Knauf PFT SILOMAT XXL D User manual

Table of Contents
2017-11-2310
Operating manual
EC Declaration of Conformity
PFT CONVEYING SYSTEM
PFT SILOMAT XXL D RAL2004
Part 2 Overview – Operation - Spare parts lists
Article number of the operating manual: 00629976
Article number of the parts list PFT SILOMAT XXL D 50 Hz RAL2004 
Article number of the parts list PFT SILOMAT XXL D 60 Hz RAL2004 
-00606758
-00603707
Read the operating manual prior to starting any work!

2
© Knauf PFT GmbH & Co. KG
P.O. Box no. 60 97343 Iphofen
Einersheimer Straße 53 97346 Iphofen
Germany
Phone [phone]
Fax [phone]
Technical hotline [phone]
[email protected]
Internet: www.pft.net

PFT CONVEYING SYSTEM Part 2 Overview – Operation - Spare
parts lists
Table of Contents
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1 Table of Contents
1 Table of Contents......................................... 3
2 EC Declaration of Conformity..................... 5
3 Inspection..................................................... 6
3.1 Inspection by machine operator .......... 6
3.2 Periodic inspection .............................. 6
4 General information..................................... 6
4.1 Information regarding the operating
manual................................................. 6
4.2 Keep the manual for future reference.. 6
4.3 Division................................................ 7
5 Accessories.................................................. 7
6 Technical data.............................................. 8
6.1 General information............................. 8
6.2 Connection values 50 Hz..................... 8
6.3 Connection values 60 Hz..................... 9
6.4 Operating conditions............................ 9
6.5 Power values 50 Hz............................. 9
6.6 Power values 60 Hz........................... 10
7 Sound power level..................................... 10
8 Vibrations ................................................... 10
9 Name plate.................................................. 10
10 Quality Control sticker .............................. 10
11 Dimension sheet PFT SILOMAT XXL D ... 11
12 Assembly and functioning:....................... 12
12.1 Overview of the assembly units......... 12
12.2 Carrier SILOMAT XXL D ................... 13
12.3 Compressor / control box SILOMAT
XXL D ................................................ 14
12.4 Overview of the control box SILOMAT
XXL D ................................................ 15
12.5 Operating modes............................... 16
13 Function...................................................... 16
13.1 Brief description................................. 16
13.2 Functional sequence ......................... 16
14 Intended use air compressor.................... 18
14.1 Intended purpose air compressor......18
14.2 Safety systems air compressor .........18
14.3 General positioning of the air
compressor........................................19
14.4 Hot surface of the air compressor ..... 19
15 Transport, packing and storage............... 20
15.1 Safety instructions for transport.........20
15.2 Transport ...........................................21
15.3 Transport inspection ..........................22
15.4 Packaging..........................................22
16 Operation....................................................23
16.1 Safety.................................................23
17 Machine preparations................................24
18 Connecting the power supply 400V.........24
19 Prepare the carrier.....................................25
19.1 Connect the carrier to the silo............25
19.2 Connect the conveying hoses and the
air hoses ............................................ 25
19.3 Laying conveyor lines........................26
20 Connections ...............................................26
21 Opening the silo discharge flap valve .....27
21.1 Hazardous dusts................................28
22 Switching on............................................... 28
22.1 Main switch........................................28
22.2 Conveying process............................28
22.3 Empty alarm of level sensor .............. 29
22.4 Switching off ......................................30
23 Shutdown in case of emergency.............. 30
24 Action in case of power cut......................31
24.1 Establishing a de-energised state .....31
25 Work on troubleshooting .......................... 32
25.1 Reaction in the event of faults ...........32
25.2 Fault displays.....................................32
25.3 Faults.................................................32
25.4 Safety.................................................33

