operating instructions dry feeder tgd 11, 18, 55,...

Dry feederTGD 11, 18, 55, 110

Operating instructions

A0414

Original Operating Instructions (2006/42/EC)Part no. 987098 BA UL 027 01/12 EN

Please carefully read these operating instructions before use! · Do not discard!The operator shall be liable for any damage caused by installation or operating errors!

Technical changes reserved.

987098, 1, en_GB

© 2012

ProMinent Dosiertechnik GmbHIm Schuhmachergewann 5 - 1169123 HeidelbergTelephone: +49 6221 842-0Fax: +49 6221 842-419email: [email protected]: www.prominent.com

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Table of contents1 Introduction........................................................................... 4

1.1 Overview of equipment................................................. 41.2 System dimensions....................................................... 5

2 Safety and responsibility....................................................... 62.1 Explanation of the safety information............................ 62.2 Users' qualifications...................................................... 72.3 General safety notes..................................................... 82.4 Correct and proper use................................................. 9

3 Accessories......................................................................... 103.1 Top hopper................................................................. 103.2 Top hopper with adapter cover................................... 10

4 Assembly and installation................................................... 114.1 Assembly.................................................................... 114.2 Installation, electrical.................................................. 11

5 Start up............................................................................... 125.1 Testing........................................................................ 125.2 Calibration................................................................... 125.3 Adjusting the liquid level sensor................................. 135.4 Decommissioning....................................................... 13

6 Maintenance and Repair..................................................... 146.1 Maintenance............................................................... 146.2 Repairs....................................................................... 14

7 Troubleshooting.................................................................. 157.1 Bridging....................................................................... 157.2 Liquid level sensor fails to trigger............................... 157.3 Caking on the feeder screw and feeder screw pipe.... 157.4 Feed chemical is not delivered when motor is run‐

ning............................................................................. 16

8 Technical data..................................................................... 178.1 Device data................................................................. 178.2 Motor data................................................................... 178.3 Performance diagrams............................................... 188.4 Spare parts................................................................. 198.4.1 Spare parts dry feeder TGD 11, TGD 18................. 198.4.2 Spare parts dry feeder TGD 55............................... 208.4.3 Spare parts dry feeder TGD 110............................. 218.5 Dimensional drawings................................................. 228.5.1 Dimensional drawing dry feeder TGD...................... 228.5.2 Dimensional drawing top hopper 50 l...................... 238.5.3 Dimensional drawing top hopper 75 l...................... 248.5.4 Dimensional drawing top hopper 100 l.................... 25

9 Declaration of Conformity................................................... 26

10 Index................................................................................... 28

Table of contents

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1 IntroductionThe dry feeder TGD is a helical metering device for continuousfeeding of dry and free-flowing polyelectrolytes. The systembelongs to ProMinent's Ultromat® range of systems. The devicecan be used for volume-proportional metering if controlled exter‐nally with a frequency converter.

In order to make it easier to read, this document uses the maleform in grammatical structures but with an implied neutral sense. Itis aimed equally at both men and women. We kindly ask femalereaders for their understanding in this simplification of the text.

1.1 Overview of equipment

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Fig. 1: Dry feeder1. Insertable cover (PP)2. Guard (steel, galvanised)3. Drive unit4. Conveyor screw with core (stainless steel)5. Feeder screw pipe (stainless steel)

6. Feed pipe heating7. Release wheel (stainless steel)8. Liquid level sensor9. Housing (PP)

About this dry feeder

General non-discriminatory approach

Introduction

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The power drive (3) is permanently bolted to the housing (9) of thedry feeder. The installed AC motor drives the conveyor screw (4)via a reduction gear system, which in turn serves to rotate arelease wheel (7). This prevents bridging of the feed chemical inthe dry feeder. The feed chemical is delivered via the feeder screwpipe (5). The dry feeder's guard (2) serves to protect the movingconveyor screw from direct contact. The insertable cover (1) actsas a lid for the hopper. The feed chemical may become lumpy ifmoisture is allowed to penetrate into the feeder screw pipe. Thefeed screw heating system (6) is clamped to the feeder screw pipeand causes any moisture to evaporate by means of warming thefeed chemical in the feeder screw pipe. The liquid level sensor (8)enables early warning in the event of insufficient feed chemical andsignalises the requirement for refilling the dry feeder.

