Instruction Manual

All-Purpose Equipment Program

Wet Granulator Type FGS

ERWEKA GmbH · Ottostr. 20-22 · 63150 Heusenstamm · Germany · Tel: +49 (0) 6104 6903-0
Directors: Werner G. Müller, Claudia Müller, Manfred Koller · District court Offenbach HRB 2382
Fax: +49 (0) 6104 6903-40 · E-mail: info@erweka.com · www.erweka.com
Document version 1.1
Date: 2016-09-26
Document No.: 21859
File name: FGS_Manual_21859_En_V1.1
Language: English
Page number: 28

Version table
Document
Date version* Change
2016-03-11 1.0
2016-09-26 1.1 editorial revision

* When the document version X.Y is increased, X means a technical change and Y – a document change only.

Copyright
The material in this document is the intellectual property of ERWEKA. Any copy or reproduction of this
document or its parts without the written permission of and reference to ERWEKA is prohibited and will
be prosecuted according to the law. All trademarks are the property of their respective owners.

Copyright© 2016 by ERWEKA

Instruction Manual
All-Purpose Equipment Program
Wet Granulator Type FGS
4 Wet Granulator Type FGS

Table of Contents

1 – Introduction 5
1.1 – About this instruction manual 5
1.2 – Service 5
1.3 – Safety instructions and symbols 6
1.4 – Protection of the environment 6

2 – Safety 7
2.1 – Safety information 7
2.2 – Intended use 7
2.3 – Safety and protective facilities 8
2.4 – Danger zone 8

3 – Overview 9
3.1 – Description 9
3.2 – Construction 10
3.3 – Technical data 11
3.3.1 – Data 11
3.3.2 – Material of parts contacting with product 11
3.4 – Type label 11

4 – Installation 12
4.1 – Storage and transport conditions 12
4.2 – Unpacking and checking 12
4.3 – Required installation environment 12
4.4 – Mounting 13
4.4.1 – Safety instructions 13
4.4.2 – Rotor dis-/mounting 14
4.4.3 – Sieve dis-/mounting 15
4.4.4 – Slide plates placement 16
4.4.5 – Filling hopper dis-/mounting 17
4.4.6 – Dis-/mounting from/on the drive unit 18

5 – Operation 19
5.1 – Hints for operation 19

6 – Maintenance 20
6.1 – Cleaning 20
6.2 – Inspection and maintenance 20
6.3 – Spare parts 21

Attachment 22

21859 - 1.1
Wet Granulator Type FGS – Introduction 5

1 – Introduction
Thank you for purchasing the ERWEKA wet granulator type FGS!

1.1 – About this instruction manual

This instruction manual supports you in work with your ERWEKA device. It describes the device, its operation and
gives you useful tips on its handling. Furthermore, read descriptions of installation and setting as well as detailed
step-by-step work operations in the present manual. Pictures facilitate the understanding of processes described
here.

The instruction manual is a part of the product. Read this manual completely and make sure you
understand its content. Keep this manual in a safe place so that it will be available for any questions at
a later date. This is important for warranty of permanent and accurate operation of the corresponding
device.

The wet granulator is an attachment unit of the ERWEKA all-purpose equipment program. An all-purpose device con-
sists of a drive unit and an attachment unit. Also read the instruction manual of the used drive unit.

The instruction manual is valid only with the instruction manuals of the used modules of the all-purpose
equipment program.

The editorial team of ERWEKA appreciates your feedback regarding the present manual. Just send an
e-mail to quality@erweka.com with your topic and “technical documentation” as a subject. Your reply
contributes to our high quality level.

1.2 – Service

Contact ERWEKA at service@erweka.com to order the spare parts, in case of technical questions or
possible repairs. Please supply the following information:
• Type of the device (on the type label)
• Serial number of the device (on the type label)
• Short description of the case

21859 - 1.1
6 Wet Granulator Type FGS – Introduction

1.3 – Safety instructions and symbols

WARNING indicates a possible hazardous situation which, if not avoided, could result in death or
serious injury.

CAUTION indicates a possible hazardous situation which, if not avoided, could result in moderate or
minor injury.

