TECHNICAL MANUAL

voluTEC
Volumetric
dosing unit
with feed station

Doc. no.: DBE-04963 Language: English

Translation of the original document
 INTRODUCTION

Copyright
Drawings, installation plans and operating instructions as well as designs,
catalogues, brochures, diagrams etc. are the intellectual property of Starlinger.
Duplication, reproduction, dissemination and distribution to third parties are
prohibited. Moreover, they must not be used to produce or have produced
machines or machine components.
Great care was taken in the creation of this documentation. However, Starlinger
reserves the right to make changes and improvements to the documentation.

Warranty and liability

The individual contractual conditions pertaining to the liability and warranty or the
respective conditions of the general sales and delivery terms of Starlinger always
apply.
Starlinger accepts no liability for damage arising due to the owner failing to
adhere to the intended use.

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 TABLE OF CONTENTS

ABOUT THIS DOCUMENT ................................................................................................ 5

1 TECHNOLOGICAL DESCRIPTION .............................................................................. 9
1.1 Area of application and intended use ................................................................... 9
1.2 Method of operation .............................................................................................. 9
1.3 Standard version................................................................................................... 9
2 TECHNICAL DATA ..................................................................................................... 12
3 INSTALLATION .......................................................................................................... 14
3.1 Installation overview ........................................................................................... 14
3.2 Installation site .................................................................................................... 14
3.3 Assembly ............................................................................................................ 15
3.3.1 Installation sequence.................................................................................. 15
3.3.2 Electrical connection .................................................................................. 16
3.3.3 Pneumatic connection ................................................................................ 16
4 SETTINGS .................................................................................................................. 17
4.1 Pneumatic operating pressure ............................................................................ 17
4.2 Feed station ........................................................................................................ 17
4.3 Dosing unit .......................................................................................................... 20
4.3.1 Filling out the dosing protocol..................................................................... 22
4.3.2 Example calculation and values to fill out................................................... 24
4.3.3 Adjusting the mixing ratio ........................................................................... 25
4.3.4 Twisting angle for ø 32mm dosing pipes (ml / 5,000ml) ............................. 26
4.3.5 Twisting angle for ø 32mm dosing pipes (ml / 10,000 ml) .......................... 27
4.3.6 Twisting angle for ø 60 mm dosing pipes (ml / 5,000ml) ............................ 28
4.3.7 Twisting angle for ø 60 mm dosing pipes (ml / 10,000ml) .......................... 29
4.3.8 Twisting angle for ø 120mm dosing pipes (l / 5,000ml) .............................. 30
5 COMMISSIONING AND OPERATION ....................................................................... 31
5.1 Before initial commissioning ............................................................................... 31
5.2 Controls and display elements............................................................................ 32
5.3 Commissioning ................................................................................................... 34
5.4 Operation ............................................................................................................ 34
5.4.1 Workstations............................................................................................... 35
5.4.2 Machine operating modes .......................................................................... 35
5.4.3 Tasks to perform on the machine ............................................................... 36
5.5 Switching off the machine ................................................................................... 37
5.6 Shutting down the machine ................................................................................ 37
6 MAINTENANCE .......................................................................................................... 39
6.1 Lubrication .......................................................................................................... 40
6.2 Lubrication chart ................................................................................................. 42
6.2.1 Oils ............................................................................................................. 42

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 TABLE OF CONTENTS

6.2.2 Greases ...................................................................................................... 43

6.3 Maintenance overview ........................................................................................ 44
6.3.1 Daily maintenance tasks ............................................................................ 45
6.3.2 Weekly maintenance tasks......................................................................... 45
6.3.3 Monthly maintenance tasks ........................................................................ 45
6.3.4 Six-monthly maintenance tasks.................................................................. 45
6.3.5 Electrical system ........................................................................................ 46
6.3.6 Pneumatic system ...................................................................................... 46
6.3.7 Plastic glazing ............................................................................................ 47
6.4 Specific maintenance tasks ................................................................................ 47
6.4.1 Side channel compressor ........................................................................... 47
6.4.2 Cleaning the machine................................................................................. 47
7 TROUBLESHOOTING ................................................................................................ 49
7.1 Feed station ........................................................................................................ 49
7.1.1 Mechanical faults........................................................................................ 49
7.1.2 Alarms on the operating unit ...................................................................... 50
7.2 DC drives ............................................................................................................ 50
8 ENCLOSURES ........................................................................................................... 51
Tightening torques ...................................................................................................... 51
DOSING PROTOCOL ................................................................................................. 52

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 ABOUT THIS DOCUMENT

ABOUT THIS DOCUMENT

Information
This document is part of the documentation series for the "voluTEC" volumetric
dosing unit with feed station, that comprises the following documents:
• General safety instructions
• Technical manual
• Manufacturer's documentation

The documentation series is intended for use by technically qualified and trained
personnel who are responsible for the installation, operation, servicing and
maintenance of the machine. It contains all of the information needed to work on
or with the machine safely and properly and must therefore be observed
precisely. Compliance with the stated instructions and guidelines will also
increase the service life and optimise the performance of the machine.

NOTE!
The documentation series must always be at hand where the
machine is used and must be read and used by everyone who
works on or with the machine.

Notation
This manual uses the following notation:

Notation Representation Example

Reference Italics See the Layout plan
Designation, information Quotation marks "voluTEC"
(Push) button, switch Angle brackets <Main switch>

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 ABOUT THIS DOCUMENT

Multi-step instructions
In this document, multi-step instructions are presented as follows:
1. Step 1
2. Step 2
- Subtask
3. Step 3
 Result

Lists
In this document, lists are presented as follows:
• List item 1
• List item 2
- Sub-item / Subtask
• List item 3
 Result

Steps which do not have a particular defined order are also presented in the form
of lists. In such cases, the lists may have subtasks and results.

Indicator words
The following table provides an overview of the indicator words used and their
meaning:

Indicator word Meaning

Immediately hazardous situation which will lead to death or
DANGER!
serious injuries if the safety measures are not followed
Potentially hazardous situation, which may lead to death or
WARNING!
serious injuries if the safety measures are not followed
Potentially hazardous situation, which may lead to minor or
CAUTION!
slight injuries if the safety measures are not followed
Possible damage to property which may occur if the safety
NOTE!
measures are not followed

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 ABOUT THIS DOCUMENT

Pictograms
The machine bears a number of pictograms (see the Spare parts catalogue as
well as the manufacturer's documentation). Pictograms which are missing,
illegible or damaged must always be replaced immediately.
The following table provides information on the pictograms which are used and
their meaning:

Risk of slipping

Warning: electrical voltage

Wear ear protectors

Wear safety goggles

Use breathing protection

Wear protective gloves

De-energise before carrying out maintenance or repair

Pay attention to the manual

This document contains additional pictograms with various purposes. The

following table provides information on the pictograms which are used and their
meaning:

General warning: risk of injury

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 ABOUT THIS DOCUMENT

General notice: potential damage to property

Important information

Reference to further information

Terms and abbreviations

In this document, the "voluTEC" volumetric dosing unit with feed station is
referred to in short as "the machine". Among other designations, the overarching
term "the material" is applied to the terms main component and secondary
component. A material mixture of main and secondary components is also
described as "the mixture" for short. All important abbreviations are explained
within the document.

