MULTICOR - S160/260

Operation Manual

BVH2106GB
PASS - Service you can rely on.
Fast, comprehensive, anywhere in the world

Quality and reliability are the cornerstones of our companys philosophy. That is why we consider a
comprehensive service concept simply par for the course, from strict quality control, installation and
commissioning through to seamless support across the entire product life cycle.

With over 30 service stations and over 180 service specialists, you can count on us to be there whenever
and wherever you need us. It doesnt matter where you are, our specialists are there to advise and assist
with the best in worldwide, personal, comprehensive service.

During office hours, service specialists from all divisions are on hand to analyse problems and failures.
Look at www.schenckprocess.com for your nearest Schenck Process Location.

Customised to meet your requirements, our comprehensive Process Advanced Service System provides
you with the best service. Are you looking for individual, perfect-fit service solutions?

Then our, the modular service system PASS, is the ticket. It covers the entire service spectrum, from
simple inspections through to full service. Interested? Then find out more about the individual components
at www.schenckprocess.com/en/service.

Free 24 h Emergency Service Hotline in Germany

Are you experiencing a failure or problem outside normal office hours? Our service staff are on call around
the clock to deal with failures, service planning and other emergencies.
J +49 171 2 251195 Heavy and Light excluding Static Weighing Equipment

J +49 172 6 501700 Transport Automation and Static Weighing Equipment

by Schenck Process GmbH, 2008

Pallaswiesenstrae 100, 64293 Darmstadt, Germany
J +49 61 51-15 31 0
www.schenckprocess.com

All information is given without obligation. All specifications are subject to change.

Note: Translation of the original instructions

 Table of contents

Table of contents
1. Safety Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1. Use As Originally Intended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2. Qualification of Installation Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3. Explosion protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4. Hazards Resulting From Feed Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4.1. Cleaning In Enclosed State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5. Hazards Resulting From Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2. Transit Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3. Installation Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1. Mounting MULTICOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4. Installation Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1. Direct Installation in Conveyor Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2. Direct Installation in Conveyor Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5. Storing MULTICOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1. Measures for Long-Time Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

6. Installation Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.1. Wiring MULTICOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.1.1. General Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.2. Connecting MULTICOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

7. Construction and Operating Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7.1. Material Route and Measuring Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.2. Measuring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.3. Measuring Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7.4. Measuring Force Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7.5. Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

8. Interference Forces Affecting Measuring Accuracy . . . . . . . . . . . . . . . . . . . . . . 13

8.1. Platform Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8.2. Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8.3. Material Build-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8.4. Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8.5. Pulsating Material Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8.6. Mechanical Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

9. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9.1. Maintaining MULTICOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9.2. Performing Inspection and Maintenance Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9.2.1. Checking Measuring Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
9.2.2. Checking Measuring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9.2.3. Measuring Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9.2.4. Checking Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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9.2.5. Maintaining Measuring Joint and Drive Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.2.6. Checking Flanged Connections for Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.3. Troubleshooting Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

10. Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Indic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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Safety Hints 1.2. Qualification of Installation Personnel

1. Safety Hints
1.1. Use As Originally Intended
n Your MULTICOR is designed for measuring the feed rate of materials in
accordance with the CORIOLIS principle.
n Install, adjust, commission and operate device in accordance with this set of
instructions, TECHNICAL DATA, order-specific planning documentation and
Electronic Evaluation System manual. Use the material specified in the order.
n The unit is inappropriate for all bulk materials which are not in accordance with
the material specification.
n For safety reasons, MULTICOR - S may only be put into operation after having
it installed in an enclosed conveyor route by a skilled technician.
n Perform work on device (including inspection work) only when the feeder is in
the OFF state. Check to see that all power lines are separated from mains.
Protect system from inadvertent start-up.
n Never perform technical modifications on device without prior written consent
of Schenck Process.
n BE CAREFUL IN CASE OF WELDING!!
Connect the negative pole directly to the welding point in order to protect the
load cell.
n Upon commissioning or restart, even in the case of trial runs, ensure that lines
to device are properly connected and all guards remounted.

