ProTec Polymer Processing FG 20 Series User manual

FG 20x conveyors
with control system SOMOS®control-basic
Operating Manual
Technical customer service
T [phone]
F [phone]
[email protected]
ProTec Polymer Processing GmbH
Stubenwald-Allee 9
64625 Bensheim
Germany
T [phone]
F+49 6251 77061-500
[e-mail]
www.sp-protec.com

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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

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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

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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

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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).

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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.
1
Device description and series
2
Consecutive serial number and year of manufacture
3
Component number/ order number / possible
position number in the order
4
Data on power connection

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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.

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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!
Follow
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.

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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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2.3.2 Special operating modes
Comply with settings, service and inspection activities and intervals including information on
replacing parts / subassemblies specified in the operating manual. These activities must
only be performed by specialist authorised personnel.
Inform operating personnel before starting to perform special and maintenance work! Name
supervisors!
Ensure that the maintenance area is as adequately secured as necessary! If the system is
completely switched off during maintenance and repair work it must be secured against
restart:
Lock the main command device and pull out the key
Attach a warning sign on the main switch
Always tighten any loosened screwed connections during maintenance and repair work!
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 assemblies must be carefully fastened and secured on hoisting gear
during replacement, so that no hazards occur here. Use only suitable and technically
correct hoisting devices and load attachment devices with sufficient load carrying capacity!
Do not stand or work under swinging loads!
When performing installation work above body height use ascending aids and work
platforms provided for this or other safety-related ones. Do not use system parts as
ascending aid! Wear fall protection when working at great heights!
Keep all handles, steps, railings, pedestals, platforms, ladders, etc. free of dirt!
Clean the systems, and especially here connections and screwed joints, before starting
maintenance/repair of oil, fuel or cleaning materials! Do not use any aggressive cleaning
agents! Use lint-free cleaning cloths!

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2.4 Instructions for special types of risks
2.4.1 Electrical energy
Only use original fuses with specific current rating! For faults in the electrical supply, switch
off the system immediately!
Working on electrical equipment or operating equipment must only be done by an
electrician or trained persons under the guidance and supervision of an electrician
according to the electrotechnical regulations.
The power to system parts, on which inspection, service 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 parts!
The electrical equipment of the system must be inspected and checked regularly. Defects
such as loose connections or scorched cables must be rectified immediately.
If work is required on live parts, a second person who can activate the emergency- off- or
main switch in case of emergency needs to get involved. Block off the work area with a red
and white safety chain and a warning sign. Only use voltage insulated tools.
2.5 Declaration of Conformity
The Declaration of Conformity must be presented in both German and English.

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3 Technical Data and Structure
3.1 Conveyor / station designation key
Conveyor / station designation key
FG
2
0
4.
1/
2
1
C
FG = Conveyor / station
Product
ZF = Central filter
FGG = Conveyors for gravimetric dosing unit
(without floor flap)
FG3- = Conveyor installed from ∅315 to ∅200
FG 2K = 2-component conveyor/station
2 = 200 (∅conveyed goods container 200 mm)
Size
0 = Conveyor with blower, central filter installed
Unit type
2 = Conveyor station with filter cartridge cleaning with
circulating air with microcontroller control system for
separate 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
compressed air)
6 = Filter element 1.5 m2 with cleaning (circulating or
compressed air)
0 = For separately installed blower station
Blowers
1 = Installed blower (50/60 Hz) 0.8 kW
Material conveyed goods container
1 = PA, low / FGG
2 = PA, high
3 = VA, FGG
4 = VA, high
5 = VA, FGG HG2
6 = VA high HG
0 = Without controls / connection box / terminal box
Electrical design
1 = Microcontroller control system
5 = Terminal box
6 = Plug connection:
A = Murr plug connection- (custom)
B = M12-Y plug connection- (custom)
Plug connection system - design
C = Phönix plug connection
HM = Solenoid
HZ = Lift cylinder
HG2 = Hot granulate max. 150° C
(Normal temperature max. 80°C)

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3.2 Dimensional drawing FG 201 to FG 204

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3.2.1 Dimensions
H1 with/without volume expansion 550 / 750 mm
H3 (for filter change) < 200 mm
h1 with/without volume expansion 210 / 410 mm
d1 38 mm
d1 with volume expansion VA 38 or 55 mm
3.2.2 Electrical data
Mains connection 1/N PE AC 50/60Hz 230V
Blower rated output 800 W
Current consumption 4 A
Protection class IP 20
3.2.3 Environmental requirements
Max. Temperature for conveyed material +80 °C
Max. Ambient temperature in operation +5°c … +40°C
Rel. Humidity < 80 %
Noise 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 Noise emissions < 80 dB (A)
3.2.6 Options
Volume expansion Stainless steel / PA
Dosing attachment Stainless steel
Filling level indicator Capacitive
3.2.7 Weight
Conveyor without options
FG 201 8.4 kg
FG 204 9.7 kg
For automatic cleaning of the conveying air filter
Compressed air supply
3.2.8 Compressed air
For automatic cleaning of the conveying
air filter
compressed air supply
Excess pressure 4 … 6 bar
Compressed air connection PK 8
Compressed air consumption 3 net litres / conveying cycle
1) Standard design not suitable for use with food!

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3.3 Dimensional drawing FG 205 to FG 206
FG 205 without options
FG 206 without options

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3.3.1 Dimensions
FG 205
H1 with/without volume expansion: 585 / 785 mm
H3 (for filter change) min. 200 mm
FG 206
H1 with/without volume expansion 785 / 985 mm
H3 (for filter change) min. 400 mm
FG 205.x/3x
H1 without volume expansion 515 mm
H1 with volume expansion 775 mm
H3 (for filter change) min. 200 mm
FG 206.x/3x
H1 without volume expansion 715 mm
H1 with volume expansion 975 mm
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 / 410 mm
d1 38 mm
d1 with volume expansion VA 38 or 55 mm
FG 206.x/4x
H1 without volume expansion 775 mm
H1 with volume expansion 1,035 mm
H3 (for filter change) min. 400 mm
FG 205 and FG 206
h1 with/without volume expansion 180 / 380 mm
d1 38 mm
d1 with volume expansion VA 38 or 55 mm
3.3.2 Electrical data
Mains connection 1/N PE AC 50/60Hz 230V
Blower rated output 800 W
Control magnet rated output 400 VA
Current consumption 4 A
Protection class IP 20

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3.3.3 Environmental requirements
Max. Temperature for conveyed material +80 °c
Max. Ambient temp. of operation +5 … +50 °c
Rel. Humidity: < 80 %
3.3.4 Materials
Filter 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 Stainless steel / PA
Dosing attachment Stainless steel
Filling level indicator Capacitive
3.3.7 Weight of conveyor without options
FG 205 12.3 kg
FG 206 14.2 kg
3.3.8 Compressed air
Operating pressure 4 to 6 bar, ideal 5 bar

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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
7
Check valve
8
Compressed air connection
8
7
4
3
2
6
5
1

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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
Check valve
8
Compressed air connection
8
2
3
1
4
5
7
6