PFT G 4 User manual

PFT G 4 Operating Instructions 07.2009

Knauf PFT GmbH & Co. KG

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OPERATING INSTRUCTIONS

(Item number of operating instructions: 00 08 32 98)

(Item number of parts list: 00 08 31 19)

MIXING PUMP

PFT G 4

WE KEEP THINGS MOVING

PFT G 4 Operating Instructions 07.2009

Knauf PFT GmbH & Co. KG

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It is prohibited to forward this document, even excerpts, without our written authorisation. All

technical specifications, diagrams etc. are subject to copyright law. All rights, errors and

modifications reserved.

PFT G 4 Operating Instructions 07.2009

Knauf PFT GmbH & Co. KG

3

Dear Customer,

Congratulations on your purchase. You have made a wise choice, because you appreciate the

quality of a brand from a company with a name that exemplifies quality.

The PFT G 4 mixing pump uses state-of-the-art technology. It was designed in a task-optimised

way so that it can be a trustworthy aid for rough construction site conditions.

These operating instructions should always be stored and kept at hand at the machine’s site of

use. They contain information on the various functions of the system. Study the operating

instructions thoroughly before starting the machine, as we claim no responsibility for accidents or

damage to the machine caused by incorrect operation.

The PFT G 4 mixing pump will be a trustworthy aid, if it is operated correctly and handled with

care.

Initial inspection after delivery

An important task of all technicians delivering the PFT G 4 mixing pump is the inspection of the

machine settings at the end of the first work phase. The factory settings can be changed during the

first operation. If these changes are not corrected in time, immediately after initial start-up, then

problems during operation can be expected.

After putting the PFT G 4 mixing pump into service and giving appropriate instructions, after about

two service hours, the technician must always carry out the following checks / make the following

settings:

 Water safety switch

 Pump pressure, backpressure

 Air safety switch

 Pressure reducer

PFT G 4 Operating Instructions 07.2009

Knauf PFT GmbH & Co. KG

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EC Declaration of Conformity

Company: Knauf PFT GmbH & Co. KG

Einersheimer Straße 53

97346 Iphofen

Germany

declare under our sole responsibility that the product:

Machine type: G 4

Type of device: Mixing pump

Serial number:

Guaranteed sound power level: 95 dB

is in conformity with the following CE directives:

• Outdoor directive (2000/14/EC),

• Machine directive (2006/42/EC),

• Electromagnetic Compatibility Directive (2004/108/EG).

Operative Conformity Assessment according to Outdoor Directive 2000/14/EC:

Internal production control as per article 14 paragraph 2 in connection with annex V.

This declaration relates exclusively to the machinery in the state in which it was placed on the

market, and excludes components which are added and/or operations carried out subsequently by

the final user. The declaration ceases to be valid, if the product is modified without authorisation.

Person authorised to compile the relevant technical documentation:

Dipl.-Wirtsch.-Ing. (FH) Michael Duelli, Einersheimer Straße 53, 97346 Iphofen.

The technical documentation is available from:

Knauf PFT GmbH & Co.KG, Technische Abteilung, Einersheimer Straße 53, 97346 Iphofen.

Iphofen, Dr. York Falkenberg

Managing Director

Place, Date of issue Name and signature Details about the signatory

PFT G 4 Operating Instructions 07.2009

Knauf PFT GmbH & Co. KG

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Contents

Contents...................................................................................................................................................................................................5

Proper use of the machine........................................................................................................................................................................6

Functionality.............................................................................................................................................................................................6

Basic safety instructions...........................................................................................................................................................................6

Overview of G 4........................................................................................................................................................................................9

Overview of control box..........................................................................................................................................................................10

Overview of water/air manifold ...............................................................................................................................................................11

Inspection of the setting values (factory settings)....................................................................................................................................12

Checking the conveying pressure and backpressure..............................................................................................................................14

Putting the machine into service.............................................................................................................................................................15

Operation as mixing pump......................................................................................................................................................................16

Mortar consistency.................................................................................................................................................................................19

Spraying guns and nozzles.....................................................................................................................................................................19

Interruption of work.................................................................................................................................................................................19

Measures at the end of work and when cleaning....................................................................................................................................20

