OPERATING AND

MAINTENANCE INSTRUCTIONS

Feeder KT20

Read this manual prior to operating

or servicing the equipment. This
manual contains all safety labels and
warnings.

0890000002-EN Rev. 1.0.0

 Service
If you need assistance, please call your local service center or:
K-TRON (Switzerland) Tel. 0041 (0) 62 / 885 71 71
Industrie Lenzhard Fax 0041 (0) 62 / 885 71 80
CH-5702 Niederlenz

K-TRON (U.S.) Tel. 001 (0) 856 / 589 90 83

Rt 55 and Rt 553 Fax 001 (0) 856 / 589 56 64
Pitman, NJ 08071

Web: http://www.ktron.com

Before you call...

Do you have alarm displays? Can you eliminate their causes?
Have you modified part of the system, product or operating mode?
Have you tried to eliminate the fault in accordance with the operating
instructions?
Note down the 6 digit project or job number. This can be found at the
machine or in the project manual.
Example of project number: 400545

Using the manual:

This arrow identifies an individual action.
1. Numbers identify a sequence of actions which have to be executed
step-by-step.
V This symbol identifies a general safety note.

Reference to another manual.

Important information.

This symbol indicates that tools are required for the following task.

Specifies where information or a situation must be checked.

Docu-No.: 0890000002-EN K-Tron assumes no responsibility for damages resulting from misuse of any equipment or negligence on the part of
operating personnel. Further, reference is made to the purchase order, acceptance or other document that contains
the express K-Tron disclaimer of warranties for a statement of the provisions limiting or disclaiming certain warranties
Datum: 2008/Sep/16 with respect to the Company's equipment. Except as otherwise expressly provided by K-Tron in any such document,
K-TRON MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, NOR
Original: 0890000002-EN ANY OTHER WARRANTY, EXPRESS OR IMPLIED, WITH RESPECT TO THE EQUIPMENT.
If an error or ommission is found, please contact: documentation@ktron.com.
 Table of contents

1 Safety notes ............................................................. 5

1.1 Safety symbols definitions ......................................... 5
1.1.1 Electrical Hazard Icon ............................................... 6
1.1.2 Ground Icon .............................................................. 6
1.1.3 No Hands Icon .......................................................... 6
1.1.4 Power Icon ................................................................ 6
1.2 Responsibilities of the owner .................................... 7
1.3 Proper use ................................................................. 7
1.4 Organizational measures .......................................... 7
1.5 Safety-conscious work .............................................. 8
1.6 Safety devices ........................................................... 8
1.7 High voltage .............................................................. 8
1.8 Additional equipment ................................................. 9
1.9 Customer service and repairs ................................... 9
1.10 Shut-down procedure ................................................ 9

2 Assembly and function ......................................... 10

2.1 Feeder types ........................................................... 10
2.2 Structure .................................................................. 11
2.3 Feed screw types and applications ......................... 12
2.3.1 Screw types and applications .................................. 13
2.3.2 Twin screw sizes and throughput ............................ 13
2.4 Outlet tube configurations ....................................... 14
2.5 Gearing reduction .................................................... 14
2.6 Warnings and safety devices .................................. 15
2.6.1 Safety devices ......................................................... 15
2.6.2 Warnings ................................................................. 15

3 Technical data ....................................................... 16

4 Installation ............................................................. 17
4.1 Transportation ......................................................... 17
4.2 Unpacking ............................................................... 18
4.3 Mounting the feeder ................................................ 19
4.3.1 Installing volumetric feeder ..................................... 19
4.3.2 Installing gravimetric feeder .................................... 20
4.4 Adjusting the feeder (D-Platform Scale) .................. 21
4.5 Oil ventilation plug .................................................. 21
4.6 Connecting the feeder ............................................. 22
4.7 Taking the feeder into operation ............................. 22
4.8 Storage .................................................................... 23

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 3

 5 Operation ............................................................... 24
5.1 Notes on operation .................................................. 24
5.2 Switching on/off ....................................................... 24

6 Cleaning ................................................................. 25
6.1 Switching off the machine before maintenance work 25
6.2 Cleaning .................................................................. 25
6.2.1 Cleaning without parts removal ............................... 26
6.2.2 Cleaning with parts removal .................................... 26
6.3 Replacing the hopper .............................................. 27
6.4 Replacing the feed screws ...................................... 28
6.4.1 Removing the feed screws ...................................... 28
6.4.2 Installing the feed screws ....................................... 29
6.5 Replacing the horizontal agitator ............................ 30
6.5.1 Replacing the three part agitator on KM-KT20 ........ 30
6.5.2 Replacing the three part agitator on KC-KT20 ........ 31
6.5.3 Replacing the one-piece agitator (used for ATEX) .. 31
6.6 Replacing the vertical agitator (optional) ................. 32
6.6.1 Removing the vertical agitator ................................. 32
6.6.2 Installing the vertical agitator ................................... 32
6.7 Replacing the agitator hopper ................................. 33
6.7.1 Removing the agitator hopper ................................. 33
6.7.2 Installing the agitator hopper ................................... 33

7 Maintenance .......................................................... 34
7.1 Maintenance Intervals ............................................. 34
7.2 Replacing seals ....................................................... 35
7.2.1 Replacing the screw seals ...................................... 35
7.2.2 Installing the seal ................................................... 35
7.3 Replacing the drive motor ....................................... 36
7.3.1 Preparing the removal ............................................ 36
7.3.2 Removing the motor ................................................ 36
7.3.3 Installing the motor .................................................. 36
7.4 Replacing the tachometer ...................................... 37
7.4.1 Removing the tachometer ...................................... 37
7.4.2 Installing the tachometer ......................................... 38
7.5 Lubrication ............................................................... 39
7.5.1 Oil level inspection .................................................. 39
7.5.2 Oil change ............................................................... 39
7.6 Replacing the bearings ........................................... 39

8 Troubleshooting .................................................... 40
8.1 Troubleshooting table .............................................. 41

Page 4 Docu-No.: 0890000002-EN Rev. 1.0.0

 Safety notes1
Safety symbols definitions1.1

1 Safety notes

Installation, commissioning and programming of the specified

equipment should only be undertaken by qualified personnel.