Figures
The diagrams used in this document are example images, which may deviate
from your machine slightly, depending on the particular application. In the
interests of providing a clearer overview, in some diagrams the safety guards and
other components are not shown.

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 1. TECHNOLOGICAL DESCRIPTION

1 TECHNOLOGICAL DESCRIPTION

1.1 Area of application and intended use

The machine is used to produce a homogeneous material mixture from a main
component (polyolefin pellets) and up to four secondary components (pigment
and/or additive masterbatches) with a grain size of 1-7 mm.

The machine is designed for one-person operation.

1.2 Method of operation

The pellet conveyor system conveys the material from the feed containers of the
feed station into the downpipes of the dosing unit. The downpipes of the
secondary components are connected to the downpipe of the main component by
adjustable dosing pipes. In this area, the secondary components flow in the set
mixing ratio with the main component into the collecting container. The completed
material mixture is conveyed from the collecting container to the extruder.

1.3 Standard version

The machine consists of the following components:
• Feed station with pellet conveyor system
- Side channel compressor (on machines with a max. output of 900
kg, a second side channel compressor is solely responsible for
feeding the extruder)
- Airflow distributor with pneumatically actuated valves
- One feed container for a main component with a mobile suction
lance
- Two feed containers for secondary components with fixed suction
lances
- A third feed container for a third secondary component with fixed
suction lance (option)
- A second mobile suction lance for a fourth secondary component
(optional)
- Vacuum container (tubular body with vertically guided, freely-
moveable conical valve and a cover with a dust filter on the inside
and air intake fitting on the outside) with hoses
- Switching cabinet with manual operating unit
• Dosing unit with three or five (optional) downpipes, capacitive fill level
sensors and inspection windows

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 1. TECHNOLOGICAL DESCRIPTION

The following figure provides an overview of the position of the individual

components:

Fig. 4963/1001

Feed container for secondary

1 Vacuum container for mixing 7
components
Downpipe with inspection
2 Hose 8 window for secondary
component
Vacuum container for Downpipe with inspection
3 9
components window for main component
4 Indicator light: 10 Dosing pipe
5 Pneumatic connection 11 Collecting container
Manual operating unit on the Feed container for main
6 12
switching cabinet component

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 1. TECHNOLOGICAL DESCRIPTION

Feed station
In the feed station, the individual components are stored in separate feed
containers (7) and (12). The mobile suction lance enables a component to be
conveyed from an external container (e.g. a drum or bag).
If a fill level sensor on the dosing unit reports that a defined fill level has been
exceeded in one of the downpipes (8) or (9), the feed station conveys the
component out of the feed container and into the downpipes with the help of a
pellet conveyor system, as follows:
1. The airflow distributor sucks air out of the vacuum container (3) through
the dust filter in the cover. The airflow from below closes the conical
valve.
2. A vacuum forms in the collecting duct of the vacuum container (3),
which sucks the respective components out of the relevant feed
container for the set suction period.
3. The airflow distributor briefly blows air into the collecting duct of the
vacuum container. The airflow opens the conical valve.
4. The component falls into the downpipe (8) or (9) and the blown-in air
escapes via a screen.
The mixture is conveyed from the collecting container (11) via the vacuum
container (1) into the extruder hopper by the same principle.

If multiple downpipes report having exceeded the fill level at the

same time, then they are filled in order, according to their number.

Operating unit
The operating unit (6) on the switching cabinet allows for manual operation of the
feed station or monitoring of automatic mode.

Dosing unit
In the collecting container (11) of the dosing unit, the main components and
secondary component are mixed in the set mixing ratio. The pellet conveyor
system conveys the mixture out of the collecting container (11) into the extruder
hopper.

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 2. TECHNICAL DATA

2 TECHNICAL DATA

Feed station
Volume of the feed container for the main component 900 l
Volume of the feed container for Secondary component 1 100 l
Volume of the feed container for Secondary components
50 l
2-3

Dosing unit
Downpipes 5
Dosing ratio for the secondary components Approx. 0 - 9%
Dosing ratio for the secondary components, high-volume
Approx. 0 - 30%
dosing unit (optional)

Dimensions of the standard machine

Length 2,500 mm
Width 2,700 mm
Height 3,000 mm

For information on space requirements for the machine as well as

on the required working area, see Layout plan.

For information on the technical data for the individual purchased

components see the respective manufacturer's documentation.

Production data
Max. conveying height 5m
Max. conveying length 5m
Max. output with 1 side channel compressor 450 kg/h
Max. output with 2 side channel compressors (optional) 900 kg/h

Compressed air requirements

Operating pressure 6 - 7 bar
Approx. air consumption 0.6 Nm³/h

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 2. TECHNICAL DATA

Electrical data
Connected load See the Layout plan
Electrical supply See the Circuit
(voltage, frequency and conductor cross-section) diagram

The machine is not suitable for outdoor use! The ambient

temperature for production and storage areas must be between 18
°C and 40 °C!

For further information on ambient conditions for the production

and storage areas, see the Technical specifications.

Noise
Level 83 dB(A)

Wear ear protectors!

Type plate
The type plate is located on the base frame.

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 3. INSTALLATION

3 INSTALLATION

3.1 Installation overview

Fig. 4963/3001

Vacuum container
1 Vacuum container for mixing 3
for components
Hoses of the pellet conveyor 4 Dosing unit
2
system 5 Feed station

The figure serves as an example only. The precise setup of the

machine will depend on your particular application, and may
therefore deviate from the above.
We reserve the right to modify the technical specifications as part
of the technological development process.

3.2 Installation site

The base on which the machine is positioned must be level and capable of
withstanding the resulting loads. The foundation must not transfer the vibration
which can be generated by the machine during operation. The acceptable loading
capacity of the floor must be at least 10,000 N/m².

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 3. INSTALLATION

3.3 Assembly
The machine is supplied in a pre-assembled state. For transport reasons, certain
parts can only be fitted after the machine has been unloaded from the container
or positioned.

WARNING!
Danger of death due to falling parts!
Lifting devices, forklifts and lifting gear used for loading,
transportation and installation tasks must comply with applicable
legislation and be suitable for the load.
It is not permitted to stand under a suspended load!