HAZARD due to electric shock! Indicates a possible hazardous situation which, if not avoided, can
lead to injuries due to electric shock.

This symbol indicates a possible hazardous situation which, if not avoided, can lead to equipment
damage.

This symbol emphasizes the information to ensure a smooth work process.

This symbol provides you with additional useful information.

1.4 – Protection of the environment

Note that residues of the test products must be properly disposed of in accordance with the applicable environmental
regulations. According to the valid EC directives all the electrical parts (electrical waste) must be disposed of
appropriately.

21859 - 1.1
Wet Granulator Type FGS – Safety 7

2 – Safety
2.1 – Safety information

To guarantee the health and safety, read the following safety instructions before using the device.

WARNING
Wear the personal protective outfit and glasses, if necessary!

HAZARD due to electric shock! Electric devices are to be plugged into safety sockets only! Use
the delivered network cable! The voltage of the existing current supply is to be compared to the
indications on the type label!
Before installation works always switch the corresponding device off and disconnect it from the rear
panel.

ERWEKA devices should be operated by qualified and trained personnel only!

Pay attention to the on-site safety instructions for work in the laboratory and with the laboratory equipment!

2.2 – Intended use

The ERWEKA wet granulator type FGS should be used only as an attachment unit to a drive unit proposed in the
ERWEKA all-purpose equipment program in the installation environment defined by ERWEKA. At that the conditions
defined by ERWEKA for the corresponding drive unit should be considered.

ERWEKA devices should not be used for processing:

• products that are easily flammable or explosive

• products that develop vapours which may create flammable or explosive mixtures in combination with air
• products that release harmful or poisonous substances

The device should be operated and maintained only as it is foreseen and due to the instructions presented in this
manual.

21859 - 1.1
8 Wet Granulator Type FGS – Safety

2.3 – Safety and protective facilities

Safety interlock

The FGS has a filling hopper with protective grid. This separating protective facility is equipped with a safety sensor.

The drive unit stops automatically when the separating protective facility is opened during the operation.

Safety interlock is out of operation?

Safety sensor on the attachment unit! Check the connecting cable from the safety sensor on the at-
tachment unit to the safety interlock connector on the AR 403/-S. It is absolutely necessary for the
function of the safety interlock.
More information you will find in the instruction manual for the drive unit.

2.4 – Danger zone

In the setup mode of the drive unit

• Manual access! Safety interlock is suspended! The drive unit rotates with decreased speed.

• Moving rotating parts!

WARNING Danger of squashing and clamping! Danger of seizing! Moving parts!

The authorized personnel only should enter this zone. Wear the protective outfit and keep the safety
instructions in mind. Follow the safety instructions in the drive unit’s manual.

21859 - 1.1
Wet Granulator Type FGS – Overview 9

3 – Overview
3.1 – Description

The ERWEKA wet granulator type FGS is applied during production of granules by means of wet granulation.

Granules:

Granules are applied as independent dosage form, filling of capsules or material for pressing of tablets because they
are distinguished by high slipperiness, solidity and uniformity in comparison to powders. The process of tableting
puts high requirements on the adhesion and flowabilty of the material to be pressed.

Wet granulation:

At first the powder is processed to a damp mass after adding liquid during the wet granulation. After this the damp
mass is disaggregated e.g. by pressing through sieve or punch disks. The disaggregated material is dried, cleaned
and loosened. At the end the granules are sieved and classified by grain size.

The ERWEKA wet granulator type FGS is used for separating the granulated mass. At that the rotor of FGS presses
the damp mass through a sieve.

As a module of the ERWEKA all-purpose equipment program the FGS is intended for application in the laboratory to
process small amounts, e.g. for research in pharmaceutical industry.

The FGS is available with various sieve meshes.

The filling hopper of the FGS with built-in protective grid is equipped with a safety interlock as separating protective
facility.

All parts that contact with product are detachable and easy to clean.