PFT CONVEYING SYSTEM Part 2 Overview – Operation - Spare parts lists
Table of Contents
4
25.5 Table of faults ....................................33
25.6 Work on troubleshooting....................35
26 End of work.................................................36
26.1 End of work or interruption of work....36
26.2 Remove the carrier ............................37
27 Cleaning the conveying system...............37
27.1 Cleaning.............................................37
27.2 Check / clean the dosing shaft...........37
28 Maintenance ...............................................39
28.1 Safety.................................................39
28.2 Maintenance plan...............................41
29 Maintenance work......................................41
29.1 Lubrication .........................................41
30 Clean the filter ............................................42
30.1 Remove the filter cover......................42
30.2 Check the slider width........................43
30.3 Setting values of SILOMAT XXL D....44
31 Monitor the pressure control....................45
31.1 Hand – “0” - Automatic switch............45
32 Actions after completed maintenance.....45
33 Disassembly ...............................................46
33.1 Safety.................................................46
33.2 Disassembly.......................................47
33.3 Disposal .............................................47
34 Spare parts drawing, spare parts list.......48
34.1 Supporting frame trans plus cmpl.
article number 00140428...................48
34.2 Supporting frame trans plus cmpl.
article number 00140428...................49
34.3 Rotary compressor KDT 3.145 T 7.5 /
9 KW article number 00606202 .........50
34.4 Rotary compressor KDT 3.145 T 7.5 /
9 KW article number 00606202 .........51
34.5 Rotary compressor KDT 3.145 T 7.5 /
9 KW article number 00606202 .........52
34.6 Rotary compressor KDT 3.145 T 7.5 /
9 KW article number 00606202 .........53
34.7 Pressure control.................................54
34.8 Pressure control.................................55
34.9 Pressure control.................................56
34.10 Pressure control.................................57
34.11 Control box art. no. 00604695 50Hz,
00604698 60Hz..................................58
34.12 Control box art. no. 00604695 50Hz,
00604698 60Hz..................................59
34.13 Control box art. no. 00604695 50Hz,
00604698 60Hz..................................60
34.14 Control box art. no. 00604695 50Hz,
00604698 60Hz..................................61
34.15 Carrier cmpl. SILOMAT XXL D..........62
34.16 Carrier cmpl. SILOMAT XXL D..........63
34.17 Gear motor SILOMAT XXL D.............64
34.18 Gear motor SILOMAT XXL D.............65
34.19 Carrier cmpl. SILOMAT XXL D..........66
34.20 Carrier cmpl. SILOMAT XXL D..........67
34.21 Carrier cmpl. SILOMAT XXL D..........68
34.22 Carrier cmpl. SILOMAT XXL D..........69
34.23 Connecting piece ventilates SILOMAT
XXL D art. no. 00605864 ...................70
34.24 Connecting piece ventilates SILOMAT
XXL D art. no. 00605864 ...................71
35 Index............................................................74

PFT CONVEYING SYSTEM Part 2 Overview – Operation - Spare parts lists
EC Declaration of Conformity
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2 EC Declaration of Conformity
Company: Knauf PFT GmbH & Co. KG
Einersheimer Straße 53
97346 Iphofen
Germany
declares under our sole responsibility that the machine:
Type of machine: SILOMAT XXL D
Type of equipment: Pneumatic conveying system
Serial number:
Guaranteed sound power level: 101 dB
is in conformity with the following CE directives:
•Outdoor directive (2000/14/EC),
•Machine directive (2006/42/EC),
•Electromagnetic Compatibility Directive (2014/30/EU).
Operative Conformity Assessment according to Outdoor Directive 2000/14/EC:
Internal production control as per article 14 paragraph 2 in connection with annex V.
This declaration only refers to the machine in the state in which it has been placed on the market. Parts
subsequently added by the user and/or subsequent interventions are not covered. This declaration ceases to
be valid if the product is converted or changed without consent.
Person authorised to compile the relevant technical documentation:
(Dipl. in Industrial Engineering, University of Applied Sciences) Michael Duelli, Einersheimer Straße 53,
97346 Iphofen.
The technical documentation is available from:
Knauf PFT GmbH & Co. KG, Technical Department, Einersheimer Straße 53, 97346 Iphofen.
Iphofen, Dr. York Falkenberg
Managing director
Place, Date of issue Name and signature Identification of the signatory