WARNING!
Risk of injury from loose parts!
Be careful when lowering loose components, cables and hoses!

NOTE!
Use the supplied special tools, supplies and spare parts, and then
store them in the proper manner after work is complete.

NOTE!
All nuts and bolts provided without a lock washer must be secured
during assembly with the supplied thread lock (Loctite)!

After unloading, the separate components of the machine must be positioned and
aligned in accordance with the Layout plan.

For precise information on setting up the machine, see the Layout

plan.

3.3.1 Installation sequence

The individual components of the machine are assembled in the following order:
1. Lift the feed station (5) off the pallet with a suitable lifting device, and
position according to the Layout plan.
2. Level the feed station (5) using the machine feet.
3. Attach suitable load-bearing equipment to the eyebolts on the dosing
unit (4).
4. Lift the dosing unit (4) onto the frame of the feed station (5) and attach
it.
5. Install the supplied capacitive fill level indicator in the extruder hopper
(hole Ø 32 mm).

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 3. INSTALLATION

6. Mount the vacuum container (3) to the covers of the downpipes on the
dosing unit (4)
7. Mount the vacuum container (1) to the cover of the extruder hopper

There must be a ventilation opening with a screen of Ø 100 mm

underneath the valve housing (in the extruder hopper, in the
chute, etc.). If not, one must be produced.
Without a ventilation opening, the vacuum container will not
function!

8. Connect the vacuum container to the feed station with the hoses (2).
9. All parts which were removed for transport reasons (e.g. suction lances)
must be reattached using quick-lock clamping rings, hose clamps, seals
and screws.

3.3.2 Electrical connection

Work on the electrical equipment may only be performed by qualified electricians
and must comply with local regulations.

For further information on the machine's wiring, see the Circuit

diagram.

3.3.3 Pneumatic connection

NOTE!
The pneumatic system is designed to be oil-free.
The supplied compressed air must be free of oil and water!

All lines for the compressed air supply up to the machine must be already
installed. The connection should be made in accordance with the Layout plan.

For further information on the pneumatic connection, see the

Layout plan.

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 4. SETTINGS

4 SETTINGS

WARNING!
Risk of injury from moving parts!
When configuring settings on the machine, the <Main switch>
must always be set to OFF ("0" position) and be safeguarded
against being switched back on!

The machine must remain switched on for certain tasks. If this is

the case, a notice to this effect will appear in the document.

WARNING!
Risk of injury due to residual pneumatic energy!
The pneumatic system is under pressure, even after the machine
has been switched off.
Before carrying out work on the pneumatic system, it is vital that
you depressurise the system!

4.1 Pneumatic operating pressure

The pneumatic connection and the maintenance unit are located in the feed
station's switching cabinet (see Chapter 1.3, Fig. 4963/1001 (5)). After the
pneumatic connection has been established, the operating pressure must be set
to between 6 and 7 bar on the maintenance units.

Fig. 4963/4001

1 Pressure regulator 3 Stopcock

2 Pressure gauge 4 Connection

4.2 Feed station

The feed station switching cabinet contains an airflow distributor with
pneumatically actuated valves (see Chapter 6.1, Fig. 4963/6001).

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 4. SETTINGS

The valve positions and the time setting for opening and closing the valves
determine the behaviour of the pellet conveyor system.

Valve positions

The following figures are only intended as examples. The precise

placement of the valves is always specific to the particular
application (dependent on the delivery rate and the required
secondary components), and may there differ from that shown in
the figures.

Suction
For example, if the valves (S) and (A1) are open and all remaining valves are
closed, the secondary component (A1) is sucked from the feed container into the
vacuum container.

Fig. 4963/4002

X Cylinder extended A1 Secondary component 1

Y Cylinder retracted A2 Secondary component 2
S Suction (from feed container) A3 Secondary component 3
H Extruder hopper A4 Secondary component 4
Blowing
M Main component B
(into component container)

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 4. SETTINGS

Blowing
For example, if the valves (A1) and (B) are open and all remaining valves are
closed, the secondary component (A1) is blown from the vacuum container into
the component container.

Fig. 4963/4003

X Cylinder extended A1 Secondary component 1

Y Cylinder retracted A2 Secondary component 2
S Suction (from feed container) A3 Secondary component 3
H Extruder hopper A4 Secondary component 4
Blowing
M Main component B
(into component container)

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 4. SETTINGS

Idling
All valves are closed.

Fig. 4963/4004

S Suction (from feed container) A2 Secondary component 2

H Extruder hopper A3 Secondary component 3
M Main component A4 Secondary component 4
Blowing
A1 Secondary component 1 B
(into component container)

4.3 Dosing unit

The downpipes of the components are connected to the downpipe of the main
component by dosing pipes. The settings of the dosing unit's dosing pipes
determine the mixing ratio of the main component to the secondary components.

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 4. SETTINGS

The intersection between the downpipes for the secondary components and the
downpipe for the main component has the following design:

Fig. 4963/4005

Downpipes for the secondary

1 7 Quick fastening ring
component
Downpipe for the main
2 8 Scale ring
component
3 Measuring tube 9 Guide component
4 Holder 10 Dosing pipe
5 Shut-off valve 11 Screw locking sleeve
6 Grub screw 12 Threaded rod with lever

Replacing the dosing pipe

1. Select a new dosing pipe (10) of an appropriate diameter
2. Move the measuring tube (3) upwards
3. Remove the bracket (4) with screw locking sleeve (11)
4. Pull out the old dosing pipe (10) together with the scale ring (8)

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 4. SETTINGS

5. Fit the scale ring (8) onto the new dosing pipe (10)
6. Insert the new dosing pipe (10) into the guide component (9)
7. Fit the bracket (4) with the screw locking sleeve (11)
8. Move the measuring tube (3) downwards

If less than four secondary components are being dosed, the

small dosing pipe (Ø 32) must be fitted to the downpipes which
remain empty, and set to 0°!

Adjusting the twisting angle

The twisting angle of the dosing pipe (10) is set with the scale ring (8). The scale
ring (8) is fitted to the dosing pipe (10) by the grub screw (6) and has a scale with
180 gradations. The dosing pipe (10) is inserted into a square guide component
(9), and mounted either with a threaded rod with lever (12) or a quick fastening
ring (7). The twisting angle can be read using the scale and a gradation in the
guide component, and is adjusted as follows:
1. Release the dosing pipe (10) with the lever (12) or quick fastening ring
(7)
2. Set the desired angle by twisting the scale ring (8)
3. Fix the dosing pipe (10) in place with the lever (12) or quick fastening
ring (7)

One gradation on the ring corresponds to a twisting angle of 1°.