1.1 Safety symbols definitions

V The safety alert symbol is used to alert to the potential personal in-
jury hazards. Obey all safety messages that follow this symbol to
avoid possible injury or death.

V CAUTION indicates a potentially hazardous situation which, if not

avoided, may result in property damage.

V CAUTION with safety alert indicates a potentially hazardous situ-

ation which, if not avoided, could lead to light bodily injuries.

V WARNING indicates a potentially hazardous situation which, if not

avoided, could lead to heavy bodily injury or to death.

V DANGER indicates a extremely hazardous situation which, if not

avoided, could lead to heavy bodily injury or to death.

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 5

1 Safety notes
1.1 Safety symbols definitions

1.1.1 Electrical Hazard Icon

This sign indicates an electrical hazard. It is located on covers and
doors. Only qualified personnel are allowed to remove these covers or
open the doors.

1.1.2 Ground Icon

This sign indicates that a ground/PE connection is required.

1.1.3 No Hands Icon

Do not place hands or other body parts into moving parts or machine.

1.1.4 Power Icon

Power off and disconnect air supply before working on the equipment.

Page 6 Docu-No.: 0890000002-EN Rev. 1.0.0

 Safety notes1
Responsibilities of the owner1.2

1.2 Responsibilities of the owner

V Ensure that only qualified and trained personnel work with the
feeder.
V Establish personnel responsibilities for operation and
maintenance.
V Ensure that the personnel has read and understood the operating
instructions to all installation components, particularly this chapter
"Safety notes".
V Strictly follow the operating and maintenance instructions.
V The plant owner must replace immediately damaged or missing
components.
V The operator has to avoid the entry of foreign substances reaching
the feeder (metal parts, stones) by appropriate methods.
V The plant owner is responsible for compliance with legally
prescribed accident prevention and safety regulations.

1.3 Proper use

V Use feeders for dry bulk material and liquids only as stationary
equipment.
V Only operate the feeder in conjunction with the appropriate control
and drive equipment from K-TRON.
V Only operate the feeder in accordance with the specified technical
data.
V When processing dangerous materials, also comply with the
safety notes which govern the handling of such materials.
V Any modifications and changes on safety devices are prohibited
V Do not use the equipment in a manner not intended by the
manufacturer.
V Never use feeder to process materials which may cause a
chemical reaction with the materials of the feeding units.
V Not suitable for mixing or crushing bulk material.

1.4 Organizational measures

V Always keep the operating instructions near the feeder, within

easy reach. Ensure that they are always complete and legible.
V Observe the safety notes for the connected feeding devices.
V In addition to the operating instructions, always comply with
generally prescribed safety regulations governing accident
prevention and environmental safety.

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 7

1 Safety notes
1.5 Safety-conscious work

1.5 Safety-conscious work

V Read the operating instructions, in particular these safety notes,

and follow these instructions.
V Ensure that only authorized personnel enter the working and
danger area of the feeder.
V Any changes (including changes in the operational behaviour)
which affect safety must be immediately reported to the
responsible member of the staff.
V Always keep safety in mind while working.
V Before working on the feeder always switch the feeding equipment
off at the main power switch.

1.6 Safety devices

V Operating the feeder without safety devices:

is dangerous for the health and life of the operator or third
persons
can damage the feeding units or other material
V Never alter the mechanical safety devices or the electrical control
system for the safety devices. Increased risk of accident.
V Only operate the feeder if all safety devices are installed and fully
functional.
V Check that all safety devices operate properly every day.
V Never open or remove covers or hoods while the equipment is in
operation.
V Never operate the feeder when the housing is open.
V Do not modify the electrical safety devices, for example fuses.
Increased risk of accident.
V Only use the specified fuse types when replacing fuses.
V Replace damaged cable joints and connections immediately.

1.7 High voltage

V Only qualified electricians may work on the electrical equipment of

the feeder.
V High voltage occurs at the motor connections.
V After switching off the main power supply there are still some
internal electrical components of the motor drive carrying high
voltage which discharges slowly.
V Protect electrical parts of the feeder against humidity.

Page 8 Docu-No.: 0890000002-EN Rev. 1.0.0

 Safety notes1
Additional equipment1.8

1.8 Additional equipment

V Modifications to the feeding equipment are prohibited.

V The operator is responsible for complying with all safety
regulations related to interoperation with any additional
equipment, e.g. refilling units.

1.9 Customer service and repairs

V Have repairs to the feeder carried out by

by the responsible K-Tron customer service (customer service
address is found on the inside cover)
or
by specialized personnel trained by K-Tron.
V Only use original K-Tron parts.

1.10 Shut-down procedure

V The operator is responsible for the proper removal and disposal of

the feeding equipment from service.

