BV H5003GB

MechaTronÒ Instruction Manual
Midrange Coni-Flex™ Dual Drive Feeder
BV-H5003GB
PASS - Service you can rely on
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MKTG@ACCURATEFEEDERS.com
© by Schenck AccuRate, USA-PO Box 208, Whitewater, WI, (www.sarinc.com) A subsidiary of

Schenck Process GmbH, 64293 Darmstadt, Germany (www.schenckprocess.com)
All rights reserved. Any reproduction of this documentation, regardless of method, without prior
permission by Schenck AccuRate in writing, even by excerpt, is prohibited.
Subject to change without prior notice.
Note: The Original Instruction Manual is English

Table of Contents
1 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Using the Feeder for the Intended Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Residual Risks/Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.3 Component or Stand-Alone Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.3.1 Component Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.3.2 Stand-Alone Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.4 Feeding of Bulk Solids Dangerous to Health. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.5 Damaged / Defective Seals and/or Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.6 Work on Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.7 Workmen’s Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.8 Operator’s Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.9 Safety Information for the User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.10 Safe Operating Environment for the MechaTron. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.11 Design Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.12 Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.13 Maximum Surface Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.14 Hazard Points at Material Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.14.1 Front Material Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.14.2 Lateral Material Discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2 Brief Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

2.1 Feeder Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3 Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.2 Unpacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.3 Safe Handling and Transit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.3.1 Transport with Forklift or Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
3.4 Site Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
3.5 Leveling and Anchoring the Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
3.6 Service Access Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3.7 Permissible Acceleration and Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
3.8 Attaching Extension Hoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
3.9 Attaching Feed Hoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
3.10 Installing the Nozzle and Nozzle Support Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.11 Installing the Helix and Quill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
3.12 Engaging Helix Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
3.13 Material In-Feed and Discharge Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.13.1 Volumetric Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
3.13.2 Gravimetric Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
3.14 Flexible Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
3.14.1 Mounting and Fixing Flexible Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
4 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

4.1 Connecting Electrical Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4.2 Basic Electrical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Instruction Manual MechaTron BV-H5003GB / 0902 I1

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5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
5.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
5.2 Commissioning Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
5.2.1 Applying Power to the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
5.2.2 Motor Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
5.2.3 Infeed/Discharge System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
5.3 Filling the Hopper by Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
5.4 Integration with Upstream/Downstream Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.5 Operator Interface and Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
5.6 Calibration of Bulk Material Flow-Volumetric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
5.6.1 Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
5.6.2 Feedrate Determination and Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
5.7 Examples for Volumetric Calibration Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.8 Calibration of Bulk Material Flow-Gravimetric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
5.9 System Commissioning Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
7.1 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
7.2 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
7.3 Washdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
7.4 Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
7.4.1 Remove Back Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
7.4.2 Disengage Helix Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
7.5 Remove the Quill and Helix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
7.6 Remove Feed / Extension Hoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
7.7 Remove/Replace Bearings-Adjust Agitation Paddle Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7.8 Adjust Agitation Paddle Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
7.9 Weighing Module / Load Cell Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
7.9.1 Using Feeder Lifting Device to Service Load Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.10 Placing Feeder Lifting Device for Gravimetric Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.11 Placing the Feeder Lifting Device in the Shipping Position . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.12 Changing Paddling Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
7.12.1 Exchanging Agitation Gear Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
8.1 Clearing a Foreign Object from the Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
8.2 Removing a Damaged Helix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
8.3 Material Feeding Issues. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
8.4 Material Agitation Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
8.5 Bulk Solids Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
8.6 Oil Seepage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
9 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
9.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
9.1.1 System Weight and Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
9.2 Miscellaneous System Data / Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
I2 BV-H5003GB / 0902 Instruction Manual MechaTron

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1.1 Using the Feeder for the Intended Purpose
1 Safety Information

Your MechaTron feeder is designed for accurately feeding bulk
solids within the feedrate ranges (Theoretical Feedrates) found in
TAB 4 of your MechaTron Binder.
n When commissioning your MechaTron feeder for the material

specified in your order, follow the information given in this instruc-
tion manual and refer to the technical data supplied in the system
documentation.
n Your MechaTron feeder has been configured to process the mate-
rial specified in your order. If processing alternate materials is de-
sired, reconfiguration of your system may be necessary.
n If your MechaTron feeder is a component of a larger system or
process, always determine safety considerations before commis-
sioning from the perspective of upstream and downstream
equipment.
Any change to the basic construction of the MechaTron feeder should

not be performed without the approval of SCHENCK. This warning
also applies to the installation and set up of safety devices and any
welding work on component parts of the feeder.
Spare parts must meet the technical specifications indicated by

SCHENCK. To ensure that this requirement is met, only genuine
SCHENCK spare parts should be used.
Instruction Manual MechaTron BV-H5003GB / 0902 1

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2 BV-H5003GB / 0902 Instruction Manual MechaTron

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1.2 Residual Risks/Precautions
1.2 Residual Risks/Precautions

Residual risks may be present if the system is improperly installed or
commissioned, or if it is operated by inexperienced personnel.
In this manual, you will be able to identify residual risks by the

following symbols:
Danger
The presence of this symbol indicates that the operation, procedure
or item being described has the potential to cause severe personal
injury. Follow all safety instructions to prevent an injury from occurring.
Warning
The presence of this symbol indicates that the operation, procedure or
item being described may cause damage to the machine or
components. Follow all safety instructions to prevent any damage
from occurring.
Note
The presence of this symbol indicates a precaution to be taken during
an operation or procedure. It may also point out helpful hints to make
an operation easier or safer to complete.
Gravmetric System Information

The presence of this symbol indicates that important gravimetric
information is being presented. In comparison to volumetric feeding
systems, gravimetric feeders use weight measurements and controller
feedback to accurately meter bulk solids.

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1.3 Component or Stand-Alone Use
1.3 Component or Stand-Alone Use
1.3.1 Component Use

n If the MechaTron feeder is interlinked with other devices or pro-
cesses in the plant, responsible personnel must make additional
information available to the operators of the feeder that will aug-
ment this instruction manual and ease overall system operation
and use.
1.3.2 Stand-Alone Use

n Inlet
If your MechaTron feeder is to be used as a stand-alone device,
ensure that the “filling grid” at the top of the hopper is in place and
securely fastened. If this grid is not present, make alternate
arrangements to make certain the safety of any activity at this area
of the device is ensured.
n Outlet
DANGER: Do not place hands or fingers near the helix at the
outlet of the feeder. Severe personal injury could result if this
warning is not heeded.

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1.6 Work on Electrical Equipment
1.4 Feeding of Bulk Solids Dangerous to Health

DANGER: Incomplete service interventions, aging or wear can cause
n material
n material-escaping gases and
n oxygen-displacing media (e.g. inert gas)

to emerge in quantities dangerous to health.
The user should take immediate measures for protection of health

and/or environment.
1.5 Damaged / Defective Seals and/or Components

DANGER: Worn or damaged seals and/or components can cause
material to emerge.
If the materials used are dangerous to health, immediately replace the
defective seals and/or components under consideration of the safety
regulations applying to the material in question.

DANGER: There is danger to life.
Ensure that work on electrical equipment is always performed by
skilled electricians.
Ensure that damaged or defective electrical components and

assemblies are immediately replaced and/or repaired by skilled
electricians.

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1.9 Safety Information for the User
1.7 Workmen’s Qualification

n Only trained and authorized personnel may perform the work
described in the manual(s).
n Workmen must be familiar with the construction and safe operation

of a crane or forklift if used in installing the device.
n Work on the weighing system associated with the feeder must be

performed only by skilled personnel.
n Workmen are required to know and follow all local safety regula-
tions and accident prevention rules.
1.8 Operator’s Qualification

n Only skilled and authorized personnel may operate the
MechaTron feeder in accordance with instructions provided in this
manual.
n Operators must know and follow all in-plant, safety regulations and
accident prevention rules.
1.9 Safety Information for the User

n Responsible personnel are required to be aware of all safety infor-
mation provided in this manual in addition to related items of safe
system operation. Responsible personnel must ensure that
operators understand and follow all safety instructions.
n Before commissioning, responsible personnel are required to de-
termine if the operation of the MechaTron feeder has the potential
to cause residual risks in conjunction with other plant components.
If necessary, additional safety information must be developed. In
order to prevent residual risks from occurring, responsible person-
nel associated with in-house use of the MechaTron feeder must is-
sue in-plant safety instructions and have their receipt confirmed by
the operators. Responsible personnel are required to clearly define
responsibilities regarding the operation of the MechaTron feeder in
order to avoid uncertainties in the lines of responsibility where
safety is concerned.

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1.11 Design Notes
1.10 Safe Operating Environment for the MechaTron

A safe working environment for the MechaTron is important and can
be achieved when the feeder is used for the intended purpose, as
described in section 1.1, and all safety precautions are followed.
To ensure a safe working environment and proper system operation,

these safety guidelines should be followed:
n Protect the MechaTron feeder from overfill.
n While the MechaTron feeder is in operation, access areas around

the feeder may be entered only by workmen authorized to perform
the work described in this manual.
n Walking or climbing on the MechaTron feeder at any time is not
permitted.
SAFETY INSTRUCTIONS
Before servicing the MechaTron feeder, disconnect all electrical

connections from the power supply.
n Disconnect and lock out all power to the feeder.

n Never unlock and restore power to the feeder before all equipment
guards have been closed and any safety items are restored.
1.11 Design Notes

Device configurations depicted and described in this document are
generic and may not apply to your situation. For your system, the
mechanical and electrical drawings and associated design
documentation supplied with your order should be referenced.

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1.12 Maintenance and Repair

Maintenance and repair work on the MechaTron feeder not
described in this manual should be performed only by SCHENCK
service personnel or workmen authorized by SCHENCK.
CAUTION WITH WELDING WORK!
n To perform welding work, and in order to protect the electrical

components of your MechaTron feeder, attach the negative pole of
the welder directly to the point of welding.
n Welding on safety-related or component parts of the system

should be performed only in consultation with the approval of
SCHENCK.

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1.13 Maximum Surface Temperature

The MechaTron with Coni-Flex feed hopper is designed to feed
materials in an ambient environment not to exceed 50oC (122oF).
NOTE: Surface temperatures on the MechaTron feeder could equal

or exceed 80oC (176oF) due to feed material temperatures or other
causes. Exercise extreme caution under these conditions.
DANGER: Hot surfaces on or around the feeder could create a

dangerous condition. Severe personal injury may result if the operator
does not follow all safety precautions and use recommended safety
devices. Before performing any work on the feeder, allow a sufficient
period of time for it to cool down.

