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Operating manual
Delivery pump ZP 3 XL FC-400V
Part 2 Overview, operation and service
Item no. of the operating manual:
ZP 3 XL FC-400V, 3 Ph, 50 Hz
ZP 3 XL FC-400V, 3 Ph, 50 Hz (T 10-1.5) with vibrating
screen
00199520
Item no.: 00102957
Item no.: 00148350
Read the operating manual prior to starting any work!
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Table of Contents
Related Manuals for PFT ZP 3 XL FC-400V
Summary of Contents for PFT ZP 3 XL FC-400V
- Page 1 Item no. of the operating manual: 00199520 ZP 3 XL FC-400V, 3 Ph, 50 Hz Item no.: 00102957 ZP 3 XL FC-400V, 3 Ph, 50 Hz (T 10-1.5) with vibrating screen Item no.: 00148350 Read the operating manual prior to starting any work!
- Page 2 Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service About us About us Publisher Knauf PFT GmbH & Co. KG Postfach 60 ▪ 97343 Iphofen Einersheimer Straße 53 ▪ 97346 Iphofen Germany Document name 00199520_1.0_GB Translation of the original operating manual (DE) Date of first issue 11.2022...
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Page 3: Table Of Contents
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Table of contents Table of contents 4.5.7 Mortar pressure gauge..... 1 General information........Operating modes......Information regarding the operating Accessories........manual..........5 Operation............. Division..........Display of safety and warning Safety.......... - Page 4 Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Table of contents 5.15 Reaction in the event of faults..5.15.1 Safety..........5.15.2 Faults..........5.15.3 Fault displays........5.15.4 Table of faults........5.15.5 Hose blockages........ 5.15.6 Removal of clogging in hoses..
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Page 5: General Information
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service General information General information Information regarding the operating manual This operating manual provides important information and instruc- tions on the correct use of the machine. A prerequisite for safe working is the observance of all stated safety guidelines and instructions. -
Page 6: Keep The Manual For Future Reference
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service General information Structure of the safety and warning All safety and warning notices consist of: notices The danger sign and signal word Information on the nature of the hazard... -
Page 7: Ec Declaration Of Conformity
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service General information EC Declaration of Conformity Company: Knauf PFT GmbH & Co. KG Einersheimer Straße 53 97346 Iphofen Germany declares under our sole responsibility that the machine:... -
Page 8: Quality Control Sticker
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service General information Quality Control sticker The following details can be found on the Quality Control sticker: CE confirmed as per EU directives Serial no / serial number... -
Page 9: Safety Devices Of Air Compressor
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service General information 1.8.2 Safety devices of air compressor WARNING Danger to life due to non-functioning safety equipment! Safety equipment ensures highest level of safety in oper- ation. Even if safety devices make work processes more complicated, they must never be disabled. -
Page 10: Technical Data
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Technical data Technical data General information 2.255 Figure 3: Dimension sheet in mm Detail Value Unit Empty weight approx. item no. 00102957 Empty weight approx. item no. -
Page 11: Operating Conditions
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Technical data Operating conditions Environment Detail Value Unit Temperature range 2 - 45 °C Relative humidity, max. Duration Detail Value Unit Max. operating time at a stretch... -
Page 12: Vibrations
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Technical data Vibrations Weighted effective value of acceleration to which the upper body parts are exposed <2.5 m/s² page 12 / 60... -
Page 13: Transport, Packing And Storage
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Transport, packing and storage Transport, packing and storage Safety instructions for transport Improper transport NOTE Damage from improper transport! Improper transport may cause substantial property damage. Therefore:... -
Page 14: Transport Inspection
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Transport, packing and storage Transport inspection On receipt check the delivery immediately for completeness and trans- port damage. In case of externally visible transport damage, proceed as follows: Do not accept the delivery or under reserve only. -
Page 15: Transport
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Transport, packing and storage Transport Anchor the machine at the four marked anchor points (1) for transport by crane. Observe the following conditions: The crane and lifting equipment have to be designed for the weight of the packages. -
Page 16: Description
In combination with an air compressor and a spray gun, they can also be used to apply plasters and paints. If very high delivery rates are required, the PFT ZP 3 XL is the right choice. -
Page 17: Fields Of Application
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Description Fields of application For all materials such as: Masonry mortar/light mortar Floor screed (from truck mixer) Levelling compounds Gunite ... and much more Flowability / flow characteristics The pump unit R 7–3 can be used up to 30 bar oper-... -
Page 18: Description Of Assemblies
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Description Description of assemblies The PFT ZP 3 XL delivery pump consists of the main components described in the following chapters. 4.5.1 Control box item no. 00103142... -
Page 19: Frame With Material Hopper
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Description 4.5.2 Frame with material hopper Frame with protective grille Cover hood Tube slide support Wheel with steel rim Frame with material hopper Protective grille Figure 10: Frame assembly... -
Page 20: Pump Motor 7.5 Kw, 175 Rpm
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Description 4.5.5 Pump motor 7.5 kW, 175 rpm Item no. 20143501 Figure 14: Gear motor 4.5.6 Vibrating screen, complete Item no. 00148146 Figure 15: Vibrating screen 4.5.7... -
Page 21: Operating Modes
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Description Operating modes Pump motor selector switch The pump motor has three operating modes: Switch position "0": The machine is switched off. Switch position "right" (latching): Figure 17: Pump motor selector switch The machine starts up when the power supply is correctly and completely switched on. - Page 22 Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Description Extension cable 5 x 4 mm², RED 5-32 A – 50 m (400 V, 3 Ph) Item no. 20423900 Extension cable 5 x 6 mm², RED 5-32 A – 25 m (400 V, 3 Ph) Item no.
