Simar FX 2004 Technical manual

Item no: 5080120_GB
Edition : 2/11
File : J:\Wamser\FX2504_GB
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SIMAR GmbH
Am Fuchsloch 7 D-71665 Vaihingen/Enz
07042/903 0 Fax: [phone]
Operation Instruction FX 2004
Hopper loader FX 2504
6/14

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Index
1 Safety................................................................................................ 3
1.1 Correct Usage ...........................................................................................................3
1.2 Safety Markings.........................................................................................................3
1.3 Safety Information .....................................................................................................4
1.4 Protective Measures..................................................................................................5
1.5 Residual Hazards ......................................................................................................6
1.6 Requirements on personnel and duty of care ............................................................6
2 Transport.......................................................................................... 7
3 Commissioning................................................................................ 8
3.1 Feeding hose.............................................................................................................9
3.2 Flap ...........................................................................................................................9
3.3 Connection FX- controller to EKO - blow unit...........................................................10
4 Technical Data ............................................................................... 11
5 Trouble shooting............................................................................ 12
6 Maintenance ................................................................................... 13
6.1 Safety Information for Maintenance and Repairs .....................................................13
6.2 Filter cleaning..........................................................................................................13
6.3 Electronic control unit ..............................................................................................14
7 Dismantling and Disposal ............................................................. 14
8 Accessories.................................................................................... 15
8.1 Mixing valve.............................................................................................................15
8.2 Clean out valve........................................................................................................17
9 Connecting terminal control unit FX ............................................ 18
10 Dimension sheet ............................................................................ 19
10.1 Dimension sheet FX 2004 .......................................................................................19
10.2 Dimension sheet FX 2504 .......................................................................................20
11 Spare parts..................................................................................... 21
11.1 Spare parts FX 2004 ...............................................................................................21
11.2 Spare parts FX 2504 ..............................................................................................23
12 Operating the Controller................................................................ 25
13 Declaration of Conformity............................................................. 26

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1 Safety
1.1 Correct Usage
Pneumatic feeding of plastic granules or other dry bulk materials.
The machine is only intended for use of this type.
If the machine is used outside its field of application, SIMAR GmbH is not liable
for damage or faults arising during operation.
Before commissioning the drying machine, the Operating Manual must be read
carefully. The notes on safety information must be followed to the letter.
Only trained and fully inducted operating personnel are qualified to operate the
machines and to carry out maintenance work.
Correct usage also involves compliance with inspection and maintenance work
schedules.
1.2 Safety Markings
In this document the following signal words are used in combination with safety
signs to represent potential hazards.
Danger !
Fatality, serious injury or extensive damage to property will occur if the
relevant precautionary measures are not taken.
Warning !
Fatality, serious injury or extensive damage to property may occur if the
relevant precautionary measures are not taken.
Beware !
Slight injury may occur if the relevant precautionary measures are not
taken.
Caution !
Damage to property may occur, if the relevant precautionary measures
are not taken.

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1.3 Safety Information
Knowledge of basic safety information and safety in the workplace instructions
is a precondition for safe handling and problem-free operation of the machine.
This Operating Manual includes all the important information needed to operate
the machine safely.
The in-house safety in the workplace regulations must be followed.
Caution !
Conveying hose and suction pipe necessarily earthing!
Warning !
Unless indicated otherwise, do not operate on voltages other than
230V/50Hz or 60 Hz
Caution !
See technical data sheet !
Danger !
Touching live parts is potentially fatal.
Always keep control cabinets locked.
Do not carry out any work on live parts.
Work on the electrical fittings may only be carried out by authorised
electrical specialists.
Access to the control cabinets is only permitted for authorised personnel
with a key or tools.
Cables may not become trapped or squashed.
Cables must be laid in such a way that they do not constitute a trip
hazard nor are liable to be damaged.
Danger !
Do not work in explosive areas.
No conveying explosive materials.
No conveying liquids .