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1.17 Hazard Points at Material Discharge
1.17.1 Front Material Discharge

Danger
If discharge elements are designed with bigger diameters, fingers may
be drawn in and get crushed.
Disconnect and lock out all power to the feeder before starting work at
the discharge point.
<Stllss-25.cdr>
Figure 1: Hazard at the front material discharge

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1.17.2 Lateral Material Discharge

Danger of pinch point hazards between the screw flights and the
nozzle. Material characteristics do not always allow for the installation
of a protective device.
Disconnect and lock out all power to the feeder before performing
work at the discharge point.
<Stllss-16.cdr>
Figure 2: Hazards at the material discharge

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2 Brief Description
This manual documents installation, operation and maintenance of the
midrange, dual-drive, Coni-Flex MechaTron feeder system. A motor
controller is used to adjust and control feedrate. External agitation of
the Coni-Flex feed hopper is also regulated by the motor controller.
The steep-wall design of the feed hopper readily facilitates material

mass flow and movement to the helix. Consistent, external agitation
ensures flowable bulk materials without bridging. Complete filling of all
helix flights producing reliable feedrates is a positive result of both
design and agitation. The MechaTron feeder is fully accessible from
the back (service side) of the feeder, aiding servicing and cleaning
activities while allowing the process side (front) to remain in place.
System electrical connection points are protected in an electrical
junction box at the side of the feeder. An extremely stable, functional,
feeder lifting device (FLD) is employed to lift and move the feeder and
help service load cells.
To facilitate transport it may be necessary to supply the feeder by
single components. The chapters below contain instructions for
reassembly.
Figures 3 and 4 on pages 16 and 17 (respectively) depict the

MechaTron feeder and components from two different views.
Figure 3 shows the MechaTron in an exploded-view format and

indicates essential building blocks of the feeder system.
Figure 4 depicts a line drawing of the MechaTron with system

components identified.

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2 1
1a
12
10
2
5
11 9
7 4 12
3
6 5
8 <MECH-BB.cdr>
Figure 3: MechaTron Feeder Building Blocks
Figures 3 and 4 call-outs:

1 Extension hopper w/infeed and vent
1a Feed hopper (Fig. 3 only)
2 Feeder lifting device (FLD)
3 Electrical junction box
4 Feeder structural support
5 Feeder leveling and anchoring base
6 Agitation gear motor
7 Swivel drive casting (Fig. 3 only)
8 Helix drive motor (Fig. 3 only)
9 Feeder frame
10 Back panel (Fig. 3 only)
11 Cast back plate (Fig. 3 only)
12 Weigh modules
13 Nozzle, support flange and bracket (Fig. 4 only).

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NOTE: Service side is at the back (left) of the feeder, process side is
at the front (right) of the feeder in Figure 4 with the FLD’s at the sides
of the feeder.
2
2
12
6 9
13
12
5
3
4
5
<MECHFrtInside.cdr>
Figure 4: MechaTron Feeder Outline

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2.1 Feeder Characteristics

Bulk material handling devices share certain characteristics.
In general, all feeders contain:
Active Section (also known as the Weighed Section in

gravimetric systems-see item 2, figure 5, page 20) that includes:
n Material hopper (which may include agitation of some type)
n Discharge device (such as a feed screw or helix)
n Motor and drive
n Feeder frame
Inactive Section (also known as the Non-Weighed Section in

gravimetric systems-see item 1, figure 5, page 20) that includes:
n Support structure
n Electrical enclosure
Transfer Section (also known as the Bridge Section-see item 3,

figure 5, page 20) that includes:
n Weighing mechanism (i.e., load cell)
n Wiring from electrical control box to discharge device motor
Note: The transfer section forms a bridge between the active and
inactive sections of the feeder.
At this point, a distinction should be made between volumetric and

gravimetric feeding/metering for bulk material handling devices.
Volumetric feeding deals with volumes of bulk material and can be

described according to the following equation:
FILL VOLUME per HELIX REVOLUTION x HELIX RPM =

FEED RATE (generally in cubic liters/hr. or feet/hr.).
If we multiply this value (FEED RATE) times MATERIAL DENSITY,

we derive KILOGRAMS OR POUNDS /HR. It should be noted that
no feedback from the system is provided with volumetric systems.
Gravimetric feeding/metering deals with precise weights of bulk mate-

rials and controls feeding of bulk material via a gravimetric controller
connected to a measuring device or scale that regulates feedrate.
Feedback from the system is provided to control feedrate.

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2
3
2 2
1
<MECHSideViewS.cdr>
Figure 5: Active, Inactive and Transfer Sections of the MechaTron Feeder
Figure 5 call-outs:
1 Inactive section
2 Active section
3 Transfer section

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3.2 Unpacking Instructions
3 Mechanical Installation
3.1 Overview
Refer to Tab 5-Mechanical Drawings for mechanical installation
drawings and associated information.
Carefully select a stable, level site for your new feeder that is fully
accessible to service and material handling activities. When these
preparations are successfully performed, the functionality of the feeder
system is improved and accuracy and reliability are enhanced.
The objective of mechanical installation is to ensure:

n A stable, level surface on which to mount the feeder and controls.
n A suitable platform for the feeder and controls for accuracy of

metering and weighing.
n Appropriate connections for proper material flow to and from the
feeder for disturbance-free operation.
n Proper grounding of all electrical devices for safety and trouble-
free operation.
n Appropriate hopper venting so that “unequalized pressure” is not
present on the feeding mechanism (helix) and no material leakage
occurs.
3.2 Unpacking Instructions

Carefully remove the shipping container to expose the feeder
assembly. If the feeder is attached to a shipping pallet, retain on the
pallet and move to the installation site prior to removing the pallet.
During shipping crate disassembly, carefully inspect the feeder for any
damage during transit. If damage to the feeder is discovered,
contact your carrier immediately and file a claim for damages.
The feeder is shipped in good condition when it leaves our factory.

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3.3 Safe Handling and Transit

A functional Feeder Lifting Device (FLD) is an integral part of the
MechaTron feeder system.
NOTE: The FLD should be used for all system handling and
transit activities.
In volumetric applications, the FLD is the shipping bracket. This

FLD must remain with the feeder. See Figure 6, page 22.
In gravimetric applications, the FLD may remain connected to the

non-weighed section of the feeder during operation (see Maintenance
section 7.9, 7.10, 7.11, page 79). See figure 7, page 23.
1
2
<MFLDVol.cdr>
Figure 6 : MechaTron Feeder Lifting Device (FLD)-Volumetric
Figure 6 call-outs:
1 FLD lifting holes
2 Top retention bolts
3 Bottom retention bolts

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2 1
<MFLDGrv.cdr>
Figure 7: MechaTron Feeder Lifting Device (FLD)-Gravimetric
Figure 7 call-outs:
1 FLD lifting holes
2 Top retention bolts
3 Bottom retention/lifting bolts
4 Weighing module
3.3.1 Transport with Forklift or Crane

A heavy-duty, material handling device such as a forklift or crane
should be employed in handling or moving the feeder system. Primary
emphasis in the transportation of the feeder should be placed on
maintaining the feeder level to the ground and moving slowly and
safely to the installation site.
If the feeder is to be transported by forklift and the feeder assembly is

palletized, the tines of the fork may be inserted into the pallet and the
feeder can be carefully transported in that fashion.

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CAUTION: The tines of the forklift should never be inserted into the
framework of the feeder assembly. Severe equipment damage could
result and warranty will be void. With gravimetric feeders, always
check to see before transport that the transit restraint is activated.
Otherwise the weighing modules can get damaged.
Whether system transport is accomplished with forklift or crane,

FLD use is required.
NOTE: The extension hopper (if present) can be removed to facilitate

safe and easy transport of the feeder.
Procedure for lifting or moving the feeder with the FLD:

1. Use all four lift holes on the FLD to lift or move the feeder. Stability
will be enhanced by using all available lift holes. If chains, straps or
hooks are employed, ensure that they are rated for the weight of
the load being lifted.
2. Attach the lifting device(s) securely to the tines of the forklift or
lifting platform of the crane. Primary emphasis should be on
maintaining a level, stable orientation to the ground.
3. After securely attaching the lifting device(s) to the lift holes on
the FLD, slowly raise the feeder assembly to a minimal height
and inspect for stability and level. Next, move the assembly a
short distance and ensure that the assembly has not shifted in
transit.
4. Once satisfied that the load is stable and level, slowly move the
feeder to the installation site and carefully lower to the set-up area.
NOTE: The volumetric FLD must remain attached to the feeder. The
gravimetric FLD should remain attached to the feeder and
repositioned as appropriate to aid in load cell maintenance. See
Maintenance sections 7.10, 7.8, 7.9, 7.9, 7.10, 7.11 repositioning
instructions.

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3.5 Leveling and Anchoring the Feeder
3.4 Site Preparation

Refer to Tab 5-Mechanical Drawings for feeder dimensions and
related installation information.
The mounting base for the feeder system should be solid, level and as
disturbance-free (from external vibration, ambient conditions, winds or
fans-and other machinery in close proximity) as reasonably possible.
See section 3.7 for more information.
Any support platform that is provided for the feeder system (floor,
balcony, mezzanine) should also be solid and level to provide a sturdy
base for operations. It is strongly recommended that a carpenter’s
bubble level be employed prior to selecting a potential placement site
to determine the real characteristic of the base level. If the base is not
level, appropriate actions should be taken to compensate with the
platform on which the feeder will be placed.
Since primary access to the feeder will be from the back (or service
side), adequate space should be provided in that location. However,
service access to the sides and front (process side) will also be
necessary and should be provided. Figure 8, page 27, indicates
feeder access locations. Recommended clearances for service,
maintenance and supply activities are also listed in the call-out
section.
3.5 Leveling and Anchoring the Feeder

Floor Mount Applications
Leveling and securely anchoring the feeder are important
considerations for system accuracy, repeatability and proper
functioning. In addition to choosing a site that is level and accessible,
the platform on which the feeder assembly rests must also be level
and “true” (as determined, for example, by a carpenter’s bubble level).
To ensure that the feeder does not “travel” or move out of alignment
during operation, the feeder leveling and anchoring base(s) should be
employed for this purpose.

