PFT SILOMAT E User manual

OPERATING INSTRUCTIONS
( Item number of the operating instructions 00 07 36 12)
(Item number of the machine 00 04 40 86)
PNEUMATIC CONVEYING SYSTEM
PFT SILOMAT E
WE KEEP THINGS MOVING

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PFT SILOMAT E 1
General 10.2005
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Knauf PFT GmbH & Co.KG Telephone 09323 / 31-760
Postfach 60 Telefax 09323 / 31-770
D-97343 Iphofen Internet www.pft.de
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Dear PFT Customer,
Congratulations on your purchase. You have made a wise choice, because you ap-
preciate the quality of a brand from a company with a name that has exemplified qual-
ity.
The Pneumatic Conveying System PFT SILOMAT E uses state-of-the-art technology.
It was designed in a task-optimized way so that it can be a trustworthy aid for rough
construction site conditions.
These operating instructions should always be stored and kept at hand at the ma-
chine’s application site. They give you information on the various functions of the sys-
tem. Study the operating instructions thoroughly before starting up the machine, as we
claim no responsibility for accidents or damage to the machine caused by incorrect
operation.
The Pneumatic Conveying System PFT SILOMAT E will be a trustworthy aid, if it is
operated correctly and handled with care.
It is prohibited to forward this document, even excerpts, without written authorization
by us. All technical specifications, diagrams etc. are subject to copyright protection. All
rights, errors and modifications reserved.
Two versions of the Pneumatic Conveying System PFT SILOMAT E are available:
a carryable and a rollable version.
They comply with the strict safety regulations of the German Builder’s Guild (BBG)
and were technically approved, which is confirmed by the respective test symbol.
It is prohibited to forward this document, even excerpts, without written authorization
by us. All technical specifications, diagrams etc. are subject to copyright protection. All
rights, errors and modifications reserved.
© by Knauf PFT GmbH & Co. KG

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PFT SILOMAT E 2
General 10.2005
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Knauf PFT GmbH & Co.KG Telephone 09323 / 31-760
Postfach 60 Telefax 09323 / 31-770
D-97343 Iphofen Internet www.pft.de
_______________________________________________________________________________________
Initial inspection after delivery
An indispensable task of all technicians delivering the Pneumatic Conveying system
PFT SILOMAT E is the inspection of the machine settings at the end of the first con-
veying cycle. The factory settings can be changed during the first operation. If these
changes are not corrected in time, immediately after run-in, then operating trouble can
be expected.
After putting the Pneumatic Conveying System PFT SILOMAT E into service and
giving appropriate instructions, after about two hours, the technician must always
carry out the following checks / settings:
1. Pressure control
2. Level sensor
3. Connection cable
4. Fuses
5. Plug connections

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PFT SILOMAT E 3
Table of Contents 10.2005
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Knauf PFT GmbH & Co.KG Telephone 09323 / 31-760
Postfach 60 Telefax 09323 / 31-770
D-97343 Iphofen Internet www.pft.de
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General ...............................................................................................................................................................1
Table of Contents ...............................................................................................................................................3
Overview.............................................................................................................................................................4
Overview Control Box.........................................................................................................................................5
Connection and Functionality of the System ......................................................................................................6
Description of Functions .....................................................................................................................................7
Basic Safety Instructions ....................................................................................................................................8
Setting Values...................................................................................................................................................10
Starting up ........................................................................................................................................................11
Measures at the End of Work or During Interruptions......................................................................................13
Clearing hose blocks ........................................................................................................................................13
Check List .........................................................................................................................................................14
Maintenance .....................................................................................................................................................16
Transport ..........................................................................................................................................................19
Accessories ......................................................................................................................................................20
Spare Parts Lists ..............................................................................................................................................21
Circuit Diagrams ...............................................................................................................................................22
Technical Data..................................................................................................................................................36

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PFT SILOMAT E 4
Overview 10.2005
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Knauf PFT GmbH & Co.KG Telephone 09323 / 31-760
Postfach 60 Telefax 09323 / 31-770
D-97343 Iphofen Internet www.pft.de
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1 Vibrator 7 Compressor
2 Silo / container 8 Carrying handle
3 Intermediate piece for conveying container 9 Three phases motor for compressor
4 Bypass for conveying container 10 Control box
5 Conveying container 11 Carryable frame
6 Air manifold with air safety switch