21859 - 1.1
10 Wet Granulator Type FGS – Overview

3.2 – Construction

8
6 5 4

Pict.: mounted FGS (on the AR 403, with connected safety sensor)

1) Filling hopper with protective grid

2) Safety interlock
3) Accepting flange with two short knurled nuts
4) Two accepting bolts, each with a knurled nut
5) Slide plate (2 pieces)
6) Knurled screw
7) Rotor wheel
8) Sieve tie rods with knurled-head screws

21859 - 1.1
Wet Granulator Type FGS – Overview 11

3.3 – Technical data

3.3.1 – Data

FGS
Weight:
ca. 21 kg
Rotor:
4 rods
Length: 164 mm
Diameter: 75 mm
Rotor oscillation angle:
90°
Rotor movements:
0 - 150 per minute, stepless adjustment
Rotor power:
max. 30 kg/h, depending on the material to be processed and mesh size
Sieve mesh sizes [mm]:
available: 0.315; 0.63; 0.8; 1.0; 1.25; 1.6; 2.0; 2.5; 3.15
in delivery scope: 1.0; 1.6

3.3.2 – Material of parts contacting with product

FGS
Rotor:
Cam disc 1.4305, AISI 303
Tension plate 1.4305, AISI 303
Rod 1.4301, AISI 304
Sieve:
Screen cloth 1.4301, AISI 304
Fixing rail 1.4571, AISI 306 Ti
Slide plate:
1.4301, AISI 304
Cover plates:
1.4301, AISI 304
Hopper:
1.4301, AISI 304

3.4 – Type label

The type label is placed on the rear panel of the device and contains following data:

Typ: Device type

Serial No: Serial number
PN: Normal output in Volt Amper [VA]
IN: Nominal current in Amper [A]
U: Voltage in Volt [V]
F: Frequency in Hertz [Hz]

21859 - 1.1
12 Wet Granulator Type FGS – Installation

4 – Installation
4.1 – Storage and transport conditions

The device should not be exposed to punches and vibrations.

Temperature and humidity should not be lower or higher than the values defined by ERWEKA (see
4.3 – Required installation environment).

4.2 – Unpacking and checking

Upon receiving the delivery, check that no physical damage has occurred to the packaging and device during the
transportation.

If available, check the tilt indicator label for undue turning of the packaging. In case of 60° inclination the colored
quartz sand flows into the display field and is visible there.

If undue transporting or any damage is evident, take a photo of this and send it to our ERWEKA
Service immediately.

4.3 – Required installation environment

Ambient temperature in operation: +10°C up to +30°C

Storage and transport temperature: -10°C up to +55°C
Relative humidity: 25-80% no condensation

21859 - 1.1
Wet Granulator Type FGS – Installation 13

4.4 – Mounting

4.4.1 – Safety instructions

WARNING
Falling object!
Insecure positioning can lead to the injuries.

WARNING
Danger of squashing and clamping! Danger of seizing! Moving parts!
Long hair or hanging down clothes can be seized into the rotating part of the accepting flange or the
attachment unit!

• Tie long hair back.

• Wear fitted clothes only.
• Do not wear any neckties, scarfs etc.

In case of emergency press the emergency switch immediately!

After each mounting of an attachment unit set the initial speed of the drive unit to the lowest value!
After operation start the speed can be adjusted as necessary within the permitted limits.

Pay attention to the safety instructions in the instruction manual of the used drive unit!

For mounting the attachment unit use 4 knurled nuts from the delivery scope only!

You will find the information about mounting of the attachment unit also in the instruction manual of
the used drive unit.

Before operating the FGS following components must be mounted:

• Rotor, sieve and slide plates

• Filling hopper
• FGS on the drive unit

21859 - 1.1
14 Wet Granulator Type FGS – Installation

4.4.2 – Rotor dis-/mounting

Pay attention to the safety instructions from the section 4.4.1 – Safety instructions!

Rotor:
1

1) Rod 2
2) Cam disc
3) Tension plate
3

B
C

Procedure:

1. Loosen the handwheel [C] and pressure spindle [B].

2. Insert the rotor [A].

3. Fix the rotor by fastening the pressure spindle [B].

4. Rotate the big handwheel [C] until it stops against the housing. By doing this you fix the setting of [B].

To prevent axial movements of the rotor, the pressure spindle must be fastened and fixed before
operation!

