PFT G 4 X FU Series Operating Manual
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PFT G 4 X FU Series Operating Manual

Mixing pump 230/400v
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2020-01-07
Operating Manual
Mixing pump G 4 X FU 230/400V
Part 2 EC Declaration of Conformity
Overview - Operation
Article number of the operating manual: 00 43 75 45
Article number of the machine: 00 26 06 21
Article number of the machine: 00 42 34 08
Article number of the machine: 00 42 21 35
Article number of the machine: 00 42 39 50
Read the operating manual prior to starting any work!

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  • Page 1 Table of Contents 2020-01-07 Operating Manual Mixing pump G 4 X FU 230/400V Part 2 EC Declaration of Conformity Overview - Operation Article number of the operating manual: 00 43 75 45 Article number of the machine: 00 26 06 21 Article number of the machine: 00 42 21 35 Article number of the machine: 00 42 34 08 Article number of the machine: 00 42 39 50...
  • Page 2 © Knauf PFT GmbH & Co. KG P.O. Box no. 60 97343 Iphofen Einersheimer Straße 53 97346 Iphofen Germany Phone: +49 (0) 93 23/31-760 Fax: +49 (0) 0 93 23/31-770 Technical hotline +49 9323 31-1818 info@pft.net Internet: www.pft.net 2020-01-07...

  • Page 3: Table Of Contents

    5.2 Power connection ........10 15.4 Dry-running air compressor ....21 5.3 Operating conditions ......10 5.4 Power values ......... 11 16 Description PFT Booster pump 5.5 Sound power level ......... 11 (Accessory) ........22 5.6 Vibrations ..........11 16.1 Scope of application Booster pump ..22 16.2 Intended use .........
  • Page 4 Mixing pump G 4 X FU 230/400V Overview - Operation Table of Contents 23 Transport, packing and storage ..26 35.2 Connect mortar hose ......39 23.1 Safety instructions for transport ... 26 36 Compressed air supply ....40 23.2 Transport inspection......27 36.1 Connect air hose ........
  • Page 5 Mixing pump G 4 X FU 230/400V Overview - Operation Table of Contents 42.5 Switch the machine back on after the 48 Changing the pump / Cleaning the blockage has been removed (230V) . 52 pump ..........59 48.1 Fold up mixing tube ......59 43 Connection of power supply 48.2 Clean rubber mixing section ....

  • Page 6: Ec Declaration Of Conformity

    Person authorised to compile the relevant technical documentation: Diploma in industrial engineering (FH) Michael Duelli, Einersheimer Straße 53, 97346 Iphofen. The technical documentation is available from: Knauf PFT GmbH & Co.KG, Technical Department, Einersheimer Straße 53, 97346 Iphofen. Iphofen Dr. York Falkenberg...

  • Page 7: Examination

    Mixing pump G 4 X FU 230/400V Overview - Operation Examination 2 Examination 2.1 Examination by machine operator  Prior to each shift, the machine operator has to examine the effectiveness of the control and safety devices as well as the proper fitting of the protection devices.

  • Page 8: General Information

    Part 2 Overview, operation and service (this manual). For safe operation of the device both parts have to be read and observed. Together they form one operating manual. 3.4 Spare parts lists Spare parts lists for the machine can be found on the Internet at www.pft.eu. 2020-01-07...

  • Page 9: Spare Part Lists

    Mixing pump G 4 X FU 230/400V Overview - Operation Spare part lists 4 Spare part lists You can find spare part lists for the machine in the Internet under www.pft.net 4.1 Accessories 2020-01-07...

  • Page 10: Technical Data

    Mixing pump G 4 X FU 230/400V Overview - Operation Technical data 5 Technical data 5.1 General information Detail Value Unit Weight approx. 308 kg Length 1200 mm Width 720 mm Height 1530 mm Individual weights Detail Value Unit Weight pump motor with tilt flange 51 kg Weight of mixing pump module 81 kg...