PFT CONVEYING SYSTEM Part 2 Overview – Operation - Spare parts lists
Inspection
6
3 Inspection
3.1 Inspection by machine operator
Prior to each shift, the machine operator has to examine the effectiveness of the
control and safety devices, as well as the proper fitting of the protection devices.
The safe working condition of construction machinery has to be checked by the
machine operator during operation.
If the safety devices show any defects or if any other defects are detected that
compromise a safe operation, the supervisor has to be informed immediately.
In case of defects that cause harm to persons, the operation of the construction
machine has to be stopped to eliminate the defects.
3.2 Periodic inspection
Construction machinery has to be inspected for their safe working condition in
accordance with the operating conditions and the operational requirements as
needed, however at least once a year by an expert.
Pressure vessels have to undergo the prescribed expert inspections.
The inspection results have to be documented and kept at least until the next
inspection.
4 General information
4.1 Information regarding the operating manual
This operating manual gives important information on handling the device. A
prerequisite for safe working is the observance of all stated safety guidelines
and instructions.
Furthermore, the local accident prevention guidelines and general safety
instructions for the application area of the device are to be adhered to.
Read the operating manual thoroughly before starting any work! It is a part of
the product and has to be kept near the tool and easily accessible to the
personnel at all times.
If the tool is given to third parties, also include the operating manual.
The figures in this manual are for presentation purposes of facts, not
necessarily to scale and may slightly differ from the actual model of the device.
4.2 Keep the manual for future reference
The operating manual has to be available during the whole service life of the
product.

PFT CONVEYING SYSTEM Part 2 Overview – Operation - Spare parts lists
Accessories
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4.3 Division
The operating manual is divided into 2 books:
Part 1 Safety
General safety instructions about article number
00132670
Part 2 Overview, operation, service and spare parts lists.
(This book)
For safe operation of the device, both the parts have to be
observed. Together they form one operating manual .
5 Accessories
For recommended accessories/equipment, see PFT machines and device catalogue or under www.pft.net or
at your PFT- construction machinery dealer.

PFT CONVEYING SYSTEM Part 2 Overview – Operation - Spare parts lists
Technical data
8
6 Technical data
6.1 General information
SILOMAT XXL D 50 Hz 00 60 67 58
SILOMAT XXL D 60 Hz 00 60 37 07
Weight of the complete conveying
system
Detail Value Unit
SILOMAT XXL D 50 / 60Hz 366 kg
6.2 Connection values 50 Hz
Electrical details
Detail Value Unit
Voltage 3Ph./ 50Hz 400 V
Power consumption approximately 20 A
Power input 9.2 kW
Connection 32 A
Fuse protection, at least 32A type C
Fig. 1: Motor protection switch
Power Unit Designation
Compressor motor 7.5 kW 16.2 A Q2
Actuator 0.18 kW 0.65 A Q3
Dosing drive 1.1 kW 2.3 A Q4
Control air
compressor 0.15 kW 0.6 A Q5
Vibrating unit 0.2 kW 0.3 A Q6
Detail Value Unit
Length 1150 mm
Width 660 mm
Height 742 mm
Carrier cmpl. 135 kg

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Technical data
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6.3 Connection values 60 Hz
Electrical details
Detail Value Unit
Voltage 3Ph./ 50Hz 400 V
Power consumption approximately 21.7 A
Power input 10.7 kW
Connection 32 A
Fuse protection, at least 32A type C
Fig. 2: Motor protection switch
Power Unit Designation
Compressor motor 9.0 kW 17.9 A Q2
Actuator 0.18 kW 0.65 A Q3
Dosing drive 1.1 kW 2.3 A Q4
Control air
compressor 0.15 kW 0.6 A Q5
Vibrating unit 0.2 kW 0.3 A Q6
6.4 Operating conditions
Environment
Detail Value Unit
Temperature range 2-45 °C
Relative humidity, max. 80 %
Duration
Detail Value Unit
Max. operating time at a stretch 8 hours
6.5 Power values 50 Hz
Detail Value Unit
Pump capacity, approx. at 140m 20 kg/min
Feed range in m* 140 Metre
Operating pressure, max. 2.5 bar
Compressor ventilation system
performance 122
Nm³/h
* Reference value depending on the material quality, material weight and
conveying height

