PFT AV 1000, Operating Manual

Page 1: ...standalone with integrated pressure switch off and flow meter AV1000 with Handle 230V 50Hz Safety Overview Operation Spare Parts Lists Item number of operating manual 00254386 Item number of the machine parts list 00493686 Read the operating manual before starting any work ...

Page 2: ...21 05 12 Knauf PFT GmbH Co KG Postfach 60 97343 Iphofen Einersheimer Straße 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 net www pft net ...

Page 3: ...1000 19 8 Overview High pressure pump AV1000 20 10 Description PFT AV1000 21 10 1 Advantages of PFT AV1000 21 10 2 AV1000 fields of application 21 10 3 Proper use of the machine 21 11 Transport storage and packaging 22 11 1 Safety instructions for transport 22 11 2 Transportation checklist 22 11 3 Packaging 22 12 Safety 23 12 1 Fundamental safety instructions 23 13 Preparation High pressure pump A...

Page 4: ...SERVICE the pump is running 36 25 4 OUT OF SERVICE 36 25 5 ERROR stopped temporarily due to dry running 36 25 6 ERROR temporary shut down due to frequent start up 37 26 Low water level 39 27 Spare parts drawing spare parts list 40 27 1 Spare parts drawing High pressure pump AV1000 40 27 2 Spare parts list of the assemblies 41 27 3 Spare parts drawing High pressure pump AV1000 42 27 4 Spare parts l...

Page 5: ...ude 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 not necessarily shown to the correct scale and may vary slightly from the actual equipment used 1 2 Information on the safety instructions These safety instructions give important notes and instructions o...

Page 6: ...l damage if it is not avoided Tips and recommendations NOTE Contains useful tips and recommendations plus further information on efficient and problem free operation Special safety instructions The following symbols are used in conjunction with safety instructions in order to illustrate certain types of danger DANGER Danger of death due to electric current Indicates a potentially life threatening ...

Page 7: ...onally the obligations defined in the delivery contract the general terms and conditions the delivery requirements of the manufacturer and the valid regulations at the time of contract conclusion all apply 1 5 Copyright protection Keep the manual and its contents confidential It is only to be used by personnel who actively use the machine Forwarding of the manual to third parties without prior wri...

Page 8: ...ements 2 Safety This section provides an overview of all important safety aspects These offer optimal levels of safety for personnel and safe and problem free operation Significant danger may result from non compliance with the operating steps and safety instructions detailed in this manual 2 1 Owner responsibility The equipment is intended for industrial use The owner of the equipment is therefor...

Page 9: ...r the technical functionality and condition of the equipment The following rules apply here The owner must ensure that the maintenance intervals detailed in this operating manual are observed The owner must have all safety devices regularly checked for functionality and completeness The owner must provide the personnel with the necessary protective equipment 2 2 Operating personnel 2 2 1 Requireme...

Page 10: ...vironment in question and are aware of the relevant standards and instructions Only persons that carry out their work responsibly are permitted to work with the system Persons with impaired reactions e g due to drugs alcohol or medication are not permitted Observe the age and job specific regulations when selecting personnel for the work on site Unauthorised individuals WARNING Unauthorised indivi...

Page 11: ...to improper use of the machine Improper or unauthorised additional use of the system can lead to dangerous situations Therefore Use the machine only for its intended purpose Always observe all processing guidelines from the material manufacturer Strictly observe all instructions in this operating manual We accept no responsibility for damages caused by improper or unauthorised use The owner is sol...

Page 12: ...as protection from being caught by moving machine parts Do not wear rings chains and other jewellery Safety shoes Protect against heavy falling parts and slipping on slippery surfaces Safety goggles Protect the eyes from flying projectiles and splashing liquids Ear protection Protects against damage caused by loud noises Safety helmet Protects against falling and flying parts and materials Safety ...

Page 13: ...ealth risks and avoid dangerous situations Electric current DANGER Danger of death due to electric current Contact with live components can lead to death or serious injury Damage to electrical insulation or individual components can be potentially life threatening Therefore If insulation damage occurs switch off the electrical supply immediately and organise repairs Work on electrical systems shou...