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3.6 Service Access Areas

Service access areas to the feeder are important considerations for
feeder placement and service/maintenance activities. As depicted in
Figure 8, page 27, service access areas may be defined in three
general locations around the feeder:
Primary Service Area

Located at the service side (back) of the feeder, the primary service
area allows access to:
n Quill/Helix
n Drive mechanism(s)
n Sprocket(s)
n Motors (agitation and helix drives)
n Seal(s)
n Feed and extension hoppers.
Secondary Service Area

Located at the sides of the feeder, secondary service areas allow
access to:
n Electrical junction box (power and control connections)
n Load cells (if present)
n FLD (Feeder Lifting Device).
Tertiary Service Area

Located at the process side (front) of the feeder, the tertiary service
area allows access to:
n Nozzle, nozzle support bracket and flange.

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1 7
6
2 4 2
8
3 <MServAccAreas.cdr>
Figure 8: MechaTron Service Access Areas
Figure 8 call-outs:
1 Primary Service Area
Recommended clearance: 610mm (2 feet), including
helix length.
2 Secondary Service Area
Recommended clearance: 610mm (2 feet).
3 Tertiary Service Area
Recommended clearance: 610mm (2 feet).
4 Feed hopper
5 Electrical junction box
6 Agitation motor drive assembly
7 Helix motor swivel drive assembly
8 Nozzle and helix support flange.

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3.7 Permissible Acceleration and Displacement

Pay attention to the following limits for gravimetric applications.
At one vibration of feeder support area for frequency “f”:
The diagrams show the limit curves of the acceleration amplitude “a”
and displacement amplitude “x”, which separate the ranges of
admissible and inadmissible amplitudes.
a = Acceleration amplitude in [m/s2]

x = Displacement amplitude in [m]
f = Frequency in [Hz]
g = Acceleration due to gravity = 9.81m/s2
Acceleration amplitude a/g
For f > 2Hz a 0.02g
Inadmissible
range
For 0.5Hz<f<2Hz
f-0.5Hz
-5
a= 10 g+0.0133g----------
Hz
For f<0.5Hz
a 10 -5 g Admissible range
Frequency / Hz <Beschl2gb.cdr>
Figure 9: Acceleration amplitude

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Displacement x in [mm]
1
10
Inadmissible Range
10 0
a
10
-1 x = ---------
(2 f )2
-2
10
Admissible Range
10-3
0
10-1 10 10
1
Frequency / Hz
<Weg2gb.cdr>
Figure 10 : Displacement
The diagrams make clear that:

n Vibration-isolated support of the feeder may become necessary.
n As a general rule, the support should be very rigid.
In general, the generation of vibrations should therefore be countered

by using appropriate dampening and stiffening measures.

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3.8 Attaching Extension Hoppers

When installed properly, the lower flange at the base of the extension
hopper and the upper flange at the top of the feed hopper are secured
to the feeder frame and locked in place via a band clamp and
retention bolts at the top of the frame. See figure 11, page 32, for an
illustration, for feed and extension hopper orientation.
To attach extension and feed hoppers:

1. Remove the back panel and feed hopper from the feeder frame. If
any system components are stored in the feed hopper, remove
them and place in a safe area for future use.
2. Remove the four bolts from the top of the feed hopper cavity, if
present.
3. Place the extension hopper on top of the feeder frame and align
bolt holes on both components. The lower flange of the extension
hopper should be visible inside the feeder frame.
4. Insert bolts and lock washers through the bolt holes of the upper
flange of the extension hopper and top of the feeder frame, then
tighten.
5. Ensure that the band clamp is inside the feeder. Location of the
clamp should be above the lower flange of the extension hopper,
resting on the clamp positioning pin.
6. Replace the feed hopper in the feeder frame with the longer nozzle
at the base of the feed hopper oriented toward and inserted into
the opening at the front (process side) of the feeder.
7. Reach inside the feeder from the service side and align the lower
flange of the extension hopper with the upper flange of the feed
hopper.
8. Open the band clamp and place it completely around both flanges
described in step 7. Prior to closing the clamp, ensure that both
flanges are within the inner lip of the clamp.
9. Close and tighten the band clamp.
NOTE: Visually inspect the clamp union to ensure that both flanges
are enclosed within the band clamp and are tightened securely prior to
system operation.

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5 1
6 3
4
< MExtHopRingPin.cdr >
Figure 11: Extension Hopper with Flange Ring and Clamp Positioning Pin
Figure 11 call-outs:
1 Upper flange-Extension hopper
2 Lower flange-Extension hopper
3 Feeder frame
4 Clamp positioning pin
5 Retaining bolt
6 Band clamp position prior to tightening
7 Back panel retention bolt

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3.9 Attaching Feed Hoppers

When installed properly, the lower flange at the base of the extension
hopper and the upper flange at the top of the feed hopper are secured
to the feeder frame and locked in place via a band clamp and
retention bolts at the top of the frame.
Note: As a point of reference, the part number on the feed hopper
should face the back (service side) of the feeder.
7 7
2
4
5
3
<MExtFdHoppersD.cdr>
8
Figure 12: MechaTron Extension and Feed Hoppers
1 Extension hopper
2 Feed hopper
4 Electrical enclosure/electrical junction box
5 Feeder back plate
6 Hopper band clamp
7 Weighing module(s), if present
8 Feeder leveling and anchoring base(s).

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3.10 Installing the Nozzle and Nozzle Support Flange
3.10 Installing the Nozzle and Nozzle Support Flange

The nozzle and nozzle support assembly are key elements for helix
guidance and stability. The nozzle support assembly contains nozzle,
support bracket, flange and spacer. See figures 13 and 14, page 35 .
To install the nozzle and nozzle support assembly:

1. Locate the nozzle (89mm tube-possibly with spacer) at the process
side of the feeder and nozzle support flange with keyed, slotted
areas.
2. Place the nozzle assembly (nozzle, flange and spacer) into the
nozzle support bracket.
3. Rotate the assembly 90° to lock, then tighten the bolts on the
flange for front discharge applications.
4. For side discharge applications, the nozzle assembly can be
rotated ± 45° per material requirements (see figure 2, page14).
2
2
3 3
4 4
5 5
1 1
<NozFlangeOpen.cdr> <NozFlangeClos.cdr>
Figure 13: Nozzle and Nozzle Support Flange (open) Figure 14: Nozzle and Nozzle Support Flange ( closed)
Figures 13 and 14 call-outs:

1 Feeder structural frame
2 Nozzle support bracket
3 Nozzle and spacer
4 Nozzle support flange
5 Feeder leveling and anchoring base.

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3.11 Installing the Helix and Quill

The purpose of the helix/quill assembly is to provide a reliable,
repeatable and accurate means of emptying the feed hopper in a
controlled fashion. The back of the quill assembly is attached to a
drive motor that regulates helix speed and feedrate. Proper installation
of the helix and quill assembly are important factors in the correct
functioning and accurate output of the feeder assembly.
Danger: Ensure that all power is disconnected and locked out from
the feeder before attempting this procedure.
To assemble helix, quill and T-drive:

1. Locate the helix, quill and T-drive (see figure 15, page 37).
2. Orient the parts as shown in the figure, so that the helix is in front,
quill in the center and T-drive is at the back.
3. Assemble the parts by inserting the T-drive into the rear of the quill
and helix into the front.
4. Carefully screw the T-drive into the back of the helix until tight.
To install and remove the helix/quill assembly:

1. Locate the hose clamp and place it around the hopper spout.
2. The helix/quill assembly includes a metal quill clamp that is
attached to the quill and secures it to the back plate. Insert the
helix/quill assembly into the back of the hopper spout and push
carefully forward so that the front of the helix lodges in the nozzle
in the nozzle support at the front (process side) of the feeder.
Ensure that the shoulder of the quill is flush with the end of the
hopper spout (service end). The slots on the quill clamp should
bottom out on the retaining bolts.
3. Tighten the hose clamp at the back of the quill assembly (service
side-feed hopper spout to quill assembly) to ensure that the
components don’t move around in the hopper trough. Also, tighten
the two bolts on the sides of the quill clamp.
4. To remove the quill assembly, loosen the two bolts on the sides of
the quill clamp and pull carefully out and away from the hopper
spout.
NOTE: The quill clamp should remain attached to the quill.

Refer to figure 15, page 37 for component identification.
Refer to figure 16, page 38 for quill section identification.

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6 1
3
4
5
<TDrvAssy.cdr>
Figure 15: Helix, Quill and T-Drive Assembly
1 T-drive
2 Quill clamp and retaining screw
3 Quill
4 Hose clamp
5 Helix (insert into base of item #6 in figure)
6 Feed hopper

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2 6
4
3
5
1
5
3
4
<MQuillSec.cdr>
9 8 2 7 2
Figure 16: MechaTron Quill Section (side view)
1 T-drive shaft assembly
2 Quill
3 Bushings (2)
4 Quill insert
5 Seal
6 Quill clamp screw hole
7 Drop-out hole
8 Feed hopper
9 Saddle

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3.12 Engaging Helix Drive Motor

Before operating the feeder:
1. Ensure that the T-drive shaft pins and motor drive shaft end align
properly before engaging. The T-drive shaft can be manually
rotated into the correct position. The motor drive shaft can be
rotated using a wrench.
2. Grasp the helix drive motor by the casting and carefully swivel
down into the operating position.
3. Tighten the swivel stop bolt (item 5 figure 17, page 40) to hold the
assembly firmly in place during operation.
4. Locate the back panel and replace at the back (service side) of the
feeder. Tighten the retention bolts at the top of the panel to secure.
See figure 17, page 40.

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1
2
4
3
5
7
6 <MSerView.cdr>
Figure 17 : Helix-Drive Motor - MechaTron Service View
1 Back panel and retention bolt locations

2 Gear drive motor
3 Helix Drive Motor
4 Back panel with transport handle
5 Swivel stop bolt
6 Feeder leveling and anchoring base(s)
7 Feeder structural support.

