DRW Manual

OPERATING INSTRUCTIONS
Rotor Weighfeeder DRW 4.10/4.12/4.14/4.16

TRF / 2016-11-23 550.096.60.04-BD-p-GB
ROTOR WEIGHFEEDER
DRW 4.10/4.12/4.14/4.16
FLSmidth Pfister GmbH, D-86165 Augsburg Page 1/2

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OPERATING INSTRUCTIONS
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The persons responsible for transport, assembly, commissioning, operation, maintenance

and repairs must read and apply the operating instructions. This is a prerequisite for fault-
free operation and serves to prevent damage and hazards, particularly with regard to
explosion protection.
The operating instructions must always be kept near to the unit, because they contain
important information about maintenance and repairs.
Before starting work, consult our customer service department if you do not understand
information related to safety. They will also be please to answer any other questions.
We can accept no liability for damage or breakdown caused by failure to observe

these operating instructions!
These operating instructions are compiled in accordance with the valid regulations for
machines, electrical systems and explosion protection and are made up of the following
sections:
Contents ...................................................................... Document no.
Unit description ........................................................... 550.096.60.04-GB-e-GB

Safety sheet ................................................................ 550.096.60.04-SI-c-GB
Transport instructions ................................................. 550.096.60.04-TA-b-GB
Mounting instructions ..................................................550.096.60.04-MA-d-GB
Commissioning instructions.........................................550.096.60.04-IN-h-GB
Operator’s manual ....................................................... 550.096.60.04-BA-c-GB
Maintenance instructions.............................................550.096.60.04-WA-f-GB
Repair instructions ...................................................... 550.096.60.04-IS-g-GB
We reserve the right to make changes due to technical advancements which may cause
deviations from the illustrations and information contained in these operating instructions.

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ROTOR WEIGHFEEDER
DRW 4.10/4.12/4.14/4.16
Contents .................................................................................. Page
1 General description ............................................................................ 2

2 Operating method of the rotor weighfeeder............................................ 2
3 Construction...................................................................................... 3
4 Proportioning system .......................................................................... 5
5 Intended use ..................................................................................... 6
5.1 Explosion protection ................................................................... 6
5.2 Bulk materials ........................................................................... 7
5.3 Temperatures ............................................................................ 8
5.4 Operating pressures ................................................................... 8
6 Index History .................................................................................... 8

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1 General description
The rotor weighfeeder is employed for the continuous, gravimetric proportioning of coal
dust and coke dust in the cement burn process. This architecturally simple, enclosed
proportioning device integrates the bulk material outlet, the weighing, the regulation of the
proportioning flow, and the bulk material delivery in the pneumatic delivery piping.
2 Operating method of the rotor weighfeeder
The rotor weighfeeder uses the operating principle of a gravimetric functioning, horizontally
lying sluice (Fig. 1). Through the rotor (cellular wheel), the bulk material is extracted
directly out of the silo or prehopper, led over the weighing section, proportioned in the
pneumatic delivery piping and with the ventilator generated carrier air delivered directly in
the operation.
1 Load cell
2 Joint
3 Foundation frame
4 Bulk material inlet
5 Rotor chamber
6 Blow-out pipe
7 Air supply
8 Bulk material outlet
9 Bulk material inlet
A-A Weighing axis
B Weighing point
Fig. 1: Operating principle of the rotor weighfeeder
The weighing axis runs through the connection compensators between the bulk material
delivery, the pneumatic delivery piping and the rotor, whereby secondary power reactions
resulting from pressure fluctuations are completely compensated and thereby have no effect
on the proportioning outcome. The bulk material content found at the moment in the rotor
weighing section is gathered in weighing section B. The bulk material content with the
attending position is registered in the weighing electronics; that is to say, the local load of
the rotor is already known before the discharge. The angular velocity required for discharge
is computed in advance and aligned through the rotor propulsion according to the
designated conveyor strength set value and the registered bulk material content. The rotor
weighfeeder is able through this principle of long range regulation to realize a disturbance
variable compensation resulting in the highest short-time precision.

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UNIT DESCRIPTION
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3 Construction
3 6 73
2
5
A A
1
2
A A
A-A Swiveling axis

B Load cell
C Inlet field
D Blow-out head
1 Rotor housing
2 Foundation frame
3 Weighing joint
4 Weighing device
5 Clean gas compensator
6 Outlet compensator
7 Inlet compensator
8 Rotor
9 Drive
Fig.2: Construction of the rotor weighfeeder

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The rotor housing (1) with rotor, drive and transport air distribution is situated on the
foundation frame (2) in the weighing joints (3) and hanged in the weighing device (4) (Fig.
2).
The swivelling axis A-A, structured through the pendulum bearing, is hereby so situated
that it runs through the blow pipe compensators (5) and (6) and compensator (7) of the
bulk material inlet. Because of the required pressure shock resistance, the horizontal rotor
(8) is enclosed by stabile sealing plates supported over the elliptical rotor housing. The bulk
material flows under the gravity effect out of the silo into rotor chamber C. Through the
rotation of the rotor, the bulk material reaches the ejection position in blow-out head D.
The ventilator generated transport air is equally distributed on all three rotor chamber rows.
Reliable discharge of the bulk material is guaranteed by flow velocities between 18 and 35
m/s. The large number of rotor chamber webs between the bulk material inlet and the
blow-out head, as well as the axial adjustability of the seal opening guaranty the maximum
air-tightness between the bulk material outlet and blow pipe.
Through the large number of rotor chambers in connection with a regulating range of 1:10,
the rotor weighfeeder can also proportion very low dose rates of bulk material virtually
pulsation free.

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4 Proportioning system
Fig. 3: Proportioning system for coal dust
The coal dust deposited in the silo (1) is drawn off with the aid of ventilation (2) and bulk
material activator (4) and is carried to the prehopper (11) by the frequency-controlled
rotary valve (6). Extraction from the prehopper is supported by the prehopper ventilation.
A prehopper stirring device (10) can be used here to make the material constant and to
prevent it baking onto the vessel wall. If there is a risk of the condensation point being
fallen below, the walls of the silo and of the prehopper are insulated and, if necessary,
heated.

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The rotor weighfeeder (17) transports, weighs and meters the coal dust, and feeds it into
the pneumatic transport line to the burner.
Automatic control measurements are carried out cyclically in the prehopper mounted on
load cells (18). In the DRW 4.16 the load cells are located under the base console. The
rotary valve (6) is stopped and the shut-off gate (5) is closed. A defined quantity of
material is taken out of the prehopper, compared with the rotor weighfeeder’s counter and
the zero point of the rotor weighfeeder is readjusted if there is any deviation. After the
control measurement ends, the shut-off gate (5) is opened again, the rotor weighfeeder
starts and the prehopper is brought back to its normal filling level. The filling level limit
switch (8) prevents overfilling of the vessel.
To prevent pressure fluctuations in the system influencing the control measurement,

pressure compensation in the prehopper is carried out by a pressure measurement (9).
Force changes resulting from pressure changes in the transport line are compensated for by
the compensators arranged opposite each other in the blow-in pipe (14) and the blow-out
pipe (13).
Please refer to the descriptions for the supplied system for more detailed functional
descriptions and switching sequences.
5 Intended use
Use of the appliance for any other than the intended application is
prohibited.
The manufacturer shall not be liable for any damage resulting

herefrom. The operator bears the sole responsibility for risk.
The rotor weighfeeder is built in keeping with the latest technological developments and
recognised technical safety regulations. It complies with the relevant EC directives, in
particular with
2006/42/EC (Machine directive)
2014/35/EU (Low-voltage directive)
2014/30/EU (Electromagnetic compatibility)
2014/34/EU (Equipment intended for use in potentially explosive atmospheres).
5.1 Explosion protection
The Rotor Weighfeeder is suitable for use in explosive atmospheres. The appliance can be
supplied with category Ex II 1/3 D or EX II 1/2 D.
The applicable category and the temperature class can be obtained from the name plate or
from the certificate of conformity. Use is only permitted in the zone stipulated for the
category, in compliance with operating instructions, and safety instructions for explosion
protection contained therein.

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Ex-marking and CE-marking
The Rotor Weighfeeder DRW 4.10 is, in addition, tested by a designated authority for safety
against ignitable disruptive discharges in case of dust explosions.
The appliance is designed to be pressure shock-resistant.
It must be ensured that no larger foreign bodies can get into the bulk material. Otherwise
constructive explosion protection measures must be applied, e.g. decoupling of the systems
etc.
During operation and servicing of the Rotor Weighfeeder the local safety regulations, in
particular the regulations for potentially explosive areas, are to be observed.
5.2 Bulk materials
Permitted bulk materials are combustible dusts such as brown-coal dust, hard-coal dust,
powdered charcoal and breeze, above all petroleum coke dusts. These products can also be
a combination of one with another, or even a combination with other substances, such as
fly ashes, filter dusts, animal meal, etc. The explosive overpressure of the bulk materials
used is permitted to amount to a maximum of 10 bar.
The Rotor Weighfeeder must only be used for the bulk materials stated in the order
confirmation and in the data sheet, including specified grain size and humidity.