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 9

2 Assembly and function
2.1 Feeder types

2 Assembly and function

2.1 Feeder types

The feeder is available in the following types:

Type Description Field of application

Volumetric
K-MV-KT20 Twin screw feeders with a maximum Feeding of bulk materials which flow
K-CV-KT20 feed screw diameter of 20 mm. The easily to heavily. Heavy-flowing
feeding tools can be exchanged powders (e.g. pressed, humid or
rapidly. bridging) as well as fibers and flakes
can require a flow aid which prevents
Gravimetric bridging (optional).
K-ML-KT20 Gravimetric feeders are equipped with
a weighing system. As a rule the Different feed screws are available for
weighing system consists of 3 K-SFT the various requirements placed by the
load cells which are mounted on a bulk material (see the machine data
frame. sheet or spare parts list).

K-ML-D5-KT20 KT20 feeders can be mounted on a D5

scales in special cases.

K-CL-24-KT20 KT20 Compact feeder is mounted on a

SFS24 scale.

K-MV-KT20 K-ML-D5-KT20 K-ML-KT20

K-CV-KT20 K-CL-24-KT20

Fig. 2.1 Feeder types

Page 10 Docu-No.: 0890000002-EN Rev. 1.0.0

 Assembly and function2
Structure2.2

2.2 Structure

Overall view Modular KM and Compact KC production series

(1) Hopper lid
(2) Seal
1
(3) Hopper
2
(4) Gearbox for agitator and 11
feed screw
(5) Agitator hopper 3
(6) Outlet tube
(7) Feeding screws
(8) Horizontal agitator 10
4
(9) V-clamping ring 9 10
4
(10) Motor 8
5
(11) v-clamping ring
6
(12) Base plate 7
7 12

Fig. 2.2 Overall view

Method of operation
The feeder is part of a feeding equipment. The minimum configuration
of the equipment consists of a feeder, controller and motor control
unit.
The feed material (Bulk material) is transported from the refill system
to the hopper onto the feed screw. A motor drives the feed screw and
the horizontal agitator (screw filler). The feed screws transport the
bulk material outwards in a constant flow. The feed rate is controlled
by the controller via the speed of the motor and the gearing reduction.
Options:
A vertical agitator with separate motor drive prevents bridging in the
hopper (only on KM series).
Shear Hopper (moving inner rubber hopper) with separate motor
drive prevents bridging in the hopper (only on KM series).
Different hopper sizes available (only on KM series).
Air purge for screw seals.

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 11

2 Assembly and function
2.3 Feed screw types and applications

2.3 Feed screw types and applications

Type Code Feeding Screws

Floodable and mildly cohesive powder.

Twin concave TCC Low friction when compresses.
coarse
TCF
Twin concave fine
Free flowing and non- free flowing pow-
Twin spiral coarse TSC ders, hygroscopic materials, flakes.
Used only in special cases
Twin spiral fine TSF

Free flowing and compacting, sticky

Twin auger coarse TAC powders. Hygroscopic materials, flakes.

Twin auger fine TAF

Very free flowing, free flowing, dusty.

Double spiral DSC hygroscopic Flakes, Pellets, Granules
coarse
Double spiral fine DSF

Twin and double screws are used in pairs.

Many other screw configurations exist. Extended length screws and
ones with outboard support bearings are available.
Nominal twin screw diameters are roughly the model size. e.g. T20
has 20 mm diameter screw sets.
Double screw flights do not intermesh, twin screws flights inter-
mesh.

Page 12 Docu-No.: 0890000002-EN Rev. 1.0.0

 Assembly and function2
Feed screw types and applications2.3

2.3.1 Screw types and applications

1. Auger screw
2. Spiral screw 6
3. Concave screw
4. Diameter 1 4
5. Tube length 5
6. Pitch
for concave screws double
pitch is indicated (Tab 2.3.2)
2

Fig. 2.3 Screw applications

2.3.2 Twin screw sizes and throughput

Capacity is nominal. The properties of the bulk material being fed may
result in a different capacity than that shown.

Screw type Nominal Dia Capacity Pitch

mm 3
dm /u mm/inch

T20 twin concave coarse 20 0.0033 20 / 0.79

T20 twin concave fine 20 0.0013 11 / 0.43
T20 twin auger coarse 20 0.0054 20 / 0.79
T20 twin auger fine 20 0.0019 8 / 0.31
T20 twin spiral coarse 20 0.0039 20 / 0.79
T20 twin spiral fine 20 0.0019 10 / 0.39
T20 double spiral coarse 20 0.0033 20 / 0.79
T20 double spiral fine 20 0.0016 10 / 0.39

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 13

2 Assembly and function
2.4 Outlet tube configurations

2.4 Outlet tube configurations

1. Tube diameter
1
2. Horizontal discharge
3. Tube length
4. Cap
5. Vertical discharge with outboard bearings
6. Bellow (Flexible connection)
2 7. Outboard bearings
3

7
5

Fig. 2.4 Outlet tube configurations

2.5 Gearing reduction

At the feeders the gearing reduction is controlled by changing the gear
box with different gear reductions.
Type Gearing Gearing reduction (at a motor speed
of 2000 r.p.m)

KM...KT20 A 2,683 : 1 auf 745 U/min

KC...KT20 B 5,6 : 1 auf 357 U/min
C 12,95 : 1 auf 154 U/min
D 1,634 : 1 auf 1223 U/min

Page 14 Docu-No.: 0890000002-EN Rev. 1.0.0

 Assembly and function2
Warnings and safety devices2.6

2.6 Warnings and safety devices

2.6.1 Safety devices

Safety devices are located at the following positions on the feeder:
Outlet tube (7)
1 2
3 Hopper (5)
Connected refilling unit with bellow (2)
4
Filter bag on the hopper ventilation nozzle (1)
5 Only for volumetric devices: Safety grid in the hopper (4)

8
7

Fig. 2.5 Safety devices

V Operate the feeding device only with the installed safety devices.
V Do not reach into the rotating feed screw or agitator.

