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PICOTE Xpress Coating System Operation & Installation Manual

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Picote Solutions Oy Ltd
MINI CLEANER
MINI CLEANER
MINI MILLER 8/16 | MINI MILLER +C 8/16
MINI MILLER 8/16 | MINI MILLER +C 8/16
These instructions are for your personal safety. Always ensure that you
have read and understood these instructions before using the equipment.
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.
www.picoteinstitute.com

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Summary of Contents for PICOTE Xpress Coating System

  • Page 1 MINI MILLER 8/16 | MINI MILLER +C 8/16 These instructions are for your personal safety. Always ensure that you have read and understood these instructions before using the equipment. SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE. Picote Solutions Oy Ltd www.picoteinstitute.com...
  • Page 2 Standard Hose Reel Heating Blanket Remote Control Initial Setup (Installing & Charging Battery, Reel Setup, Filling & Bleeding System) Picote Millers: 8mm (1/3”) Shaft Picote Millers: 10-12mm (3/8 - 1/2”) Shaft Pipe Preparation Assembly: Brushes Assembly: Delivery Hose & Camera...
  • Page 3 Suitable heat and cut-resistant gloves to help prevent any hand injuries. Any open injuries or skin irritations should always be covered to avoid contact with sewage, chemicals or dust. Suitable respirator to prevent any dust or fumes being inhaled or consumed, which could cause occupational asthma or dermatitis. Picote Solutions Oy Ltd www.picoteinstitute.com...
  • Page 4 This section contains important safety information. Failure to comply could result in serious injury or death. 1. Resin SDS Sheets, please scan the QR code from the resin bucket(s) or download from the Picote Institute (picoteinstitute.com) 2. Always wear eye and ear protection as well as chemical, heat and cut-resistant gloves.
  • Page 5 If the Xpress Coating System has been stored in an environment colder than +10°C or 50°F, it should be stood at room temperature for 24 hours before use. If the Xpress Coating System has been stored for a long period of time (over 1 months), it should be checked and tested according to the maintenance programme before use.
  • Page 6 CE DECLARATION OF CONFORMITY SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE We Picote Solutions Oy Ltd as the responsible manufacturer, declare that the following Picote Solutions Oy Ltd machine: Xpress Coating Pump is of series production and Conforms to the following EU Directive:...
  • Page 7 CE DECLARATION OF CONFORMITY SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE We Picote Solutions Oy Ltd as the responsible manufacturer, declare that the following Picote Solutions Oy Ltd machine: Xpress Hose Reel is of series production and Conforms to the following EU Directive:...
  • Page 8 CE DECLARATION OF CONFORMITY SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE We Picote Solutions Oy Ltd as the responsible manufacturer, declare that the following Picote Solutions Oy Ltd machine: Xpress Hose Reel Heating Blanket is of series production and...
  • Page 9 PUMP SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE General Description: Lubricant Reservoir Resin Reservoirs (BASE & CATALYST) Safety Screen Reservoir Valve Pumping Volume Indicator Cylinder Actuator Resin Supply Hose Connector Pressure Gauge Picote Solutions Oy Ltd www.picoteinstitute.com...
  • Page 10 9. Pump Display Intended Use: Picote Brush Coating pipes from DN32-300 (1¼-12’’) in diameter Voltage: All variants of the Xpress Coating System operate within 90-240VAC 50/60Hz. Battery: The Xpress Coating Pump has an internal 48V, 882Wh Li-Ion battery. Picote Solutions Oy Ltd...
  • Page 11 PUMP SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE Emergency Stop: On the Xpress Coating System there are a total of three Emergency Stops: 1. One on the Pump 2. One on the Hose Reel 3. One on the Remote Control...
  • Page 12 Check button is used to check messages shown on the pump display. Actions that require Check Button to be pressed are presented with an audible beep. Press the button firmly. NOTE! This button is NOT the same as the Emergency Check Button! Picote Solutions Oy Ltd www.picoteinstitute.com...
  • Page 13 (cylinders are full). Resin Calculator: The Picote Xpress Resin Calculator is an Excel spreadsheet that can be downloaded from the Picote Institute online learning platform at picoteinstitute.com. It calculates project resin usage based on pipe diameter, number of coats, and repair length.
