PFT 00 28 08 02, Operating Manual

Page 1: ...Item number of operating manual 00 41 53 52 Item number of the machine 00 45 13 21 Item number of the machine 00 43 23 95 Item number of the machine 00 45 13 65 Item number of the machine 00 28 08 02...

Page 2: ...7 04 Knauf PFT GmbH Co KG Postfach 60 97343 Iphofen Einersheimer Stra e 53 97346 Iphofen Germany Tel 49 0 93 23 31 760 Fax 49 0 0 93 23 31 770 Technical hotline 49 9323 31 1818 info pft iphofen de www...

Page 3: ...2L6 ZP 3 L 14 10 4 Pump unit R7 3S 14 10 5 VARIO gear motor 5 5 kW item number 00280460 14 10 6 Control box ZP 3 L item number 00280800 15 11 Accessories 15 12 Recommended accessories 16 13 Intended...

Page 4: ...1 10 Working without air 34 32 Interruption of work 34 32 1 In the event of prolonged work stoppages 34 32 2 Switching off the air compressor 35 33 Switching off in an emergency 35 34 Measures to be t...

Page 5: ...shaft 56 42 6 Spare parts list Pump unit 2L6 57 42 7 Pump unit 2L6 with pump shaft Render Star 58 42 8 Spare parts list Pump unit 2L6 Render Star 59 42 9 Pump unit R7 3S 60 42 10 Spare parts list Pum...

Page 6: ...0 14 EG Interne Fertigungskontrolle nach Artikel 14 Absatz 2 in Verbindung mit Anhang V Diese Erkl rung bezieht sich nur auf die Maschine in dem Zustand in dem sie in Verkehr gebracht wurde Vom Endnut...

Page 7: ...ctiveness of the control and safety devices as well as the proper fitting of the protection devices The safe working condition of the machine has to be checked by the machine operator during operation...

Page 8: ...include the operating manual when transferring the machine to third parties The diagrams and illustrations shown in the manual are intended for better understanding of tasks and descriptions They are...

Page 9: ...y ZP 3 L 120 litres Container capacity ZP 3 L up to protective grille 80 litres Max mixing hopper MULTIMIX 140 litres Capacity for ready mixed product approx 80 litres Maximum particle size 6 mm 5 2 C...

Page 10: ...ng period 8 hours 5 4 Output values Pump output 2L6 standard equipment Specification Value Unit Pump output approx 10 39 l min Max operating pressure 20 bar Granulation max 6 mm Pumping distance max f...

Page 11: ...The type plate is found on the pump side material hopper and contains the following details Manufacturer Type Year built Machine number Permissible operating pressure 8 Quality control sticker Fig 4...

Page 12: ...X 1 Material hopper ZP 3 L with frame 2 Protective grille ZP 3 L 3 Multimix material outlet 4 Multimix material hopper 5 Protective grille for MULTIMIX with bag opener 6 Water inlet 7 MULTIMIX limit s...

Page 13: ...ug mains connection 7 Hand wheel Vario gearbox 8 Gear motor Vario 9 Wheel with steel rim 10 Cleaning nozzle 11 Pump unit 2L6 12 Mortar pressure gauge 13 Mortar hose connection 10 2 MULTIMIX for ZP3 L...

Page 14: ...h handle 7 Coupling 35M part 8 Mortar pressure gauge 10 4 Pump unit R7 3S 1 2 3 4 5 6 7 8 Fig 9 Pump unit 1 Rotor R7 3S 2 Stator R7 3S 3 Clamp 4 Tie rods 5 Pressure flange 6 Push handle 7 Coupling 50M...

Page 15: ...6A air compressor 10 CEE panel mounted socket 5 x 16A MULTIMIX WARNING Danger to life from rotating parts Improper operation may lead to serious damage to persons or property The motor must be operate...

Page 16: ...ompressor is intended exclusively for the generation of compressed air and is to be used with connected implement Any other use or use beyond what is specified such as with freely accessible and or op...

Page 17: ...compressor complies with the national and international safety regulations and can therefore also be used in damp rooms and or outdoors Areas with clean and dry air should be preferred Ensure that th...

Page 18: ...pumps the mixed material directly to the application site The pumping capacity can be adapted to the material requirements The PFT ZP 3 L MULTIMIX can be switched on and off using a remote control 16...

Page 19: ...ctive unit together with the machine Failure to follow these recommendations will result not only in the voiding of the warranty but the quality of the mortar you are producing will also suffer 18 Mor...

Page 20: ...suspension points provided Only remove packaging shortly before assembly Suspended loads WARNING Danger of death due to suspended loads Falling or swinging parts can pose a fatal hazard when heavy loa...

