High Accuracy Feeders GDU 201 GDU 451

Transcription

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
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
List of spare parts .............................................................................................................................. 24
Disposal ........................................................................................................................................... 25
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Page 2
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.

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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.

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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).

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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.
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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.
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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.
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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.

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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
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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.

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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.
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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.

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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

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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

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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.

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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.

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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

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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.
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

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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
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.
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
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
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
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
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

High Accuracy Feeders GDU 201 GDU 451

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