage supply for the weigh-belt feeder as well as for the controller.
♦ Check the sense of rotation of the belt drive. (fig.4).
INLET

SENSE OF ROTATION OF THE BELT

OUTLET

Fig. 4: Sense of rotation of the belt

♦ A tachometer permits to check the adjustment of the speed controller of the feed drive. If
the drive has a nominal speed of 3000 min-1, the speed has to be 300 min-1 if the speed
is 10 % and 2700 min-1 if the speed is 90 % . Should there be deviations despite the
preadjustment in our works, they have to be adjusted by means of our "adjustment
instructions for speed controllers".
♦ After completion of the a.m. checks the installation can be stopped again.

7.2.2 Checking the weighing system

♦ Compare the memorised calibration data of the microcomputer controller with the "test
certificate" that is also part of the delivery, possibly you have to change them.
♦ The weighing unit will now be relieved from the belt by inserting the red transport
protection sheet. By a brief loading and unloading of the strain gauge load cell of the
weigh-belt feeder (add/take off weight, do not exceed the weighing range!) check
whether the display is free from changes. This means that the weight display must always
show the initial value if the control weight has been taken off or the total value if the
control weight has been added. If a change occurs you have to check the complete
mechanical structure of the feeder.

Static inspection of the first feeder is now concluded. This check has to be effected
separately for all the feeders. If this has been done you can go on with the commissioning of
the individual feeders.

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7.3 Commissioning with product

♦ Material is now to be fed into the inlet shaft of the weigh-belt feeder.
♦ After entering a setpoint and after the start of the feeder the level slide valve should be
set in such a way that the speed of the belt drive motor is app. 40% with an output of
50%.

If it is not possible or very convenient to check the weighing bridge with the original product,
this check may also be carried out without the original product. In such case, a plastic bag, a
jute sack or anything similar must be filled with water or sand, etc., and well sealed so that it
can function as a known test weight.
♦ Once the installation has been started place the test weight in front of the weighing bridge
and collect it again at the feeder outlet. After that, the system can be stopped again.

The weigh-belt feeder is now ready for operation.

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8. Maintenance and repair

Before maintenance operations the following has to be observed:
♦ Disconnect the installation from the mains and protect it against reclosing.
♦ Run the belt and the prefeeder (if fitted) empty and ensure that no product material can
flow unintentionally into the unit (close separate slide valve).

8.1 Maintenance and inspection list

Element Points to check Interval
Mechanics 1. Clean feeder of all product residues using a n
vacuum cleaner, a soft brush or low pressure air.
2. Check belt for wear or damage. n
3. Check ease of movement of all rollers (drive
n
rollers, idle rollers and belt guide rollers), check
proper swivelling of belt guide roller. Change
bearing, if necessary.
5. Check chain drive and replace complete unit if n
strongly worn, otherwise retension and lubricate,
if necessary.
Electrics 7. If your installation is equipped with filter fans,
n
check or exchange, the filter mats that are in the
fans.
Motors 8. Check and exchange, if necessary, the sealings.
s
9. Check the carbon brushes of the motor, n
exchange them, if necessary.
10. Check the oil level of the motor(s), in case of an m
oil leakage, top up with oil. Please see the
separate maintenance instructions of the motor.
Weighing 11. Static checking (without product): every two
system weeks static measuring, additional checking after n
cleaning, conversion, repair or exchange of the
sleeves.
12. Dynamic checking (with product): take three
measured values of the feed rate with 10%, 50% l
and 100%, dynamic checking also after repair.

Legend:
s = weekly n = fortnightly l = monthly m = twice a year

As a function of the application the a.m. intervals may be shorter or longer.

Before cleaning, servicing or maintenance works the loss-in-weight feeder has

to be dead and protected against reclosing.

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8.2 Disassembly and reassembly

8.2.1 Belt change

Fig. 5: Change of the belt of the DBW

Removal
For changing the belt lift up the belt tensioning weight and lock in its upper position with the
holder plate and the hexagonal-head screw (belt tensioning weight: metal roller in inner belt
space; see sketch).
Now draw the belt out of the belt guide at the front. Lift up the internal belt scraper in front of
the drive roller and undo the two quick lock couplings. The belt can now be drawn from the
rollers. Should it be very tight, the drive roller can be raised by loosening the hexagon nut on
the guide axle so that the belt will become less tight.
Now clean the weighing bridge, the rollers, the scrapers and the belt guide.

