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ProTec Polymer Processing FG 20 Series, Operating Manual, Page: 8 / 76

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ProTec Polymer Processing FG 20 Series Operating Manual Download Page 8

 

ProTec Polymer Processing GmbH 

 

Foerdergeraet_FG201-FG206_BA_1v0_2018_en  

 

8 

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. 

 

 

 

Summary of Contents for FG 20 Series

Page 1: ...c Operating Manual Technical customer service T 49 6251 77061 251 F 49 6251 77061 570 service sp protec com ProTec Polymer Processing GmbH Stubenwald Allee 9 64625 Bensheim Germany T 49 6251 77061 0 F...

Page 2: ...ProTec Polymer Processing GmbH Foerdergeraet_FG201 FG206_BA_1v0_2018_en 2...

Page 3: ...ration 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 3 Technical Data and Structure 13 3 1 Conveyor sta...

Page 4: ...rame 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...

Page 5: ...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...

Page 6: ...id 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...

Page 7: ...tions 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 devi...

Page 8: ...luence 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 ce...

Page 9: ...wer 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 commi...

Page 10: ...rained 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...

Page 11: ...k If the removal of safety equipment is required during fitting maintenance and repair it should be reassembled immediately after completing the maintenance repair work Larger single parts and assembl...

Page 12: ...ce and repair work is performed must be switched off if so specified First check the parts that are switched off if there is no voltage then ground and short circuit as well as insulate adjacent live...

Page 13: ...te fan station 4 Conveying station 1 Cloth filter without cleaning Filter type 3 Filter plate 4 Cloth filter with cleaning compressed air 5 Filter element 0 2 m2 with cleaning circulating or compresse...

Page 14: ...ProTec Polymer Processing GmbH Foerdergeraet_FG201 FG206_BA_1v0_2018_en 14 3 2 Dimensional drawing FG 201 to FG 204...

Page 15: ...ise emissions 80 dB A 3 2 4 Materials Conveying air filter Cloth filter Conveyed goods container PA Discharge flap Stainless steel Seals EPDM Perbunan 1 Balance filter Polyester woven fabric 3 2 5 Noi...

Page 16: ...ProTec Polymer Processing GmbH Foerdergeraet_FG201 FG206_BA_1v0_2018_en 16 3 3 Dimensional drawing FG 205 to FG 206 FG 205 without options FG 206 without options...

Page 17: ...H3 for filter change min 400 mm FG 205 x 4x H1 without volume expansion 575 mm H1 with volume expansion 835 mm H3 for filter change min 200 mm FG 205 and FG 206 h1 with without volume expansion 210 41...

Page 18: ...lter element Polyester Conveyed goods container PA Discharge flap Stainless steel Seals EPDM Perbunan Balance filter Polyester woven fabric 3 3 5 Noise emissions 80 dB A 3 3 6 Options Volume expansion...

Page 19: ...BA_1v0_2018_en 19 3 4 Assembling 3 4 1 FG 201 to FG 204 1 Blower hood with controls 2 Filter insert cloth filter 3 Conveyed goods container 4 Floor flap unit 5 Filling level sensor Optional 6 Nozzles...

Page 20: ...6_BA_1v0_2018_en 20 3 4 2 2K Conveyor FG 201 to FG 204 1 Blower hood with controls 2 Filter insert cloth filter 3 2K attachment_A FG200 change fct 4 Lower part FG200 PA 5 Floor flap unit 6 Nozzles 7 C...

Page 21: ...01 FG206_BA_1v0_2018_en 21 3 4 3 Conveyor FG 205 to FG 206 1 Blower hood with controls 2 Solenoid 3 Filter insert cartridge 4 Conveyed goods container 5 Balance filter 6 Floor flap unit 7 Filling leve...

Page 22: ...s off Through its own weight the material presses on the discharge flap opens it and flows out When the conveyed goods container is empty the discharge flap closes automatically and a new conveying cy...