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3.9 Material In-Feed and Discharge Considerations

Material in-feed and discharge connections to and from the feeder
may dramatically impact feeder system output and accuracy. These
connections must be carefully thought out and correctly installed to
ensure optimal performance for your system. Since gravimetric
systems are very sensitive to disturbances and vibration, and since
these problems can impact feeding accuracy, special measures may
be necessary to neutralize or eliminate them. If your site
experiences disturbance or vibration problems and feeding
accuracy is not meeting expectations, contact your SCHENCK
representative for assistance.
3.9.1 Volumetric Applications

Without Weighing Module
In-feed and discharge considerations for volumetric applications
center primarily around dust control and containment. The hopper
cover, if present, contains two openings: the larger opening (inlet) is
for material in-feed, the smaller opening (vent) allows air to escape
during refill. See figure 18, page 41.
1 2
3
4
4
<MInfeedDis.cdr>
Figure 18: Material In-feed and Discharge
1 Hopper cover
2 Material in-feed spout
3 Discharge vent
4 Feeder lifting device (FLD).

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For volumetric systems, an appropriate method of connecting inlet

opening to material source is acceptable as long as it is attached in a
manner that will not result in material flow issues. For dust control, the
vent should be connected to either a dust containment system or an
adequate filtering system.
If dust or material containment is a consideration when connecting the

feeder nozzle (outlet) to a receiving vessel, care must be taken to
ensure that pressure build-up (unequalized pressure) from material
discharge is not an issue. The impact of unequalized pressure
could include false feedrates which would negatively impact system
accuracy. In these cases, proper venting of the receiving vessel is
very important. Whether or not material or dust containment is an
issue, the opening (diameter) of the receiving vessel should be a
minimum of 25% larger than the feeder discharge nozzle to provide
for an air escape path and to prevent material build up and blockage.
3.9.2 Gravimetric Applications

With Weighing Module
In gravimetric applications, material in-feed and discharge
considerations are more complex and focus on neutralizing or
dissipating disturbances and vibration.
NOTE: Any external disturbance that is registered by the weighing

module may impact system performance and accuracy.
As with volumetric applications, the hopper cover has two openings-

inlet for material infeed and vent for air expulsion during refill.
Material in-feed and air vent connections must not influence the
weighing module. SCHENCK recommends the following criteria
when connecting material in-feed and venting:
n Length of flexible connections should be kept to a minimum:
102mm to 152mm (4 to 6 inches) is recommended. It is very
important that enough clearance exists between connected parts
so that unwanted disturbances to the system do not occur.
n Tension, flexing or bending should not be present on the flexible
connector.
n Unequalized pressure must not be present in the system. If it ex-
ists, measures (i.e., venting or pressure release) should be
employed to contain or eliminate.
n Use of approved SCHENCK flexible connectors is recommended.
See figure 19, page 43, and figures 20 and 21, pages 45 and 46, for
flexible connector installation information and outline.

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NOTE: The same criteria should be used when connecting the feeder
discharge nozzle to the receiving vessel.
2
3
7 <MFlxConS.cdr>
Figure 19: Flexible Connections-Discharge Outlet Installation
1 MechaTron feeder-extension hopper
2 Feeder outlet (nozzle and nozzle support assembly)
3 Downturn
4 Flexible connection (upper-isolates feeder from process)
5 Stationary support
6 Flexible connection (lower-isolates process from feeder)
7 Outlet to receiving vessel.

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3.11 Flexible Connectors

If the feeder is interlinked with other devices or processes in the
plant, the flexible connectors at material infeed and discharge
points serve to protect the operator from contact with the
rotating parts and bulk solids.
No feeder must be interlinked without the use of these flexible
connectors.
When using flexible connectors at the material infeed and discharge

points, observe the following:
The alignment offset (A) between the tubes linked by using a

flexible connector must not exceed 2mm (0.078 in.).
The distance (B) between the two tubes must comply with the
indication of the drawing supplied with your order (cf. Tab 5 of the
binder).
<Stllss-22.cdr>
Figure 20: Flexible Connectors distance between tubes
Length of flexible connections should be kept to a minimum:

102 - 152mm (4 to 6 inches) is recommended. It is very important that
enough clearance exists between connected parts so that unwanted
disturbances to the system do not occur.

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3.11.1 Mounting and Fixing Flexible Connectors

Mount flexible connectors so that the arrows (1) point downward.
<Stllss-23.cdr>
D
Figure 21: Flexible connectors mounting and attaching
n Draw the flexible connector lower sleeve (2) towards the end of the
lower tube.
n Orient the flexible connector upper sleeve so that the flexible con-
nector is free from tension, flexing and bending.
When using the tension strips (hose clamps) for securely

attaching flexible connectors, observe the following criteria:
n Tension strip length “L” results from:

L = (D x 3.14) + 10cm (3.9 in).
n Debur tension strip to protect persons from injury and flexible con-
nectors from damage.
n Bend the tension strip at one end (A ) by approx. 5cm (1.9 in),
hook this end into the turnbuckle and bend strip completely,
as above.
n Place tension strip around the flexible connector sleeve and hook it
onto the turnbuckle nose.
n Tighten tension strip with the use of the turnbuckle. Damage,
flexing or bending should not be present on flexible connector.

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4.2 Basic Electrical Information
4 Electrical Installation
Refer to Tab 6-Electrical Drawings for electrical schematics,
lay-out drawings and additional information.
4.1 Connecting Electrical Equipment

Electrical wiring is performed in the electrical enclosure/electrical
junction box.
For specific information concerning connection of power to your feeder

system, refer to Tab 6- Electrical Drawings of the system binder.

Sound earth grounding techniques should be employed to ensure
system safety and functionality:
n All power supplies terminated in the electrical enclosure/electrical
junction box must originate from a common ground bus.
n The ground cables to the feeder and separate control enclosure(s)
must originate from a common ground bus.
n Ground cables must be equal to (in gauge) or larger than the cor-
responding current-carrying conductors.
n Attach all control cable shields according to instructions in the ap-
propriate system manual (refer to information in Tab 3-
Measuring and Automation System of the system binder).
Quality of power entering the system is an important consideration

and should be employed to ensure system safety and functionality:
n UPS (uninterruptible power source) is recommended for power
systems that experience frequent interruptions and/or periodic volt-
age fluctuations.
n A lightning arrester is recommended for power systems that expe-
rience frequent voltage surges due to lightning or large inductive
loads.
n A line reactor is recommended for power systems that experience
frequent voltage spikes.

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5.2 Commissioning Procedures
5 Commissioning
5.1 Overview
System set-up drawings and electrical schematics for your
MechaTron feeder can be found at Tab 5-Mechanical Drawings
and Tab 6-Electrical Drawings.
Commissioning is the act of fine tuning and running a system properly

once set-up and installation activities have been completed. Systems
may be self-commissioned (i.e., the customer performs the activity) or
commissioning may be performed by a competent third party such as
SCHENCK. In any case, these instructions will help you achieve
timely, accurate system commissioning and operation for greater
control and system functionality.
Mechanical and electrical installation procedures can be found in

Chapters and 4 respectively of this instruction manual.
Calibration information can be found in this chapter (Items 5.6, page

53 and 5.8, page 61) of the manual.
Operation and maintenance information can be found in Chapters 6

and 7 respectively of this manual.
And finally, troubleshooting information and related system data can

be found in Chapters 8 and 9 respectively of this manual.

n Applying power to the system.
n Ensuring that the motor controller is working properly.
n Ensuring that the entire infeed/discharge system (feed hopper, en-
closure for discharge element and T-drive, helix, nozzle and down-
turn) is working properly.
n Securing appropriate infeed and discharge connections that are
adequate for your requirements and do not introduce undesired
disturbances into the system.
n Calibrating the system and ensuring output accuracy prior to
operation.

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5.2.1 Applying Power to the System

Chapter 4 of this manual details applying power to the MechaTron
feeder system. Refer to this section prior to and during commissioning
activities to ensure that all safety and customer requirements have
been satisfied.
5.2.2 Motor Control Operation

A key to proper functioning of the MechaTron feeder system is
accurate motor controller functioning.
Performance information, specifications and related data concerning

your motor controller can be found at Tab 2- Volumetric Controls
and Tab 7- Accessories of the system binder.
Danger: The motor control for feedrate should be set to “0” or OFF
before power is applied. If this precaution is not followed, significant
equipment damage and or bodily injury could occur. Refer to Tab 2-
Volumetric Controls, for operating information concerning your
feeder.
5.2.3 Infeed/Discharge System Operation

The infeed/discharge system is at the heart of the MechaTron feeder
system. When this system works properly, system accuracy and
operability are enhanced. Before proceeding, ensure that all
infeed/discharge system components have been installed and are
operating properly.

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5.4 Integration with Upstream/Downstream Devices
5.3 Filling the Hopper by Hand

The MechaTron hopper (feed or extension) may require hand filling
during commissioning for calibration, first-run or a variety of other
functional tasks.
DANGER: Be careful not to reach into the feed hopper when the
feeder is running. Serious injury from the helix could result.
To fill the hopper by hand:

1. Ensure that the feed and/or extension hopper and enclosure for
discharge element and T-drive have been installed properly.
2. Place an appropriately-sized container at the process end of the
feeder beneath the nozzle outlet or downturn to catch the output.
3. Attain a safe position relative to the hopper to hand-feed (via
bucket, scoop, etc.) enough material into the hopper to ensure
complete covering of the helix flights and filling of the lower portion
of the hopper.
4. Turn the drive motor on and observe evacuation of the hopper via
the helix. Make adjustments to feedrate or modify other parameters
as appropriate.
5. Observe the feed level in the hopper closely during system
operation. If it appears that feed material will run out prior to the
end of the test or operation at hand, refill the hopper from the outlet
container or with fresh material.
5.4 Integration with Upstream/Downstream Devices

When installed in a total system environment, it is extremely important
that careful consideration be given to the MechaTron feeder and its
place in the overall system. Integration of the feeder with upstream
and downstream processes and devices is key to proper functioning of
the entire system.
Key integration considerations include:

n Appropriate connections to and from the feeder for upstream and
downstream devices.
n Appropriate discharge vessel diameter at the outlet of the feeder.
n Adequate in-feed and venting for any dust collection or contain-

ment system that may be employed.
n Use of disturbance-controlled connections and SCHENCK sup-
plied or approved flexible connectors.
See Items 3.9, page 41 and 3.11, page 47 of this manual for more
information.

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5.5 Operator Interface and Commissioning
5.5 Operator Interface and Commissioning

Operator interface information, including motor control data and
additional control parameters, can be found at:
Tab 2- Volumetric Controls,
Tab 3- Measuring and Automation System and
Tab 7- Accessories.

