ProTec Polymer Processing FG 20 Series Manuel utilisateur

FG 20x conveyors

with control system SOMOS®control-basic

Operating Manual

Technical customer service

T +49 6251 77061- 251

F +49 6251 77061- 570

[email protected]

ProTec Polymer Processing GmbH

Stubenwald-Allee 9

64625 Bensheim

Germany

T +49 6251 77061-0

F+49 6251 77061-500

info@sp-protec.com

www.sp-protec.com

ProTec Polymer Processing GmbH Foerdergeraet_FG201-FG206_BA_1v0_2018_en

Table of Contents

1Introduction......................................................................................6

1.1 The FG 20x conveyor................................................................................. 6

1.1.1 Intended use ............................................................................................................. 6

1.1.1 Improper use............................................................................................................. 6

1.2 About this Manual ...................................................................................... 6

1.3 Model plates and serial number.................................................................. 7

1.4 Warranty .................................................................................................... 7

2Safety................................................................................................8

2.1 Safety labelling........................................................................................... 8

2.1.1 Structure of the warning information......................................................................... 8

2.1.2 Safety labelling and meanings.................................................................................. 9

2.2 Personnel selection and qualification ........................................................10

2.3 Safety-related instructions for specific operating phases...........................10

2.3.1 Normal operation .................................................................................................... 10

2.3.2 Special operating modes ........................................................................................ 11

2.4 Instructions for special types of risks.........................................................12

2.4.1 Electrical energy ..................................................................................................... 12

2.5 Declaration of Conformity..........................................................................12

3Technical Data and Structure .......................................................13

3.1 Conveyor / station designation key............................................................13

3.2 Dimensional drawing FG 201 to FG 204....................................................14

3.2.1 Dimensions ............................................................................................................. 15

3.2.2 Electrical data..........................................................................................................15

3.2.3 Environmental requirements................................................................................... 15

3.2.4 Materials.................................................................................................................. 15

3.2.5 Noise emissions < 80 dB (A) ................................................................................ 15

3.2.6 Options....................................................................................................................15

3.2.7 Weight.....................................................................................................................15

3.2.8 Compressed air.......................................................................................................15

3.3 Dimensional drawing FG 205 to FG 206....................................................16

3.3.1 Dimensions ............................................................................................................. 17

3.3.2 Electrical data..........................................................................................................17

3.3.3 Environmental requirements................................................................................... 18

3.3.4 Materials.................................................................................................................. 18

3.3.5 Noise emissions < 80 dB (A) ................................................................................ 18

3.3.6 Options....................................................................................................................18

3.3.7 Weight of conveyor without options........................................................................ 18

ProTec Polymer Processing GmbH Foerdergeraet_FG201-FG206_BA_1v0_2018_en

3.3.8 Compressed air.......................................................................................................18

3.4 Assembling ...............................................................................................19

3.4.1 FG 201 to FG 204................................................................................................... 19

3.4.2 2K - Conveyor FG 201 to FG 204........................................................................... 20

3.4.3 Conveyor FG 205 to FG 206...................................................................................21

3.4.4 Function .................................................................................................................. 22

3.4.5 Automatic cleaning of the conveying air filter .........................................................22

3.4.6 Feed of a 2nd component.......................................................................................23

3.4.7 Empty suctioning (suction valve, accessory).......................................................... 23

3.5 OPTION and function: Separator OFF- and acknowledgement switch ......23

4Assembly/Disassembly.................................................................24

4.1 Mounting accessories................................................................................25

4.2 Connecting conveying line.........................................................................26

4.2.1 Earthing of conveyors and conveyor lines.............................................................. 26

4.2.2 Earthing the conveyor line ...................................................................................... 27

4.2.3 Earthing on a base plate / frame (example)............................................................ 30

4.2.4 Mounting a suction hose.........................................................................................31

4.2.5 Devices with automatic cleaning of the conveying air filter / dosing attachment.... 32

4.3 Disassembly..............................................................................................33

4.4 Storage and transport................................................................................33

4.5 Disposal....................................................................................................34

5Commissioning..............................................................................35

6SOMOS® control/basic –device control system........................36

7Options + Accessories..................................................................37