  • Page 11: Power Values

    Mixing pump G 4 X FU 230/400V Overview - Operation Technical data Duration Detail Value Unit Max. operating time at a stretch 8 hours Detail Value Unit Electrical details voltage, three-phase current 50 Hz 230 / 400 V Power consumption, max. 18 A Power input, max.

  • Page 12: Dimension Sheet

    Mixing pump G 4 X FU 230/400V Overview - Operation Dimension sheet 6 Dimension sheet 1200 Fig. 2: Dimension sheet 7 Name plate The type plate is located at the right bottom of the hopper and includes the following information: Manufacturer Type Year of manufacture...

  • Page 13: Assembly

    Mixing pump G 4 X FU 230/400V Overview - Operation Assembly 9 Assembly 9.1 Overview Fig. 5: Table of the assembly groups 1. Pump motor 10. Booster pump 2. Motor protection handle 11. Water tap 3. Deflector plate 12. Connection for mortar hose 4.

  • Page 14: Description Of Assemblies

    Mixing pump G 4 X FU 230/400V Overview - Operation Description of assemblies 10 Description of assemblies The mixing pump PFT G 4 X consists of the following main components: 10.1 Hopper  Hopper with frame and protective grille Fig. 6: Assembly unit hopper 10.2 Control cabinet article number 00 25 46 51...

  • Page 15: Mixing Tube With Motor And Pump

    Mixing pump G 4 X FU 230/400V Overview - Operation Description of assemblies 10.3 Mixing tube with motor and pump 1. Pump motor 5.5kW 2. Mixing tube with rubber mixing section 3. Pump unit SD6-3 SLIMLINE Fig. 8: Assembly unit mixing tube with motor 10.4 Water fitting 1.

  • Page 16: Connections

    Mixing pump G 4 X FU 230/400V Overview - Operation Connections 11 Connections 1. Main terminal 2. Connections material hoses 3. Connection water supply from mains 4. Connection air to spray gun 1 2 3 Fig. 11: Connections 12 Operating modes 12.1 Selector switch star wheel The star wheel can be operated in three operating modes: Selector switch position “0”:...

  • Page 17: Selector Switch Pressure Booster Pump

    (article number 20 60 05 00) The PFT delivery hood is used for feeding dry material to the mixing pump PFT G 4 directly from the silo / container. In case of an empty alarm in the hopper, the mixing pump is switched of via the remote control socket.

  • Page 18: Adapter Cable

    Power cable 5 x 4 mm² 25m with CEE plug and coupling 5 x 32A 6h red (article number 20 42 39 20) Fig. 22: Power cable 13.1 Adapter cable Adapter cable reversible plug Schuko/coupling (Article number 00 22 65 38) Fig. 23: Adapter cable Further accessories can be found at www.pft.eu 2020-01-07...

  • Page 19: Intended Use Control Panel

    Mixing pump G 4 X FU 230/400V Overview - Operation Intended use Control panel 14 Intended use Control panel 14.1 Intended purpose control panel The tool is conceptualised and designed exclusively for the purpose of use specified here. Scope of application: Primary use for water and neutral, non-adhesive liquids.

  • Page 20: Intended Use Air Compressor

    Mixing pump G 4 X FU 230/400V Overview - Operation Intended use air compressor WARNING! Danger due to improper use! Any case of use beyond the specified purpose of use and/ or any other sort of use of the tool can lead to dangerous situations.

  • Page 21: Safety Systems Air Compressor

    Mixing pump G 4 X FU 230/400V Overview - Operation Intended use air compressor 15.2 Safety systems air compressor WARNING! Danger of death due to non-functioning safety equipment! Safety equipment ensure highest level of safety in operation. Even if work processes become a little more complicated due to safety equipment, they must never be decommissioned.

  • Page 22: Description Pft Booster Pump (Accessory)

    16 Description PFT Booster pump (Accessory) 16.1 Scope of application Booster pump The PFT booster pump is mainly used as booster pump for interposing at the mortar mixer and mortar mixing pumps with insufficient water pressure. Moreover it can be used as suction pump to suck liquids from containers, to empty smaller pools and ponds, for cellar drainage and irrigation.