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5.6 Calibration of Bulk Material Flow-Volumetric

NOTE: Refer to Tab 2- Volumetric Controls and / or
Tab 7- Accessories for additional information on the motor controller
that has been supplied with your system.
Your MechaTron feeder has been electronically calibrated at the

factory to ensure linear helix speed (RPMs) throughout the range of
motor speeds. However, it is difficult to accurately calculate material
feedrate based on helix speed alone because:
q The bulk density of the material being fed may vary.

q Consistency and accuracy of filled helix flights is estimated.
For these reasons, your system should be calibrated on site for the
material that will be used with the system.
The purpose of system calibration is to determine the parameters

necessary to calculate the amount of material that will be fed at each
motor speed setting.
NOTE: This calibration procedure will work for most materials. If gross
material inconsistencies or other unusual conditions are present,
alternate calibration or adjustments in agitation speed methods may
be required. Contact your SCHENCK representative for more
information.
5.6.1 Calibration Procedure

A correct feedrate is determined by:
q Helix speed
q Material bulk density
q Size and type of helix employed
Equipment required for this procedure:

q A large container to catch the test material
q An accurate scale to weigh the container and material
q An accurate timing device (i.e., stopwatch)

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Calibration Procedure
1. Run the feeder for 5 to 10 minutes to ensure stable motor
temperature.
2. Place the empty, large container on the scale and record the
weight.
3. Fill the feed hopper with the material to be processed (see
section 5.3, page 51).
4. Turn the feeder ON and run until the discharge nozzle is full of
process material.
5. Set the feed rate potentiometer at 75% of maximum speed.
See TAB 2 - Volumetric Controls for information on setting the
potentiometer speed.
6. Collect and weigh 3 separate catch samples by running the
feeder for one-minute intervals and weighing the samples after each
interval. Record the data on the calibration calculation table on page
57 (see also Examples on page 59).
Note:
Shorter test intervals may be used if the catch container will not hold
one-minute interval samples. If a shorter test interval is used, the
measured weight must be equalized to the appropriate unit of time
(weight/min or weight/hr). For example, a 30-second sample weight
will be multiplied by 2 to compare to one-minute samples.
Longer test intervals to attain a measurable sample may be required if
the feedrate is very low. If a longer test interval is used, the measured
weight must be equalized to the appropriate unit of time (weight/min or
weight/hr). For example, a 3-minute sample weight will be divided by
3 to compare to one-minute samples.
7. Next set the potentiometer at 50% of maximum speed.

8. Repeat step 6. Continue using 25% and 10% potentiometer
settings and enter the values in the Calibration Calculation table,
page 57.
Note:
Additional catch samples at other potentiometer settings may be
required for some difficult to feed materials. Repeat step 6 as
required with other potentiometer settings.
9. Calculate the Average Sample Weight by adding the three catch

samples together and dividing by three.
Note:
Make sure that all samples are adjusted to use the same unit of time
(weight / min or weight / hr).
10. Calculate the Average Net Weight by subtracting the sample

container weight from the Average Sample Weight.

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11. Plot the Average Net Weight for the various potentiometer
settings on the calibration graph on page 58.
To determine the scale for the vertical axis (Net Weight), multiply
the Net Weight value at the 50% potentiometer setting by 0.2 to get
the Vertical Axis Scale Value.
Multiply the Vertical Axis Scale Value by 1 and enter this in

position (a) on the graph. Multiply the Vertical Axis Scale Value by 2
and enter into position (b) and so on through position (j); see for
example on page 59 and 60.
12. Connect the Average Net Weight points to determine the

feedrate curve for the specific material in this feeder. This curve
provides an estimated potentiometer setting for a selected feedrate.
Note:
The plotted curve of the Average Net Weight for the various motor
speed settings (potentiometer setting) may not be a straight line.
1 1
2 2
<VolCalCurvTyp.cdr>
Figure 22: Typical Plotted Feedrate Curves
Figure 22 Call-outs:
1 Weight per unit time
2 Potentiometer setting (motor speed)

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5.6.2 Feedrate Determination and Calculation

Once the volumetric calibration procedure has been completed, you
will be able to find a motor speed setting (potentiometer setting) to
obtain a desired feedrate.
Note:
If the plotted feedrate curve is not a straight line, a feedrate may have
two motor speed settings. Always use the lowest motor speed setting.
B
1 2 <VolCalCurvRanges.cdr>
Figure 23 : 1 Acceptable and 2 unacceptable Operating Ranges
1 Acceptable range
2 Unacceptable ranges
A Net. weight value
B Potentiometer setting
1. Select a weight per unit time (weight/min or weight/hr) from the

vertical axis that corresponds to the desired feedrate.
2. Move along a straight horizontal line to the right until the plotted
feedrate curve is intersected.
3. Move down in a straight line to intersect the horizontal axis and
read the corresponding motor speed setting for that feedrate.
4. Verify the motor setting by running at the motor speed setting from
the selected Calibration Graph. Obtain several catch samples and
determine the feedrate (see item 5.6.1, step 6). Minor adjustments
to the motor speed setting may be required to achieve the desired
feedrate.
5. Repeat step 4 as required.

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Note:
The bulk solid properties could change over time. So it maybe
necessary to check the calibration calculation periodically.
Potentiometer Actual Average Sample Average

Setting Sample Sample Container Net
Weights Weight Weight Weight
75 %
50 %
25 %
10 %
Table 1 : Volumetric Calibration Calculation Table
Vertical Axis Scale Value = Avg. Net Weight at 50% Potentiometer setting ______ x 0.2 =_______
Vertical Axis Scale Value at position:

(a) = 1x Vertical Axis Scale Value=______
(b) = 2x Vertical Axis Scale Value=______
(c) = 3x Vertical Axis Scale Value=______
(d) = 4x Vertical Axis Scale Value=______
(e) = 5x Vertical Axis Scale Value=______
(f) = 6x Vertical Axis Scale Value=______
(g) = 7x Vertical Axis Scale Value=______
(h) = 8x Vertical Axis Scale Value=______
(i) = 9x Vertical Axis Scale Value=______

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(J) 10x Vertical Axis Scale Value=______
(j)
(i)
(h)
(g)
(f)
1 (e)
(d)
(c)
(b)
(a)
0 10 25 50 75
2
Table 2: Volumetric Calibration Graph
Table 2 call-outs:
1 Average Net Weight in____per ____(weight /min. or weight / hr.)
2 Potentiometer Setting (%)

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5.7 Examples for Volumetric Calibration Calculation
Potentiometer Actual Average Sample Average

Setting Sample Sample Container Net
Weights Weight Weight Weight
75 % 204
208
213 208 3 205
50 % 180
175
179 178 3 175
25 % 85
87
83 85 3 82
10 % 35
33
33 34 3 31
Table 3 : Example vor Volumetric Calibration Calculation Table
Vertical Axis Scale Value = Avg. Net Weight at 50% Potentiometer setting 175 x 0.2 = 35
Vertical Axis Scale Value at position:

(a) = 1x Vertical Axis Scale Value= 35
(b) = 2x Vertical Axis Scale Value= 70
(c) = 3x Vertical Axis Scale Value= 105
(d) = 4x Vertical Axis Scale Value= 140
(e) = 5x Vertical Axis Scale Value= 175
(f) = 6x Vertical Axis Scale Value= 210
(g) = 7x Vertical Axis Scale Value= 245
(h) = 8x Vertical Axis Scale Value= 280
(i) = 9x Vertical Axis Scale Value= 315
(j) = 10x Vertical Axis Scale Value= 350

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(j) 350
(i) 315
(h) 280
(g) 245
(f) 210
1 (e) 175
(d) 140
(c) 105
(b) 70
(a) 35
0 10 25 50 75
2
Table 4: Example for Volumetric Calibration Graph
Table 4 call-outs:
1 Average Net Weight in______per ____(weight/min. or weight/hr.)
2 Potentiometer Setting (%)

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5.8 Calibration of Bulk Material Flow-Gravimetric

Gravimetric calibration of your feeder system is dependent on the type
of gravimetric system controller being employed. If the controller has
been provided by SCHENCK, calibration information will be found at
Tab 3, Measuring and Automation System. If the system controller
has not been provided by SCHENCK, consult alternate supplier
information manual(s).

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5.9 System Commissioning Checklist

The system commissioning checklist:
n Is a handy reference to ensure that all system components are in-
stalled properly and working according to requirements.
n Prompts you to check all connections to upstream/downstream de-
vices to ensure that they are appropriate for requirements.
System Commissioning Checklist
Before system operation, verify that:

q An appropriate system site has been chosen and properly
prepared.
q An adequate support structure has been provided for feeder
system placement.
q The support structure for the feeder, controls and peripheral
devices has a surface area equal to, or greater than, the total
area required for equipment placement and servicing.
q System site location provides easy access for all service, main-
tenance and cleaning activities for the feeder and adequate op-
erator activity room.
q System site location provides easy access to forklifts or other
material handling devices that may operate in the area.
q All system components have been carefully unpacked, identi-
fied, verified to be in good physical condition, checked off the

packing list or customer order sheet and placed in a secure lo-
cation, convenient for installation activities.
q Responsible personnel, familiar with system design parame-
ters,
interconnection requirements and all safety considerations are
closely involved with installation, commissioning and operation
activities.
q Responsible personnel have familiarized themselves with all
system manuals and technical documentation, all locally ap-

proved
safety procedures and requirements and any site or customer-
specific issues prior to system installation and operation.
q Responsible personnel supervise the physical installation of the
system. Only qualified and properly-trained personnel perform

electrical connection hook-ups and any other tasks that require
advanced knowledge or skills to properly install the system.
q All component parts of the system are properly installed, appro-
priately connected and set up per overall system requirements

and engineering drawings.
q All connections to and from the feeder are appropriate for the
requirements of the system.

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q The feeder is level and true to the ground and appropriately

secured to its base for optimum functionality.
q Electrical grounding and quality of power considerations have
been adequately addressed to ensure safe and accurate oper-
ation of the feeder system.
q All mechanical connections to upstream/downstream devices
and processes are appropriate, secure and stable.
q All mechanical/electrical connections to system components
are secure, stable and appropriate per the engineering draw-
ings and customer requirements.
q Any outstanding issues that have arisen during installation,
commissioning or operation have been identified and resolved.