Page 21: ...ransport observe the following requirements The crane and lifting equipment must be suitable for the package weight The operator must be authorised to operate the crane Fastening the lifting gear 1 At...

Page 22: ...separate the materials according to type and size and reuse or recycle them accordingly CAUTION Environmental damage can result from improper disposal of materials Packaging materials are valuable res...

Page 23: ...y Components and tools that are stacked on one another or left lying around can cause accidents An increased noise level can cause permanent hearing loss Operation can result in noise that exceeds 95...

Page 24: ...th due to electric current The electrical connection must be fused correctly Only connect the machine to a power source with an approved FI circuit breaker 30 mA RCD residual current device of type A...

Page 25: ...f the mixing arms 2 The mixing unit runs anticlockwise 1 2 Fig 26 ZP 3 L Switching on 1 Check whether the connector plug MULTIMIX 1 is connected to the control box 2 Switch on the ZP 3 L using the mai...

Page 26: ...0 Item number 00 13 02 05 Float switch for AV3000 Item number 00 13 09 32 NOTE When working with water from the barrel the inlet strainer must be fitted with a filter screen item no 00136619 Bleed the...

Page 27: ...I position 3 Press the green push button 3 to switch the control voltage ON 26 3 Changing the direction of rotation 1 2 Fig 34 Switching on the MULTIMIX NOTE If the direction of rotation is incorrect...

Page 28: ...t tear off can lash wildly and injure those standing nearby Never detach hose couplings if the mortar hoses are under pressure check mortar pressure gauge Mixed material can escape under pressure and...

Page 29: ...hine operator or the person working in the dusty area must always wear a dust mask when filling the machine The decisions of the Committee for Hazardous Materials AGS can be read in the Technical Rule...

Page 30: ...s a risk of injury Therefore Before opening the protective grille always switch off the MULTIMIX at the main reversing switch Never reach into the machine while it is running 28 4 Danger of crushing b...

Page 31: ...k into the spraying gun Always wear protective goggles Always position the machine so that you cannot be hit should mortar escape NOTE The maximum pumping distance depends primarily on the flow charac...

Page 32: ...regulations 4 Switch off the machine at the red push button 2 so the control voltage is OFF NOTE Never allow the pump to run dry since this will shorten its service life considerably 31 3 Connecting...

Page 33: ...artially adhere to the sides of the material hopper resulting in the formation of tunnels The mortar level in the material hopper should not be higher than absolutely necessary 31 7 Switching on the Z...

Page 34: ...and off by a 42 V remote control coupling To do this the dummy plug 1 must be removed from the coupling and the remote control plug 2 must be connected 32 Interruption of work Fig 55 Closing the air...

Page 35: ...h against being activated again using a padlock 3 Inform supervisors at the site 4 If necessary call emergency services 5 Remove persons from the danger zone and carry out first aid measures 6 Ensure...

Page 36: ...ed manner and injure the operator Only open the machine if the pressure has fallen to 0 bar DANGER Danger of injury due to leaking mortar Escaping mortar can lead to injuries to the eyes and face Ther...

Page 37: ...pecialists do so NOTE A table below lists particular malfunctions and who is authorised to handle them 35 2 Fault displays The following equipment indicates a fault Fig 60 Fault displays Pos LED signa...

Page 38: ...Contactor is defective Replace the contactor Service Control plug not connected Plug in control plug Operator Fuse is defective Replace the fuse Service Limit switch on protective grille Close the pr...

Page 39: ...e connection cable Service technician Rotor worn or faulty Replace the rotor Service technician Stator worn or clamped too loosely Tighten the clamp or replace the stator Service technician Part not o...

Page 40: ...ies In accordance with the accident prevention regulations of the Builder s Guild all personnel clearing blockages should wear personal safety equipment safety goggles protective gloves and position t...

Page 41: ...mortar hoses if the pressure has fallen to 0 bar 36 3 Detaching coupling connections Fig 64 Hose blockages 1 Cover coupling connections with tear resistant film 2 Undo both nuts 1 on the pressure fla...

Page 42: ...ly reattached when work is finished 37 2 Cleaning ZP 3 L MULTIMIX CAUTION Water can enter sensitive machine parts Before cleaning the machine seal all openings where water could enter and impair the s...

Page 43: ...ortar pressure gauge 1 to see if the pressure has fallen to 0 bar DANGER Overpressure on the machine When opening machine components these can fly open in an uncontrolled manner and injure the operato...

Page 44: ...merges at the end of the spray gun 6 Repeat this procedure if heavily soiled 7 For different hose diameters the mortar hoses should be cleaned separately with the appropriate sponge balls 38 Cleaning...