1.2 System dimensions

NOTICE!The output data is derived from measured values andestimated values based on polyelectrolyte powder incombination with the applicable test conditions, espe‐cially air humidity and ambient temperature. For thisreason, independent on-site calibration is required.

The dry feeder is available in four different sizes. Selection shouldbe based on the required metering capacity.

Part no. 1036201 1020800 1021030 1021031

Dry feeder TGD 11 TGD 18 TGD 55 TGD 110

Maximum capacity 11 kg/h 18 kg/h 55 kg/h 110 kg/h

Volume in litres 13 13 13 13

The actual capacity can vary from the specified metering capacitydepending on the feed chemical used.

Functional description

Introduction

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2 Safety and responsibility

2.1 Explanation of the safety informationThese operating instructions provide information on the technicaldata and functions of the product. These operating instructions pro‐vide detailed safety information and are provided as clear step-by-step instructions.

The safety information and notes are categorised according to thefollowing scheme. A number of different symbols are used todenote different situations. The symbols shown here serve only asexamples.

DANGER!Nature and source of the dangerConsequence: Fatal or very serious injuries.

Measure to be taken to avoid this danger

Danger!

– Denotes an immediate threatening danger. If this isdisregarded, it will result in fatal or very seriousinjuries.

WARNING!Nature and source of the dangerPossible consequence: Fatal or very serious injuries.


Warning!

– Denotes a possibly hazardous situation. If this isdisregarded, it could result in fatal or very seriousinjuries.

CAUTION!Nature and source of the dangerPossible consequence: Slight or minor injuries, mate‐rial damage.


Caution!

– Denotes a possibly hazardous situation. If this isdisregarded, it could result in slight or minor inju‐ries. May also be used as a warning about materialdamage.

Introduction

Safety and responsibility

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NOTICE!Nature and source of the dangerDamage to the product or its surroundings


Note!

– Denotes a possibly damaging situation. If this isdisregarded, the product or an object in its vicinitycould be damaged.

Type of informationHints on use and additional informationSource of the information, additional measuresInformation!– Denotes hints on use and other useful information.

It does not indicate a hazardous or damaging sit‐uation.

2.2 Users' qualifications

WARNING!Danger of injury with inadequately qualified personnel!The operator of the plant / device is responsible forensuring that the qualifications are fulfilled.

If inadequately qualified personnel work on the unit orloiter in the hazard zone of the unit, this could result indangers that could cause serious injuries and materialdamage.

– All work on the unit should therefore only be con‐ducted by qualified personnel.

– Unqualified personnel should be kept away fromthe hazard zone

Training Definition

Instructed personnel An instructed person is deemed to be a person who has been instructed and,if required, trained in the tasks assigned to him/her and possible dangers thatcould result from improper behaviour, as well as having been instructed in therequired protective equipment and protective measures.

Trained user A trained user is a person who fulfils the requirements made of an instructedperson and who has also received additional training specific to the systemfrom ProMinent or another authorised distribution partner.


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Training Definition

Trained qualified per‐sonnel

A qualified employee is deemed to be a person who is able to assess thetasks assigned to him and recognize possible hazards based on his/hertraining, knowledge and experience, as well as knowledge of pertinent regula‐tions. The assessment of a person's technical training can also be based onseveral years of work in the relevant field.

Electrician Electricians are deemed to be people, who are able to complete work on elec‐trical systems and recognize and avoid possible hazards independently basedon his/her technical training and experience, as well as knowledge of pertinentstandards and regulations.

Electricians should be specifically trained for the working environment inwhich the are employed and know the relevant standards and regulations.

Electricians must comply with the provisions of the applicable statutory direc‐tives on accident prevention.