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PFT SILOMAT E 4
Overview 10.2005
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_______________________________________________________________________________________
Knauf PFT GmbH & Co.KG Telephone 09323 / 31-760
Postfach 60 Telefax 09323 / 31-770
D-97343 Iphofen Internet www.pft.de
_______________________________________________________________________________________

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PFT SILOMAT E 6
Connection and Functionality of the System 10.2005
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Knauf PFT GmbH & Co.KG Telephone 09323 / 31-760
Postfach 60 Telefax 09323 / 31-770
D-97343 Iphofen Internet www.pft.de
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1 Rotary switch hand 0 automatic 6 Socket white, CEE 3x16 A for level sensor
2 Pressure switch red “Operation OFF” 7 Earthling outlet continuous current 220 V
3 Illuminated pressure button green
“Operation ON”
8 Socket red, CEE 4x16 A for vibrator
4 Control lamp red “Fault” 9 Connection cable with plug 10-pin for motor and drive
5 Main reversing switch 10 Main power supply CEE 5x32 A

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PFT SILOMAT E 6
Connection and Functionality of the System 10.2005
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Knauf PFT GmbH & Co.KG Telephone 09323 / 31-760
Postfach 60 Telefax 09323 / 31-770
D-97343 Iphofen Internet www.pft.de
_______________________________________________________________________________________
1 Connection control box – level sensor 4 Connection control box motor and drive
2 Connection conveying container – cleaning machine 5 Connection worksite power control box
3 Connection compressor – conveying container 6 Connection control box – vibrator

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PFT SILOMAT E 7
Description of Functions 10.2005
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_______________________________________________________________________________________
Knauf PFT GmbH & Co.KG Telephone 09323 / 31-760
Postfach 60 Telefax 09323 / 31-770
D-97343 Iphofen Internet www.pft.de
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The conveying system PFT SILOMAT E is a pneumatic, fully automatic conveying
system for transporting ready-mix dry mortar from the silo / container to the cleaning
machine.
Please observe the processing guidelines of the material manufacturer.
The machine consists of carryable single components of small, handy dimensions and
light weight that allow fast, convenient transport.
The following aspects must be observed for operation:
1. Connection worksite power – control box
2. Connection control box – level sensor
3. Connection control box – motor and drive
4. Connection control box – vibrator
5. Connection compressor – conveying container
6. Connection conveying container – cleaning machine
Operating sequence
When the level sensor of the cleaning machine reports “Empty”, the flap opens
(“Open” position) and the conveying container is filled with approx. 55 l of dry mortar
while the silo butterfly valve is open. The vibrator runs at the same time, to support the
flow of mortar from the silo / container.
When the fill time has passed, the flap closes again (“Closed” position). The convey-
ing container is now sealed pressure-tight to the silo / container.
Now the compressor begins to work and blows air through the emulgator filter into the
conveying container. In this way, the mortar is aerated and pressed through the ex-
traction connection of the conveying container into the conveying line and on to the
cleaning machine. Pressure is built up in the conveying line that is monitored with a
safety switch. If it falls below a set value, that means that conveying container and line
are empty. The system completes the conveying cycle and shuts down. As soon as
there is a new signal by the level sensor at the control box of the SILOMAT unit, a
new conveying cycle is started.
The distribution of air can be controlled by hand using the bypass at the conveying
container. In this way the system can be adapted, depending on the mortar (specific
weight).

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PFT SILOMAT E 8
Basic Safety Instructions 10.2005
____________________________________________________________________________________________________________
_______________________________________________________________________________________
Knauf PFT GmbH & Co.KG Telephone 09323 / 31-760
Postfach 60 Telefax 09323 / 31-770
D-97343 Iphofen Internet www.pft.de
_______________________________________________________________________________________
The following terms and symbols are used in this manual for particularly important
information:
NOTE:
Special information for running the machine efficiently.
WARNING!
Precautionary information for preventing accidents.
WARNING!
The machine should only be used if it is in technically perfect condition and in compli-
ance with the regulations. Pay attention to safety and the operating instructions. It is
especially important to immediately rectify all faults which could impair safety. Proper
machine operation includes following the instructions in the operating manual and
complying with the inspection and maintenance conditions.
In order to make operating our machines as easy as possible for you, we would like to
briefly inform you of the most important safety regulations. Compliance with these
instructions will enable you to obtain long-lasting quality service from our machine.