Clearing hose blocks..............................................................................................................................................................................22

Measures to taken in the event of a power failure...................................................................................................................................22

Measures to taken in the event of a breakdown of the water supply.......................................................................................................23

Measures to taken if there is a risk of frost..............................................................................................................................................23

Transport................................................................................................................................................................................................24

Maintenance...........................................................................................................................................................................................24

Accessories............................................................................................................................................................................................25

Fault – Cause – Remedy........................................................................................................................................................................26

Spare parts drawing for material hopper and frame................................................................................................................................28

Spare parts list for material hopper and frame........................................................................................................................................29

Spare parts drawing for star wheel.........................................................................................................................................................30

Spare parts list for star wheel.................................................................................................................................................................31

Spare parts drawing for mixing tube and gear motor...............................................................................................................................32

Spare parts list for mixing tube and gear motor.......................................................................................................................................33

Spare parts drawing for pump unit..........................................................................................................................................................34

Spare parts list for pump unit..................................................................................................................................................................35

Spare parts drawing for control box 00045963........................................................................................................................................36

Spare parts list for control box................................................................................................................................................................37

Spare parts drawing for control box........................................................................................................................................................38

Spare parts list for control box................................................................................................................................................................39

Spare parts drawing for water manifold..................................................................................................................................................40

Spare parts list for water manifold ..........................................................................................................................................................41

Spare parts drawing compressor............................................................................................................................................................42

Spare parts list compressor....................................................................................................................................................................43

Spare parts drawing of Water pressure booster pump AV 3 400 V.........................................................................................................44

Spare parts list Water pressure booster pump AV 3 400 V.....................................................................................................................45

Spraying gun 25 mm cap F14 (flat) 200 mm smartline............................................................................................................................46

Check list for annual specialist inspection (master copy)........................................................................................................................49

Technical data........................................................................................................................................................................................50

PFT G 4 Operating Instructions 07.2009

Knauf PFT GmbH & Co. KG

6

Proper use of the machine

The PFT G 4 is a continuously operating mixing pump for pre-mixed machinable mortar with a

particle size of up to 3 mm.

Follow all processing guidelines from the mortar manufacturer.

Functionality

The PFT G 4 mixing pump is a continuously operating mixing pump for pre-mixed ready-to-use dry

mortar. It can be filled either with bagged material or using the delivery or injection hood.

Please observe the processing guidelines of the material manufacturer.

The machine consists of portable individual components of small, handy dimensions and light

weight that allow fast, convenient transport.

When operating the machine, the following aspects must be observed:

 Connection worksite power – control box

 Connection control box – pump motor

 Connection control box – compressor

 Connection compressor – air manifold

 Connection water supply – water manifold

 Connection air manifold – air hose

 Connection air hose – spraying gun

 Connection mixing tube – mortar pressure gauge

 Connection mortar pressure gauge – mortar hose

 Connection mortar hose – spraying gun

Basic safety instructions

The following terms and symbols are used in these operating instructions for particularly important

information:

NOTE:

Special information for running the machine efficiently.

WARNING!

Special information, regulations and restrictions concerning the prevention of damage.

WARNING!

The machine should only be used if it is in technically perfect condition and in compliance with

regulations. Pay attention to safety and the operating instructions. It is especially important to

immediately eliminate all faults that could impair safety.

In order to make the operation of our machines as easy as possible for you, we would like to briefly

inform you of the most important safety regulations. If you comply with these regulations, you will

be able to use our machine in a safe and quality-assuring manner for a long time to come.

PFT G 4 Operating Instructions 07.2009

Knauf PFT GmbH & Co. KG

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General safety instructions

1. Follow the safety instructions and danger warnings on the machine. Ensure that all instructions

are legible!

2. Observe all instructions for switching the machine on and off, control indicators and signal

lamps as stated in the operating instructions.

3. Set up the machine on firm and even ground and secure it against unintentional movements. It

should neither tilt nor roll away. The machine must be set up in such a way that it cannot be hit

by any falling objects. The controls must be freely accessible.

4. Inspect the machine for visible damage and defects at least once every shift! When doing so,

pay special attention to electrical power cables, couplings, plugs, air, water and conveying

lines. Any faults detected must be eliminated immediately.