- Page 23 Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Description Rinsing hose DN10 Geka - 11 m Item no. 00113856 Assembly aid for R-pump Item no. 00478212 Vibrating screen for retrofitting for ZP 3 XL, complete Item no.
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Page 24: Operation
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation Operation Safety Personal protective equipment The following protective equipment has to be worn for all operative work: Protective clothing Protective goggles Protective gloves Safety shoes Hearing protection... -
Page 25: Monitoring The Machine
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation 5.1.2 Monitoring the machine WARNING Access by unauthorised persons! The machine may only be operated when monitored. 5.1.3 Hazardous dusts WARNING Danger of damage to health! In the long term, inhaled dust can lead to lung damage or have other adverse health effects. -
Page 26: Mortar Pressure Gauge
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation 5.1.5 Mortar pressure gauge WARNING Operating pressure too high! Machine parts can open in an uncontrolled manner and injure the operator. Do not operate the machine without mortar pressure gauge. -
Page 27: Positioning Machine
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation 5.3.2 Positioning machine 1. Install the machine on stable and even ground with the aid of the telescoping tube supports (1) and secure it against accidental movements. -
Page 28: Switching On The Machine
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation 5.3.4 Switching on the machine NOTE Fill the material hopper with approx. 3 litres of water so that the pump does not run dry during start-up. -
Page 29: Mortar Hoses
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation 5.3.6 Mortar hoses 5.3.6.1 Preparing the mortar hoses 1. Connect the cleaner coupling (1) to the water tap (2). 2. Connect the mortar hose (3) to the cleaner coupling (1). -
Page 30: Compressed Air Supply
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation 4. Turn the pump motor selector switch (3) to "right" position. 5. Allow the machine to run until all the wallpaper paste has emerged from the end of the mortar hose. -
Page 31: Feeding Material To The Machine
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation 5.3.7.3 Switching on the air compressor 1. Switch on the air compressor using the black switch (1). 2. As soon as the air compressor has built up pressure in the pipeline system, it switches off using the pressure switch-off. -
Page 32: Putting The Machine Into Operation
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation After the rescue operations WARNING Danger to life from premature reactivation! On reactivation there is danger to life for all persons in the danger zone. Ensure that the danger zone is clear before switching the machine back on. -
Page 33: Applying Mortar
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation Operation with remote control 1. Remove dummy plug from control box. 2. Connect remote control. 3. The ZP 3 can be switched on and off via the remote control. -
Page 34: Opening The Air Tap On The Spray Gun
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation 5.7.1 Opening the air tap on the spray gun 1. Turn the pump motor selector switch (1) to "right" position. 2. Point the spray gun toward the wall to be plastered. -
Page 35: In Case Of Longer Interruption Of Work / Break
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation 5.9.1 In case of longer interruption of work / break 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 interrup- tion (pay attention to outside temperature). -
Page 36: Switching Off The Machine
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation 5.11 Switching off the machine 1. Turn the pump motor selector switch (1) to the "0" position. 2. Turn the main switch (2) to position "0". -
Page 37: Discharging Mortar Pressure
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation 5.12.1 Discharging mortar pressure WARNING Overpressure on the machine! When opening machine parts they can open in an uncon- trolled manner and injure the operator. Only open the mortar hoses if the mortar pressure gauge (1) indicates the pressure has fallen to "0 bar". -
Page 38: Measures In Case Of Risk Of Frost
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation 5.13 Measures in case of risk of frost CAUTION Damage by frost! Water that expands on freezing inside the component can cause serious damage. Therefore: Only install dry parts. -
Page 39: Running The Machine Empty
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation 5.14.3 Running the machine empty The machine must be cleaned daily after work and before prolonged pauses: 1. Run the material hopper empty except for a small amount of residue. - Page 40 Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation Cleaning the mortar hose NOTE The mortar hoses and spray gun must be cleaned imme- diately at the end of work. 1. Connect the cleaner coupling (1) to the water tap (2).