The maximum flow volume is achieved at an angle of 180°.

4.3.1 Filling out the dosing protocol

The mixing ratio of the main component to the secondary components must be
defined in a dosing protocol (see Chapter 8 for the form).

The variables in the dosing protocol mean the following:

Variable Meaning
M (Main) Main component
A1 (Additive 1) Secondary component 1
A2 (Additive 2) Secondary component 2
A3 (Additive 3) Secondary component 3
A4 (Additive 4) Secondary component 4

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 4. SETTINGS

The flow volumes for the secondary components are calculated as follows:

For dosing pipes ø 32mm and For dosing pipes ø 120mm

ø 60mm ml (millilitres) l (litres)

5.000 x BM x p A1 5 x BM x p A1
VA1 = VA1 =
p M x BA1 p M x BA1
5.000 x B M x p A2 5 x BM x p A2
VA2 = VA2 =
p M x B A2 p M x BA2

For the main component, a volume of 5,000ml (5 l) is accepted. If

the calculated flow volumes are below 250ml, they should be
converted to 10,000ml (10 l) of main component, in order to
increase dosing accuracy. This means that the calculated values
must be doubled.

The diameter of the dosing pipe must be selected as follows:

ø 32mm ø 60 mm ø 120 mm
Flow volume up to 3% Flow volume up to 9% Flow volume up to 30%

Procedure
1. Enter the weight proportions (p) (the sum of the weight proportions (p)
must equal 100%.)
2. Determine and enter the bulk weight (B) of the individual materials using
a measuring beaker and a spirit level
3. Calculate and enter the flow volumes to be set on the measuring tubes
(3) and on the scale ring (8) for each component
4. Determine and enter the twisting angle of the dosing pipes from the
diagrams
5. Adjust the twisting angle (see Chapter 4.3)

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 4. SETTINGS

4.3.2 Example calculation and values to fill out

This produced a material mixture of one main and two secondary components:
• Main components (M)
- Polypropylene DM55
- pM = 97.5%
- BM = 540g
• Secondary components (A1)
- TIN 770
- pA1 = 0.5%
- BA1 = 527g/l
• Secondary component (A2)
- UMX 183A
- pA2 = 2%
- BA2 = 1,060g/l

Calculation of flow volumes for the secondary components:

5.000 x 540 x 0,5

VA1 = = 26,27 ml
97,5 x 527

5.000 x 540 x 2
VA2 = = 52,24 ml
97,5 x 1.060

Since the values are below 250ml and therefore hard to read, a conversion to VM
= 10 l is performed:
• VA1 = 26.27 x 2 = 52.54 ≈ 52.5ml
• VA2 = 52.24 x 2 = 104.49 ≈ 104.5 ml

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 4. SETTINGS

Filled-out dosing protocol

Twisting
Flow volume
angle
Weight Bulk Dosing

Correction
Material proportion weight V (l) for pipe

Diagram
type V (ml) for
dosing
p (%) B (g/l) dosing pipes Ø
pipes
Ø 32, Ø 60
Ø 120

M PP DM55 pM 97.5 BM 540 VM 5,000 10,000 5 10 - - -

A1 TIN 770 pA1 0.5 BA1 527 VA1 26.27 52.5 32 57 °

A2 UMX 183A pA2 2 BA2 1,060 VA2 52.24 104.5 32 81 °

4.3.3 Adjusting the mixing ratio

The mixing ratio of the main component to the secondary components is adjusted
via the twisting angle of the dosing pipes (see Chapter 4.3.4 - 4.3.8 for diagrams).

Procedure
1. Set the twisting angle roughly to the right value, for each secondary
component
2. When the machine is in operation, check the actual material
consumption compared to the main component
- Add differently coloured pellet grains through the hole in the
measuring tube or dial window (at the 0ml or 0 l mark) to the main
component or whichever secondary component is to be checked
- Observe the flow volume
3. In case of a deviation from the set value, adjust the twisting angle
- Twist the dosing pipe until the desired set value is achieved
- Read the actual twisting angle, and enter in the correction column of
the dosing protocol (see Chapter 8 for form)

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 4. SETTINGS

4.3.4 Twisting angle for ø 32mm dosing pipes (ml / 5,000ml)

The following diagram shows the twisting angle (X) of the ø 32mm dosing pipes
for the flow volumes (Y) of the secondary component in ml per 5,000ml (= 5 l) of
the main component.

Fig. 4963/4006

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 4. SETTINGS

4.3.5 Twisting angle for ø 32mm dosing pipes (ml / 10,000 ml)
The following diagram shows the twisting angle (X) of the ø 32mm dosing pipes
for the flow volumes (Y) of the secondary component in ml per 10,000 ml (= 10 l)
of the main component.

Fig. 4963/4007

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 4. SETTINGS

4.3.6 Twisting angle for ø 60 mm dosing pipes (ml / 5,000ml)

The following diagram shows the twisting angle (X) of the ø 60mm dosing pipes
for the flow volumes (Y) of the secondary component in ml per 5,000ml (= 5 l) of
the main component.

Fig. 4963/4008

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 4. SETTINGS

4.3.7 Twisting angle for ø 60 mm dosing pipes (ml / 10,000ml)

The following diagram shows the twisting angle (X) of the ø 32mm dosing pipes
for the flow volumes (Y) of the secondary component in ml per 10,000 ml (= 10 l)
of the main component.

Fig. 4963/4009

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 4. SETTINGS

4.3.8 Twisting angle for ø 120mm dosing pipes (l / 5,000ml)

The following diagram shows the twisting angle (X) of the ø 120mm dosing pipes
for the flow volumes (Y) of the secondary component in l per 5,000ml (5 l) of the
main component.

Fig. 4963/4010

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 5. COMMISSIONING AND OPERATION

5 COMMISSIONING AND OPERATION

5.1 Before initial commissioning

Before initial commissioning, the following tasks must be performed:
• Check the installation (see Chapter 3)
• Check all settings (see Chapter 4)
• Check the lubricating points (see Chapter 6.1)
• Make sure that all electrical connections were performed in accordance
with the Circuit diagram
• Check all connection bolts and connection terminals on bus bars and
switchgear for firm seating and, if necessary, retighten them to the
specified tightening torque, per the manufacturer's specifications.

DANGER!
Danger from electric current!

Before work is done on connections bolts and on connection

terminals, the <Main switch> must always be set to OFF ("0"
position) and be safeguarded against being switched back on!

Before carrying out work on the connection bolts and connection

terminals on the <Main switch>, the supply line must be de-
energised!