Page 14: ... as long as absolutely necessary Moving parts WARNING Danger of injury due to moving parts Rotating and oscillating parts can cause serious injuries Therefore Do not reach into or handle moving parts during operation Do not open safety covers during operation Pay attention to run down times Before opening covers ensure that parts are no longer moving Wear close fitting protective clothing in the d...

Page 15: ...fety devices Do not block the access to safety devices such as emergency stop push buttons pull cords etc 2 7 Dealing with dangerous situations and accidents Preventative measures Always be prepared in case of accidents or fires Make first aid equipment bandages blankets etc and fire extinguishers easily accessible Inform your personnel about accident reporting first aid and rescue equipment Keep ...

Page 16: ...r unreadable Therefore Always maintain all safety warning and operating notices in legible condition Replace damaged signs or labels immediately 3 Operating Manual Knauf PFT Downloads Datenblätter Use our wizard to find specific downloads Operating Manual Devices tools accessories Water pump Select your preferred language for downloads All languages Search for downloads search 3 1 Accessories For ...

Page 17: ...ge 3 phase current 50 Hz 230 115 V Frequency 50 60 Hz Current max for 3 sec 12 A Current max for 3 sec 16 A Protection grade IP 65 Start up pressure Pm 0 8 1 5 2 2 bar Shut off f10w rate Qa 1 2 litres min Maximum morking pressure 10 bar Bursting pressure 40 bar Protection against dry running automatic restart repeated start ups Max room temperature 40 C Max liquid temperature 55 C Type of drive 1C...

Page 18: ...on Value Unit Liquid temperature 1 40 C Admissible working pressure 5 5 bar 4 4 Output values m h 0 0 3 0 6 1 2 1 5 1 8 2 4 2 7 3 0 3 3 l min 0 5 10 20 25 30 40 45 50 55 H m 48 43 39 32 29 5 27 5 23 21 5 19 5 18 5 Sound power level Sound power level LWA 75 dB A 6 Vibrations Weighted effective acceleration value to which the upper limbs are exposed 2 5 m s ...

Page 19: ...AV1000 with Handle 230V 50Hz Safety Overview Operation Spare Parts Lists Dimension sheet AV1000 2021 05 12 19 7 Dimension sheet AV1000 Fig 1 Dimension sheet High pressure pump AV1000 540 380 270 ...

Page 20: ...erview High pressure pump AV1000 Abb 2 Übersicht AV1000 1 Handle bracket 2 Pump motor 3 Pump AV1000 4 Connector 5 Water drain tap frost protection 6 Water inlet 1 7 Water filler plug 8 Operating push button ON OFF 9 Pressure controller flow monitor 10 Pressure gauge for water pressure 11 Water outlet 1 11 10 9 8 7 6 5 1 2 3 4 ...

Page 21: ...s a primer pump for drawing liquids from containers for emptying small tanks and ponds for pumping water out of cellars and for irrigation The water supply is automatically ensured from a water tank by the PFT AV1000 for the constant water supply to the PFT machine engineering The flow pressure of min 2 5 bar when the machine is running is ensured on size by drawing water from the water tank Conne...

Page 22: ...oceed as follows Do not accept the delivery or accept it only under reservations Note the damage on the transportation documents or the delivery note of the carrier Submit the appropriate claim NOTE Always submit a claim for the defects as soon as they are detected Damage claims can only be accepted within the applicable deadlines for submission 11 3 Packaging Handling the packaging materials Prov...

Page 23: ...rators must wear the following protective equipment Protective work clothing Safety goggles Safety gloves Safety shoes Ear protection NOTE The warning signs illustrated in this chapter relate to additional protective equipment that must be worn for particular working conditions Basic information WARNING Danger of injury due to improper operation Improper operation can lead to serious injuries or e...

Page 24: ...ant Ensure that the suction line or intake line is connected to the port marked Intake and the pressure line to the port marked Pressure If the pump is operated in suction mode ensure that the suction line is kept as short as possible 14 Initial operation filling the pump Fig 3 Filling the pump Before putting the PFT High Pressure Pump into operation for the first time fill the pump with water so ...