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PFT SILOMAT E 9
Basic Safety Instructions 10.2005
____________________________________________________________________________________________________________
_______________________________________________________________________________________
Knauf PFT GmbH & Co.KG Telephone 09323 / 31-760
Postfach 60 Telefax 09323 / 31-770
D-97343 Iphofen Internet www.pft.de
_______________________________________________________________________________________
1. Follow all safety instructions on the machine. Ensure that all instructions are legible!
2. Inspect the machine for visible damage and defects at least once every shift! If you notice
any safety-threatening alterations to the machine or its operating behavior, stop the ma-
chine immediately and notify your supervisor!
3. Do not attempt to modify the machine in any way which may impair its safety without first
consulting your machine dealer! This also applies to the installation of unchecked "safety
devices"!
4. All spare parts must comply with the technical requirements of the manufacturer. This is
guarantied for all original PFT parts!
5. Only trained or authorized personnel should operate the machine. Clearly define all lines
of responsibility for operation, equipping, service and maintenance!
6. Personnel undergoing training should only be allowed to operate the machine under su-
pervision of experienced personnel!
7. All electrical work should be carried out by a qualified electrician or by trained personnel
under the supervision of a qualified electrician and should comply with electro-technical
regulations.
8. Observe all instructions for turning the machine on and off. Watch control lamps for sig-
nals.
9. When the machine is completely switched off for maintenance and repair work, ensure
that it cannot be switched back on accidentally (for example, lock the main switch and
remove the key, or attach a warning sign to the main switch).
10. Before cleaning the machine with a water jet, seal all openings through which water could
enter, thereby impairing the safety and proper functioning of the machine (electric motors
and control boxes). After cleaning, remove all covers.
11. Only use original fuses with prescribed amps!
12. If work must be carried out on voltage-carrying parts, a second technician should stand
by to switch off the mains in case of emergency.
13. Disconnect the machine from any external energy source before you relocate it, even if
you are only moving it a short distance. Reconnect the machine to the mains properly be-
fore starting it up again.
14. Set up the machine on stable ground and secure it against unintentional movements.
15. Lay out the conveying lines safely. Do not rest them on sharp edges!
16. Depressurize all conveying systems before opening conveying lines!
17. When unclogging hoses, stand away from the machine to avoid injury through high-
pressure discharges of mortar. Always wear safety goggles. No other persons should be
near the machine during this procedure!
18. If the permanent noise level exceeds 85 dB(A), appropriate noise protection devices
must be provided.
19. If necessary, wear the following protective clothing while spraying: Safety goggles, safety
shoes, safety clothing, gloves, protective skin cream and respirator mask.
20. If required, have the machine inspected by a qualified person. This should however
happen at least once a year.

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PFT SILOMAT E 10
Setting Values 10.2005
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_______________________________________________________________________________________
Knauf PFT GmbH & Co.KG Telephone 09323 / 31-760
Postfach 60 Telefax 09323 / 31-770
D-97343 Iphofen Internet www.pft.de
_______________________________________________________________________________________
Relay
Function Designation Setting value
Requirement K2 3 sec.
Fill time K5 6 sec.
Transport time K8 18 sec.
Air pressure safety switches
0.8 bar switch on machine
0.5 bar switch off machine
Motor safety switch compressor motor
5.5 kW motor 400 V, 11.5 A
7.5 kW motor 400 V; 16 A
Oil level compressor
The oil level of the compressor must be between the two oil control glasses.
Hand 0 automatic switch
Hand in this position, the compressor runs continuously and can be used for blowing
out the conveying line and for venting the silo.
0System isn’t running.
Automatic in this position, the system runs automatically.
Vibrator socket
The vibrator runs automatically in the course of filling.
K8
K2
K5