2.6.2 Warnings
The warning shown in is applied to the following positions at the
feeder:
At the agitator hopper (see Fig. 2.5/6)
At the outlet tube (see Fig. 2.5/8)
At the hopper (see Fig. 2.5/5)

The warning shown in is applied to the following positions at the

feeder:
At the gearbox
At the vertical agitator

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 15

3 Technical data
2.6 Warnings and safety devices

3 Technical data

Manufacturer K-TRON (Switzerland) Ltd.

Designation K-CV-KT20
K-MV-KT20
K-ML-KT20
K-ML-D5-KT20
K-CL-24-KT20

Marking
or declaration by the manufacturer

Motor feed screws See machine data sheet, motor plate and declaration of conformity

Fusing See wiring diagram

Gearing Oil filled gearing for feeding tools and horizontal agitator
Lubrication Type Shell Cassida GL 150 or as specified
Content:
KT20: 0,12 l

Horizontal-agitator (optional) see machine data sheet

Motor vertical-agitator (optional) see machine data sheet, motor plate,

Gearing vertical-agitator (optional) see machine data sheet, motor plate,

Noise < 70 dB (A)

Feed rate see machine data sheet,

Feeding tools see machine data sheet,

Hopper capacity see machine data sheet,

Weight see mechanical drawings

Material of parts contacting feed Rust- and acid-proof steel

material DIN W.- No. 1.4404/1.4435
AISI 316L

Ambient temperature during 0 to 50C 32 to 122F

operation

Temperature of the feed material -15 to 80c 0 to 176F

Page 16 Docu-No.: 0890000002-EN Rev. 1.0.0

 Installation4
Transportation4.1

4 Installation

V Only have the feeder connected and commissioned by authorized

personnel.

Ambient conditions
V Only use explosion-proof feeders in hazardous areas.
V Install the feeder only in surroundings conforming to the technical
data (see Section 3) and in accordance with the safety notes (see
Chapter 1).

4.1 Transportation

V Before a gravimetric feeder is transported secure the load cell(s).

V Check if v-clamping ring are firmly secure.
V Only transport the feeder with a crane or equivalent lifting gear.
V In order to avoid damage to the feeder only use belts with sufficient
lifting capacity for the crane (for the weight of the feeder see the
mechanical drawings).
V Only fasten the belts at the marked points on the stand or frame
(see 4.1).
V The belts have to be sufficiently long for the belts not be overload-
ed and tear. The angle should be smaller than 60. The belt
should, however, not touch the conical extension hopper.
V Only remove the yellow transport safety guard after installation of
the feeder (see Fig. 4.6).

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 17

4 Installation
4.2 Unpacking

Fig. 4.1 Fastening and length of the transport belts

4.2 Unpacking
1. Remove the feeder carefully from the packaging.
2. Check whether the supplied goods are complete and check them
for transport damage.
3. Report any damage immediately to K-Tron.
4. Protect the cable ducts on the inside of the frame before attaching
the transport belts.
5. Fasten the belts at the marked points on the stand or frame
(see 4).
6. Ensure that the transport belts do not slip (e.g. by using clamps).

Page 18 Docu-No.: 0890000002-EN Rev. 1.0.0

 Installation4
Mounting the feeder4.3

4.3 Mounting the feeder

1. Select a level and vibration-free installation location
(max. inclination: 5 0/00 oder 0.3).
2. Clean the installation location
3. Install the feeder.

4.3.1 Installing volumetric feeder

210 50

200
Fig. 4.2 Drilling diagram for base plate

1. Drill the holes (9 mm or 11 mm) for the base plate (see Fig. 4.2).
The outlet side is on the right.
2. Position the feeder and screw it to the base plate by means of
suitable screws.

Fig. 4.3 Fastening the feeder

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 19

4 Installation
4.3 Mounting the feeder

4.3.2 Installing gravimetric feeder

V Do not throw, hit or drop the scale.

V Do not drop any objects on to the scale.
V Do not turn the scale upside down more than 5 minutes. The pos-
sibly fitted oil shock absorber will leak and become unusable.
V Only hold and lift the scale at the bottom and handle carefully.

For information on the dimensions of gravimetric feeders or feeders

with frame or stand see the dimensional drawings in the project
manual.

Install the feeder in accordance to the dimensional drawings.

Feeder KCL KT20
1. Level the scale and level out any irregularities. Max. Deviation 5 0/00
1 2. Securely mount the scale on to the mounting surface.
3 3. Remove the knurled screws (3) from the scale(1).
4. Gently place feeder (2) on to the scale and secure with the knurled
2 screws.
Mount the hopper (if not already mounted) (see chapter 6.3).
3

Fig. 4.4 Mounting feeder on to the

platform scale

Remove transport safety guard (3-Point Suspension Scale))

(1) Loosen screw (4) and remove it.
4
(2) Loosen screw (2) to lower the hopper on to the load cell (3).
(3) Remove screw (2) and transport safety guard (1).
3
1 (4) Securely fasten screw on bracket with load cell without twisting
the rubber shock absorber on top of the load cell.

Fig. 4.5 Transport safety guard

Page 20 Docu-No.: 0890000002-EN Rev. 1.0.0

 Installation4
Adjusting the feeder (D-Platform Scale)4.4

4.4 Adjusting the feeder (D-Platform Scale)

Adjust the supporting bolt (2) while the feeder is empty until it
contacts the feed screw housing (1).