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5.3 Temperatures
The maximum permitted material temperature is 80°C. The maximum permitted ambient
temperature is 40°C. Higher temperatures are only possible with special designs with
additional certification by the manufacturer.
Air should always be used for pneumatic feeding. Should the conveyor air exceed 80°C, it
must be cooled.
Where ambient temperatures are below -10°C, the appliances must be warmed up before
material transportation begins.
5.4 Operating pressures
The maximum permitted operating overpressure in respect of pressure shock resistance

amounts to 0.7 bar. The permitted operating overpressure is stated in the respective data
sheet.
6 Index History
Index Author Date of Modifications

issue
0 Ripp 2003-07-02 First issue.
a Ripp 2003-09-24 Supplementation: chapter 5 Intended use.
Introduction: chapter 6 Index history.
b Ripp 2008-04-01 Chapter 5.3: Ambient temperature -10°C,
supplemented.
c Ripp 2010-05-18 Modification: chapter 5 Intended use.
d Höger 2011-01-27 Chapter 5.1: Ex-marking and CE-marking updated.
Note regarding foreign bodies.
Adaptation for DRW 4.16.
e Keim 2016-04-19 Chapter 5: Intended use - directives adapted.
Subject to change without notice.

The technical data and specifications are valid at the time of publication of this documentation.
The information provided in this publication is, however, checked on a regular basis and any
necessary corrections made in subsequent editions.
FLSmidth Pfister GmbH reserves the right to alter these versions at any time.
We are always grateful for suggestions for improvement.

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MOUNTING INSTRUCTIONS
550.096.60.04-MA-d-GB
ROTOR WEIGHFEEDER
DRW 4.10/4.12/4.14/4.16
Contents .................................................................................. Page
FLSmidth Pfister GmbH, D-86165 Augsburg

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1 Transport
During mounting also observe the Transport Instructions, and

particularly the safety precautions contained in them.
Attach ropes etc. to the rotor weighfeeder only at the marked

points on the housing frame:
The lifting points are marked with the symbol “Lift here”.
The weighing device and the load cells can be easily damaged by
Warning!
impacts.
Fig. 1:

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2 Execution of work in potentially explosive atmospheres
When work is to be carried out in areas where explosive

atmospheres may occur, permission for the work must be obtained
from an appropriately authorised representative of the operator
before work is begun (Directive 1999/92/EC - Annex II 1.2).
Only personnel that have been trained sufficiently and
appropriately for the respective work (mechanical and electrical) in
potentially explosive atmospheres by the operator may be assigned
such work (Directive 1999/92/EC - Annex II 1.1).
It must be ensured that during assembly work, there is no
flammable atmosphere inside the system parts and in the building.
3 Tools for work in potentially explosive atmospheres
No tools that can generate sparks may be used in Zone 20. Tools
that are to be used in Zones 21 and 22 must be incorporated in a
permit system introduced by the operator of the plant (EN 1127-1
Annex A).

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4 Assembly of the rotor weighfeeder
Fig. 2:

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flammable atmosphere inside the system parts and in the
building.
4.1 Setting up the DRW
Fig. 3.1:
The stabilizer (item 2) must not be removed. Set and lock the nut
with 3 mm gap.

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Fig. 3.2:
4.2 Swiveling the shut-off gate

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4.3 Connection of pneumatic cylinder to solenoid valve
Fig. 4:
4.4 Connection of compensators
To guarantee explosion protection, all compensators must be

jumpered with the earthing strap.
Absolute care must be taken that no foreign bodies get inside

Warning! the rotor.
If work on the silo and the pipelines has not been completed, the
respective openings on the appliance remain sealed with the
assembly plates, which may only be removed after all work has
been completed.

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4.5 Connecting the blow pipe compensation
Fig. 5:
On no account may the securing screws (1) be removed. They

absorb the explosion forces on the compensator.
The two securing screws (1) remain hanging loose and are not tightened,
weighfeeder!

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4.6 Installation tolerances for compensators
Location deviations for the downpipe compensator (10); Fig. 2
Tolerance Rotor weighfeeder Compensator Dimension
Location deviations for the blow out pipe compensator (11); Fig. 2

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Location deviations for the infeed air compensator (12); Fig. 2
Installation tolerances for the inlet compensator on the prehopper

(12); Fig. 6 and 7
Tolerance Compensator Nominal Dimension

diameter/pressure

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5 Installing the dosing station for coal dust
5.1 System set-up
Fig. 6:

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5.2 Notes
5.3 Installing the prehopper
5.4 Installing the silo cone, SGA, shut-off gate and rotary valve
5.5 Installing the intermediate pipe with compensators
The weld seam must be made as shown in the production

drawing by an approved welder and for the stated calculated
pressure. The relevant national regulations for pressure vessels
must be observed.
In the European Union, the directive 97/23/EC applies to

intermediate pipes with an operating overpressure in excess of
0.5 bar. In Germany, VDI 2263 applies to intermediate pipes
with an operating pressure of 0.5 bar and below.

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Fig. 7:
6 Electrical connections
For safe operation of the proportioning station, the operator

must fit all drives with lockable repair switches.
The external electrical installation must be carried out in

accordance with the regulations for the respective Ex zone.
All metallic components are to be connected to one another with

potential equalization lines, in order to prevent sparks caused by
electrostatic discharge. Connect at the brackets provided.
The Rotor Weighfeeder should be connected at the central

earthing connection (see commissioning instructions) with the
local on-site potential equalization.

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7 Compressed air connection
8 Disassembly
Ensure that there are no dust deposits either inside or outside

the units that could cause a potentially explosive atmosphere to
build up.
9 Index History

issue

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COMMISSIONING INSTRUCTIONS
550.096.60.04-IN-h-GB
ROTOR WEIGHFEEDER
DRW 4.10/4.12/4.14/4.16
Contents .................................................................................. Page

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1 Important instructions
The operating authority of the installation is obliged to install

warning notices for the potentially explosive area.
The safety regulations for the repair work within potentially

explosive areas are to be followed.
It is not permitted to open the maintenance opening or to

disconnect product or de-dusting lines while the system is running.
The operating authority of the installation is obliged to provide a

lockable repair switch for driving the rotor weighfeeder, the rotary
valve and the stirring device.
The rotor weighfeeder may be started only when completely

assembled and closed.
2 Checking for observation of the safety regulations

Before commissioning work begins, the rotor weighfeeder must be
inspected to ensure that the safety regulations are maintained.

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Fig. 1:

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3 SGA and prehopper
Check the direction of rotation of the stirring device

Warning!
(direction sign).
4 Weighing device
4.1 Control measuring device
Fig. 2a:

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4.2 Weighing device of the rotor weighfeeder
Fig. 3:
The rotor housing must now not be stressed any more until the
Warning!
load cell stop is inspected.

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5 Air supply for the pneumatic elements
Fig. 4:

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5.1 Compressed air specification:
5.2 Filter water separator (191)
5.3 Oil mister (193)
5.4 Compensator flushing
5.5 Outer chamber flushing

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5.6 Inlet box aeration
5.7 Air supply for the shut-off gate

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6 DRW inspection
6.1 Belt drive
Fig. 5:
Do not operate the unit without the protective cover.

Risk of accidents, Tare weight change.
Warning! Do not tension the belt (134) too much.

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6.2 Foreign bodies
empty

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6.3 Balancing the scales pivot
Fig. 6:

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Do not allow the pressure in the rotor weighfeeder to rise above

0.5 bar.
6.4 Potential equalization
It should be ensured that all potential equalization lines have been

fitted, so that a spark caused by electrostatic discharge is
prevented.

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All

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7 Gap adjustment
Rotor weighfeeders used as flame blocks may only be operated
with a correctly set rotor gap, so as to ensure that they are
resistant to flame flashover.
Fig. 7:
Adjust the setting screws (22, colour red):
Adjust the adjustment screws (23, colour black):
Warning! These screws must not be screwed tightly!

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8 Rotor start
8.1 Rotor start without material
The rotor weighfeeder may be started only when completely

assembled and closed.
Warning! Permissible length of the test run without material: maximum 10

minutes.
local mode
manual operation
direction of rotation
8.2 Zero setting
8.3 Calibration
check the display

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8.4 Checking and adjusting the rotor gap during operations
Adjust the adjustment screws (23, colour black):
8.5 Power consumption

drawing of current

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9 Prehopper weigher
9.1 Calibrating prehopper weigher

empty
Dead load compensation
Calibrate
checking the display.
9.2 Calibrate pressure compensation
10 Rotor start with material

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11 Proportioning accuracy

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12 Blow pipe
Fig. 8:

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Fig. 9:

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Fig. 10:
1 2
3 max.