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PFT SILOMAT E 11
Starting up 10.2005
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_______________________________________________________________________________________
Knauf PFT GmbH & Co.KG Telephone 09323 / 31-760
Postfach 60 Telefax 09323 / 31-770
D-97343 Iphofen Internet www.pft.de
_______________________________________________________________________________________
Before starting up
WARNING!
The functionality of the pressure relief unit of the silo / container must be checked
each
time before work is started.
SILOMAT systems for free fall silos may only be connected to unpressurized silos /
containers. The dust removal lines of the silo / container must be open und unclogged.
Starting up
Set up compressor horizontally.
Check oil level.
Connect conveying container to silo outlet valve.
Connect the 10-pin control cable of the control box to the servo motor of the flap.
The level sensor (2) is connected to the panel mounted socket of the control box (3)
with the control cable (1).
Now connect the SILOMAT system with a PFT power cable 5 x 4 mm² item
no. 20 42 39 00 or 20 42 39 20 to a worksite switchgear assembly as per VDE with
approved FI safety switch 30 mA.
To avoid condensation water in the system, prior to starting work:
-Disconnect air hose from the compressor at the conveying container.
-Switch on compressor, in doing so observe direction of rotation: Air must escape at
the fast coupling (remove rubber hose). If the direction of rotation is incorrect, turn
the main reversing switch to zero position. Push the direction plate to the opposite
side and set the main switch for the other direction.
-You have now changed the direction of rotation. Let it run for approx. 5-10 minutes.
While this is happening, kink the hose several times, relieving it again after a short
pressure build-up.
-Repeat the procedure until no more water spray emerges from the hose.
-Switch off the system using the red pressure switch “OFF”.
Now connect the rubber air hose to compressor and conveying container and lay out
the conveying line between cleaning machine and conveying container outlet.
To ensure an optimum working procedure of the system for long transport distances,
the conveying line should not only be laid out flatly.
We therefore recommend that you create raises, e.g. at the hose coupling e.g. by
pallets set up on edge.

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PFT SILOMAT E 12
Starting up 10.2005
____________________________________________________________________________________________________________
_______________________________________________________________________________________
Knauf PFT GmbH & Co.KG Telephone 09323 / 31-760
Postfach 60 Telefax 09323 / 31-770
D-97343 Iphofen Internet www.pft.de
_______________________________________________________________________________________
WARNING!
In the case of a power failure, the system must be re-started.
WARNING!
When Silomat systems are in operation, the dust removal lines of the silo / container
must be open.
Now open silo outlet valve.
Turn Hand-0 automatic switch (1) to automatic position and press green operating
switch “ON” (2).
As soon as the level sensor reports “EMPTY”:
-the locking flap opens and during the set fill time
-the conveying container is filled with approx. 55 l dry mortar.
-the vibrator runs at the same time if the cable connection is established.
-the locking flap closes after the fill time has passed and the compressor starts
-after the transport time has passed and when the pressure has dropped to below
0.6 bar (if the hose is empty) it shuts down by itself.
-The system waits for a new signal to repeat the conveying cycle for the fully auto-
matic supply of the cleaning machine
NOTE
For material that is not easy to transport (e.g. external plaster), the conveying air must
be set to an optimum using the taps.
By slightly opening the tap leading upwards, part of the air is guided to the outlet of
the conveying container (bypass system) and supports the transport of the mortar.
Rule of thumb:
The heavier the material, the more the tap leading upwards must be opened.
1 2

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PFT SILOMAT E 13
Measures at the End of Work or During Interruptions 10.2005
____________________________________________________________________________________________________________
_______________________________________________________________________________________
Knauf PFT GmbH & Co.KG Telephone 09323 / 31-760
Postfach 60 Telefax 09323 / 31-770
D-97343 Iphofen Internet www.pft.de
_______________________________________________________________________________________
Measures at the end of work or during interruptions
- Switch off the system by pressing the red pressure switch (1) “OFF”.
- Turn hand-0 automatic switch (2) to position “0”.
- Turn main reversing switch (3) to position “0”.
- Disconnect electrical cables and hoses.
Clearing hose blocks
WARNING!
Prior to all work on the SILOMAT E system, the system must first be depressurized
and free of voltage.
Depressurizing
a) Turn the main reversing switch (2) to position “0”.
b) By turning the hand wheel, the locking flap of motor and drive is opened slightly so
that the silo / container is relieved of pressure.
c) Close locking flap again.
Freeing the system of voltage
Turn the main reversing switch (2) to position “0”.
For work on the control box, the power supply must be interrupted by removing the
connection cable.
WARNING!
In accordance with the safety regulations of the Builder’s Guild, all personnel clearing
hoses should wear safety goggles and should position themselves in such a way as to
avoid injury through discharged material. No other persons should be near the ma-
chine.
Clearing hose blocks:
-Depressurize system and free system of voltage (see above).
-Disconnect conveying hoses in the vicinity the blocked part.
-Shake the hose and hit the coupling on a soft surface (wood or similar) to loosen
the blocking material and remove it from the hose.
-Then reconnect the conveying hoses and make the system ready for operation.
-Start system at position HAND and let compressor run until the hose is blown free
-Then switch back to automatic operation.
1
2
3