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6 Operation
WARNING: Only skilled and authorized personnel may operate the

MechaTron feeder in accordance with instructions provided in this
manual. Operators must know and follow all in-plant safety regulations
and accident prevention rules.
The MechaTron feeder can be controlled and operated either

manually or automatically.
Before operating the system, determine which mode of operation is

desired and reference either:
n Tab 2-Volumetric Control Information of the system binder using

the system motor controls.
n Tab 3-Measuring and Automation System of the system binder
using the system controller.

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7.2 Preventive Maintenance
7 Maintenance
7.1 Inspection
DANGER:
If inspection, maintenance or repair work requires safety guards or
devices to be removed or disconnected, lock out power to the
feeder and protect the machine from inadvertent restart while work is
being performed.
Your MechaTron feeder has been designed and constructed of the

highest quality, long-life materials and components. Due to this
extended-use design, long-term, maintenance-reduced operation will
result.
NOTE: Remove back panel, belt cover and if necessary other parts to
perform these maintenance activities.
Visual Check
n During normal maintenance cycles, visually inspect these
feeder components:
q Seals
q Bearings
q Helix
If inordinate wear on any of these components is observed or irregular

performance during operation is noted, servicing and/or maintenance
should be performed.
7.2 Preventive Maintenance

A preventive maintenance schedule is strongly recommended to
maintain your MechaTron feeder at peak functionality.
n During normal maintenance cycles, visually inspect, check

and clean, as required:
q Seals
q Bearings
q Helix

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7.3 Washdown
n At regular intervals:
q Check the helix for status and attitude.
q Check the seals and bearings for wear and clean or replace as
necessary.
n On a time interval in accordance with supplier documentation:

q Perform all suggested maintenance checks and procedures.
Refer to supplier documentation for instructions.
WARNING: Excessive Agitation Speed

It is very important to keep hopper agitation speed as slow as possible
while consistently feeding material. This agitation speed should be
reviewed if feedrates change since reduction ratio changes may also
be required. Agitation speeds greater than 100 rpm may result in
load cell noise, excessive frame vibration and/or premature
component wear.
7.3 Washdown
Washdown of your Mechatron feeder should be performed on a
regular basis.
For washdown instructions, refer to the Mechatron Feeder Washdown

Instructions Addendum found in your documentation binder.

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7.4 Maintenance Procedures

SAFETY NOTE: Remove and lock out power to the feeder system
before performing any maintenance procedures. If this lock out
procedure is not performed, equipment damage and/or personal
injury, including death, could result.
7.4.1 Remove Back Panel

NOTE: Removal of the feeder back panel is necessary to expose
system components on the service side (back) of the unit.
Back panel removal:

1. Hand knobs are provided for easy removal on standard models.
2. Disconnect power to the feeder.
3. Loosen retention bolts (2) on the back panel (do not remove).
4. Grasp the back panel by the transport handle and lift away from the
feeder frame. See figure 24, page 69.
5. Place the panel in a secure location for immediate replacement
after maintenance work is completed.
3 <MBkPnl.cdr>
Figure 24: MechaTron Back Panel
1 Transport handle
2 Back panel retention bolt locations
3 Lower hopper mantle.

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NOTE: To access system components inside the feeder frame, you

must disengage the drive motor assembly and swivel it away.
7.4.2 Disengage Helix Drive Motor

Cast swivel motor assembly disengage:
1. Disconnect and lock out power to the feeder.
2. The gear motor and T-drive assembly couplings are properly
aligned during operation. To disengage this union, turn gear with a
suitable tool until the lock areas on the gear pin are in vertical
position.
NOTE: Some gear ratios may require jogging of the motor to achieve
proper in alignment.
3. Disengage the swivel stop bolt (see item 6, figure 25, page 70).
4. Grasp the swivel motor assembly casting and lift up and rotate to
the stop position (see figure 26, page 70).
5. Allow the swivel motor assembly to rest in this position while
performing service and/or maintenance activities.
6. Once these activities are completed, swivel the motor down to the
operating position, tighten the swivel stop bolt and reengage gear
motor and T-drive couplings after ensuring corrrect alignment.
7. Restore power to the system and resume operating activities.
1 1
6
4 5 5
6 4
2 2
3 3 <MSwvMtrDis.cdr>
<MSwvMtrEng.cdr>
7 7
Figure 25: Helix Drive Motor Assembly- Engaged Figure 26: Helix Drive Motor Assembly- Disengaged
Figures 25 and 26 Call-outs:

1 Back panel
2 Electrical enclosure/electrical junction box
4 Feeder leveling and anchoring base(s)
5 Helix drive motor and swivel motor casting assembly
6 Swivel stop bolt.

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7.6 Remove Feed / Extension Hoppers
7.5 Remove the Quill and Helix

Quill/Helix removal:
Ensure that the feed hopper is empty, disengage the swivel stop
bolt, grasp the motor swivel casting and rotate to the stop position.
2. Loosen the quill clamp bolts at the sides of the bracket.
3. Carefully slide the quill assembly out and away from the hopper
spout. The helix is attached to the quill via the T-drive shaft and will
be removed as the quill assembly is removed.
7.6 Remove Feed / Extension Hoppers

Feed hopper removal:
1. Prior to proceeding, ensure that:
-Power is disconnected and locked out.
-The feed hopper is empty.
-The drive motor swivel casting is swiveled away.
-The quill and helix are removed.
2. Reach inside the feeder frame and release the band clamp
connecting feed and extension hoppers.
3. Open the band clamp and place around the lower flange of the
extension hopper, then close the clamp and leave it there.
4. Carefully pull the feed hopper out and away from the feeder frame
and store in a secure location.
Extension hopper removal:

1. Disconnect and lock out power to feeder and ensure that any
connections at the top of the hopper are removed.
2. If the feed hopper is still in the feeder frame, follow the feed hopper
removal procedure.
3. Remove all four bolts at the base of the extension hopper that
screw into the top of the feeder frame.
4. Lift the extension hopper up (to clear the ring barrier) and off of the
feeder frame and store in a secure location.
See figure 27, page 72 for correct hopper orientation.

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1
7 7
2
4
5
3
<MExtFdHoppersD.cdr>

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7.7 Remove/Replace Bearings-Adjust Agitation Paddle Depth
NOTE: Although the extension hopper may remain in place for this
procedure, the feed hopper must be removed. This procedure
involves the removal of both drive motors at the back of the feeder.
To remove/replace bearings:
Warning: Support the helix drive motor assembly as the screws

are removed. Failure to do so may cause the motor to fall and
become damaged.
2. Remove helix drive motor / swivel drive motor assembly.

Loosen the swivel stop bolt at the side of the swivel drive casting
and remove the snap retaining ring (using a snap retaining ring
tool) holding the swivel box to the back plate.
3. Carefully slide the swivel casting and motor assembly off the helix
drive shaft and out and away from the back of the feeder. Place in
a dry, safe area for easy reinstallation.
4. Remove agitation gear motor assembly.
Warning: Protect the agitation gear motor from damage through
falling down.
Once the helix drive motor assembly is removed, reach inside the
feeder to the inner face of the back plate. Locate the four screws
located there and remove with a wrench.
5. Carefully slide the motor assembly out and away from the drive
shaft and back plate. Place in a dry, safe area for easy
reinstallation.
6. Remove the feed hopper from the feeder frame along with the quill,
quill clamp and T-drive assembly.
Remove the bolts fastening back plate to main feeder frame.
Remove the back plate. This action will expose the paddle shafts
and the back bearings (item 2, figure 28, page 74).
7. On the back plate, push the bearing(s) out and replace.
8. The front (process side) bearings (item 3, figure 28, page 74), are
bolted in place and these bolts must be removed before the
bearings can be replaced.

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Figure 28: MechaTron Agitation Paddle Assembly
1 Agitation paddles
2 Back (service side) bearings
3 Front (process side) bearings
4 Agitation paddle lever
5 Connector bolt (in low agitation setting)
6 Alternate (high) agitation setting
7 Agitation linkage assembly
8 Saddle

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7.8 Adjust Agitation Paddle Depth

To adjust agitation paddle depth:
1. With the feed hopper removed, reach into the feeder frame toward
the process side (front) of the feeder.
2. Locate the agitation linkage assembly (item 7 in figure 28, page 74)
near the front bearings.
3. Remove the bolt from the agitation paddle lever bar and replace in
the alternate hole beneath it. See items 4 and 6 in figure 28.
4. Repeat step 3 for the alternate side of the agitation linkage and
tighten both bolts.
NOTE: The feeder is shipped with the agitation assembly set at the
upper bolt (for standard agitation). Most applications will use this
standard agitation depth setting. Change to the lower bolt on the
assembly if deeper penetration is desired.
WARNING: Agitation paddle depth settings on both paddles must be

the same (i.e., both at standard setting or both at deeper penetration
setting). See Troubleshooting section 8.4.

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7.10 Weighing Module / Load Cell Maintenance

Weighing module or load cell maintenance may be required
periodically, especially if the load cell assembly has been subjected to
out-of-tolerance loads or accidental bumping or other types of
damage. In these cases, replacement of the load cell / weighing
module is required. Since setting the load cells between plates,
brackets and load cell stops requires exact settings, this work is best
performed by qualified SCHENCK personnel.
7.10.1 Using Feeder Lifting Device to Service Load Cells

To use the feeder lifting device (FLD) to service load cells:
See Figures 29, 30, and 31, Page 78 for illustrations.
1. Disconnect the load cell wire(s) and thread through the feeder
frame to free them (weighing module [Item 3, in figures]).
2. Loosen the nut (Item 1, in figures) at the base of the FLD (Item 6,
in figures) and slide the FLD in until it contacts the side of the
feeder frame.
3. Insert the screw (Item 2, in figures) through the slot at the upper
portion of the FLD and thread into the feeder frame (loosely).
4. Lower the FLD by loosening the nut (Item 1, in figures) at the base
of the FLD until the upper screw (Item 2, in figures) is at the top of
the upper screw slot.
5. Tighten the upper screw (Item 2, in figures) so that the FLD is
positioned tightly against the feeder frame.
6. Loosen the weighing module (Item 3, in figures) bolts (two on top,
four on bottom).
7. Raise the feeder frame approximately 3mm (0.10 inch) by turning
the nuts (Item 1, in figures) (two/FLD) clockwise.
Remove the weighing module (item 3, in figures).
8. Place a new weighing module assembly into the framework and
secure by replacing and tightening the bolts in step 6.
9. Place the FLD in the operating position (top portion of FLD away
from the feeder frame [Item 5, in figures], screws [Item 2, in figures]
removed from the feeder frame [Item 5, in figures] and nuts [Item 1,
in figures] beneath FLD tightened).