1
2

Fig. 4.6 Adjusting the feeder

4.5 Oil ventilation plug

V If the plastic screw plug is not replaced with the ventilation screw,
the overpressure created during operation will push the gear seals
out.

1. Remove the plastic screw plug (1).

2. Insert the supplied ventilation screw (marked "Oil").

Oil

Fig. 4.7 Replace ventilation screw

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 21

4 Installation
4.6 Connecting the feeder

4.6 Connecting the feeder

Improper connection of the feeder can cause danger to life through

electric shock.
V The feeder may only be connected by qualified electricians.
V Observe the local regulations.

1. Connect the feeder in accordance with the electrical wiring

diagram.
2. Ground the feeder carefully.

Connect the ground connection to a low-impedance equipotential

bonding ( 0.1 ), see the grounding information on the feeder.

Provide a lockable main switch to disconnect the main power supply

from the feeder.

Carefully follow all wiring and shielding procedures as indicated on the

provided wiring diagrams and operating instructions of the controls.

4.7 Taking the feeder into operation

V Do not place any bulk materials into the feeder until feed screw ro-
tation and security to the drive shafts are verified. Feed screws
may become disengaged if the motor rotation is incorrect.

1. Before the first activation ensure that the agitator hopper and feed
screw are free of objects such as screws, packaging rests, etc.
2. Switch on the feeder with the connected controls.
3. Check the parameters according to the machines programming
list.
For more information see controller operating and programming
instructions.

When switched on the screws turn counterclockwise.

Page 22 Docu-No.: 0890000002-EN Rev. 1.0.0

 Installation4
Storage4.8

4.8 Storage
1. Empty the feeder prior to shipment or storage and attach the
MSDS data sheet describing the product last fed in the machine.
2. Dismantle on gravimetric feeders the load cell (s).
- or -
Secure the load cell (s) with transport safety guard.

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 23

5 Operation
5.1 Notes on operation

5 Operation

5.1 Notes on operation

Risk of injury at the rotating agitator and at the rotating feed screws.
V Operate the feeder only with a hopper or a corresponding
protective grating.
V Do not reach into the hopper, agitator hopper or feed screws
during the feeding process.
V Do not bring hair, clothing and tools into the feeder.
V Only operate the feeder with the outlet tube.
V Only switch on the feeder when the gearing and motor cover are
mounted.
V Never use the feeder to process materials which may cause a
chemical reaction with the materials of the feeder, for example
feed materials containing the following substances:
Acid
Iodine
Chromium
Bromium
V When feeding dangerous materials observe the safety notes
applying for handling these materials.

Excessive vibrations will cause the feeding to become imprecise.

Avoid vibrations and do not touch the feeder during operation with
scales.

5.2 Switching on/off

Before switching on ensure that the agitator hopper and feed
screw are free of objects such as screws, packaging rests, etc.
See controllers operating instructions.
Switch on/off the feeder with the connected controls
For more information see controller operating and programming
instructions.

Page 24 Docu-No.: 0890000002-EN Rev. 1.0.0

 Cleaning6
Switching off the machine before maintenance work6.1

6 Cleaning

When carrying out maintenance work on the switched-off feeder there

is a danger of injury through unintentional switching-on.
V Switch off the feeding system before carrying out maintenance
work on the feeder and secure it against unintentional restarting
(see section 6.1).

6.1 Switching off the machine before

maintenance work

1. Switch off the machine at the main switch.

2. Secure the main switch with a lock.
3. Attach a danger sign to the main switch.
4. Turn off compressed air for all the pneumatic devices.

6.2 Cleaning

Aggressive and toxic cleaning agents damage the feeder and

represent an increased accident risk.
V Do not clean the feeder with corrosive cleaning agents.
V Use only safe cleaning agents and disinfectants in feeders used
for foods.
V Ensure that no cleaning agent residues are left on the components
which come into contact with the feed material, e.g. on hopper
connections, outlet tube and feed screw.
V Clean in the area of the drive motor only with slight air stream.
V Do not clean the agitator and feed screw with high-pressure
devices.

Docu-No.: 0890000002-EN Rev. 1.0.0 Page 25

6 Cleaning
6.2 Cleaning

6.2.1 Cleaning without parts removal

The v-clamp only forms the connection between the hopper and the
agitator hopper.
V Secure the hopper for overturn.

In case of external soiling, clean all the components of the feeder

with a damp cloth and use normal industrial cleaners.
1
Cleaning the inside
2 1. Empty the feeder.
3 2. Switch off the machine (see Section 6.1).
3. Loosen and remove the v-clamping ring (2).
4. Remove the seal (3).
5. Remove the hopper (1).
4 6. On 3-point suspension scale swivel the feeder away via the hinge
(5).
7. Rinse out the agitator hopper (4).
8. After cleaning, mount the unit in the reverse order.

Fig. 6.1 Cleaning without parts re-

moval

6.2.2 Cleaning with parts removal

1. Carry out step 1 to step 6 from section 6.2.1.
2. In order to clean the feeder more thoroughly remove the following
parts:
Agitator (see Section 6.5)
Outlet tube (see Section 6.4.1)
Feed screws (see Section 6.5.1)
3. After cleaning, mount the unit in the reverse order.

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 Cleaning6
Replacing the hopper6.3

6.3 Replacing the hopper

6mm Allen wrench

The v-clamping ring only forms the connection between the hopper
and the agitator hopper.
V Always let the retaining hinge latch in order to stabilize the feeder
(5).

The seal (3) between the agitator hopper (4) and the hopper (1) can
continue to be used when the hopper is replaced.
In case of gravimetric feeders: When loosening and mounting the v-
clamping ring always ensure that the hinge (5) remains latched in.
For KC...KT20 (see chapter 6.5.2).