5. All spare parts must comply with the technical requirements of the manufacturer. This is

guaranteed for all original PFT parts.

6. The machine may only be connected to a worksite switchgear assembly with an FI safety

switch (30 mA). If the machine has a 3-phase frequency converter, then the 30 mA FI safety

switch of the worksite switchgear assembly must be sensitive to all currents.

7. The machine may only be put into service by trained or authorised personnel. Clearly define all

lines of responsibility for operation, retrofitting, service and maintenance.

8. Personnel undergoing training should only be allowed to operate the machine under the

supervision of experienced personnel.

9. All electrical work should be carried out by a qualified electrician or by trained personnel under

the supervision of a qualified electrician and should comply with electro-technical regulations.

10. The machine must be completely switched off for maintenance and repair work. It must be

ensured that it cannot be switched back on accidentally (for example, lock the main switch and

remove the key, or attach a warning sign to the main switch).

11. If work is required on live components, a second person should be present to disconnect the

power in the case of an emergency.

12. Depressurise all conveying systems before opening conveying lines.

13. Before cleaning the machine with a water jet, seal all openings through which water could

enter, thereby impairing the safety and proper functioning of the machine (e.g.: electric motors

and control boxes). After cleaning, remove all covers.

14. Only use original fuses with the prescribed amp ratings!

15. Disconnect the machine from any external power supply before you relocate it, even if you are

only moving it a short distance. Prior to putting the machine back into service, it should be

connected to the mains correctly.

16. The machine may only be moved by crane if it is firmly strapped to a Euro pallet. All removable

parts must be dismantled first. Ensure that nobody enters the crane’s danger area. All

precautions must be taken to prevent parts from falling off.

17. Safety devices such as inclination switches, protective grilles, etc. must not be manipulated.

Before starting work, the safety devices should be inspected separately.

18. Longer work breaks will cause the mortar to set, which would result in problems during

operation. This is why the machine should always emptied and cleaned (incl. spraying gun and

conveying hoses) during long breaks.

19. Objects should never be placed in the dry mortar hopper or pump container.

20. If the permanent noise level exceeds 85 dB(A), appropriate noise protection devices must be

provided.

21. The machine must be inspected by a specialist once a year. This inspection must be

documented and include the following: visual inspection for damage, functional check,

inspection of safety devices, high-voltage check of control box.

22. In case of frost, safety-relevant components could be damaged. If there is a danger of frost,

always drain water from the machine.

23. The machine’s lubrication and maintenance schedule must be complied with, otherwise the

warranty claim will lose its validity.

PFT G 4 Operating Instructions 07.2009

Knauf PFT GmbH & Co. KG

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24. Any changes to the machine are not permitted. Knauf PFT GmbH & Co. KG will not accept any

liability for claims if changes are made.

25. For pumps and mixing pumps, the following additional safety precautions must also be

observed: Wear the following protective clothing when spraying: safety goggles, safety shoes,

safety clothing, gloves, protective skin cream and respirator mask.

When unblocking hoses, stand away from the machine to avoid injury through high-pressure

discharges of mortar. Always wear safety goggles. No other persons should be near the

machine.

Only conveying hoses with an approved operating pressure of at least 40 bar may be used.

The burst pressure of the conveying hose must be at least 2.5 times the operating pressure.

The machine may not be operated without a mortar pressure gauge.

Depressurise all conveying systems before opening mortar pressure hoses. If the machine is

remote-controlled by means of a spraying gun or remote control, the machine can be switched

on and off at all times without anyone needing to work directly at the machine.

PFT G 4 Operating Instructions 07.2009

Knauf PFT GmbH & Co. KG

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Overview of G 4

1. Mixer motor 2. Protection bail for motor

3. Protective grille 4. Compressor

5. Mortar pressure gauge 6. Pump

7. Water manifold 8. Water inlet

9. Control box 10. Tool box

11. Mixing tube

PFT G 4 Operating Instructions 07.2009

Knauf PFT GmbH & Co. KG

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Overview of control box

1. Star wheel selection switch Hand-0-Automatic 2. Water pump selection switch Hand-0-Automatic

3. Orange “Change direction of rotation” control lamp 4. Main reversing switch

5. Red “Operation OFF” pressure switch 6. Green “Operation ON” light switch

7. Water flow button 8. Control lamp motor protection switch activated

9.