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2
6
3 5
1
4 <FLDLift.cdr>
Figure 31 Feeder Lifting Device (FLD) Lifting Positon
Figures 31, 29, and 30 call-outs:

1 Nuts for lifting the FLD
2 Screws to connect the FLD with the feeder frame (main frame)
3 Weighing module.
4 Screws for the lifting nut (1)
5 Feeder frame (main frame)
6 Feeder lifting device (FLD)
5 2
1
4
<FLDLiftUpBlt.cdr> <FLDLiftLwrBlt.cdr>
Figure 29: FLD in Lifting Position Upper Screw Figure 30: FLD in Lifting Position Lower Screw

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7.11 Placing Feeder Lifting Device for Gravimetric Operation
7.11 Placing Feeder Lifting Device for Gravimetric Operation

Procedure for placing the FLD in the operating position:
See figures 29, 30 and 31, page 78 for illustrations.
1. Remove the screws (2) securing the FLD to the top of the feeder
frame (5) (two per FLD) .
2. Loosen the nuts (1) at the base of the FLD and slide the FLD away
from the feeder until the vertical (fixed) screws (4) bottom out in
their slots.
3. Tighten the nuts (1) at the base of the FLD (6).

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7.12 Placing the Feeder Lifting Device in the Shipping Position
7.12 Placing the Feeder Lifting Device in the Shipping Position

See figures 29, 30 and 31, page 78 for illustrations.
1. Loosen the nuts (1) at the base of the FLD.
2. Slide the FLD (6) in towards the feeder frame (5) until the top
portion contacts the feeder frame, then tighten the nuts at the base
of the FLD.
3. Fasten the top portion of the FLD securely to the feeder frame with
the screws (2) (two per FLD).
2
6
35
1
4 <FLDShip.cdr>
Figure 32: FLD (Feeder Lifting Device)- Shipping Position
5 2
1
<FLDShipUpBlt.cdr> <FLDShipLwrBlt.cdr> 4
Figure 33: FLD in Shipping Position Upper Screw Figure 34: FLD in Shipping Position Lower Screw

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7.12 Changing Paddling Frequency

Varying bulk solids properties may ask for a change of the paddling
frequency.
To change frequency:
n Set frequency on existing control unit in accordance with material

requirements.
If the motor controller is not yet installed, check for installation pre-
requisites and mount unit.
Inappropriate controllers can be destructive to unit or motor.
n Attaching geared motor or gearbox, with other ratio for paddle

drive.
In some cases, only the gearbox and not the complete geared mo-
tor reducer must be replaced. For relevant instructions, please see
motor reducer description included in your MechaTron binder.
Dismounting of the geared motor reducer is detailed below.

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7.12.1 Exchanging Agitation Gear Motor
1
3
5
<DualDriveGearMotor.cdr>
2
Figure 35: Agitation Gear Motor
To exchange geared motor:
Disconnect feeder from power supply and protect from

inadvertent restart.
n Dismount back panel (1) on feeder service side.
To prevent injury and damages from occurring, protect geared

motor (3) from uncontrolled slewing about the paddle drive shaft
when extracting geared motor from drive shaft.
n Remove bolts (4) from the back plate (2) side inside of feeder.
n Extract geared motor from paddle mechanics drive shaft.
n To remove spacer (5) from geared motor (3), extract spacer from
gearbox centering flange. Keep spacer (5) for reuse when mount-
ing of new geared motor.
To install new geared motor, reverse this procedure. Watch out for
damage and dirt and remove before mounting.

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8.1 Clearing a Foreign Object from the Feeder
8 Troubleshooting
NOTE: Verify that all system components have been installed

correctly and are working properly prior to proceeding with
troubleshooting activities.
DANGER: Remove and lock out power to the feeder before

performing any troubleshooting activities. Failure to do so could lead
to injury or death and/or damage to the feeder.
8.1 Clearing a Foreign Object from the Feeder

Problem: Motor stalls out or material blockage occurs.
Solution:
q Identify probable location of foreign object.
q Remove helix and nozzle and search for foreign object in that
area.
q If object is not found, remove feed and/or extension hoppers
and search for object in that area.

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8.2 Removing a Damaged Helix
8.2 Removing a Damaged Helix

Problem: Helix has been damaged and must be removed.
Solution:
q Look at discharge end (process side) of feeder. If helix is not
visible, it probably is damaged and should be removed from the
service side (back) of feeder, if possible.
q Disengage appropriate components from feeder and carefully
remove helix and nozzle.
q Order and install a new helix.
WARNING: DO NOT TRY TO REPAIR AND USE THE OLD HELIX!
NOTE: In certain extreme cases, the helix may be so damaged that

other parts may also have to be removed and replaced since they will
have been damaged in removing the helix.

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8.3 Material Feeding Issues
8.3 Material Feeding Issues

Material Bridging
Problem: Material is bridging in the hopper prior to processing.

Solution:
q Check material size and/or consistency.
Is feeder set up for this type of material?
If not, adjust the agitation paddle depth to generate deeper
paddle penetration (which may be required for lower density
material).
Material Compaction
Problem: Material is compacting in hopper and helix either freezes or

stalls out. Flights may be full and/or drive motor stalls out.
Solution:
q Install a larger helix and reduce motor speed.
q Adjust the agitation paddle setting (less penetration-standard

setting).
q Adjust helix speed or modify gearing to lower agitation paddle
speed.
Material Plugging
Problem: Due to material size or consistency, pinching, binding

and/or plugging occurs at various places in the feeder.
Solution:
q Is material binding at nozzle (material between helix and
nozzle) causing stalling and spitting?

-Try a smaller helix and run at greater speed.
q Is helix turning or is there difficulty in removing the helix?
- Try a smaller helix in the feeder and run at greater speed.

q Is a signal present from the controller?
-Check the system controller for malfunction.
Material Stalling
Problem: Feeder stalls out during operation.

Solution:
q This condition signals a helix problem. Install a smaller helix
and run the feeder at a faster rate.
Insruction Manual MechaTron BV-H5003GB / 0902 85

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8.6 Oil Seepage
8.4 Material Agitation Issues

Problem: Mechanical or Electrical?
Material agitation issues will be either mechanical or electrical in
nature.
Solution:
Is agitation running?
q Check agitation and the agitation motor.
If the agitation motor seems to be the cause, repair or replace.
8.5 Bulk Solids Leakage

Problem: Bulk solids leak from areas of feeder.
Solution:
q Material leakage appears to come from union between feed
and extension hoppers.
-Reinstall band clamp and ensure that union is tight.
q Material leakage appears to come from back (service side) of
feeder in the area of the quill assembly.
-Material seal in quill has broken down and needs replacement.
-Hose clamp needs to be tightened.
q Material leakage appears to come from front (process side) of
feeder in the area of helix and nozzle.

-Install a hose clamp at nozzle/helix junction and tighten.
8.6 Oil Seepage

Problem: Oil seepage.
This condition may occur from two areas of the feeder.
Solution:
q Gearbox
-If the gearbox leaks, this is an indication of a defective unit and

the gearbox should be replaced.
q Agitation Paddle Bushings
-These bushings may leak slightly when the feeder is first

started and during a short break-in period. After a reasonable
period of normal usage, though, they will self-seal and not pose
any problem.

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9.1 Technical Data
9 Data
9.1 Technical Data

For technical data concerning your MechaTron feeder, see the
specification sheet(s) supplied with your order.
Sound Pressure:
The continuous sound pressure levels are lower or equal then
70dB(A).
Theoretical Feedrates
See TAB 4 in your MechaTron Binder.

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9.1 Technical Data
9.1.1 System Weight and Capacity
COMPONENT WEIGHT kg (lbs) CAPACITY dm3 (cu ft)

Feeder Stand 23 (52)
Feeder (Tare *) 98 (215) 35 (1.2)
Extension Hopper (empty)
75dm3 7,1 (15.8) 75 (2.5)
3
210dm 12,7 (28) 210 (7)
3
380dm 25 (55) 380 (13.4)
Hopper Cover
75dm3 50 (110.25)
210dm3 / 380dm3 50 (110.25)
TOTALS (System Weights)
Total Volumetric Weight = Stand + Feeder + Extension Hopper (if used) + Cover (if used)
Total Gravimetric Weight = Stand + Feeder + Extension Hopper + Cover
Gravimetric Weighed Portion = Feeder + Extension Hopper (if used) + Cover (if used)
* Tare is the weighed section in gravimetric systems.
Table 5: MechaTron Component Weights and Capacities

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9.2 Miscellaneous System Data / Conversion Table
METRIC ENGLISH ENGLISH METRIC

Weight (basic unit is gram-g)
1 gram .03527 ozs. 1 oz. 28.4 g
1 kg 2.205 lbs. 1 lb. .454 kg
1 kg 35.3 ozs. 1 oz. .028 kg
1 Metric Ton 2204.6 lbs.
Length (basic unit is meter-m)
1m 3.281 ft. 1 ft. .305 m
1m 1.094 yds. 1 yard .914 m
1 cm .393 ins. 1 inch 2.54 cm
1 mm .039 ins. 1 inch 25.4 mm
Capacity (basic unit is liter-l)
1l 61.023 cu. ins. 1.057 quarts 1 liter
1l .03531 cu. ft. 1 cu. ft. 28.32 l
Force/Stress (basic unit is pascal = 1 Newton (N)/square meter
1N .225 lbs. 1 lb. 4.448 N
1 Nm 8.85 lb. ins. 1 lb in. .113 Nm
1 Nm .738 lb. ft. 1 lb. ft. 1.355 Nm
Table 6 : Metric-English Conversion Factors
NOTE: Multiply cubic feet x 28.32 to calculate liters.

Multiply liters x 0.03531 to calculate cubic feet.