2
3

Fig. 6.2 Replacing the hopper

1. Loosen and remove the v-clamping ring (2).

2. Remove the hopper (1) and seal (3).
3. Mount the new hopper (1) with seal (3) and v-clamping ring (2).
4. Tighten the v-clamping ring (2).

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6 Cleaning
6.4 Replacing the feed screws

6.4 Replacing the feed screws

Observe the following points when the feed screws is/are replaced:
Ensure that the hopper and agitator hopper are empty.
Remove the twin screws simultaneously.
Do not damage the screw bearing shaft during installation and
removal.

90 1

Fig. 6.3 Connection of feed screw

Bayonet connection
In order to loosen/lock the screw turn it by approx. 90 on the bearing
shaft.
6-mm Allen key
4mm Screw driver

6.4.1 Removing the feed screws

1. Switch off the machine (see Section 6.1).
2. Clean the agitator hopper (2) and hopper (1) thoroughly.
3. Remove the outlet tube (6). The seal (4) remains at the flange of
1
the agitator hopper (2).
4. Turn the screws by 90 counterclockwise and then pull it out.
5. Remove the feed screws (5).
6. Clean the outlet tube(6), agitator hopper (2) and bearing shafts in
2
the housing completely.
3
7. Clean the location holes of the new screws thoroughly so that they
4
can be fastened properly.

5
6

Fig. 6.4 Removing the screws

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 Cleaning6
Replacing the feed screws6.4

6.4.2 Installing the feed screws

V When installing the screws do not damage the O-ring at the screw
bearing shaft.
V Do not use a hammer to have the screws latch in.

1. Ensure that there are no feed material residues in the feed screw
housing or at the screw bearing shaft.
2. Before installing the feed screws check the screw bearing shaft for
scratches or sharp edges and eliminate these.
3. Turn the twin screws so that the helixes of the one screw move in
the gaps of the helixes of the other screw (see Fig. 6.5).

Fig. 6.5 Positioning the screws

4. Slide the screws onto the bearing shaft so that the carrier surface
1 2 in the screw holes show in the same direction as the leading-in
surface of the bearing shaft.

Fig. 6.6 Aligning the screw hole

to the bearing shaft

5. Place the screws on the bearing shaft and rotate them by

90 clockwise

Fig. 6.7 Installing the screws

6. Pull the screw carefully in order to check whether the bayonet

connection has latched in.
7. Fasten the outlet tube.
8. Let the feeder run without bulk material in order to check the
correct installation.

V Do not reach into the rotating feed screws or agitator.

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6 Cleaning
6.5 Replacing the horizontal agitator

6.5 Replacing the horizontal agitator

Danger through sharp agitator blades!

While disassembling without protective gloves, the agitator can cause
cutter wounds at the hands.
V Always wear protective gloves when working on the agitator.

Feeding different bulk materials may require the agitator to be

changed. Agitators with four blades or special agitator models can be
supplied for various applications (see spare part list).

6-mm Allen wrench

10mm Ring open end wrench

6.5.1 Replacing the three part agitator on KM-KT20

Disassembly:
1. Switch off the machine (see Section 6.1).
2. Loosen and remove the v-clamping ring (2).
3. Remove the hopper (1) and seal (3).
4. Turn the agitator (6) counterclockwise to loosen the agitator
1 retainer (7).
5. Remove the agitator retainer (7), agitator (6) and the distance
2 tube (5).

5 3
Assembly:
6 1. Clean the thread of the agitator bearing shaft (4).
7
2. Clean the inner thread of the agitator retainer (7).
3. Slide the distance tube (5) onto the agitator bearing shaft (4).
4
4. Slide the agitator retainer (7) through the new agitator (6).
5. Slide the agitator retainer (7) through the distance tube (5).
6. Screw in the agitator (6) clockwise and tighten it firmly.
7. Place the hopper (1) and seal (3) onto the hopper bowl. Ensure
that the seal does not reach into the hopper.
8. Fasten the v-clamping ring (2).
Fig. 6.8 Replacing the agitator

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 Cleaning6
Replacing the horizontal agitator6.5

6.5.2 Replacing the three part agitator on KC-KT20

Disassembly:
1. Switch off the machine (see Section 6.1).
5
2. Remove safety grid (1).
4
3. Loosen the agitator screw (2).
4. Remove the agitator retainer (3), agitator (4) and the distance
tube (5).
1
Assembly:
2
3 1. Clean the thread of the agitator screw (2).
2. Clean the inner thread of the agitator retainer (3).
3. Push in the agitator screw (2) all the way in towards the agitator
bearing.
4. Slide the distance tube (5) onto the agitator screw (2).
5. Slide the agitator retainer (3) through the new agitator (4).
6. Slide the agitator retainer (3) through the distance tube (5) and
screw it on with the agitator screw (2).
7. Mount the safety grid (1).
Fig. 6.9 Replacing the agitator

6.5.3 Replacing the one-piece agitator (used for ATEX)

Disassembly:
1. Switch off the machine (see Section 6.1).
2. Loosen and remove the v-clamping ring (2).
3. Remove the hopper (1) and seal (3).
4. Turn the agitator (6) counterclockwise to loosen and remove it.

1
Assembly:
1. Clean the thread of the agitator bearing shaft (4).
2
2. Clean the inner thread of the agitator (6).
3. Screw the agitator (6) clockwise onto the agitator bearing shaft (4)
3
and tighten it firmly.
6
4. Place the hopper (1) and seal (3) onto the hopper bowl. Ensure
that the seal does not reach into the hopper.
5. Fasten the v-clamping ring (2).