7.1 Filling level indicator (Optional) .................................................................43

7.2 2K- turnout and suction valve....................................................................44

7.3 Other connection options...........................................................................44

7.3.1 External fault indicator (lamp, alarm)...................................................................... 44

7.3.2 External START/STOP switch................................................................................ 44

7.4 Equipment and options..............................................................................45

7.4.1 Volume expansion stainless steel...........................................................................45

7.4.2 Dosing attachment (optional instead of volume expansion)................................... 46

8Service and maintenance..............................................................47

8.1 Clean conveyor .........................................................................................47

8.1.1 Cleaning or replacing conveying air filter................................................................ 49

8.1.2 Replacing the conveying air filter............................................................................ 49

8.1.3 Cleaning/replacing the balance filter (no continuous service) ................................51

8.2 Service......................................................................................................52

ProTec Polymer Processing GmbH Foerdergeraet_FG201-FG206_BA_1v0_2018_en

8.3 Removing the blower attachment..............................................................52

8.3.1 Before maintenance................................................................................................ 52

8.3.2 Replacing the carbon brushes................................................................................53

8.3.3 Replacing the blower ..............................................................................................55

8.3.4 Removing the blower (Version FG 201 and FG 204) .............................................55

8.3.5 Install new blower (Version FG 205 and FG 206)................................................... 56

8.3.6 Plug in the cable ..................................................................................................... 57

8.3.7 Earthing blower....................................................................................................... 58

8.3.8 Replacing the compressed air valve on the cleaning valve.................................... 59

8.4 Conveyed goods container........................................................................60

8.4.1 Replacing the proximity switch................................................................................ 60

8.4.2 Replacing the V-gasket on the discharge flap........................................................ 60

8.4.3 Replacing the discharge flap assembly ..................................................................61

8.4.4 Replacing the plate on the discharge flap............................................................... 61

8.4.5 Replacing check valve ............................................................................................62

8.4.6 Replacing the V-gasket on the check valve............................................................63

8.5 Dosing attachment (optional).....................................................................64

8.5.1 Replacing compressed air cylinder 2...................................................................... 65

8.5.2 Replacing compressed air cylinder 1...................................................................... 66

8.5.3 Replacing the control valve.....................................................................................67

9Appendix ........................................................................................69

9.1 Setting the fill level sensor.........................................................................69

9.2 Option: Setting the type B fill level sensor .................................................71

9.2.1 Sensor without cover flap........................................................................................ 71

9.2.2 Capacitive sensors (CAS) can be installed non-flush for level control...................71

9.3 Pneumatic connection diagram (2-K conveyor).........................................73

9.4 Chemical resistance of the material container...........................................74

ProTec Polymer Processing GmbH Foerdergeraet_FG201-FG206_BA_1v0_2018_en

1 Introduction

1.1 The FG 20x conveyor

1.1.1 Intended use

The FG 20x is a plastic granulate conveyor designed for industrial use. Its exclusive use is for

the conveying of free-flowing plastic granulate or mill stock. Any use deviating from this is not

intended use and must have a written approval from ProTec Polymer Processing GmbH. For

uncertainties in the use of your mill stock or in the operation of your conveyor please contact

ProTec Polymer Processing GmbH customer service.

1.1.1 Improper use

Conveying ignitable or metallic substances.

Conveying liquid materials.

Loads above the rating limits in terms of operating time and volume.

Use in explosion-endangered areas or in open air.

1.2 About this Manual

This operating manual should make it easier for you to learn about the system and its proper

use.

The operating manual contains important information about operating the system safely and

properly. Your compliance helps:

Hazards to avoid.

Reducing downtimes.

Increasing the reliability and lifetime.

The operating manual must be read and used by any person that is authorized to work with or

on the system and must be available and easily accessible to these persons, especially for:

Operation (including fitting, troubleshooting and error removal during work sequences,

removing production waste, care, disposal of operating and auxiliary materials).

Maintenance (maintenance, inspection, service).

ProTec Polymer Processing GmbH Foerdergeraet_FG201-FG206_BA_1v0_2018_en

1.3 Model plates and serial number

Model plate with information for device

1.4 Warranty

Exclusively use original replacement parts from ProTec Polymer Processing GmbH.