Blue pressure switch run pumpmotor bachwards

10. Mains connection 32 A

11. Remote control socket 42 V 12. Blind plug 4-pin

13. CEE socket 4 x 16 A high pressure pump 14. CEE socket 7 x 16 A pump motor

15. CEE socket 4 x 16 A compressor 16. Socket Schuko blue for 230 V 16 A

PFT G 4 Operating Instructions 07.2009

Knauf PFT GmbH & Co. KG

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Overview of water/air manifold

1. Water supply 2. Gauge for water operating pressure

3. Safety switch 1.9-2.2 bar closing unit 4. Safety switch 0.9-1.2 bar opening unit

5. Air to the spraying gun 6. Air from compressor pressure control

7. Pressure reducer 8. Solenoid valve

9. Tap ext. thread 10. Needle valve

11. Water flow meter 12. Water outlet valve

13. Water to mixing tube

PFT G 4 Operating Instructions 07.2009

Knauf PFT GmbH & Co. KG

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Inspection of the setting values (factory settings)

Safety switch

Switching on the machine Switching off the machine

Water 2.2 bar 1.9 bar

Air 1,5 bar 1.9 bar

Compressor 2.5 bar 3.1 bar

Compressor safety valve

4.0 bar against completely closed air pipe (factory setting and secured

with knurled screw)

Pressure reducing valve

1.9 bar at maximum flow (1000 l/h)

Motor protection switch

Output Setting value Description

Water pump 0,37KW 0,37A Q6

Star wheel 0.75 kW 1.96 A Q3

Mixer motor 5.5 kW 11.5 A Q5

Yellow direction of rotation control lamp

The PFT G 4 mixing pump is equipped with a phase sequence relay that

locks the machine if the direction of rotation is incorrect.

The star wheel must be turned in clockwise direction for right-hand rotation.

If the direction of rotation is incorrect (1 yellow control lamp lights up), turn

the main reversing switch to zero position. Push the laterally protruding

selection plate (2) to the opposite side to change the direction of rotation.

Then switch the machine back on.

Star wheel

Gap from star wheel to hopper floor: factory setting approx. 8 mm

Rule of thumb:

1.5 x diameter of the largest ready-

mix dry mortar particle. If required, the

star wheel distance disk (item no. 20 10 19 00) can be installed

for coarse

plaster.

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PFT G 4 Operating Instructions 07.2009

Knauf PFT GmbH & Co. KG

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WARNING!

Mortar pressure gauges are always to be used in compliance with the

safety regulations of the Builder’s Guild.

Mortar pressure gauge

PFT mortar pressure gauges monitor the mortar consistency efficiently and

easily.

The mortar pressure gauge is part of the scope of delivery

Some advantages of the mortar pressure gauge:

 Constant monitoring of the correct conveying pressure

 Early detection of clogging or overloading of the pump motor

 Establishment of zero pressure

 Significant contribution to the safety of operating personnel

 Long service life of pump components

WARNING!

Before installing/removing the mortar pump, make sure that the main switch

is off.

NOTE:

Furthermore observe that:

 A new rotor and a new stator need to be run in; real pressure values can only be determined

after the first spraying.

 Pump components which do not achieve the specified operating pressure (25 bar) are worn out

and must be replaced.

PFT G 4 Operating Instructions 07.2009

Knauf PFT GmbH & Co. KG

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Checking the conveying pressure and backpressure

 Connect a 10 m conveying hose.

 Connect a pressure tester with tap ext. thread to the end of the hose.

 Open the pressure tester’s ball valve.

 Switch on the machine and let it run with water only (without dry material) until water emerges

at the tap (the hose has now been bled).

 Now connect the ball valve to the tap ext. thread.

 Let the pump run against the closed tap until there is no more increase in pressure.

 Switch off the machine.

 If the operating pressure is not reached, the maintenance-free pump must be replaced.

 Check the backpressure.