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12.1 Adjusting the flow control valves – DRW 4.10 and DRW 4.12
0
1 2 3
1 2 3
1 0 1
1 2 3
DRW 4.10 and 4.12 with restrictor

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12.2 Adjusting the regulating flap – DRW 4.14
12.3 Adjusting the flow control valve – DRW 4.16

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13 Shutdown
13.1 Temporary stop
13.2 Running empty
13.3 Switching off the rotor weighfeeder

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14 Index History

issue

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MAINTENANCE INSTRUCTIONS
TRF / 23.11.2016 550.096.60.04-WA-f-GB
ROTOR WEIGHFEEDER
DRW 4.10/4.12/4.14/4.16
Contents .................................................................................. Page
1 Important instructions ........................................................................ 2

2 Lubrication points .............................................................................. 3
3 Lubrication intervals and lubricants....................................................... 4
4 Lubricating instruction ........................................................................ 5
4.1 Helical-Bevel Gear Unit ............................................................. 5
4.2 Helical Gear Unit ...................................................................... 5
4.3 Drive motor ............................................................................ 6
4.4 Drive shaft bearing .................................................................. 6
4.5 Drive shaft seals ...................................................................... 6
4.6 Driver and rotor hub ................................................................ 6
4.7 Weighing axis bearings ............................................................. 6
4.8 Lever bearing weighing device ................................................... 6
4.9 Oil damper weighing device ....................................................... 6
4.10 Compressed air oil mister .......................................................... 6
5 Maintenance points ............................................................................ 7
6 Maintenance intervals ......................................................................... 8
7 Maintenance work .............................................................................. 9
7.1 Check the rotor weighfeeder for settled dust and leaks.................... 9
7.2 Check the bearing for unusual noises .......................................... 10
7.3 Air supply ............................................................................... 10
7.3.1 Filter water separator (191) ............................................ 11
7.3.2 Oil mister (193) ............................................................ 11
7.3.3 Compensator flushing .................................................... 11
7.3.4 Outer chamber flushing.................................................. 11
7.3.5 Inlet box aeration ......................................................... 11
7.4 Weighing device ...................................................................... 12
7.4.1 Cleaning and check the weighing device ........................... 12
7.4.2 Checking the smoothness of operation ............................. 13
7.4.3 Checking and adjusting the zero point .............................. 13
7.4.4 Checking the calibration ................................................. 13
7.5 Adjusting the rotor gap ............................................................. 14
7.5.1 Checking and adjusting the rotor gap when the rotor is ........
stationary .................................................................... 14
7.5.2 Checking and adjusting the rotor gap during operations...... 15
7.6 Rotor, sealing plates................................................................. 15
7.7 Compensators: check condition, replace if necessary ................... 16
7.8 Check the seal (drive shaft) and replace if necessary ................... 17
7.9 Gear unit .............................................................................. 17
7.10 Three-phase motor and tacho-generator .................................... 17
7.11 Belt drive .............................................................................. 18
7.12 Material shut-off gate.............................................................. 19
8 Index History .................................................................................. 19

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Use of the unit in potentially explosive areas demands correct

maintenance and lubrication. The maintenance instructions of the
attached appliances must be observed.

It is prohibited to open the maintenance opening and to disconnect

product and de-dusting lines when the system is running.
In order to guarantee safety against flame flashover, the setting of

the rotor gap must be adjusted every 800 operating hours.
Maintenance work on weighing parts of the DRW during operation

may only be carried out in setting mode or in volumetric mode
(local).
The relevant sections of the operating instructions must be read

through carefully before any work is carried out. Pay special
attention to the instructions relating to personal safety.
Before the rotor weighfeeder is opened, all electrical and

pneumatic connections must be disconnected and the necessary
precautions taken to prevent the connection being restored again
by accident (assembly switch).
For maintenance and inspection work, please also observe the

operating instructions and safety sheet.
Always comply with national Accident Prevention Regulations t.

Special care must be taken when working on electrical installations
and facilities.
Check the correct working of the weighing system at regular intervals in accordance with
its operations.
All spare and wearing parts that are not available at short notice should be kept in stock.

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2 Lubrication points
1 Helical-Bevel Gear Unit A Ventilation / Breather Plug

2 Helical Gear Unit B Oil level
3 Motor C Oil drainage / Drain Plug
4 Driver / rotor hub
5 Drive shaft seals
6 Bearing - Weighing axis
7 Weighing lever: bearing
8 Oil damper
Fig. 1: Lubrication points

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3 Lubrication intervals and lubricants
Lubrication Designation Lubricant Lubri- Amount per Lubrica- Change Works filling
point change cant1) lubrication point tion lubrication
3)
interval Site filling
Amo- 1 st. Rechar- 3)
2) 2)
No. unt filling ge Remarks
1 1 Helical- Gear oil VG 220 8,0 8,0 ---- 20.0006) x -- At latest after
Bevel Gear Roller bearing SHC100 5 years
Unit grease
KAF 87 Sealing rings
1 1 Helical- Gear oil VG 220 15,7 15,7 ---- 20.0006) x -- At latest after
Unit grease
1 1 Helical- Gear oil VG 220 24 24 ---- 20.0006) x -- At latest after

Unit grease
2 1 Helical Gear oil VG 220 0.8 0.8 ---- 20.0006) x -- At latest after
Gear Unit Roller bearing SHC100 5 years
R 57 grease
Sealing rings
2 1 Helical Gear oil VG 220 ---- 20.0006) x -- At latest after

R 67 grease
Sealing rings
2 1 Helical Gear oil VG 220 1.2 1.2 ---- 20.0006) x -- At least every
R 77 grease
Sealing rings
4)
3 1 Drive Grease 10 10 ---- 10.0006) x --
motor filling 7
4)
4 1 Bearing - Grease 160 10 1.000 10.000 x --
drive shaft filling 7
5 1 Seal - Grease 140 2 200 ---- x --

drive shaft filling 7
5)
6 2 Bearing - Lifetime 30 30 ---- ---- x --
7)
Weighing lubrication
axis
5)
7 2 Lever Lifetime 10 10 ---- ---- x --
7)
bearing - lubrication
weighing
device
8 2 Oil damper Oil filling 0.170 0.170 ---- 20.000 -- x Oil level 6 – 8
- weighing mm above the
device damper disk
8)
9 1 Compresse Oil filling 0.120 0.100 ---- ---- x --
d air oil with reserve
mister

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DIN ISO 1. Symbols in accordance with DIN 51502 / ISO viscosity and NLGI class.
2. Oil in dm 3 (Litres), grease in cm 3
VG 220 3. Operating hours
4. Roller bearings, fill with 2/3 with grease.
5. If seal ring is defective/damaged, clean the bearings and fill 2/3
3
with grease.
6. For ambient temperatures from 0°C to +40°C
2 In case of deviations, refer to SEW Operating Instructions / Lubricant
Tables.
7. For ambient temperatures from -25°C to +60°C
VG 32
8. Check oil level monthly. where necessary refill lubricant.
4 Lubricating instruction
4.1 Helical-Bevel Gear Unit

When changing the lubricants, please observe the gear
manufacturer's instructions.
The manufacturer requires that when the gear oil is changed, the roller bearing grease and
sealing rings must also be replaced.
Guideline values for lubricant changing intervals are shown in the table. For exact values,
please refer to the manufacturer's operating instructions.
Recommended lubricant for SEW gear unit:

Gear oil: CLP 220 DIN 51517 / ISO VG 220.
Bearing grease: Mobiltemp SHC100
4.2 Helical Gear Unit

When changing the lubricants, please observe the gear
manufacturer's instructions.
The manufacturer requires that when the gear oil is changed, the roller bearing grease and
sealing rings must also be replaced.
Guideline values for lubricant changing intervals are shown in the table. For exact values,
please refer to the manufacturer's operating instructions.
Recommended lubricant for SEW gear unit:

Gear oil: CLP 220 DIN 51517 / ISO VG 220.
Bearing grease: Mobiltemp SHC100

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4.3 Drive motor
The ball bearings and shaft sealing rings have lifetime lubrication. The ball bearings and
shaft sealing rings must be replaced every 10,000 operating hours. The grease filling
must be renewed when they are replaced.
4.4 Drive shaft bearing

Lubricate the shaft bearing during operation only in setting mode
or in volumetric mode (local).
4.5 Drive shaft seals
The seals of the drive shaft can be relubricated during operation.

Relubricate weekly or every 200 operating hours.
4.6 Driver and rotor hub
Every time the rotor housing is assembled, the driver and rotor hub must be smeared with
KL 2 K DIN 51825 / NLGI 2 grease.
Do not allow grease to come into contact with the running
Warning! surfaces of the housing and the rotor.
4.7 Weighing axis bearings
The bearings are maintenance-free.

Only if the bearings are heavily soiled or a V-ring is damaged should they be washed out
and 2/3 of the space filled with grease.
4.8 Lever bearing weighing device
The bearings are maintenance-free.

Only if the bearings are heavily soiled or a V-ring is damaged should they be washed out
and 2/3 of the space filled with grease.
4.9 Oil damper weighing device

Change the damper oil if it is dirty, but no later than every 2 years.
4.10 Compressed air oil mister

Check the oil content in the container and refill if necessary. Recommended oil, viscosity
class VG 32 under ISO 3448, or DLP 32 under DIN 51502. Viscosity 32 mm²/s at 40°C.
The oil ascension pipe must always be submerged in the oil.

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5 Maintenance points
Fig. 2: Maintenance points, rotor weighfeeder

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6 Maintenance intervals
No. Maintenance activities 1 1 3 6 12 24 36 60

T M M M M M M M
7.1 Check the rotor weighfeeder for settled dust and x

leaks. If necessary, clean off the dust and seal the
leaks.
7.2 Check the bearing for unusual noises. x
7.3 Air supply:

Filter water separator: drain condensate x
Filter water separator: clean the filter x
Compensator flushing: Check flushing pressure
7.4 Weighing device:

cleaning x
check and adjusting x
(1)
7.5 Adjusting the rotor gap x x

(2)
7.6 Rotor, sealing plates: checking condition and x x

reworking or replacing if necessary (3)
7.7 Compensators: check condition, replace if necessary x x x

(3) (6)
7.8 Check the seal (drive shaft) and replace if necessary x

(4)
7.9 Gear unit:

Check the seals x
Change the shaft sealing ring (5) x
(5)
7.10 Three-phase motor and tacho-generator:

Change the shaft sealing rings and ball bearing, x
Inspect the tacho-generator. x
(5)
7.11 Belt drive:

Check the belt coating, replace the belt if necessary, x
Check the belt tension and retension the belt of x
necessary.
7.12 Material shut-off gate x

(5)
1) In the case of control measurements with a large zero point deviation immediately.
2) On rotor weighfeeders used as flame traps or with very abrasive bulk material.
3) With very abrasive bulk materials
4) Together with No. 7.6; immediately if coal escapes.
5) It is essential to follow the manufacturer’s maintenance instructions.
6) Replace the rubber compensators at latest after 5 years.
The maintenance job numbers in the left-hand column correspond with the chapters in these
maintenance instructions.
1T Daily
1M Monthly
3M Every 3 months etc.