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PFT SILOMAT E 14
Check List 10.2005
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_______________________________________________________________________________________
Knauf PFT GmbH & Co.KG Telephone 09323 / 31-760
Postfach 60 Telefax 09323 / 31-770
D-97343 Iphofen Internet www.pft.de
_______________________________________________________________________________________
How can problems with the PFT SILOMAT E be avoided or quickly rectified?
Fault Cause Remedy
High pressure valve blows
down
Fault in the air / conveying line
Clogging
Check line
See page 13
Clean emulgator filter
Check K5
Check locking flap
Check pressure control
Fault in sequence program Motor, Motor cable, Motor protection
switch or end switch at motor and
drive defective
Replace defective parts
Clogging Fill time set too high
Conveying line laid out incorrectly
End switch misadjusted
Pressure control misadjusted
Locking flap defective
Locking flap doesn’t close
Check K5
See description of pressure control
Replace
Observe display, readjust control
disc
Program is running, com-
pressor is not
Cable, motor protection switch, motor
defective
End switch at motor and drive defec-
tive
Replace end switch,
readjust
Compressor is always run-
ning
Hand-0 automatic switch is at hand
position
Emulgator filter is clogged
Conveying line kinked, clogged
Conveying relay defective
Material clumps in conveying con-
tainer outlet
Cable defective
End switch at motor and drive defec-
tive
Filter hoses at the cleaning machine
dirty or stuck
Switch to automatic
See page 16 Cleaning
Replace conveyor relay K8
See page 16
Clean emulgator filter
Replace end switch
Beat filter, if required replace
Program isn’t running Fine fuse on transformer defective
Control cable level sensor
Hand-0 automatic switch defective
Fill time (K5), conveying time (K8) or
retardment (K2) defective
End switch at motor and drive
defective or misadjusted
Replace fine fuse
Replace
Replace
Check parts, if required replace
Replace end switch or
readjust

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PFT SILOMAT E 15
Check List 10.2005
____________________________________________________________________________________________________________
_______________________________________________________________________________________
Knauf PFT GmbH & Co.KG Telephone 09323 / 31-760
Postfach 60 Telefax 09323 / 31-770
D-97343 Iphofen Internet www.pft.de
_______________________________________________________________________________________
Compressor gets too hot Fan for compressor clotted, air wheel
defective, air intake blocked
Contaminated oil
Air filter clotted
Clean
Oil level see page 18
Clean see page 18

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PFT SILOMAT E 16
Check List 10.2005
____________________________________________________________________________________________________________
_______________________________________________________________________________________
Knauf PFT GmbH & Co.KG Telephone 09323 / 31-760
Postfach 60 Telefax 09323 / 31-770
D-97343 Iphofen Internet www.pft.de
_______________________________________________________________________________________
Fault Cause Remedy
Flap opens and doesn’t
close any more
End switch at motor and drive defective
or misadjusted
Automatic plumb level (K6) FLAP
CLOSED defective
Fill time (K5) faulty
Replace or readjust end switch
Replace end K6
Replace K5
Not enough material in the
machine
Material does not flow out of the silo
Container flap is closed
Level sensor too long
Fill time set too short
Emulgator filter clogged
Fault in sequence program
Connect vibrator
Open container flap
Attach rotating wing at higher
position
Check K5
Clean see page 18
Red fault lamp lights up Fault in sequence program, possibly
due to foreign body at or near the flap
Motor safety switch activated
Relieve motor and drive
Remove foreign body
Press motor safety switch
Motor and drive possibly overloaded

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PFT SILOMAT E 17
Maintenance 10.2005
____________________________________________________________________________________________________________
_______________________________________________________________________________________
Knauf PFT GmbH & Co.KG Telephone 09323 / 31-760
Postfach 60 Telefax 09323 / 31-770
D-97343 Iphofen Internet www.pft.de
_______________________________________________________________________________________
MAINTENANCE
WARNING!
Do not clean system with steam sprayer or high-pressure cleaner.
Clean emulgator filter
The emulgator filters must be cleaned every 14 days.
To clean the emulgator filters, proceed as follows:
Cut off power to the system by turning the main reversing switch to “0”.
Observe the pressure display at the compressor!
Check if pressure hose is without pressure.
Pressure display is at “0”.
Motor and drive by turning hand wheel to position “FLAP CLOSED”
Close silo/container flap.
Turn hand-0 automatic switch (2) to position “HAND”
Turn main reversing switch (3) to position “I”.
Press operating switch (1) “ON”.
Blow conveying container empty.
Turn main reversing switch (3) to position “0”.
2
3
1