  • Page 14 MAX OIL LEVEL label when the machine has been driven to upper position. The oil level will momentarily drop when pumping. We recommend using Picote Shaft Oil for the Xpress System lubricant. Picote Solutions Oy Ltd...
  • Page 15 SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE General Description: Power Cord Resin Supply Hoses Delivery Hoses Hose Reel Speed Control Hose Reel Brake Control Emergency Stop Heating Blanket Thermostat Heating Blanket Connector Remote Control Connector Picote Solutions Oy Ltd www.picoteinstitute.com...
  • Page 16 There are several positions where the pull handle can be locked in place. When in use retract the pull handle all the way so that the Hose Reel rests on the rubber feet to help prevent the Hose Reel from accidentally moving around. Picote Solutions Oy Ltd www.picoteinstitute.com...
  • Page 17 Close and secure the Heating Blanket with the Velcro fasteners. Plug Heating Blanket into the Hose Reel connector marked “Blanket”. Once the system is powered up, the Heating Blanket will also turn ON. Picote Solutions Oy Ltd www.picoteinstitute.com...
  • Page 18 REMOTE CONTROL SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE General Description: Power Light Pumping Speed Knob Emergency Stop Hose Retraction Button Stop / Start Button for Pump Remote Control Cable Connector Picote Solutions Oy Ltd www.picoteinstitute.com...
  • Page 19 Hose Reel. This way the operator can rewind the excess hose back to the Reel without stopping the coating process. NOTE: Retraction speed and clutch strength can be adjusted at the Hose Reel. Picote Solutions Oy Ltd www.picoteinstitute.com...
  • Page 20 Connecting & Charging the Battery: The Xpress Coating System is delivered battery detached. The battery must be connected before use. It can be found behind the battery access panel. To connect it, first make sure the machine is turned OFF. Take out three screws and move the panel aside.
  • Page 21 Initial Filling and Bleeding of System: NOTE: The Xpress Coating System has been pressure tested with Picote lubricant. Residual oil and air inside the system needs to be removed by bleeding the system. BEFORE YOU START! Ensure Resin Buckets (BASE & CATALYST) are at room temperature.
  • Page 22 13. When both materials start to flow the hose reel is BLED and ready for use. 14. Stop Pump. Wait a moment for resin to stop flowing and cap Delivery Hoses. Xpress System is now ready for use. Picote Solutions Oy Ltd www.picoteinstitute.com...
  • Page 23 Refer to Miller Operation Manuals Note: The Xpress Coating System can be used with the Mini Cleaner, Battery Mini Cleaner, Mini Cleaner +C, Battery Mini Cleaner +C, Mini Miller +C, Battery Mini Miller and Battery Mini Miller +C. If using one of those Millers please read and follow that Millers’...
  • Page 24 Refer to Miller Operation Manuals Note: The Xpress Coating System can be used with the Mini Cleaner, Battery Mini Cleaner, Mini Cleaner +C, Battery Mini Cleaner +C, Mini Miller +C, Battery Mini Miller and Battery Mini Miller +C. If using one of those Millers please read and follow that Millers’...
  • Page 25 Refer to Miller Operation Manuals Note: The Xpress Coating System can be used with the Midi Cleaner, Super Midi, Maxi Miller, or the Maxi Power+. If using one of those Millers please read and follow that Millers’ Safety and Operation Manual.
  • Page 26 230V:1.5kW 152lb When is use, always lay the machine down horizontally on the floor as shown above. When not in use, some non-hazardous Picote Flexible Shaft Lubricant might leak from the hand guard. VOLTAGE: POWER SUPPLY: Ensure that the supply voltage is The machine should be connected only to a power correct.
  • Page 27 Picote Smart Cutter grinding panel, then flushed with water and dried. For PVC pipes, use PVC versions of these chains (c) and/or thoroughly abrade with Picote Smart Cutter grinding panels (e) followed by a wire brush (d) to remove dust & other remaining particles.
  • Page 28 ASSEMBLY | BRUSHES SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE Intended Use: Required Tools & Parts • Picote Coating Brushes (1 or 2) • Picote Brush Stopper • Picote Sleeve • 2.5mm Hex Key • Adjustable Wrench This section contains important safety information.