1.2. Qualification of Installation Personnel

n Only trained and instructed personnel which have been authorized for
installation may carry out the following work.
n Any person directly or indirectly involved in installation, operation, maintenance
and repair are required to have read this service manual and be familiar with
its use.
n The installation personnel must be able to handle locksmith works on its own,
has to be familiar with the handling of cranes and pay heed to safety aspects.
n The installation personnel must be familiar with the local safety and accident
prevention rules and observe them.
n The operating personnel is required to know and heed the company-internal
safety and accident prevention rules.
n According to the EC Machinery Directive, device is interlinked as machine in a
total system (plant).
The user is bound to complete the operating instructions of this manual and all
related instructions and to make them available to the operating personnel.

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1.4. Hazards Resulting From Feed Material Safety Hints

1.3. Explosion protection

DANGER: Danger to life and limb due to explosion

Danger of severe injury and material damage if your MULTICOR S is operated in

an area subject to the risk of explosion or is used for the dosing of combustible
bulk goods, without your MULTICOR S being designed for this specific usage.
Please note at all times the specific design of your MULTICOR S and the
Operating Manual, EX Supplement (BV-H2248).

1.4. Hazards Resulting From Feed Material

As a rule, every person working on MULTICOR S is required to have a material
safety data sheet in hand which specifies the degree of risk resulting from the
material used.
Contact with or exposure to dust, toxic substances, toxic gas, fire or explosion,
viruses, fungal cultures or bacteriae, etc. must be reliably ruled out.

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Safety Hints 1.5. Hazards Resulting From Noise

The table below assigns hazards to requisite device design.

MULTICOR-S...Design Risks resulting from feed material

in accordance with Safety Spec Sheet
Dust, Fire, Toxic gas Viruses,
toxic explosion fungal
substance cultures,
bacteriae
Dust-tight Standard YES YES MULTICOR MULTICOR
special special
Design pressure Standard YES YES options options
-25...+95 mbar in in
Operating pressure Standard YES YES accordance accordance
-10...+30 mbar with legal with legal
regulations regulations
Inerting By user By user

n The user ensures safe operation of MULTICOR paying heed to the

maintenance instructions of this manual.

1.4.1. Cleaning In Enclosed State

To avoid contact with toxic substances, always perform cleaning work in enclosed
state of device.
Complete decontamination, however, has to be achieved for the specific
application in cooperation with the user. Therefore, always refer to
application-specific cleaning instructions.

1.5. Hazards Resulting From Noise

Depending on grain size and material hardness, a 85dB(A) noise rate can be
exceeded. Requisite noise protection measures depend on local regulations.
Please contact Schenck Process whenever it comes to noise protection.

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1.5. Hazards Resulting From Noise Transit Hints

2. Transit Hints
IMPORTANT NOTE!!
1. Check device for possible damage in transit immediately upon receipt.
2. File claims for compensation of damage in transit in writing without
delay and send to shipper.
3. Check items supplied against enclosed shipping documents.

Transit weight ATTENTION!!

Type S 160, 260 = approx. 275kg Keep device UPRIGHT

n Transport device to site on its pallet.

n Never remove device from pallet before reaching site.
n Slowly lift or lower device.

IMPORTANT! Drive motor is part of the measuring system. Never step on

motor, nor apply forces > 200N.

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Installation Prerequisites 3.1. Mounting MULTICOR

3. Installation Prerequisites
In the early planning stage, consider the
recommendations and data
given at Item 4.1 or 4.2 and
in order specific dimensioned
drawing.

This is important for measuring system

accuracy. Please contact Schenck
Process whenever the local situtation
requires a modification.

n Size platform opening as shown in

dimensioned drawing.

3.1. Mounting MULTICOR

Make sure that MULTICOR is mounted without being distorted. The following
general recommendations apply to heavily varying local installation situations.
n Use only three of the four available mounting tabs of the device as shown on
the preceding page.

n Make three mounting angles with oblong

holes, as suggested above and

n provide beams with oblong holes. This

allows accurate, three-dimensional
alignment of the
MULTICOR with the users device inlet or
outlet.
The horizontal installation position of the device
must be accurate to level. This can be brought
about by applying the water level on the cover
of the device.

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4.2. Direct Installation in Conveyor Tubes Installation Hints

4. Installation Hints
4.1. Direct Installation in Conveyor Tubes

NOTE:
The supporting structure separate
from platform ensures that service
loads, including walking on platform,
do not cause the MULTICOR
system to incline or twist.