Fig. 6: Illustration for the changing the belt of the DBW

1 Stopper 5 Idle roller

2 Measuring bar 6 Holder plate
3 Belt tensioning weight 7 Hexagonal-head screw
4 Clamping fixture

Reassembly
Push the new or cleaned belt onto the rollers and lock the quick lock couplings again. Set the
belt guide so that the belt is properly guided but not turned up at the edges. Undo the holder
plate, let down the tensioning weight and thus tension the belt. Refit the internal scraper into
the proper functioning position again. In order to obtain directional stability of the belt, the idle

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roller may be slightly set aside along its axis. For this purpose screws A must be loosened
respectively tightened, screws B in the long hole must be loosened before this and tightened
again afterwards.

After the belt has been installed, the calibration values, such as weight test value, adjustment
and length of weighing bridge can be checked and corrected if necessary.

8.2.2 Exchange of the load cell

a. Unload the belt (see chapter 8.2.1 belt change)
b. Before demounting the load cell you disconnect the connection cables and draw them out
of the cable runs. Cable runs are the tubes inside the housing.
c. Screw out the hexagonal head screws below the load cell.
d. Take out the load cell with the measuring bar.
e. Screw the new load cell to the measuring bar by means of the hexagonal head screw M5
+ 60 that serves for suspending the test weight.
f. Reassembly is in reverse order.
g. Checking or new adjustment of the overload protection. The distance is 0,5 mm (lower
edge of measuring bar to upper edge of stopper).

8.2.3 Exchange of the bearing

Exchangeable bearings are only on the pivot of the guide roller and on the drive roller. Idle
roller and guide roller (belt guide) can only be completely exchanged.

In order to change the ball bearing of the belt guide you have to disassemble it
completely.
a. Loosen lock nut M16 (SW24) and remove upper nut.
b. Take the complete unit out of the support frame to the side.
c. Disassemble guide roller and scraper.
d. Loosen the countersunk screws from the bottom side, take off the bearing with the guide
axle, remove the snap ring and remove the guide axle towards the top.
e. Move out defect bearings. During the assembly you have to re-insert the spacer in the
new bearing.
f. Reassembly is in reverse order.

When exchanging the roller bearings the belt guide system is only mounted if the bearing
has been exchanged.

In order to exchange the flange bearing at the drive roller the belt has to be disassembled
first (see belt change, 8.2.1).
a. Remove the protective cover of the chain drive and relay the chain (loosen the nuts that
belong to the tensioning plate of the motor fixing).
b. Remove the fixing screws of the bearing, lift the roller to the front, lower it and take it out
of the housing to the side (is only possible if the belt guide has been disassembled).
c. Before putting on the bearings the journals of the roller have to be greased. Reassembly
is in reverse order.

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After reassembly the function of the scrapers has to be checked or they have to be
readjusted.

9. Trouble-shooting

Problem Cause Remedy

Deficiency of the load cell Overloading, shocks, strong Exchange load cell, if
impacts necessary.
Strong weight difference Product deposits on the Adjust the scrapers so that
bottom side of the belt or on they are able to function.
the rollers
Increasing speed of the belt Belt slippage Check tensioning weight.
Clean the rollers.
Renew the bearings.
Belt wear Renew the belt.
Chain drive defective Replace chain or sprocket
wheel.
Belt torn Renew belt.

10. Spare parts

In order to guarantee a trouble free operation of the weigh-belt feeder the user has to keep in
stock the necessary spare parts. Thus, we recommend to request a spare parts offer. We
only guarantee for original spare parts delivered by us. When mounting spare parts that have
not been delivered by us the feeder can no longer be guaranteed by Brabender Technologie
KG. Please specify the type of device and the order number (see cover sheet of this
operation manual) for each spare parts order.

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