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7 Maintenance work
7.1 Check the rotor weighfeeder for settled dust and leaks
The rotor weighfeeder and its surroundings must be checked three

times a day for dust that has settled. Layers of dust must be
removed immediately - avoid disturbing it as you do so. Leaking
points in the system must be sealed off immediately.
You must not allow a layer of dust thicker than 5 mm to build up on

motor, gear or electrical equipment.
Always vacuum dust off, do not blow it off. For vacuuming, only
use appliances approved for use in the zone.
Warning! Always vacuum off the weighing part in setting mode. The dosing
capacity can change suddenly and dramatically after vacuuming-
off.
Dust deposits and escaping air can generate potentially explosive atmospheres. For this
reason, check the rotor weighfeeder and its surroundings three times a day = once per
shift.
Close off any areas where dust escapes immediately, particularly the checking hole on
the blow-out nozzle.
If dust escapes at the opening in the lower part of the housing, replace the shaft sealing
rings.
If dust / air escapes at the compensators, immediately shut down the rotor weighfeeder
and replace the compensators.
If air escapes at the pneumatic unit or the transport air line, close the leak immediately.
The rotor weighfeeder is a measuring instrument. Dirt and dust deposits on the weighing
part (painted red) are weighed and lead to defective dosing results. For this reason they
must be removed daily, or, even better, prevented from collecting. For the same reason,
foreign bodies must not be stored on the weighing part.
When returning from setting mode to normal operation, reduce the dosage output and
increase the oxygen concentration in the furnace, because the dosage output can change
suddenly after dust or foreign bodies have been removed from the scales.
Very high temperatures can build up in the motor and gear. The heat is dissipated from
their surface. Dust deposits reduce the amount of heat given off, and can ignite on these
surfaces. Please observe the manufacturer's operating instructions.
Keep the rotor weighfeeder clean at all times and protect it against accidental
contact.

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7.2 Check the bearing for unusual noises
In order to avoid overheating, the bearings must be checked daily

for unusual noises during operation.
The bearings in the motor, gear and drive shaft can get very hot if they are overloaded, the
lubrication fails or they are soiled.
For this reason, check them daily for unusual and loud noises during operation and
lubricate the bearings if necessary. If the area of the bearings grow hot, switch the unit
off immediately.
7.3 Air supply
Fig. 3: Air supply
The rotor weighfeeder requires compressed air from the industrial supply (6 bar). The
compressed air must be purified, technically dry and free of oil. The compressed air
connection is made with a flexible tube (1 m long) and a ball valve (194) with a connecting
nipple R 1/2" or a 1/2 – 14 NPT external screw thread.

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7.3.1 Filter water separator (191)

Draining off condensation: If there is a fault in the operating network compressed air
filtration, drain off the condensation by pressing the handles on both sides. The
condensation level should never by allowed to rise above the deflector (max. mark).
Cleaning: Clean the containers and filter when the filter element is so heavily soiled that
there is a noticeable drop in pressure or the front surface of the soiling indicator reflects
in red during flow-through. Wash out the filter element in benzene or kerosene, then
blow air through it from the inside to the outside and leave it to dry before it is
reinserted. Wash the plastic containers in cold or warm water only and with a normal
household detergent.
Plastic condensation containers will be damaged if the compressed air contains
traces of synthetic oil.
7.3.2 Oil mister (193)

Cleaning: Clean plastic containers with worm or cold water and normal household
cleaners only.
7.3.3 Compensator flushing

Check the flushing pressure (2 bar) at the pressure control valve (173).
Check the function of the non-return valve (195). Unscrew the air hose on the non-
return valve. Clean possible coal dust deposits in the air hose and non-return valve with
compressed air.
7.3.4 Outer chamber flushing
The outer chamber flushing is also supplied via the pressure control valve (173). The
solenoid valve (176) is connected to the signal "Rotor start". The amount of air is limited via
restrictors at the blow-in points.
7.3.5 Inlet box aeration

Only for the DRW 4.16
The air is also supplied via the pressure control valve (173). Activation is by the solenoid
valve (177).

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7.4 Weighing device
Fig. 4: Weighing device
Dust deposits on the weighing device go into the dosing as measuring errors. To maintain
the proportioning accuracy, the weighing device must be inspected and adjusted once a
month and recalibrated if necessary.
In the case of rotor weighfeeders with prehoppers, the zero point is automatically corrected
via control weighing. Check the weighing system once annually or if there is a major zero
point deviation.
7.4.1 Cleaning and check the weighing device

Remove the lid, Fig. 4.
Deposits of dust on the weighing device are recorded as measuring errors in the dosing.
For this reason, carefully brush or vacuum off the lever (101), equalisers (110) and load
cell (100), or clean them with compressed air.
Note: Do not brush dirt into the oil damper (111).
Remove the oil damper lid and check the oil for dirt. If the oil is very dirty, change it.
The damper disk of the oil damper must not be in contact with the cylinder. Ten gap
between both parts must not be less than 0.4 mm at all places. Use a feeler gauge to
check the gap.
Note: Protect the weighing device from dirt. Replace the lid and tank after
maintenance work.

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7.4.2 Checking the smoothness of operation

Check the smoothness of operation of the weighing device at the stop nuts (107), the
overload screw (105), the suspension pieces (102 and 104) and at the locking rod on the
housing.
7.4.3 Checking and adjusting the zero point

Stop the supply of material to the rotor weighfeeder.
Empty the rotor weighfeeder and the prehopper completely.
When the rotor weighfeeder is emptied, the shut-off gates can be checked for material
leaks. If material trickles through over an extended period, service the gate in
accordance with the manufacturer’s instructions.
Perform zero value calculation according to adjustment instructions (electrical
documentation), chapter "Zero value (zero curve)".
7.4.4 Checking the calibration
After checking the zero setting, you must check the calibration.
Hang a test weight on the scale.
Select the calibration menu.
Compare the displayed calibration weight with the value stated on the test weight. Both
values must agree.
Compare calibration value in kg/U with the displayed loading. In the case of a deviation
of the two values >0.2% recalibrate according to adjustment instructions (electrical
documentation).
In the calibration menu compare the change of the input voltage on applying the test
weight with the value in the data sheet.
Possible sources of faults:

Power shunts due to inadmissible connection between weighing part (red) and frame
(grey); e.g. transport locking device, cables, weighing device, oil damper, etc.: remove
power shunt.
Large distortion in the outlet compensator: Reset / affix the outlet compensator.
Gap between load cell and its overload protection is clogged: clean.
Load cell up against its overload protection: readjust the overload protection of the load
cell according to repair instructions.
Load cell is defective: replace.

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7.5 Adjusting the rotor gap
Fig. 5: Adjusting the rotor gap
Rotor weighfeeders used as flame blocks may only be operated

with a max. rotor gap < 0.2 mm, so as to ensure that they are
resistant to flame flashover.
In the case of Rotor Weighfeeders which are used as flame blocks, the gap dimension is to
be ensured by the operator. Inspection every 3 months. With little wear the inspection
intervals can be extended, in the case of heavy wear these intervals should be shortened.
A small gap dimension also increases the service life of the rotor and sealing plates,
because the material flow via the gap and therefore the wear remains low. Inspect every 3
months. Inspect monthly if the bulk material is very abrasive.
If the gap can no longer be set as described in the instructions, inspect the rotor and
sealing plates for wear. To do this, open the rotor weighfeeder. If necessary, the rotor and
sealing plates must be reworked or replaced. Repair instructions.
7.5.1 Checking and adjusting the rotor gap when the rotor is stationary
Shut down the rotor weighfeeder and run it empty as described in the commissioning
instructions.
Open the inspection holes (25, Fig. 5).
Unlock the setting nuts (21, colour red) of the adjustment screws (23, colour black) and
undo them by ½ a turn.
Adjust the setting screws (22, colour red): Through the inspection holes (25),
measure with a feeler gauge a gap 3x on the circumference and at the top set to 0.20
mm with the setting nuts M24 x 1.5 (21) on setting screws (22, colour red). Next secure
the setting nuts (21).