4.2. Direct Installation in Conveyor Tubes

NOTE:
Service loads, including
walking on the platform, must not
cause the supporting structure of the
device to incline beyond the maximum
permissible flexing value!

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Storing MULTICOR 5.1. Measures for Long-Time Storage

5. Storing MULTICOR
Please observe the following:
Guidelines for storage and handling of the supplied components, machines and
systems BV-R2000 AA

5.1. Measures for Long-Time Storage

If the device is stored longer than 6 months from date of delivery, take these steps:

Component Up to 12 months Up to 24 months Up to 36 months

After 6 months Every 6 months Every 6 months
Complete - Unpack device. Unpack device Unpack device
device - Visually check stainless steel
parts for corrossion, if need be
Repickle and passivate.
- Visually check steel parts for
corrosion, if need be repaint.
All rubber After 6 months After 6 months Every 6 months
parts - Apply glycerine - Renew glycerine - Renew glycerine
- Protect from light protection protection

Shaft After 6 months Every 6 months Every 6 months

seals - Remove sealing sets and - Renew glycerine - Renew glycerine
store separately. protection protection
- Apply glycerine to seals.
Gearbox After 6 months Every year Every year
- Turn shaft manually. - Renew protection - Renew protection
as instructed as instructed
Motors After 6 months Every year Every year
- Turn shaft manually to - Measure insulation - See left column
distribute grease. Take resistance, if need be,
corrosion protective dry motor in hot air
measures. current, at max. 100C
- Regrease bearings. - See left column
Complete Each time after opening packing
device - Add dehydrating agent -See left column - See left column
and reseal packing.

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6.1. Wiring MULTICOR Installation Hints

6. Installation Hints
MULTICOR comes ready to be installed.

n Transport device to site as described in Transit Hints.

Install MULTICOR taking these steps:

n Check installation site for correct dimensions in accordance with order-specific

dimensioned drawing of MULTICOR and installation prerequisites (Item 2).
n Install MULTICOR horizontally with accuracy to level (also see Item 3.1
Mounting MULTICOR, in accordance with the selected Installation Hints given
at Item 4.
n Connect device outlet chute with flexible connection (compensator) to device
housing.

6.1. Wiring MULTICOR

6.1.1. General Hints
n Have device connected by authorized persons as shown in order-specific
connection diagrams, paying heed to local electrical codes.
n Preferrably use flexible cables.
n Ensure proper measuring wheel rotational direction by using appropriate
measuring motor connecting wires.

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Installation Hints 6.2. Connecting MULTICOR

6.2. Connecting MULTICOR

Sample circuit diagram shows how inputs are wired in cable boxes.
n Perform electrical connection in cable junction boxes as described in weighing
electronics manual and order specific wiring diagrams.
n Ensure that measuring wheel rotates in clockwise direction at top view.
NOTE:
Incorrect rotational direction prevents load cell measuring signal from being
output. Change measuring motor polarity in cable junction box accordingly.

n Carefully seal cable screwed connections in cable junction boxes to maintain

protection to IP 65.
n Connect central earthing line to central device earthing screw M6 as shown on
next page.

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7.1. Material Route and Measuring Principle Construction and Operating Principle

7. Construction and Operating Principle

7.1. Material Route and Measuring Principle
The material is fed in through the unit inlet and is led into the measuring wheel.
The intake can be equipped with an optional flow rectifier to improve measuring
accuracy in certain feed situations. The flow rectifier reduces the spin in the flow of
bulk solids.
When the material flows along the rotating measuring wheel, the Coriolis force
acts on the material. It is measured as torque at the motor. For this reason, the
complete drive unit is mounted in a measuring device and supported on a load
cell. Internal torque resulting from friction in the gearbox, the bearings and at the
shaft sealing rings do not have any influence on the measurement result.

IMPORTANT Property damage

There might be damage to the measuring equipment and/or faulty
measurements if the measuring motor is used as a ladder substitute or the
measuring motor is touched during operation. Avoid touching the measuring
motor when operating the MULTICOR.