Page 23: ...y suctioning suction valve accessory To prevent clogging of the conveyor line a suction valve accessory is used Shortly before the end of the conveying time the suction valve opened and air flows into...

Page 24: ...ld be damaged Depending on the mounting accessories there are the following options for fastening the conveyor Mounting accessories Necessary counter piece Fastening the conveyor 3 clamps Lever clampi...

Page 25: ...Polymer Processing GmbH Foerdergeraet_FG201 FG206_BA_1v0_2018_en 25 4 1 Mounting accessories Adapting flange material stainless steel or G Al Machine hopper material Stainless steel aluminium Net volu...

Page 26: ...e of the suction hose and connect with a conveyor hose insert made of copper or steel aluminium or ESTS piping through earth clamps with an earth conductor 4 2 1 Earthing of conveyors and conveyor lin...

Page 27: ...During assembly of the conveying hoses Expose the insert on both ends of the conveying hose approx 50 mm 1 Conveying hose 2 Insert made of copper or steel Using a PVC hose 1 Clamp the wires 1 in the h...

Page 28: ...PUR hose 1 Clamp the wire spiral with the first clamp S2 on the front tube see photo 2 Attach the hose clamp S1 for fastening Caution ONLY flexible hoses may be directly fastened no rigid tubes due to...

Page 29: ...Conveying tube 3 Connect aluminium or VA piping using earth clamps with an earth conductor The earthing must be done via earthed conveyor hose to earthed conveyor tube or suction hose see Earthing the...

Page 30: ...late frame example The earthing cables exiting the conveyor must be connected with a conductive surface or components These are for example platforms made of iron or steel or metal frames Ensure that...

Page 31: ...ening must lie above the level of the product Setting the suction hose Moving the outer pipe to means Convey less material Higher air speed in the conveying line Lower vacuum in the conveying line Les...

Page 32: ...el aluminium or ESTS piping through earth clamps with an earth conductor Only convey plastic granulate with the specified particle size If the filter screen is used the plastic granulate must be dust...

Page 33: ...on hose out of the material container 5 Remove the conveying hose from the conveyor and suction hose 6 Disconnect the accessories from the main power To do this remove the connection plug from the acc...

Page 34: ...ergeraet_FG201 FG206_BA_1v0_2018_en 34 4 5 Disposal Caution Protect the environment Dispose of the device in an environmentally manner by getting it to recycling Handling and disposal of used componen...

Page 35: ...perating manual especially the safety instructions must be read and complied with by every person that works with the system 1 Connect the conveyor with the power plug to mains power Pay attention to...

Page 36: ...oTec Polymer Processing GmbH Foerdergeraet_FG201 FG206_BA_1v0_2018_en 36 6 SOMOS control basic device control system Take information from the operating manual SOMOS control basic device control syste...

Page 37: ...e examples precise data can be obtained from Pro Tec Polymer Processing Suction hose Clamping flange for suction hose 3 sizes Steel galvanised 2 85 Kg Aluminium 0 30 Kg Stainless steel 2 45 Kg Hose Ho...

Page 38: ..._2018_en 38 90 elbow for air line 90 elbow for conveying line 90 elbow for conveying line 38x1 5 Aluminium 0 18 Kg 38x1 5 Stainless steel 2 64 Kg 40x2 5 Glass 0 73 Kg Branch for conveying line Branch...

Page 39: ...stainless steel 0 25Kg Aluminium 0 25Kg Steel galvanised 0 27 Kg Aluminium 0 10 Kg Volume expansion Volume expansion with nozzles PA St nickel plated 0 50 Kg PA Stainless steel St nickel plated 0 70 K...

Page 40: ...FG206_BA_1v0_2018_en 40 Dosing attachment Stainless steel St nickel plated 3 50 Kg Dosing turnout Suction bypass valve Aluminium stainless steel 5 00 Kg Suction valve Al RAL 5018 stainless steel 1 60...