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Adjust the adjustment screws (23, colour black): Screw the setting nuts M24x1.5
(21) by hand onto the adjustment screws (23) until they reach the unit. It should be
possible to move the washers (27) by hand after the lock nuts have been secured. Next
secure the setting nuts.
Set the screws (20) to approximately 0.4 mm vertical gap.
Close inspection holes (25).
Warning! These screws must not be screwed tightly!
7.5.2 Checking and adjusting the rotor gap during operations

Close inspection holes (25).
Allow the rotor to run for a few minutes at medium speed.
In the controller, set the adjustment mode.
Check the current input of the motor on the Pfister hand terminal.
Reduce the gap at the 3 setting screws (22) slowly one after the other while observing
the current input constantly. After each setting wait for 2 - 3 revolutions of the rotor,
whether the power consumption remains the same.
As the power consumption increases, again enlarge the gap slightly and repeat the
process.
Next secure the setting nuts (21).
Adjust the adjustment screws (23, colour black): Screw the setting nuts M24x1.5
(21) by hand onto the adjustment screws (23) until they reach the unit. It should be able
to move the washers (27) by hand after the lock nuts have been secured.
Next, secure the setting nuts.
Set the screws (20) to approximately 0.4 mm vertical gap.
In the controller, set the operating mode.
7.6 Rotor, sealing plates

Check the wear of the rotor and sealing plates annually, or every six months is very
abrasive bulk material is present.
If large-scale furrows occur, rework the rotor and sealing plates as described in the
repair instructions.
If the wear is so advanced that the rotor gap can no longer be set as described in 7.5,
the rotor and sealing plates must be reworked or replaced.

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7.7 Compensators: check condition, replace if necessary
Fig. 6: Blow-out pipe
The compensators 140 and 141 (Fig. 2) for the material feed and those 142 and 143 (Fig. 2
and Fig. 6) for the blow out are fitted with anti-wear inserts. A wear insert is not required
for the blow-in compensator (144) (Fig. 2).
Check the compensators for wear yearly. To do this, remove them, Repair Instructions. If
necessary, replace the anti-wear inserts resp. compensators. Replace the rubber
compensators at latest after 5 years.

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7.8 Check the seal (drive shaft) and replace if necessary
Check the condition of the seals yearly. To do this, dismantle the rotor,
Repair Instructions. If necessary, replace the seals.
7.9 Gear unit

A prerequisite for preserving explosion protection is maintenance
of the gear unit in accordance with the manufacturer’s operating
instructions.
Perform a visual inspection of the seals for leaks every 3000 operating hours, and at
least every 6 months.
Change the shaft sealing rings every 20,000 operating hours, depending on the oil
temperature.
7.10 Three-phase motor and tacho-generator

A prerequisite for preserving explosion protection is maintenance
of the gear unit in accordance with the manufacturer’s operating
instructions.
Burn injury hazard: The surface temperature can reach 140°C.
Change the shaft sealing rings every 10,000 operating hours. Inspect and, if necessary,
replace the ball bearings.
Inspect and service tacho-generator every 10,000 operating hours in accordance with
the supplied operating and maintenance instructions.
The surface of the motor must always be kept free of dust deposits.

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7.11 Belt drive
Fig. 7: Belt drive
The belt has an anti-static coating. Only conductive belts with a

surface resistance of < 109 may be used.

Warning! Do not tension the belt (134) too much.
The belt has an anti-static coating. Inspect the coating every 6 months. Replace the belt
if a lot of the coating has worn away.
Check the belt tension annually: Commissioning instructions.
Check the run of the belt annually: Commissioning instructions.
The run of the belt and the belt tension can be corrected with the 3 threaded bolts (133)
on the motor console.

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7.12 Material shut-off gate
The shut-off gate is operated electro-pneumatically.
The triggering of the solenoid valve (196) in automatic operations is done by the controls,
and in manual operations (local operations) at the local control box by a pushbutton switch
(valve below, open - closed).
The solenoid valve closes the shut-off gate on loss of current and keeps it closed when
power is down. The shut-off gate can also be operated with the auxiliary manual
mechanism at the solenoid valve head.
Control and maintenance:
Refer to the manufacturer's instructions for all maintenance and repair work.
Check the proximity switch (open - closed) for damage. The switching distance to the
shut-off gate blade must be 8 mm.
Check the shut-off gate for tightness.
8 Index History

issue
0 Ripp 02.07.2003 First issue.
a Ripp 24.09.2003 Supplementation: chapter 7.5 - Adjusting the rotor gap
Introduction: chapter 8 - Index history.
b Höger 29.07.2005 Chapter 7.3; 1/2 – 14 NPT external screw thread.
c Ripp 18.05.2010 Chapter 6 and 7.7 - rubber compensators added.
d Ripp 27.01.2011 Adaptation for DRW 4.16.
e Keim 29.06.2012 Belt drive (HTD 8m).
e Keim 29.06.2012 Chapter 3 Lubrication point 5 - Recharge of 10 in 2
changed.


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REPAIR INSTRUCTIONS
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ROTOR WEIGHFEEDER
DRW 4.10/4.12/4.14/4.16
Contents .................................................................................. Page
1 Important instructions ........................................................................ 2

2 Execution of work in potentially explosive atmospheres ........................... 3
3 Tools for work in potentially explosive atmospheres ................................ 3
4 Rotor housing .................................................................................... 4
4.1 Disassembly of the rotor housing ................................................. 4
4.2 Removing / replacing the rotor .................................................... 6
4.3 Removing / replacing the lower sealing plate ................................. 8
4.4 Removing / replacing the upper sealing plate ................................. 9
4.5 Reworking rotor and sealing plates ............................................. 11
4.6 Drive shaft seal ....................................................................... 12
4.6.1 Checking or replacing the sealing rings............................. 13
4.7 Drive shaft bearing .................................................................. 13
4.7.1 Dismantling and installing the drive shaft and the bearing... 13
4.7.2 Removal or replacement of the drive shaft seal ................. 14
4.8 Assembling the rotor housing .................................................... 15
5 Weighing device............................................................................... 16
5.1 Replacing the load cell .............................................................. 16
5.2 Preload compensation............................................................... 17
5.3 Oil damper .............................................................................. 17
6 Belt drive ........................................................................................ 18
7 Compensators ................................................................................. 19
8 Blow-out nozzle / blow-out pipe ......................................................... 19
8.1 Removing / replacing blow-out nozzle ......................................... 20
9 Blow pipe ........................................................................................ 23
10 Balancing the scales pivot ................................................................. 26
10.1 Moving the bearing (171) and (172) ......................................... 27
10.2 Balancing the inlet compensator A ............................................ 27
10.3 Balancing the blow-out compensator B...................................... 28
10.4 Balancing the blow-pipe compensator C .................................... 28
11 Drive .............................................................................................. 28
12 Shut-off gate................................................................................... 29
13 Index History .................................................................................. 29

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REPAIR INSTRUCTIONS
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Use of the unit in potentially explosive areas demands correct
maintenance and lubrication. The maintenance instructions of the
attached appliances must be observed.
Burst, cracked, embrittled, melted, leaky and otherwise noticeably

damaged parts must be repaired or replaced immediately. If there
is an explosion hazard, the system must be put out of operation
until the problem has been remedied.
Parts carrying Ex identification may only be replaced by parts that

are at least equivalent, i.e. with the same or a higher unit category
and protection type, and the same or a lower temperature class.
Parts without Ex identification may only be replaced by at least

equivalent parts, i.e. with the same or a lower surface resistance,
the same or a higher strength, temperature resistance, chemical
resistance, nominal pressure and test pressure.
Repairs, particularly the reworking of parts, may only be performed

as outlined in these repair instructions. The necessary tolerances
must be observed.
In order to guarantee the shock resistance, only original parts are

to be used.
After the repair work has been completed, the DRW may only be
put into operation as outlined in the operating instructions.
After parts are replaced, the earthing brackets must be refitted.
Fitted parts may only by repaired in accordance with the

manufacturer’s instructions.
Repairs may only be carried out by specialists trained by FLSmidth

Pfister who are familiar with the explosion protection regulations.

It is prohibited to open the maintenance opening and to disconnect

product and de-dusting lines when the system is running.
The relevant sections of these instructions must be read through

carefully before any work is carried out. Pay special attention to
the instructions relating to personal safety.
Before the rotor weighfeeder is opened, all electrical and

pneumatic connections must be disconnected and the necessary
precautions taken to prevent the connection being restored again
by accident (assembly switch).

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For repair work, please also observe the maintenance and

commissioning instructions and safety sheet.
The local accident prevention regulations must also be observed.

Particular care must be taken when working with electrical
systems and equipment.
2 Execution of work in potentially explosive atmospheres
When work is to be carried out in areas where explosive

atmospheres may occur, permission for the work must be obtained
from an appropriately authorised representative of the operator
before work is begun (Directive 1999/92/EC - Annex II 1.2).
Only personnel that have been trained sufficiently and
appropriately for the respective work (mechanical and electrical) in
potentially explosive atmospheres by the operator may be assigned
such work (Directive 1999/92/EC - Annex II 1.1).

flammable atmosphere inside the system parts and in the building.
3 Tools for work in potentially explosive atmospheres
No tools that can generate sparks may be used in Zone 20. Tools
that are to be used in Zones 21 and 22 must be incorporated in a
permit system introduced by the operator of the plant (EN 1127-1
Annex A).
Types of tools:
a) Tools that can cause only a single spark when used (e.g. screwdrivers, spanners,
impact screwdrivers).
b) Tools that cause a shower of sparks when used for cutting and grinding work.
Steel tools according to a) may be permitted in Zones 21 and 22. Steel tools according to b)
may only be permitted if the work place is shielded off from the rest of the Zone 21 and 22
areas and the following additional precautions have been taken:
c) dust deposits at the work place have been removed or
d) the work place is kept so moist that the dust cannot be raised and glowing embers
cannot arise.
The sparks arising in grinding or cutting work in Zones 21 and 22 or their surroundings can
fly long distances and cause glowing embers to form. The wider area around the work place
should therefore also be included in the precautionary measures named above.