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Danger !
The machine is only safe if all safety devices are properly installed and
in operation.
Do not operate the Drier without safety devices, or with faulty devices,
or with safety devices that have been bridged.
Safety devices may only be removed once the main switch is disabled.
Refit all safety devices once repair work is completed and test them for
proper functioning.
Anyone working on the machine must be informed prior to the start of
maintenance work of any imminent movements on the machine.
Warning !
Risk of injury due to improper handling of compressed air.
Never direct the outlets of compressed air lines towards people –
serious injury may result.
Do not pressurise any loose compressed air hoses. Any people who
may be in their vicinity may be hit.
Never hold compressed air hoses on loose objects.
Work on the compressed air devices may only be carried out by
authorised specialists.
Warning !
Risk of the pallet falling during transport.
Ensure equal loading of the pallet and that suitable means of transport
are used.
Caution !
Risk of injury due to incorrect programming.
Do not make any changes to the software on programmable systems.
1.4 Protective Measures
Warning !
Never make any unauthorised modifications to nor deactivate safety
devices. These may result in serious injury.
The warning and safety signs fitted to the machine must be observed.
They may not be changed or removed.
Damaged signs must be immediately replaced.
Protective measures may not be circumvented during operation.

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1.5 Residual Hazards
During operation of the systems, further hazards may arise that can be
prevented through safety-conscious working procedures.
Danger !
Touching live parts is potentially fatal.
Observe the warning notices fitted.
Do not remove any covers on the control cabinet.
Work on the electrical fittings may only be carried out by
authorised electrical specialists.
Caution !
Parts of the blower unit heat up during operation.
1.6 Requirements on personnel and duty of care
Work on the system may only be carried out by reliable, trained and fully
inducted personnel.
Only authorised personnel may work at the machine.
Never allow machine components to be operated by personnel who are under
the influence of sedatives, or who for health reasons are not in a fit state to
operate them.
Any personnel who are under training, induction, or who are involved in general
training, may only work at the machine under the constant supervision of a
qualified and experienced person.
Work on the electrical fittings of the individual machines may only be
undertaken by authorised electrical specialists and in compliance with the
operating manual of the electrical fittings supplier.
Only fully inducted personnel with special knowledge and experience of
pneumatics may work on compressed air devices.
Caution !
The Operating Manual must always be available at the place of use.
The operating personnel must know where it is kept.

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2 Transport
Danger !
Touching live parts is potentially fatal.
Even when making small changes in position, isolate the machine from
any external power source.
Before recommissioning the machine, it must be properly reconnected
to the mains.
Warning !
Risk of the pallet falling during transport.
Ensure equal loading of the pallet and that suitable means of transport
is used.
Ensure it is securely attached and that the load is distributed
horizontally.
Never stand under a suspended load.
Nominate a competent banksman for the lifting operation.
Pay attention to protect against external influences as hits,
moisture, dirt etc.
Only use a suitable transport vehicle with adequate load bearing capacity.
Ensure the load is reliably secure.
Prior to recommissioning, carefully fit and secure any parts that have had to
be removed for transport purposes.
On recommissioning, always power up in line with the Operating Manual.
Commissioning may only be undertaken by specially trained operating and
maintenance personnel.

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3 Commissioning
1. After unpacking check the separator for transportation damage.
2. Prepare the cover of the machine hopper:
Mount opening Ø202mm respectively Ø242mm and drill 4 holes for
screws M6 according to dimension sheet (sheet 19 and 20).
Alternately assembling with clamping ring.
3. Check the inside of the separator for residues of packing.
Remove adhesive tape from flap.
4. Mount the separator on lid of machine hopper,
mount seal between lid and separator (included in scope of delivery).
5. Mount feeding hose and suction pipe and connect to earth.
6. Connect air hose DN13 for filter cleaning,
do not use smaller diameter because of insufficient filter cleaning.
7. Max. 2,5bar !
8. Install fan, connect separator to fan; the unit is ready for operation now.
The following is to be observed:
1. Use Cekon plug for connection. Slow blowing fuse 10A.
2. All pipe joints and hose couplings to be leak proof.
3. Arrange piping vertically or horizontally; not inclined, if possible.
Never use bends with radius less than 500 mm.
4. Do not push the suction pipe into the material hopper; it will be pulled in
automatically during the first conveying processes.
5. Prevent filling through air inlet openings.