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Index
A
Active Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Agitation Paddle Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . 73,74
B
Back Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Basic Electrical Information . . . . . . . . . . . . . . . . . . . . . . . . . 47,48
Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73,74
Before operating the feeder. . . . . . . . . . . . . . . . . . . . . . . . . 39
Brief Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
bulk solids properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
C
Calibration of Bulk Material Flow-Gravimetric . . . . . . . . . . . . . . . 61,62
Calibration of Bulk Material Flow-Volumetric . . . . . . . . . . . . . . . . 53
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Commissioning Procedures . . . . . . . . . . . . . . . . . . . . . . . . 49,50
Component Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Connecting Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . 47
D
Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E
Engaging Helix Drive Motor. . . . . . . . . . . . . . . . . . . . . . . . . 39,40
Excessive Agitation Speed . . . . . . . . . . . . . . . . . . . . . . . . . 68
F
Feeder Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,20
Feeder Lifting Device (FLD) . . . . . . . . . . . . . . . . . . . . . . . . 22
Feeder Lifting Device to Service Load Cells . . . . . . . . . . . . . . . . 77
Feedrate Determination and Calculation . . . . . . . . . . . . . . . . . . 56
Figure : 1 Acceptable and 2 unacceptable Operating Ranges . . . . . 56
Figure : Acceleration amplitude . . . . . . . . . . . . . . . . . . . . . . 29
Figure : Agitation Gear Motor . . . . . . . . . . . . . . . . . . . . . . . 82
Figure : Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure : Helix Drive Motor Assembly- Disengaged . . . . . . . . . . . . 70
Figure : Helix-Drive Motor - MechaTron Service View . . . . . . . . . . . 40
Figure : MechaTron Feed and Extension Hoppers . . . . . . . . . . . . 72
Figure : MechaTron Feeder Lifting Device (FLD)-Volumetric . . . . . . . 22
Figure : MechaTron Service Access Areas . . . . . . . . . . . . . . . . 27

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Figure Feeder Lifting Device (FLD) Lifting Positon . . . . . . . . . . . . 78
Figure : Active, Inactive and Transfer Sections of the MechaTron Feeder. 20
Figure : Extension Hopper with Flange Ring and Clamp Positioning Pin . 32
Figure : FLD (Feeder Lifting Device)- Shipping Position . . . . . . . . . . 80
Figure : FLD in Lifting Position Lower Screw . . . . . . . . . . . . . . . . 78
Figure : FLD in Lifting Position Upper Screw . . . . . . . . . . . . . . . . 78
Figure : FLD in Shipping Position Lower Screw . . . . . . . . . . . . . . 80
Figure : FLD in Shipping Position Upper Screw . . . . . . . . . . . . . . 80
Figure : Flexible Connections-Discharge Outlet Installation . . . . . . . . 43
Figure : Flexible Connectors distance between tubes . . . . . . . . . . . 45
Figure : Flexible connectors mounting and attaching. . . . . . . . . . . . 46
Figure : Hazard at the front material discharge. . . . . . . . . . . . . . . 13
Figure : Hazards at the material discharge . . . . . . . . . . . . . . . . . 14
Figure : Helix Drive Motor Assembly- Engaged . . . . . . . . . . . . . . 70
Figure : Helix, Quill and T-Drive Assembly . . . . . . . . . . . . . . . . . 37
Figure : Material In-feed and Discharge . . . . . . . . . . . . . . . . . . 41
Figure : MechaTron Agitation Paddle Assembly . . . . . . . . . . . . . . 74
Figure : MechaTron Back Panel . . . . . . . . . . . . . . . . . . . . . . 69
Figure : MechaTron Extension and Feed Hoppers . . . . . . . . . . . . . 33
Figure : MechaTron Feeder Building Blocks . . . . . . . . . . . . . . . . 16
Figure : MechaTron Feeder Lifting Device (FLD)-Gravimetric . . . . . . . 23
Figure : MechaTron Feeder Outline . . . . . . . . . . . . . . . . . . . . 17
Figure : MechaTron Quill Section (side view) . . . . . . . . . . . . . . . 38
Figure : Nozzle and Nozzle Support Flange ( closed) . . . . . . . . . . . 35
Figure : Nozzle and Nozzle Support Flange (open) . . . . . . . . . . . . 35
Figure : Typical Plotted Feedrate Curves. . . . . . . . . . . . . . . . . . 55
Filling the Hopper by Hand . . . . . . . . . . . . . . . . . . . . . . . . . 51
Flexible Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45,46
Floor Mount Applications . . . . . . . . . . . . . . . . . . . . . . . . . . 25
G
Gravimetric feeding/metering . . . . . . . . . . . . . . . . . . . . . . . . 20
Gravimetric FLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Gravimetric System Information . . . . . . . . . . . . . . . . . . . . . . 3
H
Hazard Points at Material Discharge . . . . . . . . . . . . . . . . . . . . 13,14
Helix Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
I
impact of unequalized pressure . . . . . . . . . . . . . . . . . . . . . . 42
Inactive Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Installing the Helix and Quill . . . . . . . . . . . . . . . . . . . . . . . . 36,37,38

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Installing the Nozzle and Nozzle Support . . . . . . . . . . . . . . . . . 35
Integration with Upstream/Downstream Devices . . . . . . . . . . . . . . 51
L
Leveling and Anchoring the Feeder . . . . . . . . . . . . . . . . . . . . 25
M
Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 9,10
Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . 69,70
Material In-Feed and Discharge Considerations . . . . . . . . . . . . . . 41,42,43,44
Maximum Surface Temperature . . . . . . . . . . . . . . . . . . . . . . 11,12
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
MechaTron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Miscellaneous System Data / Conversion Table . . . . . . . . . . . . . . 89
Motor Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 50
N
Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
O
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Operator Interface and Commissioning . . . . . . . . . . . . . . . . . . 52
Operator’s Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
P
paddling frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Permissible Acceleration and Displacement . . . . . . . . . . . . . . . . 29,30
Placing Feeder Lifting Device for Gravimetric Operation . . . . . . . . . . 79
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 67,68
Procedure for lifting or moving the feeder with the FLD . . . . . . . . . . 24
Q
Quality of power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
R
Remove the Feed/Extension Hopper . . . . . . . . . . . . . . . . . . . . 71,72
Remove the Quill and Helix . . . . . . . . . . . . . . . . . . . . . . . . . 71
Residual Risks/Precautions. . . . . . . . . . . . . . . . . . . . . . . . . 3
S
Safe Handling and Transit . . . . . . . . . . . . . . . . . . . . . . . . . 22,23,24
Safe Operating Environment for the MechaTron . . . . . . . . . . . . . . 8
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,3

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Safety Information for the User . . . . . . . . . . . . . . . . . . . . . . . 7
Service Access Areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . 26,27,28
Service Load Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
shipping crate disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 21
Site Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Sound earth grounding techniques . . . . . . . . . . . . . . . . . . . . . 47
Sound Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Stand-Alone Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
System Commissioning Checklist . . . . . . . . . . . . . . . . . . . . . 63,64
System Weight and Capacity . . . . . . . . . . . . . . . . . . . . . . . . 88
T
Table : Volumetric Calibration Calculation Table . . . . . . . . . . . . . 57
Table : Example for Volumetric Calibration Graph . . . . . . . . . . . . . 60
Table : Example vor Volumetric Calibration Calculation Table . . . . . . . 59
Table : MechaTron Component Weights and Capacities . . . . . . . . . 88
Table : Metric-English Conversion Factors . . . . . . . . . . . . . . . . . 89
Table : Volumetric Calibration Graph . . . . . . . . . . . . . . . . . . . . 58
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87,88
The objective of mechanical installation . . . . . . . . . . . . . . . . . . 21
Theoretical Feedrates . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
To attach the extension hopper. . . . . . . . . . . . . . . . . . . . . . . 31
Transfer Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
U
Unpacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Using the Feeder for It’s Intended Purpos . . . . . . . . . . . . . . . . . 1,2
V
Volumetric feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Volumetric FLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
W
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Weighing Module/Load Cell Maintenance . . . . . . . . . . . . . . . . . 77,78
Workmen’s Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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MechaTronÒ Instruction Manual

Midrange Coni-Flex™ Dual Drive Feeder

Spare Parts and Components

© by Schenck AccuRate, USA-PO Box 208, Whitewater, WI, (www.sarinc.com) A subsidiary of

Note: The Original Instruction Manual is English

2 Brief Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

3 Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

4 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Instruction Manual MechaTron BV-H5003GB / 0902 I1

I2 BV-H5003GB / 0902 Instruction Manual MechaTron

1.1 Using the Feeder for the Intended Purpose

n When commissioning your MechaTron feeder for the material

Any change to the basic construction of the MechaTron feeder should

Spare parts must meet the technical specifications indicated by

Instruction Manual MechaTron BV-H5003GB / 0902 1

This page left intentionally blank.

2 BV-H5003GB / 0902 Instruction Manual MechaTron

1.2 Residual Risks/Precautions

In this manual, you will be able to identify residual risks by the

Gravmetric System Information

Instruction Manual MechaTron BV-H5003GB / 0902 3

1.3 Component or Stand-Alone Use

1.3.1 Component Use

1.3.2 Stand-Alone Use

4 BV-H5003GB / 0902 Instruction Manual MechaTron

1.4 Feeding of Bulk Solids Dangerous to Health

n material-escaping gases and

n oxygen-displacing media (e.g. inert gas)

The user should take immediate measures for protection of health

1.5 Damaged / Defective Seals and/or Components

1.6 Work on Electrical Equipment

Ensure that damaged or defective electrical components and

Instruction Manual MechaTron BV-H003GB / 0902 5

This page left intentionally blank.

6 BV-H5003GB / 0902 Instruction Manual MechaTron

1.7 Workmen’s Qualification

n Workmen must be familiar with the construction and safe operation

n Work on the weighing system associated with the feeder must be

1.8 Operator’s Qualification

1.9 Safety Information for the User

Instruction Manual MechaTron BV-H5003GB / 0902 7

1.10 Safe Operating Environment for the MechaTron

To ensure a safe working environment and proper system operation,

n While the MechaTron feeder is in operation, access areas around

Before servicing the MechaTron feeder, disconnect all electrical

n Disconnect and lock out all power to the feeder.

1.11 Design Notes

8 BV-H5003GB / 0902 Instruction Manual MechaTron

1.12 Maintenance and Repair

CAUTION WITH WELDING WORK!

n To perform welding work, and in order to protect the electrical

n Welding on safety-related or component parts of the system

Instruction Manual MechaTron BV-H5003GB / 0902 9

This page left intentionally blank.

10 BV-H5003GB / 0902 Instruction Manual MechaTron

1.13 Maximum Surface Temperature

NOTE: Surface temperatures on the MechaTron feeder could equal

DANGER: Hot surfaces on or around the feeder could create a