The reactive torque is proportional to mass flow; material-specific quantities such

as humidity and friction are not taken into account in the measurement. The
measuring wheel speed is measured by pole wheel and inductive speed
transducer. A flexible connection isolates the measuring system from the device
housing.

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Construction and Operating Principle 7.2. Measuring System

7.2. Measuring System

The complete drive line consisting of measuring gear and drive shaft with
protective tube is rotably mounted in a special bearing arrangement. Greased with
a special, temperature-resistant lubricant, the two bearings are maintenance-free.
An upper and a lower flexible connection piece protect the measuring system from
dirt and dust.
Load is applied to load cells via a special connecting rod. The permanently set limit
stop protects the load cell from overload during start-up and operation.

A measuring wheel drive shaft is mounted in two bearings. The upper bearing is
within the measuring device, the lower bearing is in the protective tube. This
bearing is sealed from feed material by means of two radial shaft seals.

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7.5. Wiring Construction and Operating Principle

7.3. Measuring Wheel

With the help of the measuring wheel cone, the measuring wheel, rotating in the
direction indicated by the arrow, leads the material flow onto the vanes of the
measuring wheel; thus the material particles are radially transported out of the
measuring wheel. The torque necessary to achieve this serves as a measured
variable.
The measuring wheel is connected to the measuring wheel shaft through a cone
and can be mounted/removed by means of a central mounting screw.
The measuring wheel is accessible after the outlet cone has been removed, see
Item 9.2.1.

WARNING: The weight of the workpiece may cause injury

The measuring wheel weighs 15 to 30 kg depending upon the design and
this is the reason why two persons are required for mounting and removal.

7.4. Measuring Force Application

The measuring force application device is designed to transmit the force resulting
from drive torque for measuring wheel and lever arm (radius from motor axle to
force application centre) free from influence on the load cell. The load cell is
protected from the forces occurring during motor start/stop by the overload
protection

7.5. Wiring
The wiring instructions are included in weighing system documentation. Please
also observe the order specific circuit diagrams.

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Interference Forces Affecting Measuring Accuracy 8.2. Air Flow

8. Interference Forces Affecting Measuring

Accuracy
8.1. Platform Vibrations
n Acceleration forces 0.1 g of any frequency resulting from platform vibrations
do not affect measuring accuracy.
n Platform displacements may cause temporary movement of the device.
This may adversely affect measuring accuracy of the measuring device due to
shifting of the measuring range.

During operation, the above events can be detected by monitoring of:

Silo levels, wind influence on silo, one-sided exposure to sunlight etc.
Variations in platform load, e. g. by walking on platform.

If the measures to be taken are not obvious, check by calculation whether the
building influences correspond to the values and notes specified in section 4.

Further measures should be agreed upon with Schenck Process.

8.2. Air Flow

Air currents flowing through the unit in place of material simulate a feed rate as
measuring result.
n For this reason, make sure that routes between silo and measuring units are
enclosed and tight .
n In the outlet cone and in the down spouts leading to the pneumatic conveyor,
avoid air pressure deviations from ambient atmosphere of more than +0.5mbar,
see Item 4.

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8.5. Pulsating Material Flow Interference Forces Affecting Measuring Accuracy

8.3. Material Build-Up

Build-up on the measuring wheel does not affect measuring accuracy if it is
continuously uniform and does not cause material particles to lift off the measuring
wheel vanes.

Increasing and non-uniform thickness of build-up can cause faults.

Build-up may be caused by:
adhesive substances in the material to be fed and/or
increased moisture

8.4. Wear
Abrasive material may cause wear, especially of the measuring wheel vanes, the
measuring wheel bottom and the internal housing of MULTICOR. For such
material, the measuring wheel can be designed wear-resistant and the internal
housing may be provided with a coating (option).

n During the time of commissioning, check the measuring wheel and the internal
housing during each system stop for wear and build-ups. See Item 8.3.
n If wear or build-up cannot be excluded in the long run, check the measuring
wheel and the internal unit housing at regular intervals.

8.5. Pulsating Material Flow

Pulsating material flow into the measuring wheel produces a load cell signal
associated with vibrations reducing its accuracy. For this reason, the feed quality
of the units transporting the material to the measuring wheel is very important.
Rotary feeders should therefore be provided with overlapping chambers.
Feed screws should be equipped with a feed star on the discharge chute and
operate at high speed.