• Have the condition and function of the safety switch, circuit breaker and
EMERGENCY STOP system checked by a qualified electrician
(even for modifications or retrofitting of machine parts)
• Check the direction of rotation of all of the motors
(see arrow direction on the motors)
• If air-conditioned switching cabinets or switching cabinet units are
installed, check the seal
• Make sure that all safety guards are properly attached
• Ensure that all safety doors are closed and locked
• Before use, press the test button on the RC circuit breaker
(with an external socket)
• Pneumatic system: check connections, pressure and function

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 5. COMMISSIONING AND OPERATION

WARNING!
Danger due to malfunction of the pneumatic system!
Do not reach into the danger area!
Only perform trial actuation of sensors using the right tools!

Filling the feed station

The first time the feed station is filled, proceed as follows:
1. Fill all feed containers with the components
2. Switch to manual mode (see Chapter 5.4.2)
3. Using the <Inch mode/Alarm> illuminated button (see Chapter 5.2) for
the main component, start the pellet conveyor system repeatedly until
the alarm limit for the main component is reached.
 Automatic operation of the feed station is now possible.

WARNING!
Risk of slipping due to spilled material on the floor!
Pick up material spilled on the floor immediately!

5.2 Controls and display elements

A number of controls and display elements can be found on the machine. The
<Main switch> is located on the feed station operating unit.

Rotating the <Main switch> to the "0" position immediately

interrupts the energy supply to the machine and shuts it down.
The precise layout of the EMERGENCY STOP command devices
and their method of operation is described in Chapter 5.6.

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 5. COMMISSIONING AND OPERATION

The feed station switching cabinet has an operating unit on it, which contains the
control and display elements described below.

Fig. 4963/5001

<Inch mode/Alarm> push button

<Main switch> with
1 10 (orange), Secondary component
EMERGENCY STOP function
2
<Side channel compressor <ON/OFF> switch (blue),
2 11
fault> push button Secondary component 3
<Inch mode/Alarm> push button
<ON/OFF> switch (blue), main
3 12 (orange), Secondary component
component
3
<Inch mode/Alarm> push button <ON/OFF> switch (blue),
4 13
(orange), Main component A Secondary component 4
<Inch mode/Alarm> push button
<ON/OFF> switch (blue),
5 14 (orange), Secondary component
extruder hopper
4
<Inch mode/Alarm> push button <ON/OFF> switch (blue),
6 15
(orange), extruder hopper Secondary component 5
<Inch mode/Alarm> push button
<ON/OFF> switch (blue),
7 16 (orange), Secondary component
Secondary component 1
5
<Inch mode/Alarm> push button
<Operating mode> switch for
8 (orange), Secondary component 17
automatic mode / manual mode
1
<ON/OFF> switch (blue),
9 18 Reserved
Secondary component 2

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 5. COMMISSIONING AND OPERATION

When a particular <ON/OFF> switch is in the "ON" position:

• it lights up blue when a component is being conveyed by the
feed station in automatic mode
• the respective <Inch mode/Alarm> push button for the
component lights up orange when the fill level in a particular
feed container drops below a predefined point

5.3 Commissioning

The controls listed are described in Chapter 5.2.

Switching on the machine

1. Establish the air supply on the maintenance units of the pneumatic
connections
 The air pressure must be at least 6 bar (see Chapter 4.1)
2. Switch on the machine at the <Main switch>
 The control unit starts up.
 The indicator light and all push buttons light up briefly once
the control unit has started up.
3. Turn the <Operating mode> switch to the automatic mode position.
 The feed station is in automatic mode.

5.4 Operation
Once the machine has been started up, it can be put into operation.

WARNING!
Risk of serious injury!
Before starting the machine up it must always be ensured that this
cannot place anyone at risk.

Use eye protection when replenishing the material!

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 5. COMMISSIONING AND OPERATION

Use breathing protection in accordance with the manufacturer's

documentation for the material!

Use protective gloves when replenishing the material!

Wear ear protectors!

In order to prevent contamination of the secondary components,

the cover of the feed containers must be kept closed.

5.4.1 Workstations
The main workstation is located on the operating unit of the feed station, for
monitoring the production process, and the pellet conveyor system, as well as
filling up the feed containers with the components.
In addition, the machine is equipped with several maintenance positions.

For further information on the individual working areas, see the

Layout plan.

Starting the machine

• Switch on the machine at the <Main switch>
 The machine starts up.

5.4.2 Machine operating modes

The machine has the following operating modes:
• Automatic mode
• Manual mode

The controls listed are described in Chapter 5.2.

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 5. COMMISSIONING AND OPERATION

Automatic mode
If the feed station is switched on at the <Main switch> and the <Operating mode>
switch is in the "Automatic mode" position, all functions necessary on the feed
station for production are performed automatically.
The following tasks must be performed by operating personnel when in automatic
mode:
• Monitoring the processes on the machine
• Loading the feed containers

Interrupting automatic mode

Automatic mode can be interrupted at any time, by switching the <Operating
mode> switch to the "Manual mode" position or switching off the feed station at
the <Main switch>.

Switching back to automatic mode

Automatic mode can be continued at any time, by switching the <Operating
mode> switch to the "Automatic mode" position or switching on the feed station at
the <Main switch>.

Manual mode
If the feed station is switched on at the <Main switch> and the <Operating mode>
switch is in the "Manual mode" position, the machine is in manual mode, in which
the individual functions can be performed manually, by the operator.

NOTE!
Operating incorrectly can damage property!
As performing machine movements and functions improperly can
damage the machine, great care must be taken when operating
the machine manually.

Manual mode allows components to be conveyed below the minimum fill level
and with the <Inch mode/Alarm> push button lit.

5.4.3 Tasks to perform on the machine

Monitoring the processes on the machine

The machine may only be operated under the supervision of a trained person.
The machine must be shut down immediately if its operating behaviour changes.
Malfunctions may only be corrected by authorised persons (see Chapter 7).

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 5. COMMISSIONING AND OPERATION

Loading the feed station

Depending on the model of the machine, loading the machine can encompass
the following operations:
• Filling components into the feed containers
• Fixing the manual suction lance in an external feed container

5.5 Switching off the machine

The controls listed are described in Chapter 5.2.

The machine must always be switched off at the <Main switch>. The <Main
switch> is located on the feed station operating unit and provides an
EMERGENCY STOP function. Rotating the <Main switch> to the "0" position
immediately interrupts the energy supply to the feed station and shuts down the
machine.

Fig. 4963/5002

WARNING!
Risk of serious injury!
Before starting the machine up it must always be ensured that this
cannot place anyone at risk.
In order to prevent the accidental start-up of the machine, the
<Main switch> must be secured against being switched back on
(e.g. during adjustment and maintenance work).

5.6 Shutting down the machine

Each person is required to shut down the machine, if doing so could avert the risk
of personal injury, damage to the machine or risks to ongoing work or existing
danger can be lessened.