PFT CONVEYING SYSTEM Part 2 Overview – Operation - Spare parts lists
Sound power level
10
6.6 Power values 60 Hz
Detail Value Unit
Pump capacity, approx. at 140m 20 kg/min
Feed range in m* 140 Metre
Operating pressure, max. 2.5 bar
Compressor ventilation system
performance 122
Nm³/h
* Reference value depending on the material quality, material weight and
conveying height
7 Sound power level
Sound power level L WA 101 dB (A)
8 Vibrations
Weighted effective value of acceleration to which the upper body parts are exposed <2.5 m/s²
9 Name plate
Fig. 3: Name plate
The type plate is located on the supporting frame and includes
the following information:
Manufacturer
Type
Year of manufacture
Machine number
10Quality Control sticker
Fig. 4: Quality Control sticker
The following details can be found on the Quality Control sticker:
CE confirmed as per EU directives
Serial no / serial number
Controller / signature
Date of control

PFT CONVEYING SYSTEM Part 2 Overview – Operation - Spare parts lists
Dimension sheet PFT SILOMAT XXL D
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11Dimension sheet PFT SILOMAT XXL D
Fig. 5: Dimension sheet
1410
610
1005
742
1150
660

PFT CONVEYING SYSTEM Part 2 Overview – Operation - Spare parts lists
Assembly and functioning:
12
12Assembly and functioning:
12.1Overview of the assembly units
12 11 10 9 8 7 6 5 4 3
Fig. 6: Table of the assembly groups
1. Conveying air - Bypass
2. Conveying air
3. Air filter
4. Pressure control
5. Air compressor KDT 3.145
6. Main terminal 32A
7. Control box
8. Supporting frame
9. Carrying handle
10. Material hose connection to the cleaning
machine
11. Squeeze valve
12. Carrier
13. Wheel with steel rim
14. Gear motor material dosing
15. Ventilation of the carrier
16. Shut-off unit
17. Actuator
18. Connecting piece
19. Silo discharge flap valve
20. Silo/Container
1
2
20
19
18
17
16
15
14
13

PFT CONVEYING SYSTEM Part 2 Overview – Operation - Spare parts lists
Assembly and functioning:
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12.2Carrier SILOMAT XXL D
1 2 3 4 5
12 11 10 9
Fig. 7: Table of the assembly groups
1. Ventilation of the carrier
2. Additional ventilation for silo/container
3. Fastening screws for Silo/Container
4. Connecting piece
5. Hand-wheel, butterfly valve “Open - Close”
6. Actuator type 6
7. Gear motor material dosing
8. Connection of the Control cable from control
box
9. Power supply from the control box for the gear motor
material dosing
10.Wheel with steel rim
11.Air connection of conveying air
12.Squeeze valve
13.Air connection of control air squeeze valve
14.Air connection of conveying air bypass
15.Material hose connection to the cleaning machine
6
7
8 15
14
13

PFT CONVEYING SYSTEM Part 2 Overview – Operation - Spare parts lists
Assembly and functioning:
14
12.3Compressor / control box SILOMAT XXL D
1 2 3 4 5 6 7 8
17 16 15 14 13
Fig. 8: Compressor / Control box SILOMAT XXL D
1. Solenoid valve for ventilating the carrier
2. Safety valve 4 bar
3. Solenoid valve for squeeze valve
4. Air compressor for control air
5. Pressure switch dosing
6. Blow out the pressure switch conveyor hose
7. Solenoid valve bypass
8. Solenoid valve conveyor line
9. Conveying air - Bypass
10.Conveying air
11.Safety valve 2.2 bar
12.Pre-filter
13.Air compressor KDT 3.145
14.Main terminal 32A
15.CEE-panel mounted socket 4 x 16A for connection of
vibrating unit
16.CEE-panel mounted socket 3 x 16A for requirement of
rotary paddle switch
17.Control box SILOMAT XXL D
18.Carrying handle
19.Supporting frame SILOMAT
9
10
11
12
19
18