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Page 41: Cleaning The Material Hopper
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation 4. Turn main switch (5) to position "I". 5. Turn the pump motor selector switch (6) to "right" position. 6. Pump residual material out of the mortar hose with the sponge ball. -
Page 42: Reaction In The Event Of Faults
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation 5.15 Reaction in the event of faults Reaction in the event of faults The following applies as a general rule: 1. In the event of faults presenting immediate danger to persons or property, activate the emergency OFF function immediately. -
Page 43: Fault Displays
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation 5.15.3 Fault displays The following installation indicates faults: Pos. Light signal Description Red control lamp Lights up on motor protection switch fault. → Check the motor protection switch... -
Page 44: Table Of Faults
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation 5.15.4 Table of faults Fault Possible cause Troubleshooting Rectification by Machine does Power supply not in order Repair power supply Service technician not start current Main switch not activated... -
Page 45: Hose Blockages
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation Fault Possible cause Troubleshooting Rectification by Power provided by compressor Check compressor Service technician is too low. Air duct is not connected to the Connect air supply to... -
Page 46: Removal Of Clogging In Hoses
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation 5.15.6 Removal of clogging in hoses WARNING Danger from discharged material! Never detach hose couplings if the feed pressure has not been fully released! Material to be conveyed can be discharged under pressure and cause injuries particularly to the eyes. - Page 47 Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Operation NOTE Clean mortar hoses immediately Figure 61: Detaching the coupling 3. Cover coupling connections with tear-proof film. 4. Release cam lever (3) and hose connections. 5. Remove blockage by tapping or shaking at the point of the blockage.
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Page 48: Maintenance
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Maintenance Maintenance 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 49: Remove Connection Cable
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Maintenance 6.1.1 Remove connection cable Electrical system WARNING Danger to life from electric current! There is danger to life if you come in contact with live parts. Activated electrical components can carry out Figure 63: Remove connection cable uncontrolled movements and cause serious injuries. -
Page 50: Maintenance Plan
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Maintenance Maintenance plan The following paragraphs describe the maintenance works required for an optimal 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 51: Lubricating The Sealing Unit
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Maintenance 6.4.2 Lubricating the sealing unit 1. Lubricate the sealing unit for material hopper at the grease nipple (1) weekly. 2. Lubricate sealing unit for gear unit at the grease nipple (2) monthly. -
Page 52: Adjust Clamping Of Pump
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Maintenance 3. Open the exit filter (2) at the blue cap (3). 4. Remove and clean the filter mat (4). 5. Insert the cleaned filter mat (4) and close the exit filter. -
Page 53: Periodic Inspection/Expert Inspection
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Maintenance Periodic inspection/expert inspection 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 expert. -
Page 54: Disassembly
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Disassembly Disassembly After the useful service life has been reached, the device has to be dismantled and disposed of in an environment-friendly manner. Safety Personnel Disassembly must be carried out by specially trained technical personnel only. -
Page 55: Disassembly
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Disassembly Disassembly When decommissioning, clean the device and dismantle it according to the applicable work safety and environmental protection regula- tions. Prior to starting the disassembly: Switch off device and secure against restarting. -
Page 56: Disposal
Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Disposal Disposal Provided no return or disposal agreements have been made, recycle the disassembled parts: Scrap metals. Recycle plastic elements. Dispose of remaining components, sorted according to the type of material. - Page 57 Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Disposal page 57 / 60...
- Page 58 Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Disposal page 58 / 60...
- Page 59 Delivery pump ZP 3 XL FC-400V / Part 2 Overview, operation and service Disposal page 59 / 60...
- Page 60 PFT - ALWAYS AT YOUR SITE Knauf PFT GmbH & Co. KG Postfach 60 97343 Iphofen Einersheimer Straße 53 97346 Iphofen Germany Telephone: +49 9323 31-760 Fax: +49 9323 31-770 Technical hotline: +49 9323 31-1818 info@pft.net www.pft.net...
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