  • Page 23: Preparation Booster Pump Av3 (Accessory)

    18 Initial start-up booster pump Fill the PFT booster pump with water prior to initial start-up to let the air escape from the pump housing. Check the strainer at the water inlet (1).

  • Page 24: Description G 4 X Fu 230/400V

    The dry mortar it thrown into the mixing chamber via the inclined star wheel. The PFT G 4 X can be started and refilled at any time. The star wheel is powered separately and can be quickly disassembled using a central locking mechanism.

  • Page 25: Functional Description G 4 X Fu 230/400V

    If 20 bar operating pressure are exceeded the mortar hose length has to be reduced.  In order to avoid machine faults and increased wear of the pump motor, pump shaft and the pump itself, only original PFT spare parts such as  PFT rotors ...

  • Page 26: Mortar Pressure Gauge

    Early detection of clogging or overload of the pump motor.  Relieving pressure.  Long service life of the PFT pump parts.  Is a major contribution to the safety of the operators. Fig. 30: Mortar pressure gauge 22 Safety rules...

  • Page 27: Transport Inspection

    Mixing pump G 4 X FU 230/400V Overview - Operation Transport, packing and storage Suspended loads WARNING! Danger to life from suspended loads! When lifting heavy loads there is danger to life from falling parts or uncontrolled swinging parts. Therefore: ...

  • Page 28: Transport

    Mixing pump G 4 X FU 230/400V Overview - Operation Transport, packing and storage 23.3 Transport Anchor points Anchor the machine at the anchor points with a rope for transport by crane. Observe the following conditions:  The crane and lifting equipment have to be designed for the weight of the packages.

  • Page 29: Transport In Individual Parts

    Mixing pump G 4 X FU 230/400V Overview - Operation Packaging 23.5 Transport in individual parts 1. Disassemble the machine in the units mixing tube and hopper for easier transport. These can be transported separately. Fig. 33: Transport 24 Packaging For packaging The individual packages have to be packed in accordance with the transport conditions to be expected.

  • Page 30: Operation

    Mixing pump G 4 X FU 230/400V Overview - Operation Operation 25 Operation 25.1 Safety The following protective equipment has to be worn for all operative Personal protective equipment work:  Protective clothing  Protective goggles  Protective gloves  Safety shoes ...

  • Page 31: Preparing The Machine

    Mixing pump G 4 X FU 230/400V Overview - Operation 27 Preparing the machine Prior to operating the machine carry out the following steps for preparing the machine: DANGER! Running star wheel! Risk of injury when reaching into the running star wheel.

  • Page 32: Check The Individual Connectors

    Mixing pump G 4 X FU 230/400V Overview - Operation Connecting the power supply 400V 28.1 Check the individual connectors  Connection of pump motor (1). NOTE! The booster pump is necessary should the water pressure be less than 2.5 bar when the machine is running.

  • Page 33: Connection Of Water From Water Tank

    Mixing pump G 4 X FU 230/400V Overview - Operation Connecting the power supply 400V NOTE! Never let the pump run dry as this reduces the service life of the pump. 5. Remove the water hose (5) from the mixing tube. 6.

  • Page 34: Switching On The G 4 X (400V)

    Mixing pump G 4 X FU 230/400V Overview - Operation Switching on the G 4 X (400V) 29 Switching on the G 4 X (400V) 29.1 Putting the machine into operation (400V) 1. Turn main switch (1) to position "I". 2.

  • Page 35: Soaking Of The Mixing Section

    Mixing pump G 4 X FU 230/400V Overview - Operation Mortar pressure gauge 29.3 Soaking of the mixing section NOTE! As a rule, the pump has to be soaked. The soaking process permits an easier start-up of the pump. 1. Connect the water hose (1) to the mixing tube. 2.

  • Page 36: Anti-Dust Unit For G 4 Completely

    Mixing pump G 4 X FU 230/400V Overview - Operation Feeding dry material to the machine 31.1 Anti-dust unit for G 4 completely Anti-dust unit G 4 article number 00 53 97 16. Consisting of: completely RAL2004 1. Anti-dust hood 2.