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Assembly and functioning:
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12.4Overview of the control box SILOMAT XXL D
7 6 5 4 3
Fig. 9: Description of the control box
1. Master switch is also emergency-stop switch
2. Push button for control voltage “ON/ OFF”
3. Red control lamp, motor protection switch
triggered
4. Control lamp change the direction of rotation
5. Program selection switch of vibrating unit Hand –
“0” - Automatic
6. Power supply from the control box for the gear
motor material dosing
7. Connection of control cable for actuator
8. Main terminal 32A
9. CEE-panel mounted socket 4 x 16A for
connection of vibrating unit
10.CEE-panel mounted socket 3 x 16A for
requirement of rotary paddle switch
1
2
10
9
8

PFT CONVEYING SYSTEM Part 2 Overview – Operation - Spare parts lists
Function
16
12.5Operating modes
Fig. 10: Operating modes of air
compressor
The air compressor can be operated in two different operating modes:
AUTOMATIC (right)
The air compressor operates if the rotary paddle switch requires material.
MANUAL (left)
The air compressor operates in the continuous mode in the “Hand”
setting.
The air compressor is switched off at the middle position.
13 Function
13.1Brief description
The conveying system PFT SILOMATXXL D is a pneumatic, fully automatic conveyor system and it takes
over the material transport of premixed dry mortar from the silo / container to the cleaning machine.
13.2 Functional sequence
When starting up the system, the control air compressor starts and fills both the compressed air tanks
with control air (4 bar).
Turn the hand – “0” – automatic switch to the Automatic position.
The plaster machine conveys the material using the level sensor in the material hopper of the plaster
machine. The indication of the level sensor is conveyed to the control box of the pneumatic conveying
system.
The squeeze valve is closed by the material requirement at the outlet of the carrier and the squeeze valve
is simultaneously opened at the upper side of the carrier, so that the carrier is ventilated when being filled
with dry material. The conveying air is discharged into the silo. However, it would also be conceivable that
the air is discharged into the atmosphere through a filter.
The silo outlet valve opens for approx. 10 seconds thereby starting the vibrating unit on the silo at a pulse
interval.
The silo outlet valve is closed and the vibration process is ended after the carrier has been filled with
approx. 65 ltr. volume.
The squeeze valve at the outlet of the carrier is opened thereby closing the squeeze valve at the upper
side of the carrier.

PFT CONVEYING SYSTEM Part 2 Overview – Operation - Spare parts lists
Function
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Conveying cycle:
The conveying air is now converted from the bypass air to the conveying air so that the material is
fluidised right at the end of the metering worm. The metering worm starts conveying the dry material to
the conveyor hose with a delay of 3 seconds.
The conveyor line is monitored by a pressure switch (S3). If the pressure in the conveyor line increases
above 1.8 bar, the metering worm is stopped and only the conveying air is blown into the conveyor line till
the pressure drops to 1.5 bar. Is the pressure drops to 1.5 bar, the metering worm starts again.
Advantage:
The conveying air compressor is discharged by switching off the screw conveyor (= material feed),
because the line is blown out and no new dry material is added. Thus, the formation of blockages is
effectively prevented. This helps to exclude the possibility of overheating or overloading of the conveying
air compressor.
As long as the material requirement of the plaster machine exists, the carrier is filled every 150 seconds.
During the filling process, the squeeze valve is closed at the outlet of the carrier and the conveying air is
changed over to the bypass thereby avoiding interrupting the conveying process. If the carrier is filled, the
bypass air is changed back to the conveying air.
The conveying cycle operates as long as the level sensor in the plaster machine indicates that the
material hopper is full. The last conveying cycle is still continued till the carrier is empty. The compressor
and the screw conveyor now operate as long as the pressure in the conveying line has dropped below 0.8
bar.
The screw conveyor and the squeeze valve is closed at the outlet of the carrier.
If another material requirement arises during blow-out, then the blow-out process is interrupted and the
conveying cycle is started afresh.
The new fact about this type of pneumatic conveying is that the dry material is added to the conveying
line through the metering worm. If the backpressure is too high, it can help to effectively prevent the
formation of blockages.
The amount of dry material to be added can be controlled by the pitch of the metering worm. This system
has proved successful for materials that are difficult to convey. Higher the density (= bulk weight) of a dry
material, heavier it is to convey pneumatically. The pneumatic conveying becomes difficult from a bulk
weight of 1.3 KG/dm³ onwards.
Without the metered addition of the dry material to the conveying line, the material would tend to form
blockages in the next bottleneck because the heavy material cannot be compressed.