Fig. 6.10 Replacing the agitator

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6 Cleaning
6.6 Replacing the vertical agitator (optional)

6.6 Replacing the vertical agitator (optional)

Danger through sharp agitator blades!

While disassembling without protective gloves, the agitator can cause
cutter wounds at the hands.
V Always wear protective gloves when working on the agitator.
V Use the crane to lift the hopper lid together with the agitator.

6.6.1 Removing the vertical agitator

1. Loosen air plug and cables and remove it.
2. Dismantle filter (1) and bellow (2) from the hopper lid (3).
3. Lose the v-clamping ring (3).
4. Use the crane to lift the hopper lid together with the agitator.
1 By lack of space is it possible to lift the complete feeder or to lift
2 3 the hopper together with the vertical agitator. Check for clamped
4 connection from the v-clamp.
5
5. Remove seal (5)
After cleaning dry up all component.

Fig. 6.11 Removing vertical agitator

6.6.2 Installing the vertical agitator

1. Check the parts before fitting for damage or wear and replace as
necessary.
2. Place the seal (5) on the auf den hopper seam.
3. Lift the hopper lid (3) together with the agitator into operating
position.
4. Close the v-clamping ring (3)
5. Mount the filter (1) and the bellow (2).

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 Cleaning6
Replacing the agitator hopper6.7

6.7 Replacing the agitator hopper

Carry out the steps described below when the following parts are
changed:
Agitator hopper
Seals (screws, horizontal agitator)
Bearings

6-mm Allen wrench

6.7.1 Removing the agitator hopper

1. Switch off the machine (see Section 6.1).
2. Remove the hopper and agitator (see Section 6.5.1).
1
5 3. Remove the feed screws (see Section 6.4.1).
4. Loosen the holding bolt (4) at the agitator hopper wit the Allen
2 wrench.
5. Open the retaining latch (1).
6. Remove the agitator hopper (3).
3
7. Clean all the parts.

4
Fig. 6.12 Replacing the agitator hopper

6.7.2 Installing the agitator hopper

1. Before carrying out the installation ensure that all the parts are
clean.
2. Before carrying out the installation ensure that all the seals (5) are
positioned correctly.
3. Position the agitator hopper (3) and open the retaining latch (1).
4. Align the agitator hopper (3) over the pin pair (2) and screw it tight
with both holding bolts (4).
5. Close the retaining latch (1).
6. Install the feed screws (see Section 6.4.2).
7. Install the agitator and hopper (see Section 6.5).
8. Adjust the feeder if platform scale is used (see Section 4.4).

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7 Maintenance
7.1 Maintenance Intervals

7 Maintenance

When carrying out maintenance work on the switched-off feeder there

is a danger of injury through unintentional switching-on.
V Switch off the feeding system before carrying out maintenance
work on the feeder and secure it against unintentional restarting
(see section 6.1).

Only qualified and trained personnel may carry out maintenance

work on the feeding equipment.
Only qualified electricians may work on the electrical equipment.

7.1 Maintenance Intervals

Element Checkpoints when in operation Interval

Mechanical Eliminate dust accumulation > 5 mm As required

through cleaning
Seals (leakage inspection) As required ( feed product dependent)
Oil level every 3 months
Oil change 10000 hours or 2 years
Bearings inspection 2 years
Bearing change 25000-30000 hour
Electrical Motor brushes As required (see motor specs.)

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 Maintenance7
Replacing seals7.2

7.2 Replacing seals

6-mm Allen wrench
Screwdriver, size 4, flat

There are three seals at the feeder which can be replaced as required.
Feed screw seal (1)
2
Agitator seal (2)
Sealing ring (3)
The seals prevent the bulk material from leaking out of the feeder and
the backflow of bulk material into the drive systems.
3
The sealing ring is free of wear.
Only replace the other seals if bulk material exits at the leak shafts of
the agitator and screws.

1 7.2.1 Replacing the screw seals

1. Switch off the machine (see Section 6.1).
2. Remove the hopper, agitator, screws and agitator hopper (see
Section 6.7.1).
3. Remove the old seal (1, 2 and 3) using the screw driver. Do not
damage the gearbox in the surrounding of the seal and screw
bearing shaft when removing the seal.

Fig. 7.1 Seals

7.2.2 Installing the seal

If the sealing lips are pointing to the wrong direction the sealing is not
guaranteed.

1. Clean the seal environment.

2 2. Select a seal which is suitable for the feeder type.
3. In order to ensure that the seal is not damaged when being slid
over the screw bearing shaft (2), lubricate the seal lips (3) lightly
with silicone grease and slide it onto the screw bearing shafts.
1
4. Slide the screw seal (1) onto the screw bearing shafts.
The sealing lips point towards the agitator hopper.
5. Install the agitator hopper, screws, agitator and hopper. If the
components can be assembled smoothly then the seals are
properly fitted.
6. Adjust the feeder if platform scale is used (see Section 4.4).
Fig. 7.2 Mounting direction

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7 Maintenance
7.3 Replacing the drive motor

7.3 Replacing the drive motor

13-mm wrench
2.5-mm Allen key

7.3.1 Preparing the removal

1. Switch off the machine (see Section 6.1).

2. Disconnect the motor connections at the motor terminal box.

7.3.2 Removing the motor

1. Use an 13-mm wrench to loosen the 4 screws at the motor while a
second person secures the motor.
2. Remove the motor from the drive housing.