  • Page 37: Monitoring The Machine

    Mixing pump G 4 X FU 230/400V Overview - Operation Monitoring the machine Feeding with injection hood:  Accessory article number 20 60 02 13  Put the delivery hood instead of the grille cover. DANGER! Risk of injury at the star wheel! Do not open the machine during pneumatic conveying.

  • Page 38: Putting The Machine Into Operation

    Mixing pump G 4 X FU 230/400V Overview - Operation Putting the machine into operation 34 Putting the machine into operation 34.1 Check consistency of mortar 1. Connect consistency test tube at the mortar pressure gauge. 2. Place a bucket or pan under the consistency test tube. Article number: 20104301 Consistency test tube 25m piece Fig.

  • Page 39: Mortar Hoses

    Mixing pump G 4 X FU 230/400V Overview - Operation Mortar hoses 35 Mortar hoses 35.1 Prepare mortar hoses 1. Connect the cleaner coupling (1) at the water extraction valve (2). 2. Connect the mortar hose (3) at the cleaner coupling. 3.

  • Page 40: Compressed Air Supply

    Mixing pump G 4 X FU 230/400V Overview - Operation Compressed air supply 36 Compressed air supply 36.1 Connect air hose 1. Connect compressed air hose (1) at the air fitting. DANGER! Never loosen the hose couplings as long as the compressed air hose is not depressurised.

  • Page 41: Apply Mortar

    Mixing pump G 4 X FU 230/400V Overview - Operation Apply mortar 37 Apply mortar DANGER! Risk of injury from discharged mortar! Discharged mortar may lead to injuries to eyes and face.  Never look into the spraying device.  Always wear protective goggles.

  • Page 42: Interruption Of Work

    Mixing pump G 4 X FU 230/400V Overview - Operation Apply mortar 37.2 Interruption of work NOTE! Always observe the setting time of the material to be processed: Clean the system and mortar hoses depending on the setting time of the material and the length of the interruption (pay attention to outside temperature).

  • Page 43: Remote Control

    Mixing pump G 4 X FU 230/400V Overview - Operation Remote control 38 Remote control 38.1 Working with the remote control 1. Remove dummy connector (1) from control cabinet. 2. Connect remote control (2). 3. The G 4 X can be switched on or off using the remote control. Fig.

  • Page 44: Measures In Case Of Power Cut

    Mixing pump G 4 X FU 230/400V Overview - Operation Measures in case of power cut 40 Measures in case of power cut 40.1 Main switch to position “0“ 1. Close the air tap at the spraying gun. 2. Turn the main switch (1) to position "0". 3.

  • Page 45: Work On Troubleshooting

    Mixing pump G 4 X FU 230/400V Overview - Operation Work on troubleshooting NOTE! The G 4 X is equipped with a restart interlock. In case of a power cut, the system has to be started as follows. 5. Turn main switch (3) to position "I". 6.

  • Page 46: Fault Displays

    Mixing pump G 4 X FU 230/400V Overview - Operation Work on troubleshooting 41.2 Fault displays The following installation indicates faults: Pos. Light signal Description Red pilot lamp Lights up on motor protection switch fault. Check motor protection switch Yellow pilot Lights up if the direction of rotation is lamp wrong (400V).

  • Page 47: Table Of Faults

    Mixing pump G 4 X FU 230/400V Overview - Operation Work on troubleshooting 41.5 Table of faults Fault Possible cause Solution Rectification by Machine does Water pressure too low Check water supply, clean strainer Operator/Service not start screen engineer water Pressure gauge shows less than Check booster pump Service engineer...
  • Page 48 ½ minute and then turn "thick-thin" down slowly Water safety switch set incorrectly Adjust or replace water safety switch Service engineer or defective Agitator defective; no original PFT Replace agitator with original PFT Operator agitator agitator Pressure reducer set incorrectly or...

  • Page 49: Signs For Hose Blockages

    Mixing pump G 4 X FU 230/400V Overview - Operation Work on troubleshooting Fault Possible cause Solution Rectification by Bad mixture in mixing tube Add more water Operator Mortar flow ceases (air Material is clumped and narrows Add more water or clean agitator or Operator bubbles) the mixing tube inlet...