Customer Service depart‐ment

Customer Service department refers to service technicians, who havereceived proven training and have been authorised by ProMinent to work onthe system.

Note for the system operatorThe pertinent accident prevention regulations, as wellas all other generally acknowledged safety regulations,must be adhered to!

2.3 General safety notes

WARNING!Live partsPossible consequence: Fatal or very serious injuries

– Measure: The device must be disconnected fromthe power supply before opening the housing

– Isolate damaged, faulty or manipulated devicesfrom the mains in order to de-energise.

WARNING!Emergency stop switchPossible consequence: Fatal or very serious injuries

An emergency stop switch is to be connected for theentire plant. This should enable the entire plant to beshut down in the event on an emergency in such a waythat the overall plant can be brought into a safe condi‐tion.


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WARNING!Unauthorised accessPossible consequence: Fatal or very serious injuries

– Measure: Ensure that there can be no unauthor‐ised access to the device

WARNING!Hot surfaces in the area of the feeder screw pipeSkin burns.

– Wear your personal protective equipment.– Only work on the device when it has been allowed

to cool down, if possible.

CAUTION!Risk of crushing in the area of the conveyor screwFinger and hand injuries.

– Never reach into the feeder screw or top hopper– Only work on the device when it has been

switched off, if possible

2.4 Correct and proper useThe dry feeder TGD is a helical metering device for continuousfeeding of dry and free-flowing polyelectrolytes. The systembelongs to ProMinent's Ultromat® range of systems. Modificationsor other applications are prohibited.


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3 AccessoriesThe following accessories are available for the dry feeder:

3.1 Top hopperThe top hopper increases the feed chemical reservoir for the dryfeeder (capacity dry feeder: approx. 13 l). Three additional top hop‐pers with volumetric capacities of 50, 75 and 100 litres are avail‐able. The 100 litre top hopper is equipped with a relieving cone.

3.2 Top hopper with adapter cover50, 75 and 100 l top hoppers with adapter covers are available foroperating the equipment with a conveyor unit (e.g. FG 205). Theconveyor unit can be fastened to the adapter cover with the help ofa mounting kit (3 anchor clamps with screws).

Accessories

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4 Assembly and installation4.1 Assembly

The device is assembled with the Ultromat® system ex factory. TheUltromat® system together with its integrated dry feeder is to beinstalled under dry conditions. The ambient temperature should notexceed 40°C.

4.2 Installation, electrical

WARNING!Live partsPossible consequence: Fatal or very serious injuries

– Measure: The device must be disconnected fromthe power supply before opening the housing

– Isolate damaged, faulty or manipulated devicesfrom the mains in order to de-energise.

– The electrical Installation of the device may only beundertaken by technically trained personnel withverifiable qualifications.

The dry feeder is supplied fully wired on all Ultromat® systems.When operating via a frequency converter with 3 x 230 V output,the motor is wired up as a delta connection.

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Fig. 2: Delta connection

Delta connection

Assembly and installation

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5 Start up

CAUTION!Risk of crushing in the area of the conveyor screwFinger and hand injuries.

– Never reach into the feeder screw or top hopper– Only work on the device when it has been

switched off, if possible

5.1 Testing

Abrasion of the conveyor screw in the feeder screwpipe and associated rubbing noise is unavoidable.However, this does not affect the functionality of thedevice.

Check the functions of the dry feeder while it is empty. Pay partic‐ular attention to the following points while undertaking testing:

n Check the motor's direction of rotation (change the terminalassignment by swapping the two phase wires if necessary)

n Check the switching function of the liquid level sensor

5.2 CalibrationUltromat® systems of type ULTa are equipped with a controller.Calibration is to be undertaken during the initial commissioningprocess and when changing the feed chemical used. A suitablecollecting vessel for the dosing product and a precise weighinginstrument (preferably with tare function) is required for under‐taking calibration. The following procedure is recommended:

NOTICE!Any dosing product spilled on the floor can lead to anincreased risk of slipping in the event of moisture (e.g.polyelectrolytes) and should therefore be cleaned upimmediately.