Page 45: ...be retightened 2 Do not retighten the pump during operation 3 Pump components that are unable to produce the required feed pressure must be replaced When tightening or changing the pump ensure the fol...

Page 46: ...injuries or equipment damage Ensure there is adequate space for assembly before starting any work Keep the assembly area clean and tidy Unattached components or tools left lying around or stacked on...

Page 47: ...n again 40 2 MULTIMIX Maintenance tasks Provided no increase wear can be identified during regular inspections reduce the required maintenance intervals as appropriate for the actual signs of wear For...

Page 48: ...Maintenance plan The next sections describe the maintenance tasks required for optimal problem free operation Provided no increased wear can be seen during regular inspections reduce the required main...

Page 49: ...it out 4 Replace the filter if dirt is severe 5 Insert the filter with the rigid side of the filter 2 facing inwards Filter insert D 100 item number 20134000 Fig 82 Filter cover opening 6 Unscrew the...

Page 50: ...an environmentally sound manner after reaching the end of its useful life 41 1 Safety Personnel Disassembly may only be performed by specially trained personnel Work on electrical systems may only be...

Page 51: ...n again Disconnect the entire energy supply from the unit and discharge the residual energy Remove operating and auxiliary materials as well as residual processing materials and dispose of them in an...

Page 52: ...IMIX Overview Operation Spare Parts Lists Spare parts drawing spare parts lists 52 2016 07 04 42 Spare parts drawing spare parts lists 42 1 Frame and protective grille ZP 3 L 1 2 3 4 2 5 12 11 10 16 1...

Page 53: ...ctive grille ZP 3 L without cut out cpl 5 1 00 45 13 21 Protective grille ZP 3 L without cut out RAL2004 6 4 00 02 26 01 Round head screw M6 x 20 zinc plated 7 1 00 45 13 29 Cover plate drive ZP 3 L R...

Page 54: ...PFT ZP 3 L MULTIMIX Overview Operation Spare Parts Lists Spare parts drawing spare parts lists 54 2016 07 04 42 3 Gear motor and sealing unit 1 2 15 14 13 12 11 10 9 8 7 6 5 4 3...

Page 55: ...plated 5 1 00 10 41 38 Clamping flange without lubrication groove ZP 3 XXL RAL2004 6 1 00 40 49 55 Gasket without grease hole D180 d90 7 1 00 10 41 30 Clamping flange with lubrication groove ZP 3 RAL2...

Page 56: ...ZP 3 L MULTIMIX Overview Operation Spare Parts Lists Spare parts drawing spare parts lists 56 2016 07 04 42 5 Pump unit 2L6 with pump shaft 1 2 3 4 5 6 7 8 9 10 11 12 13 14 24 23 22 21 20 19 9 18 17 1...

Page 57: ...inc plated 10 1 00 10 22 29 Mortar pressure gauge 50 mm galv cpl 11 1 00 09 90 88 Pressure gauge with plastic housing 0 100 bar 1 2 pressure transmitter VA 12 1 00 09 94 51 Coupling for gauge 2 int ex...

Page 58: ...FT ZP 3 L MULTIMIX Overview Operation Spare Parts Lists Spare parts drawing spare parts lists 58 2016 07 04 42 7 Pump unit 2L6 with pump shaft Render Star 1 2 18 17 16 15 14 13 12 11 3 4 5 6 7 8 9 10...

Page 59: ...0 20 99 21 Flanged nut M16 zinc plated 8 1 00 28 08 55 Tie rods M16 x 600 mm 1 set 2 pieces 9 1 20 20 96 01 Hex screw M10 x 45 zinc plated 10 1 00 40 66 03 Pressure flange ZP 3 L cross web 2L6 RAL2004...

Page 60: ...PFT ZP 3 L MULTIMIX Overview Operation Spare Parts Lists Spare parts drawing spare parts lists 60 2016 07 04 42 9 Pump unit R7 3S 1 2 3 4 5 6 7 8 9 10 18 7 17 16 15 14 13 2 12 11...

Page 61: ...12 20 20 90 00 Washer B 13 zinc plated 8 1 00 28 08 55 Tie rods M16 x 600 mm 1 set 2 pieces 9 1 00 47 82 12 Assambling aid R pump RAL2004 10 1 00 09 90 89 Pressure gauge with plastic housing 0 100 ba...

Page 62: ...erview Operation Spare Parts Lists Spare parts drawing spare parts lists 62 2016 07 04 42 11 MULTIMIX material hopper 1 2 3 4 5 26 25 24 23 22 21 20 19 18 17 16 37 36 35 34 33 32 31 30 29 28 27 6 2 7...