Page 41: ...hopper Mounting cover Stainless steel St nickel plated Outlet 35 und 62 mm 1 40 Kg Aluminium 2 10 Kg Counter bead Tensioning ring Stainless steel 0 33 Kg Steel nickel plated 0 17 Kg After filter Holde...

Page 42: ...Processing GmbH Foerdergeraet_FG201 FG206_BA_1v0_2018_en 42 Dust collection container Dust collection container 4 l PA St nickel plated 1 40 Kg 35 l h 590 Steel galvanised 7 70 Kg 50 l h 795 Steel gal...

Page 43: ...800 Steel RAL 7016 27 00 Kg 7 1 Filling level indicator Optional Information Installation of a fill level indicator on the conveyor only after consultation with Pro Tec Polymer Processing a Internal f...

Page 44: ...e additive material c External fill level indicator in series with the proximity switch in the storage tank of the processing machine The conveying is thus first started when the discharge flap is clo...

Page 45: ...1 FG206_BA_1v0_2018_en 45 7 4 Equipment and options 7 4 1 Volume expansion stainless steel Vol expans 38 assy without lock Vol expans 55 assy without locks 51 Lock assy 52a V gasket 38 and 55 53 Check...

Page 46: ...onal instead of volume expansion Dosing attachment assy without locks 51 Lock assy 52a V gasket 53a Support plate 53b Check valve New set with Check valve holder 18 mm LO Check valve 38 40 LO Cylinder...

Page 47: ...In a dusty or hot moist environment it is recommended to shorten the inspection intervals Clean the conveyor periodically with a material change or heavy dirt Blow out with compressed air Wipe out wi...

Page 48: ...sion Conveyed goods container Check valve or pipe elbow on suction nozzles Discharge flap Seal on discharge Balance filter 4 Fasten volume expansion with the tensioning ring 5 Place filter insert in t...

Page 49: ...power from device 3 Remove compressed air coupling 4 Disconnect plug connections 5 Open locks 6 Remove blower attachment 7 Remove filter insert 8 Clean the filter insert by striking it or blowing out...

Page 50: ...ing 42b and clean it 2 Install the sealing ring on a new conveying air filter 42 3 Place filter insert in the conveyed goods container or the volume expansion 4 Set on the blower attachment 5 Fasten l...

Page 51: ...BA_1v0_2018_en 51 8 1 3 Cleaning replacing the balance filter no continuous service 1 If dirty blow off from outside 2 Stop the conveying cycle 3 Replacing the balance filter 4 Unscrew the balance fil...

Page 52: ...The carbon brushes must be replaced since otherwise high heat development and damage to the blower will occur Information If the carbon brushes are replaced once and the blower shuts off again then it...

Page 53: ...arbon brushes every three months and change if required In a dusty or hot moist environment it is recommended to shorten the inspection intervals 1 Remove rotor hood 1a 2 To do this carefully loosen t...

Page 54: ...ending the holding lug 5b downward and then pull out the carbon brush 5 Push each of the new carbon brushes 4a so far into the holder until the holding lug is visible in the opening To secure the carb...

Page 55: ...3 Let the conveyor cool off approx 5 minutes 8 3 4 Removing the blower Version FG 201 and FG 204 1 Loosen the tensioning rings 2 Remove hood 3 Place the hood on its head 4 Loosen the screwed connectio...

Page 56: ...206 1 Insert new blower or slide sheet metal hood over the blower Step one Step two Step three 2 Notice the installation position The pins must be in the position shown in the photo The solenoid would...

Page 57: ...8_en 57 4 Check the screws for a tight seat 8 3 6 Plug in the cable Insert the cable of the control in the cable lug Note The contact for the carbon brushes must ALWAYS be on the third position from t...

Page 58: ...metal 1 Connect the earthing cable with the sheet metal protection earthing point 2 Place the hood on 3 Screw on using three screws 4 Connect power supply 5 The device is now ready for operation agai...