1. Remove the flushing device

2. Weigh the collecting vessel and compensate for its weight byusing the tare function

3. Place the collecting vessel underneath the feeder screw pipe

4. If not already done, fill the dry feeder with the designatedfeed chemical

5. Open the calibration menu on the controller and launch thecalibration process by pressing the ‘T’ key

ð The dry feeder will now run at 100% output.

Start up

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6. After a period of approx. 3 minutes, press the ‘T’ key againin order to pause the dry feeder's controller.

ð The elapsed time is shown on the controller display.

7. Weigh the net weight of the dry product delivered during thisperiod and enter the value into the controller

ð The controller calculates the capacity in grammes /minute.

8. Refasten the flushing device to the Ultromat®

5.3 Adjusting the liquid level sensorThe sensitivity of the capacitive liquid level sensor is to be matchedto the various feed chemicals:

1. Fill the dry feeder with powder until the sensor is completelycovered

2. Initially rotate the adjustment screw anticlockwise for settingthe sensitivity of the liquid level sensor (reducing the sensi‐tivity) until the LED goes out

3. Carefully rotate the adjustment screw clockwise for settingthe sensitivity of the liquid level sensor (increasing the sensi‐tivity) until the LED lights up again

4. Now rotate the adjustment screw for setting the sensitivity ofthe liquid level sensor by two additional clockwise turns

ð Check the setting of this switching function with thesystem running.

5.4 Decommissioning

NOTICE!If the dry feeder is to be taken out of service for longerthan 2 days, it is necessary to completely remove all ofthe feed chemical from the system.

This applies especially to powder polymers. Powderpolymers are hygroscopic and attract moisture fromthe ambient air. This causes clumping and may causethe metering system to fail.

Start up

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6 Maintenance and Repair6.1 Maintenance

The dry feeder's power drive system is maintenance free, as thegearbox has life-time lubrication.

6.2 Repairs1. Run the device empty prior to removing the feeder screw

A0417

Fig. 3: Exchanging the feeder screw2. Release the four flange screws (1) and pull the power drive

horizontally out of the dry feeder together with the feederscrew

ð The feeder screw is now free and can be unscrewed fromthe drive sleeve (left-hand thread!).

3. Assembly is undertaken in the opposite order

Exchanging the feeder screw

Maintenance and Repair

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7 Troubleshooting

WARNING!Danger due to electrical currents and moving machi‐neryThe device must always be disconnected from themains prior to rectifying faults which require repairwork on the feeder.

7.1 BridgingCheck the feed chemical for moisture and dry, if necessary

Mount additional unbalance motor

7.2 Liquid level sensor fails to triggerThe liquid level sensor fails to trigger as a result of feed chemicalbridging above the liquid level sensor

n Remedy: Take measures to prevent bridging

Due to a fault in the liquid level sensor itself

n Remedy: Check the liquid level sensor's connections, thenrecalibrate its sensitivity, if necessary.

7.3 Caking on the feeder screw and feeder screw pipe

WARNING!Hot surfaces in the area of the feeder screw pipeSkin burns.

– Wear your personal protective equipment.– Only work on the device when it has been allowed

to cool down, if possible.

The heating sleeve may only be lukewarm (approx. 35°C)

n Check the heating system for proper function (temperatureapprox. 35 °C).

n When using the Ultromat® controller, check the heating settings(heating on time and heating off time)

n Keep moisture at bay by means of selecting a dry installationplace

Troubleshooting

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7.4 Feed chemical is not delivered when motor is runningn Check the liquid level of the feed chemical and refill the feed

chemical reservoir if necessaryn Has bridging prevented the dry product from sliding through?