For dismounting perform the procedure in the reverse order.

21859 - 1.1
Wet Granulator Type FGS – Installation 15

4.4.3 – Sieve dis-/mounting

Pay attention to the safety instructions from the section 4.4.1 – Safety instructions!

Picture:

Pict.: FGS with sieve

Procedure:

1. Loosen the knurled-head screws [C].

2. Push the tension rods [D] into the foreseen orifices of the FGS [B].

3. Position the sieve [A] and thread its retainers into the slits [E] of the tension rods.

4. Fix the knurled-head screws [C] by slight fastening. The tension rods [D] can be turned by hand now.

5. Stretch the sieve around the rotor by consistent rotations of the tension rods.

6. Tighten the knurled-head screws [C].

The overstraining leads to quicker wearout of the sieve!

For dismounting perform the procedure in the reverse order.

21859 - 1.1
16 Wet Granulator Type FGS – Installation

4.4.4 – Slide plates placement

Pay attention to the safety instructions from the section 4.4.1 – Safety instructions!

Picture:

Procedure:

The slide plates [A] can be inserted into the retainers on the FGS [B] or taken out of them.

Pict.: FGS with inserted slide plates

21859 - 1.1
Wet Granulator Type FGS – Installation 17

4.4.5 – Filling hopper dis-/mounting

Pay attention to the safety instructions from the section 4.4.1 – Safety instructions!

Safety interlock on the filling hopper!

If the filling hopper is dismounted from the FGS, the drive unit can be switched on in the setup mode
only.

Picture:

Procedure:

1. Loosen the two knurled-head screws [B].

2. Take the filling hopper [A] out of the FGS [C].

3. Mount the filling hopper [A] by fastening it with the two knurled-nut screws [B] on the FGS.

Pict.: FGS with filling hopper

21859 - 1.1
18 Wet Granulator Type FGS – Installation

4.4.6 – Dis-/mounting from/on the drive unit

Pay attention to the safety instructions from the section 4.4.1 – Safety instructions!

Picture:

B
C C
A

F
E
E

Procedure:

1. Remove the two knurled nuts [C] from the drive unit [D] and loosen the two knurled nuts [E].

2. Set the drive unit [D] to the setup mode. If needed, unlock the emergency switch previously.

3. Switch the drive unit [D] on by pressing the Start button.

4. Push the FGS [A] with the accepting sleeves [F] onto the accepting bolts [E] of the drive unit and hold the FGS
tight.

5. Push the FGS [A] with its flange with the drive claw [B] against the drive unit until it latches.

Switch the drive unit [D] off with the Stop button only when the drive claw [B] latches hearbly.

6. Switch the drive unit off.

7. Still hold the FGS [A] tight and fix it by tightening the two knurled nuts [C] and the two knurled nuts [E] with your
hand.

8. Insert the plug of the safety sensor cable into the safety interlock jack on the drive unit and quit the error message
„ALR1“ with the Stop button.

9. Set the drive unit [D] to the operation mode. The FGS is ready for operation now.

For dismounting perform the procedure in the reverse order.

21859 - 1.1
Wet Granulator Type FGS – Operation 19

5 – Operation
5.1 – Hints for operation

Before operating the FGS the particular components and the device itself must be mounted on the drive unit appro-
priately (see 4.4 – Mounting).

WARNING
Injuries caused by the rotating parts or heavy weights!
For operation of the wet granulator type FGS the filling hopper with protective grid must be mounted
on the attachment unit!
Do not change the device position during operation!
Do not rotate attachment units forcibly from the outside by hand and do not stop them during operation!

WARNING
Long hair or hanging down clothes can be seized into the rotating part of the attachment unit!
• Tie long hair back.
• Wear fitted clothes only.
• Do not wear any neckties, scarfs etc.

In case of emergency press the emergency switch immediately!

You will find the information about operating of the attachment unit in the instruction manual of the
used drive unit.

The initial speed of the drive unit should be reset to the lowest value after each replacement of
the attachment unit. After the operation start the speed can be adjusted as necessary within the
permitted limits.