Page 25: ...r tight and that the end is immersed in the liquid to be pumped to avoid drawing in air Fig 5 Inlet strainer with filter screen Article No 00006906 The end of the suction line 3 must be fitted with an inlet strainer with filter screen and integral non return valve An additional fine filter in the suction line is recommended NOTE The delivery of the pump decreases with increasing suction line lengt...

Page 26: ...The pump must not be allowed to run dry in order to avoid damage Basic information WARNING Danger of injury due to improperly performed maintenance work Improper maintenance can lead to serious injuries or equipment damage Therefore Ensure there is adequate space for assembly before starting any work Keep the assembly area clean and tidy Loose components and parts in the operating area can cause a...

Page 27: ... place and functioning properly 16 Troubleshooting 16 1 Handling malfunctions Handling malfunctions Generally the following applies 1 For all malfunctions posing the risk of material damage or personal injury perform an emergency stop immediately 2 Determine the cause of the malfunction 3 If troubleshooting requires working in the danger zone switch off the machine and secure it against being swit...

Page 28: ...eft lying around can cause accidents If components are removed make sure they are properly reassembled with all fastening elements Electrical system DANGER Danger of death due to electric current Contact with live components can lead to death or serious injury Live electrical components can move uncontrollably and cause serious injury Before starting work switch off the electrical power supply and...

Page 29: ...d other equipment have been removed from the work area 18 Measures to be taken if there is a risk of frost Caution Damage due to frost Water that expands on freezing inside the pump can cause serious damage to the pump Carry out the following if the pump is not in operation at temperatures close to freezing Fig 6 Pump system 1 In the event of a frost risk open the water drain plug 1 and empty the ...

Page 30: ... 1 Safety Personnel Disassembly may only be performed by specially trained personnel Work on electrical systems may only be performed by qualified electricians Basic information WARNING Danger of injury due to improper disassembly Residual energy sharp edged components and corners on and around the device or on necessary tools can cause injuries Therefore Ensure there is adequate space before star...

Page 31: ...switched on again Disconnect the entire energy supply from the device and discharge the residual energy Remove operating and auxiliary materials as well as residual processing material and dispose if them in an environmentally sound manner 19 3 Disposal Provided no return or disposal agreements have been made recycle the disassembled parts Metallic parts are scrapped Plastic elements are recycled ...

Page 32: ... when the required flow rate is cancelled or drops below the cut out flow rate Qa The electronics of the flow monitor protect the pump against abnormal operating conditions such as dry running or frequent starting due to losses in the system 21 Operating conditions 21 1 Working area 21 2 Compatible non compatible fluids EASY PRESS is suitable for use with clean mater and chemically non aggressive ...

Page 33: ...age that may arise as a result of maintenance or repair work carried out by unqualified personnel and or the use of non original spare parts The use of non original spare parts tampering or improper use will invalidate any claim for replacement under guarantee When starting the installation check the following The power supply is switched 0ff The power lines can withstand the maximum current The c...

Page 34: ...p must be at least 1 1 5 bar higher than the start up pressure Pm If the pressure produced by the pumps too low EASY PRESS will stop the pump and indicate a dry running error message Attention EASY PRESS is fitted with a check valve do not use the EASY PRESS s outlet to fill the pump tor priming 23 1 Switching the pump on The red Power LED lights up EASY PRESS instantly detects that there is no pr...

Page 35: ...s 25 1 No power supply EASY PRESS is switch off Press briefly or hold down Nothing happens Power is restored EASY PRESS resumes normal service and starts the pump if necessary 25 2 NORMAL SERVICE the pump is inactive The system is pressurised All taps are turned off There is no demand for water EASY PRESS detects an assembly pressure higher than that of the start up pressure PM and no flow Press b...

Page 36: ...For instructions on how to reactivate the pump The taps are turned oft Sif there no flow for a few seconds the pomp is stopped 25 4 OUT OF SERVICE The pump has been stopped manually The pump will remain inactive until a new command is given Press briefly Nothing happens Hold down The pomp resomes NORMAL SERVICE 25 5 ERROR stopped temporarily due to dry running EASY PRESS has detected that the pump...

