PFT 00260621, Operating Instructions Manual

Page 1: ...230 400V 1 3 Ph 50 Hz with AVO 500 Item no 00260621 G 4 FC 230 400V 1 3 Ph 50 Hz without booster pump with accessories Item no 00422135 G 4 FC 230 400V 1 3 Ph 50 Hz without booster pump Item no 00423...

Page 2: ...oduction of this document exploitation or communication of its contents are prohibited unless expressly autho rised Violations may lead to damage compensation All rights are reserved in the event of p...

Page 3: ...ater manifold 23 4 5 5 Air compressor 24 4 5 6 Mortar pressure gauge 24 4 6 Connections 25 4 7 Operating modes 25 4 8 Voltage 230V 400V changing 26 4 9 Pressure booster pump 26 4 10 Accessories 27 5 O...

Page 4: ...63 6 Maintenance 67 6 1 Safety 67 6 1 1 Remove connection cable 68 6 2 Environmental protection 68 6 3 Maintenance plan 69 6 4 Maintenance work 69 6 4 1 Implementation by a service techni cian 69 6 4...

Page 5: ...are for presentation purposes of facts not necessarily to scale and may slightly differ from the actual model of the device 1 2 Division The operating manual is divided into 2 books Part 1 Safety dri...

Page 6: ...escribed Warning Death or serious injury may occur if you do not take the precautions described Caution Minor injury may occur if you do not take the precautions described Note Property damage may occ...

Page 7: ...00 14 EC Internal production control as per article 14 paragraph 2 in connection with annex V This declaration only refers to the machine in the state in which it has been placed on the market Parts s...

Page 8: ...al non flammable gases Maximum operating pressure initial pressure 16 bar After pressure infinitely adjustable from 1 5 to 6 bar Smallest possible initial pressure 2 5 bar Minimum pressure gradient in...

Page 9: ...nly use the flowmeter as intended Always adhere to the usage directives of the material manufacturer Strictly follow all instructions in this operating manual We accept no responsibility for damages c...

Page 10: ...echnically perfect condition as well as for its intended use and while taking into account the safety and hazard information in the operating manual In particular faults that can impair safety must be...

Page 11: ...only in rooms where the hazard of a potentially explosive atmosphere is not given 1 8 5 3 Hot surfaces on the air compressor General information WARNING Risk of injury due to hot surface Surface tempe...

Page 12: ...il Value Unit Empty weight approx 308 kg Length 1200 mm Width 720 mm Height 1530 mm Individual weights Detail Value Unit Pump motor with tilt flange 51 kg Mixing pump 81 kg Material hopper 162 kg Air...

Page 13: ...kW 3 3 A Q6 Water connection Detail Value Unit Operating pressure minimum 2 5 bar Connection inch 2 3 Operating conditions Environment Detail Value Unit Temperature range 2 45 C Relative humidity max...

Page 14: ...pump output Detail Value Unit Pump capacity approx 17 l min at 385 rpm Operating pressure maximum 20 bar Maximum grain size 2 mm Feed range max with 25 mm 15 m Feed range max with 35 mm 20 m Referenc...

Page 15: ...is danger to life from falling parts or uncontrolled swinging parts Therefore Never step under suspended loads Observe the instructions regarding the provided anchorage points Do not attach to project...

Page 16: ...accordance with the transport conditions to be expected Only environmentally friendly materials were used for the packaging The packaging should protect the individual components until the assembly f...

Page 17: ...ght possibly observe eccentric centre of gravity 3 5 Transport in van Figure 6 Transport 1 Remove the water hose from the mixing tube 2 Loosen the locking lever and lift the mixing tube 3 Insert the h...

Page 18: ...ies to face and eyes can occur Therefore Before opening the couplings ensure that there is no more pressure on the hoses observe display at mortar manometer Carry out the following steps before beginn...

Page 19: ...Pump motor 2 Motor protection handle 3 Deflector plate 4 Protective grille with sack opener 5 Material hopper 6 Air compressor 7 Carrying handle 8 Double stop castor 9 Water sampling valve 10 Pressure...