21859 - 1.1
20 Wet Granulator Type FGS – Maintenance

6 – Maintenance
6.1 – Cleaning

To guarantee the failure-free operation, it is recommended to clean the device regularly, after each use.

HAZARD due electric shock when cleaning the electric devices! Disconnect the mains supply for cle-
aning the electric device! Switch the device off and unplug it! Clean the electrical instruments without
liquids.

Dismount the attachment unit from the drive unit before cleaning.

To clean the FGS, take out the filling hopper, tension rods, sieve and rotor. Clean them carefully.

Wipe the device with a soft and slightly damped cloth.

Do not use an excessively damped cloth but only slightly damped one.
Do not add any chemical cleansing agents to the cleaning water.
For the lacquered housing parts use no cleansing agents which attack this material.

If needed, e.g. in case of serious dirtying, use a damp cloth and blot the cleaned surface dry.

6.2 – Inspection and maintenance

Ensure that the device is regularly inspected and each time is clean.

To ensure a long lifetime of your units and systems we recommend regular maintenance performed
by our service staff.

Check regularly:

Fixed placements of the knurled nuts on the accepting flange. In case of necessity retighten them.

21859 - 1.1
Wet Granulator Type FGS – Maintenance 21

In longer standstills:

If you do not use the device for a long time, follow the instructions:

• Dismount additional components.

• Clean the device thoroughly.
• Store the device, its components and manual under conditions defined for the installation environment.

Non-performance of the instructions given above can lead to damages!

6.3 – Spare parts

Electronic and mechanical replacements are to be made by the ERWEKA personnel or approved by
ERWEKA!

Only original spare parts or components released by ERWEKA should be used. Only repairs or changes on the device
performed by the ERWEKA technicians or approved explicitly by ERWEKA are to be made.

21859 - 1.1
22 Wet Granulator Type FGS – Attachment

Attachment
The devices of the ERWEKA all-purpose equipment program are subject to a constant improvement and further de-
velopment. To guarantee safe work with the devices also in future, the safety interlock on the AR 403/-S drive unit
was changed according to applicable guidelines.

All ERWEKA attachment units concerning their compatibility with further developed drive unit are listed and the
adaptation possibilities of older attachment units are described below.

New attachment units

An overview of the new ERWEKA attachment units driven with or without Universal Gear.

Device identifcation Type UG

Double cone mixer DKM 
Coating pan DKE / DKS 
Three-roller mill SM / SMS
Wet granulator FGS
Filling and dosing machine for ointments FDS
Filling and dosing machine for liquids FDF
Homogenizer HO
Conical mill CM
Cube mixer KB 15 / KB 15 S / KB 20 / KB 20 S / KB 30 / KB 30 S 
Ball mill KM 0 / KM 5 / KM D 5 / KM 10 / KM D 10 / KM 0 
Laboratory kneader LK 5
Laboratory high speed mixer SW 1/S
Pelletizer GTE 
Planetary stirrer PRS
Polishing drum PT 
Drum hoop mixer RM 5 / RM 10
Dry granulator TG 2000
V mixer VB 3
Y mixer YB 5
3D mixer

To connect a new attachment unit with safety sensor, plug the 8-pin connector of the attachment unit
into the safety interlock jacket on the AR 403/-S.

UG is the type designation for Universal Gear which is also available as a new attachment unit.

21859 - 1.1
Wet Granulator Type FGS – Attachment 23

Old attachment units with safety sensor

These devices have a safety sensor recognized by the AR 403/-S if they are connected through an adapter cable to
the motor.

Device identification Type

Wet granulator FGS
Conical mill CM
Laboratory kneader LK 5
Laboratory high speed mixer SW 1/S
Planetary stirrer PRS
Dry granulator TG 2000

To connect an old attachment unit with safety sensor, use the adapter cable (No. 103-003-0001). Plug
the round connector of the adaptor cable into the safety interlock jacket on the AR 403/-S. Then plug
the connector of the attachment unit into the angular connector of the adaptor cable.

When using a foot switch (see drive unit instruction manual) connect it between the adaptor cable
and AR 403/-S.