 A backpressure of approx. 2/3 of the conveying pressure of the screw pump should be

maintained in the hose.

NOTE:

The test pressure with water should be 5 to 10 bar above the expected mortar conveying pressure!

An adverse position of the screw pump in the liner will result in water flowing back to the mixing

area accompanied by a distinct gurgling noise. Switch the machine on and off repeatedly until you

find the position in which the rotor seals with the stator. If required, repeat this procedure several

times.

 An operating pressure of 30 bar should not be exceeded.

 The minimum conveying distance depends mainly on how the mortar flows. Heavy, coarse-

grained mortar does not flow easily. Fluid material flows easily.

 It is recommended to reduce the length of the hose if you exceed an operating pressure of

30 bar.

To avoid machine malfunctions and excessive wear on pump motor, mixing shaft and pump,

always use original spare parts, such as

 PFT rotors

PFT stators

PFT mixing shafts

PFT mortar pressure hoses.

These wearing components are compatible with one another and form a single constructive unit

together with the machine.

If you do not follow these recommendations, you will not only lose your warranty rights, but the

quality of the mortar you are producing will also suffer!

PFT G 4 Operating Instructions 07.2009

Knauf PFT GmbH & Co. KG

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Putting the machine into service

Lock the castor before starting the machine.

Connect the water intake to a ¾" hose. Open the water intake to vent and

clean the hose line. Close the water intake.

Connect the water hose to the water intake (1) or water pump.

Close the drainage valves on the water manifold.

At a water pressure below 2.5 bar, a water pump must be used.

The machine may only be connected to a worksite switchgear assembly

with 32 A fuse protection and a 30 mA FI safety switch that conforms to

regulations. The connection cable should correspond to version H07 RN-F

5 x 4.0 mm². For 5-pin connections only, use the earthling socket to

connect all 230 V consumers (such as portable lamps etc.) and the water

pump.

WARNING!

The protective grille must not be removed during operation or while

preparing the machine.

Before the control box is powered, the following must be observed:

Turn off the main reversing switch (1) (“0” position, lockable).

Turn the star wheel switch (2) to “0” position.

Switch off the compressor.

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PFT G 4 Operating Instructions 07.2009

Knauf PFT GmbH & Co. KG

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Operation as mixing pump

Connect the control box to the power supply.

Turn the main reversing switch (1) to I position.

Press the water flow button (2) (water pump runs).

WARNING!

The G 4 can also be supplied with water from a water barrel. If this is done,

observe that a suction inlet with filter (item no. 00 00 69 06) and a high

pressure pump must be installed.

(Bleed the water pump).

Adjust the water factor.

Adjust the expected water quantity at the needle valve (3). Follow the

mortar manufacturer’s specifications.

During operation: Every interruption of the spraying procedure results in

minor irregularities of the mortar consistency. This normalizes however, as

soon as the machine has been working for a short while. So do not change

the water quantity each time you detect irregularities, but instead wait until

the consistency of the mortar emerging at the spraying gun has self-

adjusted.

Check the water level (can be done with pump motor tilted).

IMPORTANT!

The D6-3 pump unit must always be pre-wetted!

If the 7-

pin connection plug is removed or if the mixing tube or mixing pump

motor is tilted, the control circuit is interrupted (starting lock).

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PFT G 4 Operating Instructions 07.2009

Knauf PFT GmbH & Co. KG

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To put the machine into service, the green “Operation ON” pressure switch

must be used again.

Turn the star wheel switch briefly to “Hand”.

The star wheel can be switched to the positions:

HAND

The star wheel always runs if the machine is connected and switched on. In

this position, mortar can be added to the mixing area, if the pump is not

running. For heavy or dispersion mortars we recommend “pre-wetting” it

and the brief opening of the mixing area’s lower water supply so that

excess water can be drained. (The control circuit must be interrupted by

removing the blind plug.)

ZERO

The star wheel is switched off thus interrupting the supply of mortar to the

mixing area, e.g. when cleaning the mixing area with a mixing cleaner or

when adjusting the pump.

AUTOMATIC

The star wheel runs in synchronisation with the mixing pump and is

switched on and off with the air pressure control or remote control.

Fill the storage container with dry mortar.