Page 20: ...4 X with 230V AC or 400V three phase drive was specially developed for pumping spraying and applying dry mortar pasty materials for machine use and much more up to 2 mm grain size The pump output can...

Page 21: ...wns and excessive wear on pump motor mixing shaft and pump always use orig inal PFT spare parts such as PFT rotors PFT stators PFT mixing shaft PFT mortar hoses These are compatible with each other an...

Page 22: ...y connector connection for remote control 8 Yellow control lamp wrong direction of rotation 9 Red control lamp motor protection switch activated 10 Pushbutton for control voltage ON OFF 11 Pump motor...

Page 23: ...th motor 1 Pump motor 6 05 kW 2 Mixing tube with rubber mixing section 3 SD 6 3 SLIMLINE pump unit 4 5 4 Water manifold 5 1 2 3 4 8 7 6 Figure 14 Water tap assembly 1 Water flow meter 150 1 500l h 2 P...

Page 24: ...casing and sophisticated filter system Changing filter insert for motor cooling air easy access from the outside and easy replacement The actual intake air for the compressor is taken in via two inter...

Page 25: ...or carrying out a pressure test of the pump Switch position 1 The star wheel is running in sync with the mixing pump motor and is switched on and off using the air control or remote control Figure 19...

Page 26: ...Change voltage 1 Turn the main switch to position 0 2 Open the control cabinet door 3 Switch the voltage switch 1 to 230V or 400V 4 Close the control cabinet door 5 Turn the main reversing switch to...

Page 27: ...4 10 Accessories Injection hood for G 4 RITMO XL HM 24 Item no 20600213 The PFT injection hood is used for feeding dry material to the mixing pump using the PFT SILOMAT pneumatic conveying system Deli...

Page 28: ...mixing of the material Direct drive via tang of the rotor Contents approx 1 2 l ROTOQUIRL II cpl with size 35 coupling Item no 20118400 Remixer for better decomposition and mixing of the material Dire...

Page 29: ...fety socket coupling 32A 5 pin 400 V 3 Ph Item no 00226538 Extension cable 5 x 4 mm RED 5 32 A 25 m 400 V 3 Ph Item no 20423920 Extension cable 5 x 4 mm RED 5 32 A 50 m 400 V 3 Ph Item no 20423900 You...

Page 30: ...s according to the instruc tions in this user manual Prior to starting your work ensure that all components are complete and undamaged Prior to starting your work ensure that all covers and protection...

Page 31: ...n NOTE The machine operator or the person working in the dusty area always has to wear a dust protection mask when filling the machine The rules of the Committee on Dangerous Substances AGS can be fou...

Page 32: ...rmissible operating pressure of at least 40 bar The burst pressure of the mortar hose must reach at least 2 5 times the value of the operating pressure 5 2 Inspection by machine operator Prior to each...

Page 33: ...e machine 2 Put up the machine on a stable even surface and secure against unwanted movements Do not tilt or roll the machine away Place the machine where it cannot be hit by any falling objects The c...

Page 34: ...e operation of the machine make sure that the adapter cable is connected on the mains side and not on the machine side NOTE Check extension cables and adapters for damage and ensure function before st...

Page 35: ...speed can be controlled via the poten tiometer Disadvantage As the machine is controlled via the frequency converter the gear motor no longer reaches its full capacity maximum 4 kW 5 3 3 3 Connecting...

Page 36: ...ump 5 4 3 Figure 37 Connecting the water 4 Clean the water hose 3 from the water supply and bleed 5 Connect the water hose 3 to the water inlet 4 6 Remove the water hose 5 from the mixing tube 7 Open...

Page 37: ...93686 The connected pressure booster pump ensures the required water pressure of at least 2 5 bar NOTE When working with water from the barrel the inlet strainer must be fitted with a filter screen it...

Page 38: ...lamp 4 does not light up 5 3 5 1 Setting the water quantity 1 Figure 42 Press the water supply button 2 3 4 Figure 43 Setting the water quantity 1 Press the water supply button 1 to adjust the water...