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3.1 Feeding hose
Pull out copper strand for earthing approx. 20-30mm from the sheathing and
fold it back inside the plastic spiral hose.
When hoses with earthing spiral are used, make sure that there is a metallic
contact to the socket. Slip hose onto the bright metal tube and fasten the hose
to the metal tube by means of a hose clamp.
3.2 Flap
Correct settings of the discharge flap:
The air gap „b“ is adjust able by turning the counter weight.
The discharge flap should have an air gap „b“ of 8 mm, as shown in the
illustration.
Copper strand
Hose clamp
Sheating of copper
Metal tube
Plastic spiral hose
adjustable
counter weight

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3.3 Connection FX- controller to EKO - blow unit

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4 Technical Data
Hopper
FX 2004 FX 2504
Material 1.4301 1.4301
Diameter ∅200 x 330 mm ∅250 x 407 mm
Feeding volume 2,5l 5 l
Material outlet DN 100 DN 100
Feeding pipe DN 38 oder DN 50 DN 38 oder DN 50
Weight 9,2 kg 11,4 kg
Filter
FX 2004 FX 2004
optional FX 2504 FX 2504 optional
Filter size 0,06m² 0,06 m² 0,08 m² 0,08 m²
Material Polyamid PE- needle felt Polyamid PE- needle felt
Size ∅210 x 90
conical
∅210 x 90
conical
∅240 x 140
conical
∅240 x 140
conical
Weight 0,160 kg 0,160 kg 0,190 kg 0,190 kg
Valve filter backwash Blower unit EKO
FX 2004 FX 2004/ 2504
Designation 2/2 WGV Designation EKO
Connection 1/2“ Power 1,0kW
Control voltage 24 V Operating voltage 240V
Weight 2,05kg
Pneumatic
Mixing valve - option Clean out valve - option
Designation 4/2 WGV 4/2 WGV
Connection 1/8“ 1/8“
Control voltage 24 V 24 V
Weight 0,273 kg 0,273 kg
5/2 way solenoid valve
5/2 way solenoid valve
2/2 WSV

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5 Trouble shooting
Trouble Possible Cause Possible trouble shooting
Discharge flap does not close. Clean and adjust discharge flap.
Separator full Set conveying time is too long.
Set shorter conveying time.
No conveying
although vacuum
pump in operation.
Conveying piping clogged.
Clean conveying piping;
Change setting of suction pipe,
if necessary.
Magnetic switch on flap is
defective or maladjusted.
Replace or readjust magnetic
switch on flap.
Mains fuse released Measure current consumption
and check fan for overload.
Blower unit defective Replace fan.
Check motor brushes.
Current supply interrupted Check fuse of socket
Vacuum pump does
not operate although
discharge flap is
closed
Control unit defective. Require spare control unit.
Conveying air filter clogged
Check function of filter cleaning.
Clean conveying air filter,
replace if necessary.
Conveying piping too long or
arranged adversely
Check piping arrangement;
void sharp bends and height
differences.
Use cleanout valve, if necessary
Conveying time set too short
or too long.
Set the conveying time so that
the separator is just filled
Unit works at
reduced
conveying capacity
Conveying filter is clogged Clean and check conveying air
filter for damage
Repair work is to be carried out only with mains plug
and compressed air disconnected from supply !
Our service phone: + 49 (0)7042 / 903 17
t

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6 Maintenance
6.1 Safety Information for Maintenance and Repairs
Regular maintenance and service is a precondition for reliable use of the machine.
.
Warning !
Only carry out maintenance and repair work on the machine when the
machine is switched off at the main switch.
Repair work is to be carried out by skilled personal only!
Warning !
Risk of injury due to improper handling of compressed air.
Before commencing repair work, depressurise the system sections and
pressure lines that need to be opened.
Never hold compressed air hoses on loose objects.
Warning !
The use of unauthorised spare parts may result in injury to people and
damage to the machine.
Only use original spare parts !
Please observe the details from the relevant manufacturers relating to
maintenance of the individual machine components. You can find the maintenance
details in the accompanying documentation supplied.
6.2 Filter cleaning
Depending on the dust contents of the materials, the filter should be cleaned with
compressed air at regular intervals oil and water free.
In case the desired conveying capacity is not obtained even after cleaning, the filter
may be clogged.
The old filter must be replaced by a new one.