Take measures to prevent bridgingn Check the direction of rotation for the conveyor screw and

motor

Troubleshooting

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8 Technical data8.1 Device dataDevice type TGD 11 TGD 18 TGD 55 TGD 110

Maximum metering output at 50Hz

5.5 kg/h 9.0 kg/h 27.5 kg/h 54.5 kg/h

Maximum metering output at 100Hz

11.0 kg/h 18.0 kg/h 55.0 kg/h 110.0 kg/h

Maximum metering output at 5 Hz 0.55 kg/h 0.9 kg/h 2.8 kg/h 5.5 kg/h

Hopper capacity 13 l 13 l 13 l 13 l

Noise level during metering opera‐tion

< 70 dB(A) < 70 dB(A) < 70 dB(A) < 70 dB(A)

The actual capacity can vary from the specified metering capacity depending on the feed chemical used.

8.2 Motor data

Motor type: SK1SD 40 VXZ 63 L/4

Power 0.18 kW

Number of poles 4

cos φ: 0.66

Voltage: 230/400 V

Nominal current: 1.18/0.69 A

Degree of protection: IP 55

Model: H3

Insulation class F

Motor speed: 1380 RPM (50 Hz)

Gear reduction ratio: 1 : 15

Speed of drive shaft at 50 Hz: 93 RPM

Weight: 6.5 kg

Colour RAL 2003

Technical data

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8.3 Performance diagrams

The measurements have been carried out with com‐mercially available polyelectrolyte powders. The per‐formance data derived from this are non-binding esti‐mated values which are dependent on both thestructure and free-flowing capability of the feed chem‐ical during measurement as well as the test conditionssuch as air humidity and ambient temperature.

Fig. 4: Performance diagrams for TGD 11, 18. 55.110

Technical data

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8.4 Spare parts8.4.1 Spare parts dry feeder TGD 11, TGD 18

Fig. 5: Spare parts dry feeder TGD 18

Item Number

Description Part no.

1 1 Feeder screw pipe size 18 cpl. 791741

2 1 Heating sleeve Ultromat® size 18 204251

3 4 Cyl. Hexagon screw DIN 912 M 6x 25 A2 468021

4 1 Insertable cover for TGD RC 1020860

5 1 Guard galvanised 741177

6 1 Proximity switch capacitive, M30x1.5; 3m cable 710253

7 1 Release wheel size 18 cpl. RC 1020866

8 1 Axle SW 7x150 RC 1.4305 1021032

9 1 Worm drive with core size 18 cpl. 1.4301 RC 1020863


11 1 Plain washer DIN 125 A 5.3 A2 1003393

12 1 Drive shaft d35x55 TGD RC 1020862

13 1 Set screw DIN 913 M 5x 8 A2 1008088



16 1 Intermediate plate TGD RC 1020854


Technical data

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Item Number


18 1 Drive unit 0.18 kW, i=15 (TGD 18) 1026801

1 Drive unit 0.18 kW, i=25 (TGD 11) 1037516

8.4.2 Spare parts dry feeder TGD 55


Item Number









8 1 Axle SW 7x150 RC 1.4305 1021032





Technical data

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Item Number


13 1 Set screw DIN 913 M 5x 8 A2 1008088





18 1 Drive unit 0.18 kW 1026801

8.4.3 Spare parts dry feeder TGD 110


Item Number









8 1 Axle SW 7x150 RC 1.4305 1021032

Technical data

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Item Number






13 1 Set screw DIN 913 M 5x 8 A2 1008088





18 1 Drive unit 0.18 kW 1026801

8.5 Dimensional drawings8.5.1 Dimensional drawing dry feeder TGD

Fig. 8: Dimensional drawing dry feeder TGD1 220 mm2 360 mm3 390 mm4 116 mm

5 400 mm6 504 mm7 260 mm8 115 mm

Technical data

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8.5.2 Dimensional drawing top hopper 50 l

Fig. 9: Dimensional drawing top hopper 50 l1 540 mm2 400 mm3 350 mm4 220 mm5 210 mm

6 ⌀7 mm7 490 mm8 385 mm9 180 mm

Technical data

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A0424

8.

1. 2.

3.

4.

5.6.

9.

7.