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Interference Forces Affecting Measuring Accuracy 8.6. Mechanical Faults

8.6. Mechanical Faults

The following factors can adversely affect measuring accuracy:

Exposure of dirt into measuring bearings. Damaged flexible connection has

the potential to contaminate measuring bearings.
Twists or folds in flexible connection. Twists or folds can cause interference
forces to enter into measuring result.
Twist or folds in cabling. Motor/terminal box and speed transducer
interconnecting cables must have slack in the cable to allow for motor
movement, i.e. not contacting device cover or hood.

If visual check for the above three items does not solve the problem, check
mechanical equipment as shown in FH 5447
Checking MULTICOR Zero Point instruction.

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9.1. Maintaining MULTICOR Maintenance

9. Maintenance
GENERAL SAFETY HINTS!!
n Open device only if
all wires of measuring system have been disconnected from power
power supply is locked against inadvertent restart
and
measuring motor has come to standstill
n Never let objects drop into measuring device!!
n Remove dropped objects from device. There is danger of subsequential
damage.

9.1. Maintaining MULTICOR

n Check device for abnormal noise in regular intervals.

NOTE!! Never touch measuring device / measuring motor during operation.

There is danger of measuring errors.

n Check measuring wheel and inlet cone for material build-ups if these cannot be
excluded.
n Check measuring wheel for wear if the material is liable to cause such effect.
n Use lubricants as described in Lubricating Hints F014549.

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Maintenance 9.2. Performing Inspection and Maintenance Work

9.2. Performing Inspection and Maintenance Work

Upon system inspection, perform the following checks:

Item Check Work Measured and Intervals Comments

check variables, m=monthly
equipment and a=annually
auxiliaries
9.2.1 Check measuring wheel for in accordance
build-ups and wear. with instructions
below
9.2.2 Check measuring system.
9.2.3 Check measuring motor See Lubricating
bearings. Instructions
F 014 549/01.
9.2.4 Check MULTICOR-S 160
gearbox.
9.2.5 Check upper measuring See Lubricating
bearing. Instructions
F 014 549/01.
9.2.5 Check shaft sealing rings and See Lubricating
measuring wheel bearings. Instructions
F 014 549/01.

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9.2. Performing Inspection and Maintenance Work Maintenance

9.2.1. Checking Measuring Wheel

Remove measuring wheel if visual inspection indicates build-up and/or wear.
First remove discharge cone and remove measuring wheel as follows:

n Check measuring wheel for wear. Check to see that measuring wheel vanes
are 2 mm thick over the entire surface. Use measuring gauge. Normally, outer
diameter is most liable to wear.
n Remove material build-up from measuring wheel. Consult Schenck Process if
build-up problems continue and material properties cannot be changed.
n Install wear-resistant measuring wheel and contact Schenck Process if you feel
the measuring wheel service life is too short.

18 BV-H 2106 GB/0640 Operation Manual MULTICOR S 160/260

Schenck Process
Maintenance 9.2. Performing Inspection and Maintenance Work

Reinstall measuring wheel as follows:

n Clean and degrease surfaces on drive shaft and measuring wheel cones.
n Lift the measuring wheel centrically against the stub of the drive shaft so that
you can screw on the fastening screw (hexagon wrench 8 mm).
n Screw in some threads and release measuring wheel so that it can center with
alignment chamber when screw is tightened.
n Start/restart drive motor twice and ensure proper rotational direction. Check
mounting screw for proper torque again.

9.2.2. Checking Measuring System

Check drive line flexible connection for damage and twist-fold-free seat. In
case of damage, check zero point and replace flexible connection. Replace
worn or dirty measuring bearings.
Check rubber bumper for damage.
Check measuring system measure X.

Operation Manual MULTICOR S 160/260 BV-H 2106 GB/0640 19

Schenck Process
9.2. Performing Inspection and Maintenance Work Maintenance

Check overload limit stop measure Y.

Grease articulated head with commercial grease.