Page 37: ...ASY PRESS to another position Install a model with a higher start up pressure Pm Faulty electrical connections or pump out of service Check the electrical connections and that the pump is working EASY PRESS OUT OF SERVICE Reset EASY PRESS EASY PRESS in temporary shut down due to dry running due to lack of water Wait for the automatic restart or press START to restart manually Maximum pump pressure...

Page 38: ... off flow rate Qa Check the hydraulic connections and repair any leaks lt a leak cannot be repaired install an expansion tank The pump will not stop The flow rate is higher than the shut off flow rate Oa Make sure that all taps are turned off and that there are no leaks within the system EASY PRESS check valve will not close Check that the valve is not blocked by any foreign objects and clean if n...

Page 39: ...s than 2 minutes This is caused by a flow rate of less than 1 2 litres min This can endanger the pump In the event of minor losses dripping the tank of the monitor ensures that stopping and starting occurs at intervals of at least 2 minutes less than 30 starts of the pump per hour and no abnormal conditions due to FREQUENT STARTING occur If serious losses occur in the system or in the case that th...

Page 40: ...w Operation Spare Parts Lists Spare parts drawing spare parts list 40 2021 05 12 27 Spare parts drawing spare parts list 27 1 Spare parts drawing High pressure pump AV1000 1 2 3 4 5 6 5 18 17 7 8 9 10 11 12 13 14 15 16 17 26 25 24 23 22 21 20 19 ...

Page 41: ...age AV1000 8 on request Front bearing cover AV1000 9 on request Pump body cover AV1000 10 on request O ring AV1000 pump body 11 20470008 Circlip dia AV1000 12 00598430 Impeller for pressure booster pump AV 1000 AV 1000 standalone 110 V 50 Hz 13 20207200 Impeller groove AV1000 14 on request Diffusor AV10000 15 on request AV1000 pump body 16 on request Screw pump body 17 on request Screw with gasket...

Page 42: ...witch off and flow meter 230 V 1 Ph 50 Hz 0 6 kW 2 1 00130454 Angle 1 internal thread V2A 3 1 00493685 Water pump as suction pump AV 1000 standalone 230 V 1 Ph 50 Hz 0 6 kW with pressure switch 4 1 20200800 Geka coupling 1 external thread packing unit 10 pcs 5 1 00130218 Sticker AV 1000 standalone 6 1 00130221 Pressure switch AV 1000 standalone 50 60 Hz 7 1 20201691 High pressure suction coupling ...

Page 43: ...1 05 12 43 27 5 Spare parts drawing prefilter AV1000 cpl 27 6 Spare parts list prefilter AV1000 cpl Pos Qty Item no Description 1 1 00130219 Prefilter AV1000 cpl 2 1 20201681 High pressure coupling 3 4 ext thread with seal 3 1 00130220 Pre filter AV 1000 standalone 4 1 20200910 Geka coupling 3 4 ext thread 1 2 3 4 ...

Page 44: ...ral information 5 General specifications 17 Handling malfunctions 27 How the pressure and flow monitor works 35 Index 44 Information on the safety instructions 5 Information regarding the operating manual 5 Initial start up Pressure and flow monitor 34 Instruction 9 Intended use 11 Labels 16 Liability 7 Low water level 39 Maintenance 28 Maintenance work on the machine 28 Measures to be taken if th...

Page 45: ...h pressure pump AV1000 42 Spare parts drawing prefilter AV1000 cpl 43 Spare parts drawing High pressure pump 40 Spare parts drawing spare parts list 40 Spare parts list of the assemblies 41 Spare parts list of the assemblies 42 Spare parts list prefilter AV1000 cpl 43 Special dangers 13 Specialists 10 Switching off in an emergency 27 Switching the pump on 34 Symbols in the danger zone 16 Symbols i...

Page 46: ...Spare Parts Lists 46 2021 05 12 PFT ALWAYS AT YOUR SITE Knauf PFT GmbH Co KG Postfach 60 97343 Iphofen Einersheimer Straße 53 97346 Iphofen Deutschland Telefon 49 9323 31 760 Telefax 49 9323 31 770 Technische Hotline 49 9323 31 1818 info pft net www pft net ...