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4 Rotor housing
4.1 Disassembly of the rotor housing
Fig. 1: Rotor weighfeeder DRW, assembled

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Fig. 2: Rotor weighfeeder DRW, opened
Fig. 3: Housing screws

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Switch off the DRW as shown in the Commissioning Instructions.
Disconnect blow pipe (1) at compensator and the lower part of the housing.
Disconnect the cable from the drive motor, tachogenerator and synchro-transmitter.
Detach the grease pipe (2) at the lower part of the housing.
Unscrew and remove the screws (20) between the lower and upper parts of the housing.
Position the 3 lifting elements (16) along with the hauling lugs (15) on the faces of the
upper part of the housing. Suspend the 3 hauling lugs in the fork head on the lower part
of the housing. Turn the spindles of the lifting elements upwards until the hauling lugs
are slightly tensioned.
For DRW 4.10:

Release the steering rollers (5) on the gear console: Undo 2 knurled screws for each. Lift
the locking plate and push it to the side. Tighten the knurled screws.
For DRW 4.12, 4.14 and 4.16:

Secure the 3 support wheels (17) on the bottom part of the housing.
Remove the diagonal stay (3) and the cross stay (4) from the supporting frame.
Unlocking the setting nuts (21): Release the setting nuts by undoing the 3 hexagon
socket screws.
Remove the setting nuts (21) from the setting screws (22, colour red) and the adjusting
screws (23, colour black).
Lower approx. 200 mm the lower part of the housing with the drive unit by turning the
crank at the 3 lifting element evenly.
Remove 3 setting and adjusting screws (thread M 24 x 1.5) from the lower part of the
housing.
Lower the lower part of the housing again.
Remove the 3 hauling lugs at the fork head of the lower part of the housing and remove
the lifting elements.
4.2 Removing / replacing the rotor
Remove the lower part of the housing with the drive unit from the supporting frame.
There is an M 16/20 deep threaded hole in the middle of the rotor for screwing in a ring
bolt (31) to lift the rotor out the rotor (30) from the lower part of the housing.
With lifting gear hoist the rotor at least 120 mm by means of the ring bolt and take it out
over the drive shaft.

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Weights and Shaft height H Rotor weight

dimensions
DRW 4.10 95 mm 350 kg
DRW 4.12 105 mm 530 kg
DRW 4.14 120 mm 940 kg
DRW 4.16 120 mm 910 kg
Fig. 4: Replacing the rotor
Before installing a new or reworked rotor, check the evenness and parallelism of the
sealing surfaces. See chapter 4.5 for tolerances.
Clean the rotor hub (33) and lubricate lightly.
Lightly lubricate the O-ring (34), the concentric collar (35) and the drive shaft (32).
Lead the rotor over the drive shaft and lower carefully. Take care that the hub nut and
the twin edges of the shaft are in the same position.
Remove the ring bolt (31).

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4.3 Removing / replacing the lower sealing plate
Fig. 5: Replacing the lower sealing plate
Unscrew the fasteners (41) and (42).
Screw 3 M12 ring bolts (43). With lifting gear, lift the sealing plate from the lower part of
the housing using the three ring bolts.
Weight of the lower sealing plate
DRW 4.10 135 kg
DRW 4.12 195 kg
DRW 4.14 320 kg
DRW 4.16 415 kg
Before installing a new or reworked sealing plate check the evenness and parallelism of
the sealing surfaces.
See chapter 4.5 for tolerances.
Clean the sealing surfaces on the lower part of the housing and the sealing plate. Put a
new plate seal on the lower part of the housing in correct position.
A plate seal is not used in the DRW 4.16.
Put on the sealing plate and screw firmly in correct position. On the DRW 4.10 and 4.12,
the screws 41 are accessible from the outside. The screws 42 M12x25 are screwed in
from the inside with copper sealing rings and fluid protection.
No copper sealing rings are required in the DRW 4.16.

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4.4 Removing / replacing the upper sealing plate
Fig. 6: Replacing the upper sealing plate
Unscrew 3 fastening screws (48) distributed evenly around the perimeter.
Set the spacer tube (50) and nut (51) on the spindles (52). Screw threaded spindles
firmly into the sealing plate instead of the 3 fastening screws (47). On the DRW 4.14, the
3 threaded spindles are screwed into the upper part of the housing from below.
The threaded spindles are placed on one of the rotor supporting feet.
Unscrew the remaining screws (48, 49). 2 screws (47) are accessible on the
DRW 4.10/4.12/4.14 from the feeder box.
The sealing plate (45) is now lowered on the 3 spindles by turning the nuts (51) and
lifted out with lifting gear.
Hold onto the threaded rods by the lock nuts (53) while lowering
so that the threaded rods cannot turn. Otherwise the danger exists,
that the sealing plate can drop.

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Weight of the upper sealing plate
DRW 4.10 135 kg
DRW 4.12 170 kg
DRW 4.14 270 kg
DRW 4.16 345 kg
Before installing a new or reworked sealing plate check the evenness and parallelism of
the sealing surfaces.
See chapter 4.5 for tolerances.
Clean the sealing surfaces on the upper part of the housing and the sealing plate. Put a
new plate seal on the upper part of the housing in correct position. A plate seal is not
used in the DRW 4.16.
Set the sealing plate into the upper part of the housing and screw the firmly in the
correct position.
The screws (47) M12 are accessible from outside, 2 screws (47) M12 are accessible on the
DRW 4.10/4.12/4.14 from the feeder box. The remaining screws (48, 49) M12x25 are
screwed in from the inside with copper sealing rings and fluid protection.
In the DRW 4.16 copper sealing rings are only used for the outside screw (47).

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4.5 Reworking rotor and sealing plates

The rotor and sealing plates may only be reworked as described in
these repair instructions. The required dimensions and tolerances
must be observed.
Fig. 7: Reworking rotor and sealing plates
Dimension A B C
DRW 4.10 125 / 160 mm 40 mm 25 mm
DRW 4.12 200 mm 50 mm 25 mm
DRW 4.14 / 4.16 300 mm 50 mm 30 mm
In order to avoid functional faults with the DRW, the minimum height or thickness of the
rotor and sealing plates must be adhered to.

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4.6 Drive shaft seal
Fig. 8: Drive shaft sealing
The drive shaft is sealed by 4 sealing rings. The sealing rings (60) for the drive shaft seal
are in the liner (61).
If the shaft seal (60) is defective, coal dust can be seen coming out of the 2 discharge
openings (62) and the housing openings (63).The defective sealing rings must be replaced
as soon as possible as otherwise the shaft bearing underneath will be damaged.

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4.6.1 Checking or replacing the sealing rings
The lining (61) is pulled out of the hub (64) to check or replace the packing.
Unscrew 3 M8x16 screws (65).
Press the lining out of the hub using the pulling screw 3xM12.
Remove the safety rings (66) and press the sealing rings (60) out using a tool (tube
jointing sleeve).
Clean the 2 O-rings (67), check and replace if damages.
Use only original PTFE sealing rings.
Clean the lining and oil lightly.

Fit new or cleaned lining with new sealing rings. Check that the supporting ring (68) as
well as the protection disk (71) are fit accurately.
Fill the sealing rings in the lining evenly with grease.
Clean the drill hole in the hub (64) and oil lightly.
Place the lining over the drive shaft, guide into the hub and screw in.
Press in grease via the grease pipe (2, see fig. 1) until it penetrates between the drive
shaft (32) and the protection disk (71).
4.7 Drive shaft bearing
4.7.1 Dismantling and installing the drive shaft and the bearing
Remove the switch disk (75) for the synchronous transmitter at underside of the gear
unit.
Unscrew the connections (76) of the drive shaft (32) in the hollow gear unit shaft (77).
Mount the drive unit underneath, ensuring that it stands safety.
Remove the screws (78) on the gear unit flange.
Lift the lower part of the housing from the drive unit. The drive shaft is drawn out of the
hollow gear unit shaft.
Ensure the drive unit stands securely while pulling the drive shaft
out of the hollow gear unit shaft, in order to prevent the drive shaft
from becoming skewed or tipping over.
Turn the lower part of the housing and put in a safe place. Watch out for the projecting
square end of the drive shaft.
Dismantle the shaft safety disk (79).
Pull the drive shaft carefully out of the bearing. Use the M20 thread at the shaft end to
do this.
To remove the shaft bearing and/or the shaft seal, the whole hub can be removed from
the lower part of the housing after the lubricating pipes have been dismantled.
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Unscrew the lubricating pipes (80) and (81) at the connection and push the tubes back
into the housing chamber (82).
Remove the 6 screws (83) and the hub (64) using the 3 pulling M24 screws (84).
4.7.2 Removal or replacement of the drive shaft seal
Unscrew the bearing cover (85), clean the sealing ring (86), check and replace if
damaged.
Remove the spherical roller bearing (87), the sealing ring (88), the O-ring (89), clean,
check and replace if damaged.
Use only original spherical roller bearings.
Clean the whole of the hub, oil, and fit sealing rings, bearing and O-ring. The spaces in
the spherical roller bearing should be 2/3 filled with grease.
Fasten the bearing cover (85) with 3 M10x30 screws and 3 M10x120 setting screws. The
setting screws are set to a height of 110 mm.
Fill the spaces between the sealing rings and the bearing with grease.
Guide the hub into the lower part of the housing and fasten with 6 M16x50 screws.
Check the position of the discharge openings (62).
Connect the lubricating pipes.
The pipe (80) is fed with the lubricant via the lubrication point on the outside of the lower
part of the housing. After being connected to the lubrication pipe on the outside of the lower
part of the housing, the pipe (81) is supplied with grease.
Oil the drive shaft and guide carefully through the bearing and the seal.
Place the shaft safety disk (79) in the centering shoulder of the lower part of the
housing. Place the nuts on the three setting screws at the disk (79) and screw in.
Place the lower part of the housing on the gear unit and screw to the gear unit flange.
When guiding the drive shaft into the hollow gear unit shaft, check the correct position of
the feather key (90).
Screw the drive shaft into the hollow gear unit shaft.
Install the switch disk (75) for the synchronous transmitter (91). The switch distance
from the outer circumference of the switch disk to the synchronous transmitter is 5 mm.