9.2.3. Measuring Motor

Removing Measuring Motor
You can remove the measuring motor without removing the
MULTICOR S. Check to see that environment is clean.
Remove planetary gear sealing plugs and unscrew the two screws on the motor
shaft hub.
SW6 at S 160 to 75t/h, at S 260 to 65t/h
SW8 at S 160 to 150t/h, at S 260 to 100t/h.
Check and maintain the motor in accordance with suppliers documentation. If
need be, order a Schenck Process replacement motor which meets the special
specifications required for the MULTICOR measuring accuracy.

Reassembling Measuring Motor

Reassemble the measuring motor in accordance with supplier*s documentation
(attached). Requisite tools:

S 160 to 75t/h, S 260 to 65t/h Long hexagon socket attachment, SW 6

torque wrench
torque 39 Nm

S 160 to 150t/h, S 260 to 65t/h: Long hexagon socket attachment, SW 8

torque wrench
torque 77 Nm

20 BV-H 2106 GB/0640 Operation Manual MULTICOR S 160/260

Schenck Process
Maintenance 9.2. Performing Inspection and Maintenance Work

9.2.4. Checking Gearbox

The gearbox is lubricated for life with high-quality synthetic grease.

There is an indication of gearbox damage from:

rough running noises,
impacting running noises,
gearbox temperature >80 C,
lubricants escaping

n Check for above conditions during operation.

If gearbox is in perfect condition, it makes a
uniform, humming noise.

n Check MULTICOR zero point. Big variations in

measuring results can be caused by
excessive play between driving and driven
gear shafts.

In case of gearbox damage, we recommend

replacing the gearbox.

Operation Manual MULTICOR S 160/260 BV-H 2106 GB/0640 21

Schenck Process
9.2. Performing Inspection and Maintenance Work Maintenance

Removing Gearbox
You can remove the gearbox without removing the
MULTICOR. If space is limited, we recommend removing motor as described at
Item 9.2.3.
With models up S 260 to 65t/h appox. S 160 to 75t/h (see Fig.), remove speed
transducer.
Remove the four fixing screws on the gearbox flanged connection and pull off the
gearbox from above.

Mounting the gearbox

Check the elastomer star of the claw clutch for deformation or cracks and change
it whenever necessary. Adjust the half of the claw on the side of the gearbox as
follows:

IMPORTANT: There might be vibrations and damage to the drive if there is not the required
space between the front sides of the claw clutches.

There has to be a space of 1-2 mm between the front sides of the claw clutches.
Use the depth gauge to check this and push half of the claw on the gear driven
shaft. Use the grub screw to fasten the half of the claw. Attach the gearbox and
tighten the fastening screws crosswise.
torque:
S 260 (65 t/h), S 160 (75 t/h): 25 Nm
S 260 (100 t/h), S 160 (150 t/h): 40 Nm

Use LOCTITE 221 to tighten the screws (low strength)

9.2.5. Maintaining Measuring Joint and Drive Line

Have maintenance work performed by skilled labour in a clean environment. When
in doubt, ask for a Schenck Process
service engineer. Complete drive line has to be removed.

Removing Complete Drive Line

Remove measuring wheel as described at Item 9.2.1.
Disconnect measuring motor and speed transducer.
For easy handling of drive line, remove measuring motor and gearbox as
described at Items 9.2.3 and 9.2.4. Protect open drive line from dirt.
Remove drive line mounting screws from cover support ribs.
Pull drive line out of device housing from above. Ensure that sealing washer
and O-ring do not get lost.

22 BV-H 2106 GB/0640 Operation Manual MULTICOR S 160/260

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Maintenance 9.2. Performing Inspection and Maintenance Work

Dismantling Drive Line

First remove material residues from drive line. Apply compressed air carefully so
that flexible connections are not damaged.

Remove clamping sleeves of upper (big) flexible connection.

Turn drive line upside down. Unscrew the six screws and re-
move protective sleeve of lower (small) flexible connection.
Remove clamping sleeves and flexible connection.
Pull out load transducer articulated head. Unscrew the load transducer 4
mounting screws and remove complete load transducer (including load cells
and coupling).
Remove housing cover to access the 6 central mounting screws of bearing
tube and measuring bearings.
Remove mounting screws and pull out complete bearing tube including
coupling.