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 5. COMMISSIONING AND OPERATION

WARNING!
When performing maintenance on the machine, the <Main
switch> must always be set to OFF ("0" position) and be
safeguarded against being switched back on!

The controls listed are described in Chapter 5.2.

Triggering an EMERGENCY STOP

• Set the <Main switch> to OFF (position "0")
 The machine is shut down.
 The power supply for the drives is interrupted.

Cancelling an EMERGENCY STOP

1. Rectify the cause of the EMERGENCY STOP
2. Set the <Main switch> to ON (position "1")
 The machine is ready for operation again.

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 6. MAINTENANCE

6 MAINTENANCE

In order to ensure the full functionality and performance of the machine, all
instructions pertaining to maintenance work on the machine must be complied
with to the letter. All maintenance tasks which are performed must be recorded in
a machine logbook, including the respective number of operating hours.

WARNING!
Risk of injury from moving parts!
Before lubrication and maintenance work is performed on the
machine, the <Main switch> must always be set to OFF ("0"
position) and be safeguarded against being switched back on!

WARNING!
Risk of injury due to residual pneumatic energy!
The pneumatic system is under pressure, even after the machine
has been switched off.
Before carrying out work on the pneumatic system, it is vital that
you depressurise the system!

WARNING!
Risk of slipping due to spilled material on the floor!
Pick up material spilled on the floor immediately!

WARNING!
Risk of injury from forgotten objects!
Ejected objects can cause serious injuries and property damage.
After maintenance work:
• Remove tools from the machine
• Ensure there are no foreign objects in the machine

CAUTION!
Risk of injury due to unsuitable tool!
• Observe the instructions on the use of special tools
• Only use tools that are in a flawless condition
• Remove tools after work is complete and store them properly

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 6. MAINTENANCE

NOTE!
Potential for damage to property through failure to comply with the
stipulated lubrication and maintenance intervals!
Comply with the stipulated lubrication and maintenance intervals
without fail!

NOTE!
Damaged hoses can cause property damage!
Never kink, crush, rupture, pull or drive over hoses!

6.1 Lubrication
In order to achieve optimum performance and largely eliminate operational faults,
the machine must be lubricated using suitable lubricants (see lubrication chart in
Chapter 6.2) at regular intervals.

NOTE!
Potential for damage to property from inadequate lubrication!
Mixing different oils and greases must be avoided at all costs!

The specified lubricant amounts are recommended amounts. The

decisive measure of the amounts to be used are the marks on the
respective component (sight glass, dipstick, etc.).

Special instructions on the proper lubrication of purchased

components can be found on the respective type plates or in the
manufacturer's documentation.
Follow the manufacturers' instructions!

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 6. MAINTENANCE

Lubrication points

Fig. 4963/6001

Lubrication point Lubricant DIN 51502 Quantity Interval

Klüberlub
Valve rods of the BE 41-542
1 - - Monthly
airflow distributor
by Klüber

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 6. MAINTENANCE

6.2 Lubrication chart

The following tables provide information about which lubricants are suitable for
lubricating the machine. Other lubricants may only be used if they are shown to
have similar properties.

6.2.1 Oils

Labelling in
accordance with Lubricant
DIN 51502

Velocite Oil
HL 10 Hydraulic oil ---------- Hyspin AWS 10 ---------- Morlina S2 BL 10
No. 6

HL 32 Hydraulic oil ---------- Hyspin AWS 32 ---------- DTE Oil Light Tellus S2 M 32

HL 46 Hydraulic oil ---------- Hyspin AWS 46 ---------- DTE Oil Medium Morlina S2 B 46

Energol
HLP 32 Hydraulic oil Hyspin AWS 32 LAMORA HLP 32 DTE 24 Tellus S2 M 32
HLP HM 32

Energol
HLP 46 Hydraulic oil Hyspin AWS 46 LAMORA HLP 46 DTE 25 Tellus S2 M 46
HLP HM 46

Energol
HLP 68 Hydraulic oil Hyspin AWS 68 LAMORA HLP 68 DTE 26 Tellus S2 M 68
HLP HM 68

Energol
HLP 100 Hydraulic oil Hyspin AWS 100 ---------- DTE 27 Tellus S2 M 100
HLP HM 100

Energol Mobil Hydraulic Oil

HLPD 32 Hydraulic oil Hyspin DSP 32 ---------- Tellus S2 MA 32
HLP D 32 HLPD 32

Energol Mobil Hydraulic Oil

HLPD 46 Hydraulic oil Hyspin DSP 46 ---------- Tellus S2 MA 46
HLP D 46 HLPD 46

Energol Mobil Hydraulic Oil

HLPD 68 Hydraulic oil Hyspin DSP 68 ---------- ----------
HLP D 68 HLPD 68

Bartran
HVLP 32 Hydraulic oil Hyspin AWH-M 32 ---------- Mobil SHC 524 Tellus S2 V 32
HV 32

Bartran
HVLP 46 Hydraulic oil Hyspin AWH-M 46 ---------- Mobil SHC 525 Tellus S2 V 46
HV 46

Bartran
HVLP 68 Hydraulic oil Hyspin AWH-M 68 ---------- Mobil SHC 526 Tellus S2 V 68
HV 68

Gear oil, Energol Klüberoil Mobilgear

CLP 68 ALPHA SP 68 Omala S2 G 68
mineral-oil based GR-XP 68 GEM 1-68 N 600 XP 68

Gear oil, Energol Klüberoil Mobilgear

CLP 100 ALPHA SP 100 Omala S2 G 100
mineral-oil based GR-XP 100 GEM 1-100 N 600 XP 100

Gear oil, Energol Klüberoil Mobilgear

CLP 150 ALPHA SP 150 Omala S2 G 150
mineral-oil based GR-XP 150 GEM 1-150 N 600 XP 150

Gear oil, Energol Klüberoil Mobilgear

CLP 220 ALPHA SP 220 Omala S2 G 220
mineral-oil based GR-XP 220 GEM 1-220 N 600 XP 220

Gear oil, Energol Klüberoil Mobilgear

CLP 320 ALPHA SP 320 Omala S2 G 320
mineral-oil based GR-XP 320 GEM 1-320 N 600 XP 320

Gear oil, Energol Klüberoil Mobilgear

CLP 460 ALPHA SP 460 Omala S2 G 460
mineral-oil based GR-XP 460 GEM 1-460 N 600 XP 460

Gear oil, Energol Klüberoil Mobilgear

CLP 680 ALPHA SP 680 Omala S2 G 680
mineral-oil based GR-XP 680 GEM 1-680 N 600 XP 680