Page 39: ...45 Preparing the mortar hose 1 Connect the cleaner coupling 1 at the water extraction valve 2 2 Connect the mortar hose 3 to the cleaner coupling 2 3 Open the water sampling valve 2 and water the mort...

Page 40: ...hoses do not kink 3 Carefully secure risers so that they do not tear away from their own weight 3 Figure 47 Switching on 4 Turn the pump motor selector switch 3 to right position 5 Allow the machine...

Page 41: ...hing on the air compressor 1 Switch on the air compressor using the green toggle switch 1 2 As soon as the air compressor has built up pressure in the pipeline system it switches off using the pressur...

Page 42: ...e master switch main reversing switch and interrupt the power supply NOTE First feed material to the mixing pump G 4 X Pull the dummy connector or switch off the machine using pres sure control air St...

Page 43: ...best if the suction flange is also filled at that time 5 3 9 2 Putting the pressure booster pump into operation 1 2 Figure 55 Connect lines The following instructions have to be observed before operat...

Page 44: ...till air in the pump and this has to be completely vented again The suction line has a leak and the pump draws air The suction side screen is clogged There is a kink in the suction hose The maximum su...

Page 45: ...unctional 5 5 Putting the machine into operation 5 5 1 Checking the mortar consistency Figure 57 Consistency inspection tube 1 Connect consistency inspection tube to the mortar pressure gauge 2 Place...

Page 46: ...3 The G 4 X can be switched on or off using the remote control 5 7 Applying mortar WARNING Danger of injury from discharged mortar Discharged mortar may lead to injuries to eyes and face Never look i...

Page 47: ...be sprayed we recommend application on wall surfaces from top to bottom Uniform mixing and spraying cannot be ensured if the amount of water is insufficient This can clog the hoses and the pumping co...

Page 48: ...to be observed regarding breaks 1 Figure 64 Closing the air tap 1 Close the air tap 1 if the work is interrupted for an extended period of time 2 Figure 65 Switching off the machine 2 Turn the pump mo...

Page 49: ...to the 0 position 2 Turn the main reversing switch 2 to position 0 5 11 Action in case of power failure Figure 68 Turn the main reversing switch to the 0 position Turn the main reversing switch to th...

Page 50: ...ed mortar may lead to injuries to eyes and face Never look into the spray gun Always wear protective goggles Always position yourself in such a way that you are not hit by the mortar being discharged...

Page 51: ...ector switch 5 to right position 8 The machine starts again as soon as the air tap at the spray gun is re opened NOTE In case of a longer power cut the machine and the mortar hoses have to be cleaned...

Page 52: ...manifold dry 2 Turn the star wheel selector switch 4 to the 0 position 3 Turn the booster pump selector switch 5 to the 0 position 4 Turn the pump motor selector switch 6 to the 0 position 5 Turn the...

Page 53: ...danger area Before starting work switch off all electrical power supplies and secure them against being switched back on again If the protective covers are removed for cleaning purposes it is essenti...

Page 54: ...ar hoses and spray gun must be cleaned imme diately at the end of work 1 Connect the cleaner coupling 1 at the water extraction valve 2 2 Press the water saturated sponge ball 3 into the mortar hose 4...

Page 55: ...otor tilt flange and tilt the motor 2 Remove the mixing shaft 1 and clean it 5 13 6 1 Inserting the mixing tube cleaner 1 2 Figure 81 Inserting the mixing tube cleaner 1 Take the mixing tube cleaner 1...

Page 56: ...h 5 to right position 5 Allow the machine to run for approx 5 10 seconds until the mixing tube is cleaned 6 Turn the pump motor selector switch 5 to the 0 position 7 Turn the main reversing switch 3 t...

Page 57: ...se 1 from the mixing tube 2 Undo nuts 2 3 Remove pump unit 3 with pressure flange 4 and mortar pres sure gauge and clean NOTE Only store assembled pumps rotor in stator for a few days since longer sto...

Page 58: ...t 5 14 1 Safety Personnel The work for rectification of faults described here can be carried out by the operator unless marked otherwise Some works must be carried out only by specially trained skille...