7.3.3 Installing the motor

1. Adjust the motor coupling sprocket (2) by using a 2.5-mm Allen
2
key so that the coupling (3) fits between coupling sprockets (4) and
5 4 3 1
(2) leaving 1 mm gap.
2. Slide the motor (1) to its place. Guide the coupling so that it latches
in into its counterpart in the coupling sleeve (3).
3. Insert the mounting bolts and tighten them .
4. Connect the motor and take the feeder into operation.
Fig. 7.3 Installing the motor

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 Maintenance7
Replacing the tachometer7.4

7.4 Replacing the tachometer

3 mm Screwdriver
Test equipment for tachometer
Gauge
Feeler gauge (0,2 mm/0.0078")

The gearwheel of the tachometer generator is mounted at one end of

the coupling. (see Fig. 7.3 /5).

7.4.1 Removing the tachometer

1. Switch off the machine (see Section 6.1).
X 2. Screw off the cable cover of the tachometer and disconnect the
cable (4) from the tachometer generator.
4
3. Remove the tachometer (1) with bracket (2) from the gearbox.
4. Measure Distance X from the surface of the tachometer to the
bracket and note it.
5. Loosen the nuts (3) and remove the tachometer from the bracket.
1
3
2

Fig. 7.4 Removing the tachometer

generator

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7 Maintenance
7.4 Replacing the tachometer

7.4.2 Installing the tachometer

1. Mount the new tachometer with the supplied accessories to the
bracket.
+ 5 VD C
com 2. Screw the nuts so far onto the tachometer generator that the
measured Distance X between the surface of the tachometer and
the bracket is reached.
3. Fasten the bracket with tachometer by means of the mounting
bolts (2 pieces) only loosely to the gearbox.
1
4. Use the feeler gauge to set gap A between the gearwheel (2) and
the tachometer (1) so that the feeler gauge can still be moved
slightly in the gap.
A
2 5. Tighten the mounting bolts at the bracket.
6. Remove the feeler gauge and turn the gearwheel.
The gearwheel and tachometer generator may not touch each
other.
7. Connect the tachometer generator cable and mount the cover
sheet.
8. Supply the tachometer generator with the test equipment with
power and check whether it functions correctly while the
gearwheel rotates. No pulse may be missing during one rotation of
the gearwheel.
9. In order to check the correct installation let the feeder run without
bulk material.
Fig. 7.5 Installing the tachometer
generator

For more technical information about the tachometer

see project manual.

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 Maintenance7
Lubrication7.5

7.5 Lubrication

V Remove any oil spillage immediately with an oil-binding agent in

compliance with environmental requirements.

V Signs of changes in the oil can be seen with the naked eye. Fresh
oil is clear to the eye and has a typical smell and a specific product
color. Clouding or dark appearance indicate water and/or contam-
ination. If you detect such abnormalities, the oil must be changed
immediately.

For oil type and content refer to chapter 3, technical data.

7.5.1 Oil level inspection

Quarterly
Check the oil level on the gear box through the inspection plug with
the oil sight glass.
The oil level must be in the middle of the sight glass (1If there is not
enough oil do following:
1. Unscrew slightly the oil inspection plug (2), oil must run out.
2. If there is insufficient oil, fill in oil through the ventilation hole (1)
Oil until oil runs out of the oil-level inspection hole.
1 2 3. Tighten oil inspection plug.

Fig. 7.6 Lubrication

7.5.2 Oil change

1. Loosen ventilation plug (1).
2. Remove inspection plug (2) and drain off oil in a proper container.
3. Screw in slightly the oil inspection plug (2) do not tighten it.
4. Fill up oil through the ventilation hole (1) until it flows out of the
inspection hole (2).
5. Tighten both oil inspection and ventilation plug.
6. Check oil level according to chapter 7.5.1.

7.6 Replacing the bearings

Check the temperature of the drive housing. If the temperature
rises and unusual noises are to be heard in the drive housing, the
bearing are damaged.
Replace the bearings in case of damage.

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8 Troubleshooting
7.6 Replacing the bearings

8 Troubleshooting

Eliminating faults in a feeder which is running can cause serious

accidents.
V Switch off the feeding system before every intervention and secure
it against unintentional restarting (see Section 6.1).
V Gravimetric feeding units have a plug-in connection to the feeder
motor. In order to disconnect the feeder motor from the power
supply, disconnect the plug-in connection.

1. Always switch off the feeders before carrying out repairs.

2. Check the feeder (see Section 8.1).
3. Please observe the error messages which are displayed on the
connected control device or host computer (see operating
instructions for the relevant control device).
4. Document faults and call the local service center (customer
service see inside cover).

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 Troubleshooting8
Troubleshooting table8.1

8.1 Troubleshooting table

Malfunction/Error Possible cause Remedy

Feeder does not No connection or no power Check the connections.

transport any
material
Screws rotates Motor connections incorrect Check the connections.
incorrectly
Screws and/or Foreign bodies in feeder Remove the foreign bodies.
agitator does/do not Feed material piling-up in the outlet Dismantle the outlet tube and
rotate tube eliminate the pile-up.
Motor does not get any power from Check the settings at the motor
the motor controller controller.
Check the motor controller.
Check wiring.
Gear box overheated Check oil level and quality.
Check bearings.
Feed rate not Foreign bodies in feed material Empty and clean the feeder.
constant Feed material forms bridging in the Empty the feeder and check the
hopper material flow in the hopper.
Gear box leaking Internal pressure to high Check ventilation plug.
Damaged sealing Replace sealing (K-Tron).

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8 Troubleshooting
8.1 Troubleshooting table

Page 42 Docu-No.: 0890000002-EN Rev. 1.0.0