Old attachment units without safety sensor

These devices have no safety sensor. If you use them with the AR 403/-S further on, you must drill the device flange
in a predefined place.

WARNING
Hazard of injuries in case of changing existing safety devices!
The drilling procedure described below should be applied only to the attachment units without safety
sensor listed in the table.

Device identification Type UG

Double cone mixer DKM 
Coating pan DKE / DKS 
Three-roller mill SM / SMS
Filling and dosing machine for ointments FDS
Filling and dosing machine for liquids FDF
Homogenizer HO / HHO
Cube mixer KB 
Ball mill KM KM 0 
Pelletizer GTE 
Polishing drum PT 
Drum hoop mixer RM 5 / RM 10

21859 - 1.1
24 Wet Granulator Type FGS – Attachment

Device identification Type UG

Suppository and lipstick moulding machine SG 4/W
Universal gear UG ---

Y mixer YB 5

Drilling procedure:

To connect an old attachment unit without safety sensor, drill a hole of 10.0 mm diameter and 5.0 mm depth in the
device flange. Use the drilling template No.103-230-0002. Fix the template with 2 M8 screws on the old attachment
unit.

WARNING
Hazard of injuries in case of false performance!
The procedure described here should be performed by the authorized personnel only (metall
processing). Safety instructions for metall processing must be followed.

1. Use the drilling template No. 103-230-0002 to correctly

position the bore.

2. Fix the drilling template with 2 M8 screws on the old

attachment unit without safety sensor. (black arrows)

3. Fix the attachment unit.

4. Drill a hole of 10.0 mm diameter and 5.0 mm depth. (red

arrow)

5. Mount the old attachment unit without safety sensor with

drilled hole.

21859 - 1.1
Certificate of Compliance for
Konformitätserklärung für
All-Purpose Equipment, drive unit and attachement units
AR 403/S
CM, DKM, DKE/DKS, FGS, FDF, FDS, GTE, HO/HHO/-UA, KB/-S, KM/KMD, LK 5/DER, PT, PRS/DER/DW, RM, SG 4/W, SW/1S, SM/S, TG
2000, UG, VB 3, VT/VS/PS/S, YB 5, 3D-Mixer

We, ERWEKA GmbH, declare under our sole responsibility that the product to which this declara-
tion relates is in conformity with the following EU-Directives and harmonized standards:

■ Low Voltage Directive (LVD) 2014 / 35 / EU

■ Safety requirements for electrical equipment for measurement, control and laboratory use; EN 61010-1
■ Electromagnetic Compatibility, (EMC) Directive 2014 / 30 / EU
■ Electrical equipment for measurement, control and laboratory use; EN 61326-1

Wir, die ERWEKA GmbH, erklären in alleiniger Verantwortung, dass das Produkt, auf das sich die-
se Erklärung bezieht, mit folgenden EU-Richtlinien und harmonisierten Normen übereinstimmt:

■ Niederspannungsrichtlinie 2014 / 35 / EU
■ Sicherheitsbestimmungen für elektrische Mess-, Steuer-, Regel- und Laborgeräte; EN 61010-1
■ Elektromagnetische Verträglichkeit, EMV-Richtlinie 2014 / 30 / EU
■ Mess-, Steuer-, Regel- und Laborgeräte, EN 61326-1

Heusenstamm, 08.03.2016

Manfred Koller
-CTO-

ERWEKA GmbH · Ottostr. 20-22 · 63150 Heusenstamm · Germany · Tel: +49 6104 6903-0
Fax: +49 6104 6903-40 · E-mail: info@erweka.com · www.erweka.com
Managing Director & CEO: Werner G. Müller, Claudia Müller, Manfred Koller · District court Offenbach HRB 2382
ERWEKA GmbH · Ottostr. 20-22 · 63150 Heusenstamm · Germany · Tel: +49 (0) 6104 6903-0
Directors: Werner G. Müller, Claudia Müller, Manfred Koller · District court Offenbach HRB 2382
Fax: +49 (0) 6104 6903-40 · E-mail: info@erweka.com · www.erweka.com