Page 59: ...Figure 88 Fault displays The following installation indicates faults Pos Light signal Description 1 Red control lamp Lights up on motor protection switch fault Check the motor protection switch 2 Yell...

Page 60: ...t current Fuse defective Change fuse Service technician Insufficient drop in pressure in the remote control due to blocked air duct or air nozzle pipe Clean blocked air duct or air nozzle pipe Operato...

Page 61: ...et or replace air pressure safety switch Service technician Compressed air hose or gaskets defective Replace compressed air hose replace gaskets or check compressor Service technician Air tap on spray...

Page 62: ...vice technician During opera tion water rises in the mixing tube Hose blockage due to mortar being too thick high pressure due to low water factor Remedy hose blockage increase water factor Service te...

Page 63: ...rticularly to the eyes Persons commissioned with the cleaning of clogged hoses have to wear personal protective equipment protective goggles gloves for safety reasons and must position themselves in s...

Page 64: ...auge has dropped to 0 bar 10 Turn the pump motor selector switch 4 to the 0 position 11 Turn the main reversing switch 1 to position 0 5 14 6 2 Blockage cannot be cleared 2 1 Figure 91 Check and relie...

Page 65: ...1 Turn the main reversing switch 1 to position I 2 Press the green pushbutton 2 control voltage ON 3 Switch on the air compressor using the green toggle switch 4 Turn the booster pump selector switch...

Page 66: ...pump selector switch 4 to the AUTO position 6 Turn the star wheel selector switch 5 to the 1 position 7 Turn the pump motor selector switch 6 to right position 8 Let the machine run for a short while...

Page 67: ...vere injuries or considerable property damage Prior to starting the works ensure that there is enough space to carry out the works Ensure order and safety at the assembly site Unat tached components o...

Page 68: ...ing WARNING Danger to life from unauthorised restarting When working with the tool there is the risk that the energy supply is switched on without authorisation This poses a danger to life for the per...

Page 69: ...n replace filter of compressor Service technician Monthly Clean replace plastic screen in strainer Operator Monthly Clean replace the strainer screen in the pressure reducer Service technician 6 4 Mai...

Page 70: ...iner 1 2 Figure 97 Plastic screen Implementation by operator 1 Remove the closure cap 1 from the strainer 2 Take out the plastic screen 2 from the strainer monthly 3 Clean the screen 4 Replace the scr...

Page 71: ...h air 1 Machine switches ON Machine switches OFF Air 0 9 bar 1 2 bar 6 4 7 Setting value pressure switch air compressor Air compressor switches ON Air compressor switches OFF Compressor 2 5 bar 3 1 ba...

Page 72: ...ection Construction machinery has to be inspected for safe working condition in accordance with the operating conditions and the oper ational requirements as needed however at least once a year by an...

Page 73: ...p G 4 X FU 230 400V Part 2 Overview operation and service Maintenance 6 8 1 Accessories Recommended accessories equipment can be found in the PFT machine and equipment catalogue or under www pft net p...

Page 74: ...fore Prior to starting the works ensure that there is suffi cient space Carefully handle components with sharp edges Ensure order and cleanliness at the working place Loose components and tools on top...

Page 75: ...ble work safety and environmental protection regula tions Prior to starting the disassembly Switch off device and secure against restarting Disconnect the entire energy supply from the machine and dis...

Page 76: ...spose of remaining components sorted according to the type of material NOTE Environmental damage due to incorrect disposal Electrical scrap and components lubricants and other process materials are su...

Page 77: ...Mixing pump G 4 X FU 230 400V Part 2 Overview operation and service Disposal page 77 80...

Page 78: ...Mixing pump G 4 X FU 230 400V Part 2 Overview operation and service Disposal page 78 80...

Page 79: ...Mixing pump G 4 X FU 230 400V Part 2 Overview operation and service Disposal page 79 80...

Page 80: ...S AT YOUR SITE Knauf PFT GmbH Co KG Postfach 60 97343 Iphofen Einersheimer Stra e 53 97346 Iphofen Germany Telephone 49 9323 31 760 Fax 49 9323 31 770 Technical hotline 49 9323 31 1818 info pft net ww...