Independent modifications or add-ons and the use of replacement parts that are not approved by

ProTec Polymer Processing GmbH lead to the loss of warranty and guarantee. The illustrations

in this operating manual can deviate from the actual design. This does not affect informational

content and facts.

Device description and series

Consecutive serial number and year of manufacture

Component number/ order number / possible

position number in the order

Data on power connection

ProTec Polymer Processing GmbH Foerdergeraet_FG201-FG206_BA_1v0_2018_en

2 Safety

The system was built to the technical state of the art and the recognised safety rules and

regulations. However, with its use, there can occur hazards for life and limb of the user or third

parties or negative influences on the system and other property.

The system must only be used in technically perfect condition as well as to intended use, safety

and hazard conscious observing this operating manual! Especially malfunctions that could

negatively influence the safety must be remedied immediately.

2.1 Safety labelling

2.1.1 Structure of the warning information

The following signal words are used in connection with the safety labelling to display certain

hazards in this document.

Danger!

Death or severe injuries will occur, if the corresponding

precautionary measures are not made.

Warning!

Death or severe injuries may occur, if the corresponding

precautionary measures are not made.

Caution!

Slight injuries can occur if the corresponding precautionary

measures are not made.

Caution!

Property damage may occur if the corresponding precautionary

measures are not made.

Information

Here you receive information and instructions for effective and safe

execution of the following activities.

ProTec Polymer Processing GmbH Foerdergeraet_FG201-FG206_BA_1v0_2018_en

2.1.2 Safety labelling and meanings

The meaning of safety labels is indicated by their shape and colour.

Shape

Colour

Meaning

Safety colour red

Contrast colour white

Prohibited

Safety colour yellow

Contrast colour black

Warning

Safety colour blue

Contrast colour white

Order

The following symbols are used in the manual:

Symbol

Description

Symbol

Description

Symbol

Description

Warning!

information!

Caution!

Fine dust:

Wear breathing

protection!

Caution! Danger!

Disconnect device

from power!

Danger!

Electric

current!

Danger to life!

Danger of injury!

Hot!

Do not touch!

Caution!

Damages to the

equipment

possible.

Only open or remove protective and safety equipment for service work. Before

commissioning, these must be remounted / repowered.

Systems and units must be depressurised before opening.

Comply with maintenance and service intervals!

Keep all safety instructions and hazard warnings on the equipment complete and legible!

Carry out daily visual inspections for outwardly recognisable damage and deficiency!

Immediately report any changes that occur (including the operating behaviour) to the

responsible department/ person! In the case of functional faults the equipment must be

immediately shut down and secured! Malfunctions should be immediately remedied.

ProTec Polymer Processing GmbH Foerdergeraet_FG201-FG206_BA_1v0_2018_en

Never do this:

Operating the equipment outside of given parameters.

Any changes to the device NOT APPROVED by ProTec Polymer Processing GmbH.

2.2 Personnel selection and qualification

Only use trained or instructed personnel. Clearly establish responsibilities of the personnel

for operation, fitting, servicing and repair!

Make sure that only authorised personnel are working on the system!

Establish responsibilities of the system operator and empower him to reject unfavourable

safety instructions from third parties!

Personnel that are being trained, instructed or are in the scope of a general apprenticeship

should only be working on the system under the continual supervision of an experienced

person!

Working on electrical equipment of the system must only be done by an electrician or

trained persons under the guidance and supervision of an electrician according to the

electrotechnical regulations!

Work on hydraulic equipment may only be performed by personnel with special hydraulic

knowledge and experience!

2.3 Safety-related instructions for specific operating phases

2.3.1 Normal operation

Only operate the machine if all safety equipment and safety-related equipment, e.g.

removable safety equipment, Emergency Stop equipment, soundproofing, exhaust

equipment, etc. are present and functional!

Support highly constructed equipment! Especially in connection with dynamic loads, high

constructional parts on the system have to be additional support.

At least once per shift check the system for visible damage and deficiencies! Immediately

report any changes that occur (including the operating behaviour) to the responsible person

/ department! If necessary, immediately stop the system and secure it!

Before switching on / engaging the system make sure that no one is endangered by the

running system!

Observe switching on and off processes, control indicators.

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