Operation Manual MULTICOR S 160/260 BV-H 2106 GB/0640 23

Schenck Process
9.2. Performing Inspection and Maintenance Work Maintenance

Checking Measuring Bearings

Pull hub out of measuring bearings.
Check to see that measuring bearings are absolutely clean and can be turned
easily by hand.
When in doubt, replace measuring bearings. Lubricate
measuring bearings using SCHENCK special oil (see Lubricating Instructions
F014549).

Checking and Maintaining Bearing Tube

Check to see that drive shaft can be turned easily
by hand. The relatively high force expenditure is
due to the special shaft sealing rings. When in
doubt, dismantle bearing tube and replace bearings
and seals.
Extract coupling and remove bearing bore snap
ring.
Pull out drive shaft with the two sealing washers
from above. Since mounting forces are applied via
bearing, you must replace upper bearing after
disassembling.
Remove shaft sealing rings by means of a lever
and replace. Remove bearing bore snap ring and
pull out bearing.
Inspecting drive shaft:
Check to see that the measuring wheel alignment
chamfer is clean and free from grooves. Make sure
that shaft sealing rings running surfaces are bright
and free from scratches.
It is recommended to replace all bearings and seals
following the general inspection. Only use the
genuine Schenck Process spare parts,
particularly where shaft sealing rings are
concerned. These are specially suited to the
sealing situation.
To loosen the bonded connections of the shaft
protective sleeve and inner ring, heat them to
approx. 160C.
Always replace the cylinder roller bearings in pairs, i.e. complete with inner
ring. Normally, single parts are paired!
Carefully clean new inner ring and protective sleeve, roughen and degrease.
Apply LOCTITE 601 to shaft, heat inner ring and protective sleeve to 150C
and push on.

24 BV-H 2106 GB/0640 Operation Manual MULTICOR S 160/260

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Maintenance 9.2. Performing Inspection and Maintenance Work

Grease the two bearings; the area between the bearing and the first shaft
sealing ring completely, and the area between the first and second shaft
sealing ring 2/3 as described in Lubricating Instructions F014549.
Reassemble bearing tube in reverse order of sequence.
NOTE: Never apply mounting forces using rollers.
Always use mounting sleeves.

Reassembling Drive Line

Proceed in reverse order of sequence.
Tighten central mounting screws crosswise to 18Nm torque. Secure with
LOCTITE 241.
Use new flexible connections.
Before tightening the tension strips, mount complete load transducer.
Check flexible connection for twist-fold-free seat and tighten tensioning strips.
With models up to S 260 to 100t/h or S 160 to 150t/h , set speed transducer to
measure Z = 1.5 0.5mm as shown at Item 9.2.2.
Check load transducer as described at Item 9.2.2.
Mount drive line in housing.
Mount gearbox and motor as described at Items 9.2.3 and 9.2.4.

Operation Manual MULTICOR S 160/260 BV-H 2106 GB/0640 25

Schenck Process
9.2. Performing Inspection and Maintenance Work Maintenance

9.2.6. Checking Flanged Connections for Tightness

For the following reasons, no feed material (or material dust) may escape at any
point of the measuring unit:
to keep the workplace clean,
to avoid spark penetration,
to maintain the measuring accuracy of MULTICOR S 160

n Use the inspection intervals to provide for tight flanged connections and pipe
connections by adhering to the specified tightening torques of the screws.
n Remove loose flanged connections. Eliminate the cause, e.g.

by replacing the seal and / or

by levelling the flange and / or removing burs from the flange and / or
by levelling/aligning of the flange planes.

26 BV-H 2106 GB/0640 Operation Manual MULTICOR S 160/260

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Maintenance 9.3. Troubleshooting Quick Reference

9.3. Troubleshooting Quick Reference

Fault Cause Remedy
Fault: MULTICOR does not start operating
1 Excess current - Measuring wheel blocked - Remove material and
circuit by material in the inlet check measuring wheel as
breaker responds shown at 9.2.1

- Measuring wheel blocked by - Vacuum off material and

material in the outlet cone check measuring wheel as
shown at 9.2.1
- Sluggish gear - Check gear as shown at 9.2.4.
- Sluggish measuring wheel shaft - Check measuring wheel shaft
as shown at 9.5.2.
- Measuring motor damage - Check measuring motor in
accordance with manu-
facturers instructions 9.2.3.
Fault: MULTICOR failure during operation
2 Evaluation system - Material runs through feeder - Check tightness of feeder
switches off due to without control connections and mounting.
excess of measur-
ing range
Fault: Variations in feed rate indication
3 Actual value error - Measuring device inhibited
- -Check measuring device as
> tolerance shown at 7.2 and 9.2.1.