Page 59: ...air valve 36a 4 Unscrew connection 5 nipple 19 and locking screw 18 and fasten on the new compressed air valve 5 Tightly screw on the compressed air valve 36a with the nut 5 6 Stick the hose in the n...

Page 60: ...plug from the proximity switch 67 4 Loosen the lock nut and unscrew the switch 5 Screw in new proximity switch There must be a gap of approx 1 0 to 1 3 mm between the switch and the lever of the disch...

Page 61: ...cap 1 and dispose of it 5 Pull out pin 2 and dispose of it 6 Pull out discharge flap 75 7 Insert new discharge flap and fix with the new pin Slide the new cap on the pin and push tightly 8 Refasten t...

Page 62: ...achment 4 Remove filter insert 5 Loosen screws 1 on the conveying goods container 6 Remove the check valve 3 and holder plate 2 from the inside 7 Apply Loctite 242 on the screws threads 8 Insert the n...

Page 63: ...wer attachment 4 Remove check valve 3 refer to section Replacing check valve 5 Pull the V gasket 4 from the inlet nozzles and remove 6 Clean the contact surface of the V gasket 7 Insert a new V gasket...

Page 64: ...h off power from device 3 Disconnect the device from the compressed air system 4 Depressurise the compressed air supply line 5 Remove the compressed air supply line 1 from the control valve see figure...

Page 65: ...nder tight 7 Screw off the pin 10 and the nut 11 8 Screw nuts 6 11 and the pin 10 onto a new compressed air cylinder 9 Screw on the nut 11 up to the end of the threads 10 Apply Loctite 272 onto the th...

Page 66: ...13 from the compressed air nipple 5 and loosen the nut 6 2 Screw out the compressed air cylinder 57b 3 Hold the piston 9 of the compressed air cylinder tight 4 Screw off the pin 10 and the nut 11 5 T...

Page 67: ...15 and pull it off 2 Pull the compressed air hose 13 from the throttle check valve 16 3 Unscrew the throttle check valve 16 Factory setting of the throttle screws must not be changed Extend cylinder...

Page 68: ...n the lever tensioning ring 3 Place the filter insert on the dosing attachment 4 Place the blower insert on the dosing attachment 5 Fasten locks 51 6 Mount the conveying hoses 7 Connect the device to...

Page 69: ...e ideal setting is reached Depending on the design of the sensor the potentiometer could be located at another location We differentiate adjustable sensors with the position of the potentiometer under...

Page 70: ...fill level indicator Figure 1 View of the safety flap Figure 2 Safety flap open Figure 3 Turning the screwdriver Half turn to the right clockwise Sensitivity of the fill level indicator is increased...

Page 71: ...put is OFF and the target is not detected OFF ON The output ON and the target is detected ON ON The output is ON and the sensor is in a stable ON state 1 Potentiometer 2 Yellow LED 3 Green LED Setting...

Page 72: ...he sensor The variant used is the non flush installable type Dimension e corresponds to the thread free zone or 25 mm The dimension min 3x d1 corresponds to the specified minimum free surface whereby...

Page 73: ...ProTec Polymer Processing GmbH Foerdergeraet_FG201 FG206_BA_1v0_2018_en 73 9 3 Pneumatic connection diagram 2 K conveyor...

Page 74: ...ProTec Polymer Processing GmbH Foerdergeraet_FG201 FG206_BA_1v0_2018_en 74 9 4 Chemical resistance of the material container Evonik Industries AG...

Page 75: ...ProTec Polymer Processing GmbH Foerdergeraet_FG201 FG206_BA_1v0_2018_en 75 Evonik Industries AG...

Page 76: ...ventil Dosing Valve Dosage De la Valve Option Abreinigen Cleaning decolmatge Abreinigungsventil Cleaning Valve Vanne de decolmatage Option Dosieren 2 dosing 2 dosage 2 Dosierventil 2 Option Auslaufkla...

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