Turn the star wheel switch (1) to automatic. The machine is now running.

The mortar consistency can now be checked at the mortar outlet flange

(do not connect the mortar hose yet). While the motor is running, adjust the

water quantity to approx. 10 % above the reference value. The reference

value is the water setting at which the mortar has the right flowing

consistency, e.g.: Knauf – MP 75 – reference value approx. 650 to 750 l/h.

If mortar emerges, correct the water supply for the best consistency by

adjusting the water quantity using the needle valve –

visible at the cone of

the water flow meter.

Turn the hand wheel in clockwise direction to reduce the f

low of water. Turn

it in the opposite direction to increase the flow.

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PFT G 4 Operating Instructions 07.2009

Knauf PFT GmbH & Co. KG

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Press the red “Operation OFF” pressure switch (the machine stops).

Connect the air hose to the air manifold and spraying gun.

Switch on the compressor.

Connect all required mortar hoses to each other and flush with water to avoid hose blocks (do not

leave water in hoses). To do so, use the cleaner coupling (in the tool bag).

If the mortar quality is

unknown, pour approx. 3 litres of lime or plaster slurry into the first hose after the machine.

WARNING!

Make sure that the coupling is clean and correctly joined.

Connect hoses to the mortar pressure gauge and again observe the mortar

hose seal.

Connect the spraying gun (finishing coat gun or crimp valve gun) to the

mortar hose.

Press the green “Operation On” pressure switch and open the air tap on the

spraying gun. The machine starts; cleaning can now be started.

At first, mortar of thin consistency emerges at the spraying gun, then m

ortar

of the correct consistency. It can also be readjusted using the needle valve.

PFT G 4 Operating Instructions 07.2009

Knauf PFT GmbH & Co. KG

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Open and close the air tap on the spraying gun to switch the machine on

and off.

Mortar consistency

The mortar consistency is correct when the material on the sur

face being sprayed flows into itself,

forming a consistent coat (we recommend that you apply material to wall surfaces from top to

bottom). If the material is too dry, even mixing and spraying cannot take place. There may be

clogging in the hose. Pump components are thus subject to greater wear and tear.

Spraying guns and nozzles

Use spraying nozzles of 10, 12, 14, 16 or 18 mm, depending on the mortar consistency. Larger

nozzles reduce the projection speed and thus the rebound effect. Smaller nozzles create better

atomisation. Note that the gap between the air nozzle tube and the nozzle outlet should

correspond to the diameter of the nozzle.

Interruption of work

Warning!

Follow all instructions from the mortar manufacturer when interrupting

spraying work.

It is recommended to clean the pump prior to longer interruptions. To do so,

see the corresponding page 20 – Measures at the end of work and when

cleaning.

Every interruption of the spraying procedure results in minor irregul

arities of

the mortar consistency. This normalizes however, as soon as the machine

has been working for a short while. So do not change the water supply

each time you detect irregularities, but instead wait until the consistency of

the mortar emerging at the spraying gun has self-adjusted.

PFT G 4 Operating Instructions 07.2009

Knauf PFT GmbH & Co. KG

20

Measures at the end of work and when cleaning

WARNING!

Prior to dismantling the screw pump and opening the motor flange, make

sure under all circumstances that pump and hoses are depressurised.

At the end of work, switch off the mortar supply (star wheel),

turn the star wheel switch (1) to “0” position.

Empty the mixing tube.

Press the red “Operation OFF” pressure switch (2).

Switch off the compressor and open the tap on the spraying gun.

Disconnect the mortar hose (only when depressurised).

Release the snap lock (1) on the motor flange and tilt the motor.

Remove and clean the mixing shaft (2).

Clean the mixing area with a spatula.

Insert the cleaning shaft and mixing tube cleaning agent with the scrapers

at the bottom.

Close the motor flange and lock it with the snap lock.

Press the green “Operation ON” pressure switch for approx. 5 -

10 seconds

and let the machine run until the mixing tube is clean.

Press the red “Operation OFF” pressure switch, remove the mixer cleaner.

Install the cleaned mixing shaft. Close the motor flange and lock it with the

snap lock.

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PFT G 4 User manual

PFT G 4 User manual

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