Synthetic Enersyn Alphasyn Klübersynth

CLPPG 150 Glygoyle 22 Omala S4 WE 150
gear oil SG-XP 150 PG 150 GH 6-150

Synthetic Enersyn Alphasyn Klübersynth

CLPPG 220 Glygoyle 30 Omala S4 WE 220
gear oil SG-XP 220 PG 220 GH 6-220

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 6. MAINTENANCE

Labelling in
accordance with Lubricant
DIN 51502

Synthetic Enersyn Alphasyn Klübersynth

CLPPG 320 Glygoyle 320 Omala S4 WE 320
gear oil SG-XP 320 PG 320 GH 6-320

Synthetic Enersyn Alphasyn Klübersynth

CLPPG 460 Glygoyle 460 Omala S4 WE 460
gear oil SG-XP 460 PG 460 GH 6-460

Synthetic Enersyn Alphasyn Klübersynth

CLPPG 680 Glygoyle 680 ----------
gear oil SG-XP 680 PG 680 GH 6-680

Synthetic Enersyn Klübersynth

CLPHC 150 Alphasyn HTX 150 Mobil SHC Gear 150 Omala S4 GX 150
gear oil HTX 150 GEM 4-150 N

Synthetic Enersyn Klübersynth

CLPHC 220 Alphasyn T 220 Mobil SHC Gear 220 Omala S4 GX 220
gear oil HTX 220 GEM 4-220 N

Synthetic Enersyn Klübersynth

CLPHC 320 Alphasyn T 320 Mobil SHC Gear 320 Omala S4 GX 320
gear oil HTX 320 GEM 4-320 N

Synthetic Enersyn Klübersynth

CLPHC 460 Alphasyn T 460 Mobil SHC Gear 460 Omala S4 GX 460
gear oil HTX 460 GEM 4-460 N

CGLP 220 Track oil Maccurat D 220 Magnaglide D220 LAMORA D 220 Vactra Oil No. 4 Tonna S2 M 220

6.2.2 Greases

Labelling in
accordance with Lubricant
DIN 51502

Energrease SPHEEROL
K 2 K-20 Grease CENTOPLEX 2 Mobilux EP 2 Gadus S2 V100 2
LS 2 EP 2

Energrease Olista STABURAGS

K 3 K-20 Grease Mobilux EP 3 Gadus S2 V100 3
LS 3 Longtime 3 N 12

Energrease Optimol Klüberplex

KP 1 K-20 Grease Mobilux EP 1 Gadus S2 V220 1
LS-EP 1 Longtime PD 1 BEM 41-141

CENTOPLEX
KP 2 K-20 Grease Energrease LZ ALV Mobilux EP 2 Gadus S2 V220 2
2 EP

Energrease Optimol Klüberplex

KP 2 K-30 Grease Mobilith SHC 220 Naturelle EP 2
LS-EP 2 Longtime PD 2 BEM 41-132

Energrease SPHEEROL STABURAGS

K 3 G-20 Grease Mobilux 3 Gadus S2 V100 3
LS 3 AP 3 N 12

Olista STABURAGS
K3N Grease ---------- Unirex N3 Gadus S2 V100 3
Longtime 3 N 12

Klüberplex
GP 00 G-20 Grease ---------- CLS Grease Mobilux EP 004 Gadus S2 V220 00
GE 11-680

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 6. MAINTENANCE

6.3 Maintenance overview

The following table provides information about maintenance work to be carried
out and the corresponding maintenance intervals.

WARNING!
Risk of injury from moving parts!
Before performing maintenance on the machine, the <Main
switch> must always be set to OFF ("0" position) and be
safeguarded against being switched back on!

WARNING!
Risk of injury due to residual pneumatic energy!
The pneumatic system is under pressure, even after the machine
has been switched off.
Before performing maintenance work on the pneumatic system, it
is vital that you depressurise the system!

WARNING!
Risk of slipping due to spilled material on the floor!
Pick up material spilled on the floor immediately!

WARNING!
Risk of injury from forgotten objects!
Ejected objects can cause serious injuries and property damage.
After maintenance work:
• Remove tools from the machine
• Ensure there are no foreign objects in the machine

CAUTION!
Risk of injury due to unsuitable tool!
• Observe the instructions on the use of special tools
• Only use tools that are in a flawless condition
• Remove tools after work is complete and store them properly

NOTE!
Damaged hoses can cause property damage!
Never kink, crush, rupture, pull or drive over hoses!

Refer to the manufacturer's documentation for special instructions

on the proper maintenance of purchased components.
Follow the manufacturers' instructions!

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 6. MAINTENANCE

6.3.1 Daily maintenance tasks

• Inspect the machine for coarse soiling and clean as necessary
• Inspect fans of motors and filter of the side channel compressor for dirt
and clean them as necessary

6.3.2 Weekly maintenance tasks

• Check the screens of the downpipes and dust filters on the cover of the
vacuum container of the main component and of the extruder hopper,
and clean or replace as necessary
• Inspect switching cabinet for dust and dirt and vacuum out as necessary
• Inspect cable ducts for dirt and infestation by small animals, clean as
necessary
• Clean the floor under the machine

6.3.3 Monthly maintenance tasks

• Check safety doors and protective guards for completeness; replace if
necessary
• Check safety stickers are intact; replace if necessary
• Have the condition and function of the safety switch, circuit breaker and
EMERGENCY STOP system tested by an electrician

For further information, see the Circuit diagram.

• Clean inspection windows on the downpipes (see Chapter 6.3.7)

• Check the screens of the downpipes and dust filters on the cover of the
vacuum container of the secondary components, and clean or replace
as necessary
• Check the side channel compressor (see the manufacturer's
documentation)

6.3.4 Six-monthly maintenance tasks

• Check cables and protective sleeves for damage and replace if
necessary
• On switching cabinets:
- Seal the cable ducts and cable entry points
- Clean fans and filter mats (only for switching cabinets with air
cooling)

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6.3.5 Electrical system

Extended, scheduled shut-downs of the machine can also be used as an
opportunity to check all connection bolts and connection terminals on bus bars
and switchgear. In any case, this check should be performed at least once a
year, in order to avoid possible damage to the electrical equipment.

DANGER!
Danger from electric current!

Before work is done on connections bolts and on connection

terminals, the <Main switch> must always be set to OFF ("0"
position) and be safeguarded against being switched back on!

Before carrying out work on the connection bolts and connection

terminals on the <Main switch>, the supply line must be de-
energised!

• Check all connection bolts and connection terminals on bus bars and
switchgear for firm seating and, if necessary, retighten them to the
specified tightening torque, per the manufacturer's specifications.

6.3.6 Pneumatic system

WARNING!
Risk of injury due to residual pneumatic energy!
The pneumatic system is under pressure, even after the machine
has been switched off.
Before performing maintenance work on the pneumatic system, it
is vital that you depressurise the system!