PFT CONVEYING SYSTEM Part 2 Overview – Operation - Spare parts lists
Intended use air compressor
18
14Intended use air compressor
14.1Intended purpose air compressor
The tool is conceptualised and designed exclusively for the
purpose of use specified here.
Attention!
The air compressor is intended exclusively for the
generation of compressed air and is to be used with
connected implement. Any other use or use beyond what
is specified, such as with freely accessible and/or open
hoses and pipelines, is deemed to be not for the intended
purpose. Connected implements or components are to be
designed for the maximum generated pressure of 2.5 bar.
The air compressor is to be used only in technically
perfect condition, as well as for its intended use and while
taking into account the safety and hazard information in
the operating instructions!
Particularly malfunctions that may compromise safety
have to be eliminated immediately prior to putting the
compressor back into operation.
14.2Safety systems air compressor
WARNING!
Danger to life due to non-functioning safety
equipment!
Safety equipment ensures highest level of safety in
operation. Even if work processes become a little more
complicated due to safety equipment, they must never be
decommissioned. The safety is guaranteed only with
intact safety equipment.
Therefore:
Before starting work, check if the safety equipment is
functioning properly and has been correctly installed.
Use safety equipment at all times.
Do not obstruct access to safety systems such as
emergency stop buttons, pull cords etc.

PFT CONVEYING SYSTEM Part 2 Overview – Operation - Spare parts lists
Intended use air compressor
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14.3General positioning of the air compressor
The air compressor complies with the national and international safety
regulations and can therefore also be used in damp rooms and/or
outdoors. Areas with clean and dry air should be preferred. Ensure that the
device can freely suck in the air. This applies in particular if an installation
is intended.
The air compressor should only be set up in such a way that no dangerous
additives, such as solvents, vapours, dusts or other harmful substances
can be sucked in. The device should be positioned only in rooms where the
hazard of a potentially explosive atmosphere is not given.
The specifications are applicable up to a height of 800 m above sea level.
14.4Hot surface of the air compressor
General information
WARNING!
Danger of injury due to hot surface!
During operation the compressor can reach a surface
temperature of up to 100 °C. Therefore, it has to be
ensured that the device does not get into contact with bare
body parts during use as well as for some time after use,
in relation to the heating temperature.

PFT CONVEYING SYSTEM Part 2 Overview – Operation - Spare parts lists
Transport, packing and storage
20
15Transport, packing and storage
15.1Safety instructions for transport
Improper transport
ATTENTION!
Damage from improper transport!
Improper transport may cause substantial property
damage.
Therefore:
When unloading the packages on delivery, as well as
transport within the company, pay attention and
observe the symbols and instruction on the package.
Use only the specified anchorage points.
Remove packaging only shortly before the assembly.
Suspended loads
WARNING!
Danger to life from suspended loads!
When lifting heavy loads, there is danger to life from falling
parts or uncontrolled swinging parts.
Therefore:
Never step under suspended loads.
Observe the instructions regarding the provided
anchorage points and ensure safe fit of the sling gear.
Do not fix to projecting machine parts or eyelets of
attached components.
Use only approved lifting gear and sling gear with
sufficient lifting capacity.
Do not rest ropes and belts at sharp edges and corners,
do not knot or twist.