6 ⌀ 7 mm7 535 mm8 330 mm9 490 mm

Technical data

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A0424

8.

1. 2.

3.

4.

5.6.

9.

7.


6 ⌀ 7 mm7 685 mm8 480 mm9 490 mm

Technical data

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9 Declaration of Conformity

Manufacturer's declaration of conformity

We, PPrrooMMiinneenntt SSyysstteemmss ssppooll.. ss rr..oo..FFüggnneerroovvaa uull.. 556677333366 0011 BBlloovviicceeCCeesskkä rreeppuubblliikkaa

hereby declare that, the product specified in the following complies with the relevant basic health and safety rules of the EC Directive, on the basis of its functional concept and design and in the version

marketed by us.

This declaration loses its validity in the event of a modification to the product not agreed with us.

The product is intended to be integrated into a machine or combined with other components to form a machine.

For this reason, it is prohibited to commission the machine until such time as it has been verified that the machine conforms with machinery directive 98/37/EEC, the EC declaration of conformity has been issued,

and the machine is labelled with the CE symbol.

PPrroodduucctt DDeessccrriippttiioonn:: DDrryy FFeeeeddeerrThe dry feeder device serves to enable continuous metering of dry and free-flowing polyelectrolytes.

TTeecchhnniiccaall ssttaannddaarrddss::

- EN ISO 12100-1:2004 - Safety of Machines. Basic Terminology, General Principles for Design.Part 1: Basic Terminology, Methodology

- EN ISO 12100-2:2004 - Safety of Machines. Basic Terminology, General Principles for Design.Part 2: Technical Principles

- EN ISO 614-1:2006 - Safety of Machines. Ergonomic Design Principles.Part 1: Terminology and General Principles

- EN 60204-1:2000 - Safety of Machines. Electrical Equipment of Machines.Part 1: General requirements

- EN 61000-6-4:2002 EMC - Part 6-4: Generic standards - Disturbance signal emissions for industrial environments

- EN 61000-6-2:2002 EMC - Part 6-2: Generic standards - Immunity for industrial environments

- EN 55011:1999 - Industrial, scientific and medical (ISM) radio-frequency equipment. Radio disturbance characteristics - limit values and methods of measurement

PPrrooMMiinneenntt SSyysstteemmss ssppooll.. ss rr..oo..333366 0011 BBlloovviiccee,, FFüggnneerroovvaa uull.. PPOOBB 3322TTeell.. 0000442200 -- 337788 222277--115533 FFaaxx 0000442200 -- 337788 222277--113399

PPaaggee 11 ooff 22

Fig. 12: Manufacturer's declaration of conformity page 1

Declaration of Conformity

26

EN 294:1993 - Safety of Machines. Safety distances to prevent dange r zones be ing reached by the uppe r limbs.

EN 953:1998 - Safety of Machines. Isolating protective equ ipment. General requirements for the design and construction of fixed and movable gua rds.

Blovice 3. 12.2007

CCEEOO - Dipl.-Ing. (FH) Stefan Maile

PPrrooMMiinneenntt SSyyss tteemmss ssppooll.. ss rr..oo.. 333366 0011 BBlloovviiccee, F üggnneerroovvaa ul. PPOOBB 3322 TTee ll.. 0000442200 -- 337788 222277--115533 FFaaxx 0000442200 -- 337788 222277--113399

PPaaggee 2 ooff 2

Fig. 13: Manufacturer's declaration of conformity page 2

Declaration of Conformity

27

10 IndexEEmergency stop switch.......................................... 9GGeneral non-discriminatory approach.................... 4HHeating sleeve..................................................... 15Hot surfaces..................................................... 9, 15LLive parts................................................................ 8NNon-discriminatory approach................................. 4

RRisk of crushing................................................ 9, 12SSafety information.................................................. 6Safety notes........................................................... 8Sensitivity............................................................. 13UUnauthorised access.............................................. 9Users' qualifications............................................... 7

Index

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operating instructions dry feeder tgd 11, 18, 55,...

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