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4.8 Assembling the rotor housing
Clean and grease the O-ring (36) and the locating surface.
On the DRW 4.10, check the position of the O-ring: Rotor height 160 mm, O-ring in the
upper groove, rotor height 125 mm, O-ring in the lower groove.
Guide the lower part of the housing with the drive unit into the supporting frame.
Position the 3 lifting elements (16) with the hauling lugs (15) on the faces of the upper
part of the housing. Suspend the 3 hauling lugs into the fork head of the lower part of
the housing. Turn the rods for the lifting elements upwards, until the hauling lugs are
slightly tensioned.
Crank the lifting elements evenly and raise the elements until the rotor extends into the
upper part of the housing by 10 mm.
On the DRW 4.10, secure the steering rollers (5) to prevent them turning.
On the DRW 4.12 / 4.14, remove the 3 support wheels (17) from the lower part of the
housing.
Insert 3 setting screws (22, colour red) in the original places, near the inspection holes
(25).
Insert 3 adjusting screw (23, colour black) in the original places.
Screw new M24x1.5 self-locking nuts (26) onto the setting screws (22) and the adjusting
screws (23) and screw down at the lower part.
M24x1,5 Tightening torque 200 Nm,
M30x2 Tightening torque 350 Nm.
Raise the lower part of the housing further by cranking the lifting elements evenly. Take
care that the rotor in the upper part does not tilt. The setting bolt (24) must fit into the
flange of the lower part.
Now tighten the setting nuts M24x1,5 (21) over the 3 red setting screws (22).
Initially set the gap between the star feeder and the upper sealing plate at approx. 0.5
mm with the 3 setting nuts. This gap can be measured with a feeler gauge through the
observation holes (25) next to each setting screw.
Place the disk (27) over the 3 black adjusting screws (23) and tighten the remaining
setting nuts (21) by hand.
Detach the 3 hauling lugs from the fork head in the lower part of the housing and
remove the lifting elements.
Replace the diagonal stay (3) and the cross stay (4) on the supporting frame.
Screw the remaining screws (20) in by at least 1mm height, but do not screw tight!
Connect the grease pipe (2) at the lower part of the housing.
Reconnect the electrical connections at the drive.
Replace the blow pipe (1) at the lower part of the housing.
Care must be taken that all pipes and cables run vertically through the scale's pivot.
Re-attach potential equalization lines, see also commissioning instructions.
See the commissioning instructions for zeroing and calibration.

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The rotor weighfeeder may only be commissioned following

adjustment of the rotor gap as described in the commissioning
instructions.
5 Weighing device
Fig. 9: Weighing device
5.1 Replacing the load cell

Free the lever (101) and suspension (102) with the M16 nut (103).
Replace load cell (100). Keep to the original position of the ratings plate. Hang the
suspension (104).
Guide the cable through the protective tube outside into the local control box and
connect.
First screw the overload screw (105) down so that it presses the guide bolt of the
triangular knife (106).
Load the load cell by loosening (and locking) the nut (103).

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Set the overload screw (105) and lock so that a maximum load of 1.2 x rated load can be
effective. This value corresponds to 29 mV output voltage at the load cell. Check on the
Pfister hand terminal. The overload is reached by lifting the lever.
In this procedure care must be taken that the lever (101) does not touch the stopping
nuts (107). These nuts are then set with a vertical clearance of 4 mm with a testing
weight in position.
After the load cells have been replaced, the zero point and the measuring range must be
reset as laid down in the User Manual - Rotor weighfeeder DRW with proportioning
controller.
5.2 Preload compensation
The mechanical preload of the load cell can be altered where required by displacing the
compensating weight (110). Displacing this weight in the direction of the load cell increases
the preload.
The mechanical preload at the load cell is set to 50 % of the load cell rated load.
This corresponds to half the nominal load of the load cell or 12 mV output voltage. The
output voltage can be read off on the Pfister hand terminal.
5.3 Oil damper
Change the damper oil when it is dirty, at the latest after two years.
Loosen the damper disk with the retaining plate (112) at the lever.
Unscrew the cylinder (113) and pull both parts upwards.
Clean the damper.
Install the damper.
Set the damper disk at approx. 12 mm distance from the upper edge of the cylinder.
The damper disk must not touch the cylinder.
The clearance between both parts must be at least 0.4 mm all round. Check with gauge.
Fill damper oil (see Lubricating Instructions, lubricating point no. 8) by moving the lever
up and down - make sure that air does not enter the cylinder.
Oil level between 6 - 8 m above the damper disk.

Replace the damper cover (114).

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6 Belt drive
Fig. 10: Belt drive
The belt has an anti-static coating. Only conductive belts with a

surface resistance of < 109 may be used.

After replacing the belt, set the running of the belt and the belt tension as described in
the commissioning instructions.

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7 Compensators
Only conductive compensators with a surface resistance of < 10 9
may be used.
The compensators 140 and 141 (Fig. 1.) for the material feed and those 142 and 143 for
the blow out are fitted with wear inserts. A wear insert is not required for the blow-in
compensator 144.
The wear inserts of the compensators 141 and 143 can be checked for wear or damage
when the rotor housing is open and then replaced if necessary.
The assembly dimension must be checked for the compensators (140) and (142).
Assembly dimensions Compensator (140) Compensator (142)
dimension x (mm) dimension y (mm)
DRW 4.10 178 ± 5 150 + 5 – 0
DRW 4.12 / 4.14 / 4.16 242 ± 5 200 + 5 – 0
If the assembly dimension of the compensator (142) is too small, this can destroy the DRW.
When replacing, check the correct position of the inserts and seals.
The potential equalization lines, which the compensators bridge or

the individual components connect, must be re-attached, see
commissioning instructions.
Note:
Following repairs work on the compensators 141, 143, and 144 a new balancing of
the scales pivot will be necessary. See chapter 10.
It will also be necessary to carry out a zero setting of the DRW using the User
Manual - Rotor weighfeeder DRW with proportioning controller.
8 Blow-out nozzle / blow-out pipe
By maintenance and control work under chapter 7 it is recommended that the condition of
the blow-out nozzle (150) and the blow-out tube (151) is checked and that they are
replaced if necessary.

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8.1 Removing / replacing blow-out nozzle

DRW 4.10 / 4.12 / 4.14
During operations, a check can be made at the control R 3/8" bore hole (152) of whether
the blow-out nozzle (150) has worn through. If the blow-out nozzle has worn through, air
or coal is expelled from the control bore hole. To prevent damage to the upper part of the
housing and weighing errors caused by changes to the tare, the blow-out nozzle must be
replaced.
Remove the compensators (142) and (143).
Unscrew the blow-out tube (151) from the frame and lift.
The upper part of the housing must be removed from the housing frame prior to
exchanging the blow-out nozzle!
Loosen the connections (153) of the blow-out nozzle, press the nozzle out of the snug fit
with the three M20 pressing screws, and lift it out of the upper part of the housing.
Fig. 11a: Blow-out nozzle and blow-out pipe

DRW 4.10 / 4.12 / 4.14

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Clean the housing opening and grease the sealing surface for the O-ring (154) lightly.
Place the new blow-out nozzle in position and screw up.
Assemble the compensators with the wear inserts and blow-out tube.
Note: The following work must be done after repair work on the blow-out nozzle
or blow-out pipe:

Balancing of the scales pivot, see chapter 10.
See the commissioning instructions for zeroing and calibration of the DRW.
Removing / replacing blow-out nozzle

DRW 4.16
Fig. 11b: Blow-out nozzle and blow-out pipe

DRW 4.16

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Remove the compensator (143) with spacers (144).

Loosen the connections (153) of the blow-out nozzle.
Loosen the 3 threaded spindles (155), turn around and screw into the M30 pressing
screw. Press the blow-out nozzle (150) out of its snug fit with the spindles and lift.
Push the sheet metal plate (156), approx. 5 mm thick, between the upper part of the
housing and the blow-out nozzle. The sheet metal plate must lie on the upper part of the
housing and on the U-section at the back of the frame. The height of the U-section can
be changed.
Place the blow-out nozzle down on the sheet metal plate by turning out the threaded
spindles and pull out of the DRW.
Clean the housing opening and grease the sealing surface for the O-ring (154) lightly.
Place the new blow-out nozzle in position and screw up.
Assemble the compensators with spacers.
Note: The following work must be done after repair work on the blow-out nozzle
or blow-out pipe:

Balancing of the scales pivot, see chapter 10.