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6.3 Electronic control unit
The control unit needs no service.
Adjustments see chapter „FX-controller“.
7 Dismantling and Disposal
When replacing machine components and disposing of them, statutory regulations
must be followed.
Please do not intervene in the control unit since
otherwise the warranty claim will extinguish.

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8 Accessories
8.1 Mixing valve
Design and function
In conjunction with hopper loaders, the mixing valve MZX provides for automatic
metered addition of a second material, e.g. regrind material. The desired additional
quantity can be pre-selected digitally in percentages at the control unit. (Refer also
to operating instructions of control unit ).
A separator conveying pipe is connected to the mixing valve for each component.
The pneumatically actuated mixing valve is controlled by the electronic control unit
of the hopper loader.
There by the mixing valves are opened automatically within a dosing interval in
accordance with the set percentages.
The accuracy of the set percentages also depends on the length of the conveying
line. Optimum values are obtained with a conveying line length up to 5m.
It is preferred to select the lower percentage as component K1 (e.g. regrind
material).
In the event of only one component required, set k1 to „0“.
Mixing valve
Z1 Z2
1
2
3
4
Regrind K1 Natural K2
24VDC connection on control
unit outlet „mixing valve
Compressed air 4-6 bar
customers part

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Construction
Assembly
Normally the mixing valve is delivered assembled ready for operation, together
with hopper loader.
If added to existing hopper loader please observe separate mounting instructions.
Connection of the conveyor piping
Make sure that both pipes are of approximately the same length.
The number of pipe bends shall also be the same.
If not appropriate allowance, which have to be determined by test, have to be
set when setting the percentages.
Pos Art.- no. Mixing valve
10 60-11005
Cylinder
20 10-38003
Valve disk MZX 38
o.20 10-38005
Valve disk MZX 50
30 59-30004
Split pin
40 60-01023
Solenoid valve 24V
50 87-00026
Flat sealing SBR
MZX 38/50
60 93-00095
Cover plate
plexiglass for
MZX 38/50
70 98-00094
Distance bush for
MZX 38/50 Al
60-01028

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8.2 Clean out valve
The clean out valve is used to evacuate the conveying line after each conveying
cycle. It is necessary used in case where vertical conveying line of more than 5 m
difference in height are required. It is also used in connection with driers, in order
to avoid pre-dried materials remain in the conveying line.
The clean out valve should be installed at the beginning of the conveying line;
i. e. directly at the suction pipe or fixed the suction point.
Electric connection to terminals LS- and LS+.
Installation of clean out valve
Suction filter
art.-no 5301001
Solenoid valve
art.-no 6001023
Cylinder
art.-no 6011005
Valve disk
art.-no 1038005
Splint
art.-no 5930004
6001028

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9 Connecting terminal control unit FX
230 VAC in/outputs (6,3 mm flat connectors)
X1 L1
X2 PE
X3 PE
X4 Motor N 1,0kVA
X5 Motor L 1,0kVA
X6 N1
24V DC outputs (2,8mm flat connectors) 24V DC inputs (2,8mm flat connectors)
ST 1 and ST 2 Backwash valve 12W ST11 Light barrier input
ST 3 and ST 4 Mixing valve 12W ST12 0V
ST 5 and ST 6 Clean out valve 12W ST13 Reed contact input
ST 7 and ST 8 Fault lamp,internal 2W ST14 0V
ST 9 and ST10 Fault lamp,external 12W ST15 +24V
ST16 0V
ST17 +24V
ST18 0V
If box XD1 is used, following
wiring is valid
Cable no. to control unit-FX
1 ST15
2 ST13
Walther-plug-wiring
3 ST 2
4 ST 1
Cable no.
5 ST 5 1 to 1
6 ST 3 2 to 2 etc.
7 ST 9
PE X 2

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10 Dimension sheet
10.1 Dimension sheet FX 2004

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10.2 Dimension sheet FX 2504