• Check the pneumatic lines once a week for leak-tightness, damage and
wear, and replace if necessary
• Check for proper fastening
• On the maintenance unit:
- Empty the water separator once a week
- Clean the filter once a week and replace if necessary

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 6. MAINTENANCE

6.3.7 Plastic glazing

Plastic glazing must always be free of dirt, and must be cleaned with a suitable
cleaning agent at regular intervals.

NOTE!
Surface damage (scratches, blind spots) may be caused by
improper cleaning!
Only use mild plastic cleaning agents!
• Never use glass cleaners or abrasive cleaners!
• Do not use any pointed or sharp-edged objects, such as
scrapers, razor blades, putty knives, etc.!

Procedure
1. Rinse off the surfaces with running water
2. Prepare warm water in a suitable container
3. Mix in a small amount of a mild plastic cleaner
4. Clean surfaces with a soft, lint-free cloth

6.4 Specific maintenance tasks

Individual maintenance tasks are explained in detail in the following chapter. The
same safety instructions provided in the maintenance overview apply here.
Specific hazards are addressed individually.

6.4.1 Side channel compressor

For information on the maintenance tasks for the side channel

compressor, see the manufacturer's documentation.

6.4.2 Cleaning the machine

Before the material is changed then the machine must be cleaned.

WARNING!
Risk of slipping due to spilled material on the floor!
Pick up material spilled on the floor immediately!

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 6. MAINTENANCE

CAUTION!
Potential for material spillage!
Before opening the component containers or the mixer door, use
the inspection window to check if there is still material inside.

Wear safety goggles!

Use breathing protection in accordance with the manufacturer's

documentation for the material!

Wear protective gloves!

Cleaning the feed station

Before switching to another main secondary component, the corresponding feed
container must be emptied with the mobile suction lance or a vacuum cleaner.

Cleaning the vacuum container

1. Remove the connection hose from the vacuum container
2. Remove the cover of the vacuum container, along with the dust filter
3. Lay down the cover with the dust filter on the ground on a suitable base
4. Clean or replace the dust filter
5. Fit the cover with dust filter to the vacuum container
6. Secure the connection hose to the vacuum container
7. Remove tools from inside the machine and store safely

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 7. TROUBLESHOOTING

7 TROUBLESHOOTING

All troubleshooting tasks which are performed must be recorded in a machine

logbook, including the respective number of operating hours.
When contacting our Customer Service Center, please have the following
information to hand:
• Serial number of the machine
• General description of the problem
• As precise details as possible about when and under what
circumstances the fault occurred
• If you have already carried out tests, as precise details as possible
about the results obtained
• Name of the person familiar with the problem
• Your phone number and e-mail address

The characteristics of a machine depend on the respective

customer's specifications.

7.1 Feed station

7.1.1 Mechanical faults

Jolting, thrusting movement in the hoses or poor delivery rate

Causes Remedy
Check the position of the mobile suction
Mobile suction lance incorrectly positioned
lance
Valves do not close Check valves
Hoses kinked or defective Check hoses
Dust filter moved in the vacuum container Clean dust filter and replace if necessary
Conical valve in the vacuum container is Clean conical valve in the vacuum
sluggish container and check the sealing ring
Screens moved in the component Check screens in the component
containers containers

Indicator light comes on

Causes Remedy
Too little material in one of the feed
Top up material
containers

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 7. TROUBLESHOOTING

Charging of the extruder does not work

Causes Remedy
Valves do not close Check valves
Hoses kinked or defective Check hoses
Dust filter moved in the vacuum container Clean dust filter and replace if necessary
Conical valve in the vacuum container is Clean conical valve in the vacuum
sluggish container and check the sealing ring
Vent moved in extruder hopper Check the screens

7.1.2 Alarms on the operating unit

<Side channel compressor fault> push button lights up

Causes Remedy
• See Chapter 7.2
Motor protection has tripped • Press the <Side channel compressor
fault> push button again

7.2 DC drives

Determining the cause that triggered the motor protection

Procedure
1. Compare set current value on the triggering device with the value on the
motor type plate
2. Check power supply
3. Check cable connection
4. Check motor temperature
5. Check mechanism for ease of movement
6. Check gearbox and maintain as necessary
- Check the oil level
- Check the bearing
7. Check direction of rotation
8. Check the motor for short-circuit/short-circuit to earth and other
malfunctions
9. Perform maintenance (see the manufacturer's documentation)

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 8. ENCLOSURES

8 ENCLOSURES

Tightening torques
The maximum permissible tightening torques in the table are based on VDI 2230
and apply to:
• Hexagon bolts, ISO 4014 - 4018
• Hex socket head cap screws, ISO 4762
• Screws/bolts with similar head rigidity and head bearing surfaces of
strength categories 8.8 - 12.9

at a 90% utilisation of the yield point ReL/0.2%-yield strength Rp0.2.

NOTE!
The tightening torques in the following table are permissible
maximum values and do not incorporate any safety factors!
Only use them where no other tightening torques are specified
(see particularly the information from the manufacturer)!

Strength categories in accordance with ISO

Width across 898/1
Thread
flats
M 8.8 10.9 12.9
s
Max. tightening torque (Nm)
M4 7 2.6 3.9 4.5
M5 8 5.2 7.6 8.9
M6 10 9 13.2 15.4
M8 13 21.6 31.8 37.2
M10 17 43 63 73
M12 19 73 108 126
M16 24 180 264 309
M20 30 363 517 605
M24 36 625 890 1,041
M30 46 1,246 1,775 2,077
M36 55 2,164 3,082 3,607

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 8. ENCLOSURES

DOSING PROTOCOL

FILM MATERIAL DATE

FILM WIDTH NAME

COLOUR

VM ⋅BM⋅p A1 VM ⋅BM⋅p A 2 VM ⋅BM⋅p A 3 VM ⋅BM⋅p A 4

VA1= VA 2 = VA 3 = VA 4 =
pM ⋅B A1 pM ⋅B A 2 pM ⋅B A 3 pM ⋅B A 4

Twisting
Flow volume
angle
Weight Bulk Dosing

Correction
Material proportion weight V (l) for pipe

Diagram
type V (ml) for
dosing
p (%) B (g/l) dosing pipes Ø
pipes
Ø 32, Ø 60
Ø 120

M pM BM VM 5,000 10,000 5 10 - - -

A1 pA1 BA1 VA1

A2 pA2 BA2 VA2

A3 pA3 BA3 VA3

A4 pA4 BA4 VA4

voluTEC DBE-04963 PAGE 52 / 53

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 8. ENCLOSURES

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voluTEC DBE-04963 PAGE 53 / 53

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