  • Page 50: Causes For This Can Be

    Mixing pump G 4 X FU 230/400V Overview - Operation Removal of blockages in the hose 41.7 Causes for this can be: Highly worn mortar hoses, badly greased mortar hoses, residual water in mortar hose, clogging of the pressure flange, strong tapering at the couplings, kink in mortar hose, leaks at the couplings,...

  • Page 51: Change The Direction Of Rotation Of The Mixing Pump Motor In Case Of Blockages In The Hose (230V)

    Mixing pump G 4 X FU 230/400V Overview - Operation Removal of blockages in the hose 1. Turn main switch (1) to position "I". 2. Press the green push button (2) control voltage “ON”. 3. The yellow pilot lamp (3) for changing the direction of rotation lights up (400V).

  • Page 52: Switch The Machine Back On After The Blockage Has Been Removed (400V)

    4. If required, insert a rinsing hose into the mortar hose and flush Fig. 80: Loosen coupling out the material (PFT rinsing hose art. no. 00113856). 42.4 Switch the machine back on after the blockage has been removed (400V) 1. With the main switch (1) in position “0”, push the metal bracket (2) into the opposite direction.

  • Page 53: Connection Of Power Supply (230V)

    Mixing pump G 4 X FU 230/400V Overview - Operation Connection of power supply (230V) 43 Connection of power supply (230V) 43.1 Voltage 230V 1. Open control cabinet and turn voltage selector to 230V. 2. Turn the potentiometer (2) for the motor speed and/or the material quantity to level 10.

  • Page 54: Switching On (230V)

    Mixing pump G 4 X FU 230/400V Overview - Operation Switching on (230V) NOTE! To ensure smooth running of the machine it has to be ensures that the adapter cable is connected on the mains side (see fig. 45 Switching on (230V) 45.1 Putting the machine into operation (230V) 1.

  • Page 55: Cleaning The Machine After Work

    Mixing pump G 4 X FU 230/400V Overview - Operation Cleaning the machine after work 47 Cleaning the machine after work 47.1 Empty the mixing tube The machine has to be cleaned daily after work: 1. Shortly before finishing your work turn the selector switch of the star wheel to position “0”.

  • Page 56: Cleaning The G 4 X

    Mixing pump G 4 X FU 230/400V Overview - Operation Cleaning the machine after work 47.3 Cleaning the G 4 X ATTENTION! Water can enter sensitive machine parts!  Before cleaning the machine cover all openings in which no water must enter for safety and functional reasons (e.g electric motors and control cabinets).

  • Page 57: Remove The Water Hose

    Mixing pump G 4 X FU 230/400V Overview - Operation Cleaning the machine after work 4. Remove the fine plaster spraying nozzle (5) from the spraying gun. 5. Loosen the ring screw (6) and pull the air nozzle tube (7) out of the spray head.

  • Page 58: Close Motor Tilt Flange

    Mixing pump G 4 X FU 230/400V Overview - Operation Cleaning the machine after work 47.9 Close motor tilt flange DANGER! Risk of contusion at the motor tilt flange! There is a risk of contusion when closing the motor tilt flange. ...

  • Page 59: Cleaning The Hopper

    Mixing pump G 4 X FU 230/400V Overview - Operation Changing the pump / Cleaning the pump 47.11 Cleaning the hopper  The inside of the hopper can be cleaned with a water hose after having been emptied completely. 48 Changing the pump / Cleaning the pump 48.1 Fold up mixing tube 1.

  • Page 60: Switch Off G 4 X

    Mixing pump G 4 X FU 230/400V Overview - Operation Switch off G 4 X 49 Switch off G 4 X 1. Switch off the machine at the selector switch of the pump motor (1) (position "0"). 2. Turn main switch (2) to position "0". Fig.

  • Page 61: Blow Dry Water Fitting

    Mixing pump G 4 X FU 230/400V Overview - Operation Measures in case of risk of frost 4. Open and empty strainer. 5. Reassemble the strainer. Fig. 104: Strainer 50.1 Blow dry water fitting 1. Connect water/air hose (1) with EWO and Geka coupling to the water inlet (2) and to the outlet of the air fitting (3).