- Measuring wheel geometry - Check measuring wheel as

changed by build-up or wear shown at 9.2.1.

- Discontinuous feeding of - Ensure continuous material

material feed.
Fault: Zero point variations
4 Zero point check - Measuring device inhibited - Check measuring device as
shows varying shown at 7.2 and 9.2.1.
values - Check measuring wheel shaft
as shown at 9.2.5.
- Check flexible connection
pieces as shown at 7.2 and
9.2.5.
- Too much gear play - Check gearbox as shown at
9.2.4.
5 Material and /or - Flanged connections loose - Check flanged connections in
dust escape accordance with 9.2.7.
- Unit outlet flange loose - Check tightness of the device
outlet in accordance with 9.2.7.

Operation Manual MULTICOR S 160/260 BV-H 2106 GB/0640 27

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9.3. Troubleshooting Quick Reference Maintenance

28 BV-H 2106 GB/0640 Operation Manual MULTICOR S 160/260

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Appendix

10. Appendix
You will find special information on specific subassemblies in the appendix.

Operation Manual MULTICOR S 160/260 BV-H 2106 GB/0640 29

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 SCHENCK Erzeugnis Typ - Gre Bildteil-Nr. Ersatzteilliste Nr. Datum / Date
Produkt / Produit Planetengetriebe Type - Size / Type - Grandeur Drawing No. / Plan No. List No. / Liste No.
SCHENCK PROCESS GMBH 29.08.2002 / Gansmann
Landwehrstrae 55
Type SG, SGE PW250
D-64293 Darmstadt 298 DE Seite / Page Von / of
1 2
 SCHENCK Erzeugnis Typ - Gre Bildteil-Nr. Ersatzteilliste Nr. Datum / Date
Produkt / Produit Planetengetriebe Type - Size / Type - Grandeur Drawing No. / Plan No. List No. / Liste No.
SCHENCK PROCESS GMBH 29.08.2002 / Gansmann
Landwehrstrae 55
Type SG, SGE und PW250
D-64293 Darmstadt 298 DE Seite / Page Von / of
2 2
 SCHENCK Erzeugnis Typ - Gre Bildteil-Nr. Ersatzteilliste Nr. Datum / Date
Produkt / Produit Planetengetriebe Type - Size / Type - Grandeur Drawing No. / Plan No. List No. / Liste No.
SCHENCK PROCESS GMBH 29.08.2002 / Gansmann
Landwehrstrae 55
Type SG, SGE und PW250
D-64293 Darmstadt 298 GB Seite / Page Von / of
1 2
 SCHENCK Erzeugnis Typ - Gre Bildteil-Nr. Ersatzteilliste Nr. Datum / Date
Produkt / Produit Planetengetriebe Type - Size / Type - Grandeur Drawing No. / Plan No. List No. / Liste No.
SCHENCK PROCESS GMBH 29.08.2002 / Gansmann
Landwehrstrae 55
Type SG, SGE PW250
D-64293 Darmstadt 298 GB Seite / Page Von / of
2 2
 Appendix

36 BV-H 2106 GB/0640 Operation Manual MULTICOR S 160/260

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Indic
A
Air currents flowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
C
Checking Measuring Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
cleaning instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CORIOLIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D
DANGER: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
G
gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GENERAL SAFETY HINTS!!. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
I
Installation Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
installation personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
L
load cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
M
maintain protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
material flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
measuring wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
O
operating personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
P
Performing Inspection and Maintenance Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Property damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
R
recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
rotational direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
S
special information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Storing MULTICOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
T
The installation personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
The weight of the workpiece may cause injury . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
toxic substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Operation Manual MULTICOR S 160/260 BV-H 2106 GB/0640 37

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 - Reserved for users notes -

38 BV-H 2106 GB/0640 Operation Manual MULTICOR S 160/260

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