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9 Blow pipe
Fig. 12: Blow pipe - DRW 4.10 and DRW 4.12

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Fig. 13a: Blow pipe - DRW 4.14

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Fig. 13b: Blow pipe - DRW 4.16
The airflow of the blow pipes is divided into 3 part flows. Part flow 1 and 2 clear the feeder
chamber series. Part flow 3 clears the inner chambers of the rotor.
During operations and with the rated dosing output the 3 flow control valves or regulating
flap are set by measuring the air speed, so that there is a speed ratio in the pipes.
Replace damaged parts and with parts of the same quality. Follow Figures 12 and 13a and
13b for disassembly and assembly.
Note: The following work must be done after repairs to the blow pipe:
Balancing the scales pivot, see chapter 10.

See the commissioning instructions for adjustment of the flow control valves.

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10 Balancing the scales pivot
Fig. 14: Balancing the scales pivot
Fig. 15: Air supply

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If the scales system is to function correctly, it is necessary to balance the compensators in

the scales pivot point by displacing the bearing. By displacing the bearing the scales pivot is
set exactly on the centre of the effective cross-sections of the compensators A and B.
10.1 Moving the bearing (171) and (172)
Loosen the upper and lower bearing screws.

Move the bearing evenly in the desired direction in the upper and lower guide (176) with
the forcing screws (177). The opposite forcing screws must be screwed back to the
correct distance.
Adjust all the forcing screws at the bearing and tighten.
Tighten the upper and lower bearing connections.
10.2 Balancing the inlet compensator A
An air pressure of 0.5 bar is built up in the unit for this. If the balancing is correct, between
a pressure of 0 and 0.5 there is no force change on the load cell.
Close the system above the compensator A with the shut-off gate and below the
compensator B and below the compensator C with intermediate plates. Instead of the
DRW shut-off gate, it is also possible to close the silo gate or the prehopper inlet
compensator with an intermediate plate.
Move the bearing (171) to the middle of the upper and lower bearing guide.
See chapter 10.1- moving the bearing.
Fit a control pressure gauge (range 0 – 1 bar) at an adjustment hole (174).
Do not allow the pressure in the rotor weighfeeder to rise above

0.5 bar.
Set a pressure of 0.5 bar at the pressure control valve (173, Fig. 15). To do this, turn the
hand wheel to the left until the pressure has fallen below 0.5 bar, then precisely set the
new pressure by turning the hand wheel to the right.
Switch the valve (175).
The set pressure of 0.5 bar is built up in the unit.
Check the output voltage of the load cell for the load on the hand terminal. If the
compensator is balanced correctly, if the pressure increases the deviation of the load cell
output voltage UA is within the tolerance of ± 0,02 mV or the load display within 0.5%.
If the output voltage UA of the load cell or the load changes towards plus, the bearing
(172, Fig 14) is pushed towards +.
With a minus deviation, the bearing (172) is pushed in the opposite direction.
The pressure in the rotor housing can be released by turning the pressure reducing valve
(173) back.
If the balancing of the compensator is correct, the deviation of the load cell output
voltage UA is within the tolerance ± 0.02 mV or the load display within 0.5% when the
pressure increases.

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10.3 Balancing the blow-out compensator B
Remove the armature endplate underneath the compensator B. Screw compensator B

tightly.
Close the blow-out pipe above compensator D with the intermediate plate.
Measure output voltage UA or the load.
Build up 0.5 bar pressure in rotor housing.
If the output voltage UA or the load deviates, push the bearing (171) in the appropriate
direction. See drawing.
Measure the displacement of the bearing (171) with a caliper gauge. After every
displacement of the bearing (171) the bearing (172) must be moved 0.4 times as far in the
opposite direction. The forcing screws and bearing screws must be tight when measuring
the bearing displacement. Measure the lower and upper displacement at every bearing;
they must both be approximately the same.
Repeat the procedure until the deviation of the load cell output voltage UA is within the
tolerance ± 0.02 mV or the load display within 0.5% when the pressure increases.
10.4 Balancing the blow-pipe compensator C
Remove the intermediate plate underneath the compensator C and seal the flange
tightly.
Close the blow-pipe above compensator E with the intermediate plate.
Measure output voltage UA.
Build up 0.5 bar pressure in rotor housing.
In case of changes of output voltage the compensator C together with console (179) has
to be shifted.
The console (179) will be unscrewed (180) a little on and shifted at housing frame.
Finally, all screws will be tightened.
If the balancing of the blow pipe tubes is correct, the deviation of the load cell output
voltage UA is within the tolerance ± 0.02 mV or the load display within 0.5% when the
pressure increases.
After the balancing of the scales pivot has been completed, the intermediate plates are
removed from the pipes and the flange connections tightened.
Reverse the solenoid valve (175) again.
11 Drive
The proportioning rotor weighfeeder is driven by a frequency-controlled three-phase motor

and a helical bevel gear unit or a straight bevel gear unit. A toothed belt drive transmits the
torque.
Gear units and motors may only be repaired in accordance with the

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12 Shut-off gate
The shut-off gate is actuated electro-pneumatically. The solenoid valve (196) is controlled in
Automatic mode by the controller and in Manual (Local) mode via pushbuttons on the local
control box.
The solenoid valve closes the gate if there is a power failure and keeps it closed in the de-
energized state. The gate can also by operated with the auxiliary manual actuator on the
solenoid valve head.
The shut-off gate may only be repaired in accordance with the
13 Index History

issue
0 Ripp 02.07.2003 First issue.
a Ripp 24.09.2003 Supplementation:
chapter 2.8 Assembling the rotor housing
chapter 5 Compensators
chapter 6.1 Removing / replacing blow-out nozzle
Introduction: chapter 11 Index history.
b Höger 22.05.2006 Fig. 8, 12 supplemented and updated.
c Ripp 18.05.2010 Introduction: chapter 2 “Execution of work in
potentially explosive atmospheres” and chapter 3
”Tools for work in potentially explosive atmospheres”.
d Ripp 14.07.2010 Chapter 10 Balancing supplemented.
e Ripp 27.01.2011 Adaptation for DRW 4.16.
f Keim 29.06.2012 Belt drive, Fig. 10.
g Höger 12.07.2016 Chapter 4.3 and 4.4 use of plate seals.
Fig. 12 and 13b updated.


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OPERATING INSTRUCTIONS

Rotor Weighfeeder DRW 4.10/4.12/4.14/4.16

FLSmidth Pfister GmbH, D-86165 Augsburg Page 1/2

The persons responsible for transport, assembly, commissioning, operation, maintenance

We can accept no liability for damage or breakdown caused by failure to observe

Contents ...................................................................... Document no.

Unit description ........................................................... 550.096.60.04-GB-e-GB

FLSmidth Pfister GmbH, D-86165 Augsburg Page 2/2

Contents .................................................................................. Page

1 General description ............................................................................ 2

FLSmidth Pfister GmbH, D-86165 Augsburg Page 1/8

2 Operating method of the rotor weighfeeder

4 Bulk material inlet

8 Bulk material outlet

9 Bulk material inlet

A-A Weighing axis

Fig. 1: Operating principle of the rotor weighfeeder

FLSmidth Pfister GmbH, D-86165 Augsburg Page 2/8

A-A Swiveling axis

Fig.2: Construction of the rotor weighfeeder

FLSmidth Pfister GmbH, D-86165 Augsburg Page 3/8

FLSmidth Pfister GmbH, D-86165 Augsburg Page 4/8

Fig. 3: Proportioning system for coal dust

FLSmidth Pfister GmbH, D-86165 Augsburg Page 5/8

To prevent pressure fluctuations in the system influencing the control measurement,

The manufacturer shall not be liable for any damage resulting

5.1 Explosion protection

FLSmidth Pfister GmbH, D-86165 Augsburg Page 6/8

Ex-marking and CE-marking

The appliance is designed to be pressure shock-resistant.

5.2 Bulk materials

FLSmidth Pfister GmbH, D-86165 Augsburg Page 7/8

5.4 Operating pressures

The maximum permitted operating overpressure in respect of pressure shock resistance

Index Author Date of Modifications

Subject to change without notice.

FLSmidth Pfister GmbH, D-86165 Augsburg Page 8/8

Contents .................................................................................. Page

FLSmidth Pfister GmbH, D-86165 Augsburg

During mounting also observe the Transport Instructions, and

Attach ropes etc. to the rotor weighfeeder only at the marked

FLSmidth Pfister GmbH, D-86165 Augsburg

2 Execution of work in potentially explosive atmospheres

When work is to be carried out in areas where explosive

3 Tools for work in potentially explosive atmospheres

FLSmidth Pfister GmbH, D-86165 Augsburg

4 Assembly of the rotor weighfeeder

FLSmidth Pfister GmbH, D-86165 Augsburg

It must be ensured that during assembly work, there is no

4.1 Setting up the DRW

FLSmidth Pfister GmbH, D-86165 Augsburg

4.2 Swiveling the shut-off gate

FLSmidth Pfister GmbH, D-86165 Augsburg

4.3 Connection of pneumatic cylinder to solenoid valve

4.4 Connection of compensators

To guarantee explosion protection, all compensators must be

Absolute care must be taken that no foreign bodies get inside

FLSmidth Pfister GmbH, D-86165 Augsburg