  • Page 62: Maintenance

    Mixing pump G 4 X FU 230/400V Overview - Operation Maintenance 51 Maintenance 51.1 Safety Personnel  The maintenance works described here can be carried out by the operator, unless marked otherwise.  Some maintenance work must only be carried out by specially trained technical personnel or exclusively by the manufacturer.

  • Page 63: Remove Connection Cable

    Mixing pump G 4 X FU 230/400V Overview - Operation Maintenance 51.2 Remove connection cable Electrical system DANGER! Danger of death from electric current! There is danger to life if you come in contact with live parts. Activated electrical components can carry out uncontrolled movements and cause serious injuries.

  • Page 64: Maintenance Plan

    Mixing pump G 4 X FU 230/400V Overview - Operation Maintenance 51.4 Maintenance plan The following paragraphs describe the maintenance works that are require for an ideal and trouble-free operation. In the event that increased wear is detected during regular checks, the required maintenance intervals have to be shortened according to the actual signs of wear.
  • Page 65 Mixing pump G 4 X FU 230/400V Overview - Operation Maintenance 51.5.2 Plastic sieve  Implementation by operator. 1. Remove the closure cap (1) from the strainer. 2. Take out the plastic sieve (2) from the strainer (monthly). 3. Clean the sieve. 4.

  • Page 66: Adjust Locking Lever

    Mixing pump G 4 X FU 230/400V Overview - Operation Maintenance 51.5.5 Setting value pressure switch air Switching on the Switching off the machine machine 0.9 bar 1.2 bar Fig. 113: Pressure switch air 51.5.6 Setting value pressure switch air compressor Switch on air Switch off air compressor...

  • Page 67: Disassembly

    Mixing pump G 4 X FU 230/400V Overview - Operation Disassembly 5. Clean the work area and remove any spilled materials such as liquids, processing material or similar. 6. Ensure that all safety systems of the installation work perfectly. 52 Disassembly After the useful service life has been reached, the device has to be dismantled and disposed of in an environmental-friendly manner.

  • Page 68: Disassembly

    Mixing pump G 4 X FU 230/400V Overview - Operation Disposal Electrical system DANGER! Danger of death from electric current! There is danger to life if you come in contact with live parts. Activated electrical components can carry out uncontrolled movements and cause serious injuries. Therefore: ...

  • Page 69: Index

    Adjust locking lever ..........66 Decouple mortar hose ........56 Air compressor DELTA2 230V with pressure Description of assemblies ........14 switch-off ............15 Description PFT Booster pump (Accessory) ..22 Air filter compressor ..........64 Dimension sheet ..........12 Anti-dust unit G 4 ..........36 Disassembly............68 Apply mortar ............
  • Page 70 Mixing pump G 4 X FU 230/400V Overview - Operation Index Insert the mixing tube cleaner ......57 Preparing the machine ........31 Intended purpose air compressor ...... 20 Pressure switch-off air compressor....21 Intended purpose control panel ......19 Protective gear Intended purpose flow meter ......
  • Page 71 Mixing pump G 4 X FU 230/400V Overview - Operation Index Stopping in case of emergency Emergency-stop Transport.............28 switch .............. 43 Transport in individual parts........29 Strainer screen in pressure reducer ....65 Transport inspection ...........27 Switch off air compressor ........42 Transport with van ..........28 Switch off G 4 X ..........
  • Page 72 Mixing pump G 4 X FU 230/400V Overview - Operation Index PFT - THE FLOW OF PRODUCTIVITY Knauf PFT GmbH & Co. KG P.O. Box no. 60 97343 Iphofen Einersheimer Straße 53 97346 Iphofen Germany Phone +49 9323 31-760 Fax +49 9323 31-770 Technical hotline +49 9323 31-1818 info@pft.net...

This manual is also suitable for:

00 26 06 2100 42 34 0800 42 21 3500 42 39 50G 4 x fu 230/400vG 4 x fu

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