Page 63: ...t D 4 5 with ring 15 1 00 28 42 98 Mortar outlet canted ZP 3 L RAL9002 16 1 00 00 79 86 Pin MULTIMIX outlet zinc plated 17 4 20 20 93 19 Washer 13 x 37 x 3 zinc plated 18 4 20 20 89 00 Safety nut M12...

Page 64: ...FT ZP 3 L MULTIMIX Overview Operation Spare Parts Lists Spare parts drawing spare parts lists 64 2016 07 04 42 13 Mixing unit with gear motor 1 2 3 4 5 6 7 8 9 10 11 12 13 14 19 18 17 23 22 21 20 15 1...

Page 65: ...asher B 13 zinc plated 8 6 20 20 91 10 Spring washer B 12 zinc plated 9 6 20 20 99 62 Screw M12 x 35 zinc plated 10 1 00 28 47 16 Mixing arm inside MULTIMIX RAL9002 11 1 00 28 47 35 Mixing arm outside...

Page 66: ...PFT ZP 3 L MULTIMIX Overview Operation Spare Parts Lists Spare parts drawing spare parts lists 66 2016 07 04 42 15 Air compressor Item no 00414337 1 2 3 4 5 6 7 8 7 9 8 10 7 11 14 13 12 8 17 16 15...

Page 67: ...4 int thread galv 7 3 20 20 36 50 Angle 1 4 int thread ext thread galv 8 3 20 20 37 12 Screwed joint 1 4 ext thread brass for pressure switch 9 1 20 21 90 51 Double counter flow valve 1 4 int thread...

Page 68: ...PFT ZP 3 L MULTIMIX Overview Operation Spare Parts Lists Spare parts drawing spare parts lists 68 2016 07 04 42 17 Pressure switch off 1 2 3 4 5 6 7 8 9 10 11 18 6 17 16 15 14 13 12...

Page 69: ...ead non blocking 6 2 00 05 91 96 Hose clamp 19 21 7 1 20 19 04 11 Hose screw joint 1 4 ext thread socket 1 2 8 1 20 20 45 70 T piece 1 4 int thread galv 9 1 20 20 36 50 Angle 1 4 int thread ext thread...

Page 70: ...2 1 20 19 61 00 Spray head 35 mm 3 1 20 20 99 80 Ring bolt M10 x 19 zinc plated 4 1 20 19 01 00 Air nozzle tube 140 mm 5 1 20 19 05 10 Hose section 9 mm x 310 mm 6 2 20 20 261 1 Hose clip 14 17 7 1 2...

Page 71: ...3 L RAL 9002 structure 5 1 00036249 Lock for switching box double bit key 6 1 00206458 Main reversing switch 4 pin 7 1 00053832 Light switch On Off twin button 8 1 00053831 Membrane rectangular for tw...

Page 72: ...A PKZM0 10 5 1 00042602 Motor protection switch 10 16A PKZM 0 16 6 1 00021401 Auxiliary contact NHI 11 PKZO 7 2 00084224 Air break contactor DIL M15 10 42 V 8 1 00206458 Main reversing switch 4 pin 9...

Page 73: ...PFT ZP 3 L MULTIMIX Overview Operation Spare Parts Lists Spare parts drawing spare parts lists 2016 07 04 73 42 21 Circuit diagram S1211...

Page 74: ...PFT ZP 3 L MULTIMIX Overview Operation Spare Parts Lists Spare parts drawing spare parts lists 74 2016 07 04...

Page 75: ...ling with malfunctions 37 Description 18 Design and function 12 Detaching coupling connections 41 Dimension sheet ZP 3 L MULTIMIX 11 Disassembly 51 Disassembly 50 Discharging mortar pressure 36 Dispos...

Page 76: ...tective equipment Installation 37 Protective equipment for operators 22 Pump unit 2L6 56 Pump unit 2L6 with pump shaft Render Star 58 Pump unit 2L6 ZP 3 L 14 Pump unit R7 3S 14 Pump unit R7 3S 60 R Re...

Page 77: ...L and putting it into service 31 Switching on the ZP 3 L briefly 32 T Table of malfunctions 38 Technical data ZP 3 L MULTIMIX 9 Transport 20 21 Transport by crane 21 Transport checklist 21 Troublesho...

Page 78: ...PFT ZP 3 L MULTIMIX Overview Operation Spare Parts Lists 78 2016 07 04...

Page 79: ...PFT ZP 3 L MULTIMIX Overview Operation Spare Parts Lists 2016 07 04 79...

Page 80: ...Parts Lists 80 2016 07 04 THE FLOW OF PRODUCTIVITY Knauf PFT GmbH Co KG Postfach 60 97343 Iphofen Einersheimer Stra e 53 97346 Iphofen Germany Tel 49 9323 31 760 Fax 49 9323 31 770 Technical hotline 4...