  • Page 29 275mm (11”) 250mm (10”) 25-50mm (1-2”) DN225 (9”) 275mm (11”) 300mm (12”) 275mm (11”) 25-50mm (1-2”) DN250 (10”) 300mm (12”) 350mm (14”) 300mm (12”) 25-50mm (1-2”) DN300 (12”) 350mm (14”) 350mm (14”) 350mm (14”) 25-50mm (1-2”) Picote Solutions Oy Ltd www.picoteinstitute.com...
  • Page 30 Refer to Brush Assembly table for proper distance between the STEP 4 front and rear brushes. Do not use shaft casing between the brushes to ensure needed flexibility around bends. ONCE BRUSHES ARE SET UP, MOVE ON TO DELIVERY HOSE AND CAMERA PREPERATION. Picote Solutions Oy Ltd www.picoteinstitute.com...
  • Page 31 Once the brush is in full view on the screen, tape the STEP 3 camera head from the far end all the way past the camera spring. This will help ensure the camera spring and connectors stay clean. Picote Solutions Oy Ltd www.picoteinstitute.com...
  • Page 32 RESIN PREPERATION SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE Before Beginning Preperation: Required Tools & Parts • Xpress Coating System TIP: Resins have limited work time. • Picote Xpress Epoxy Higher temperatures will decrease the work time. • Picote Reel Heating Blanket If too cold, the resin may become difficult to pump.
  • Page 33 Using a smaller pitcher to pour the resin will help avoid spills. Be extremely careful not to mix up the BASE (White) and CATALYST (Black) Resins vs their corresponding Resin Reservoirs. Failure to do this can cause permanent damage to the system! Picote Solutions Oy Ltd www.picoteinstitute.com...
  • Page 34 Be sure to attach the correct hose to corresponding BASE or CATALYST Resin Reservoir to avoid adding the wrong Resin component into the wrong reservoir. Not ensuring this could cause serious damage to the Xpress Coating System. 11. Start with Pistons fully raised.
  • Page 35 DANGER, Risk of serious injury from moving parts! • Be sure that all machines have the required power supply. • Test machines and power source to ensure adequate and safe operation. • Read Operation and Safety Manual. Picote Solutions Oy Ltd www.picoteinstitute.com...
  • Page 36 SYSTEM PREPERATION SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE Before coating with the XPRESS Coating System, the system needs to be bled of any air and filled with resin. Connect Hose Reel Resin Supply Hoses to Pump. STEP 1 Open Reservoir Valves to relief pressure buildup inside cylinders.
  • Page 37 COATING PROCESS SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE Before Beginning Coating: Required Tools & Parts: • Xpress Coating System • Picote Miller • Picote Xpress Resin • Nitrile Gloves • Scissors • Paper Towels • Acetone • Waste Container •...
  • Page 38 Watch CCTV screen for resin flow. Note: it may be difficult to see the flow of resin if camera is turned upside-down. Watch closely. Move camera and Miller shaft back and forth if necessary to check for resin flow. Picote Solutions Oy Ltd www.picoteinstitute.com...
  • Page 39 To speed up drying time, allow resin to gel for 10 minutes after STEP 16 a coat is complete, then apply heat using the Picote Heater. If the next coat is applied after 12 hours, the pipe will need to be...
  • Page 40 Have plenty of gloves, towels, rags, acetone and a spill kit available in case of spills or accidents. • Have buckets ready for cleaning the brushes and camera. • Have a roll of PVC or duct tape and a large waste container nearby. Picote Solutions Oy Ltd www.picoteinstitute.com...
  • Page 41 NOTE! Mixed resin will generate heat while curing. Do not place large amounts of mixed resin inside waste bags or buckets before it has cured. Keep excess mixed resin in a well ventilated location while curing. Picote Solutions Oy Ltd www.picoteinstitute.com...
  • Page 42 1 hr at +25°C (77°F) if Picote Heater is used. Note: When adding heat the coating should be allowed to gel 15 minutes after each coat before applying the Picote Heater. The pipe should never exceed a constant temperature of +65°C (150°F). ADDITIONAL COATS: Refer to the chart below to determine the recommended number of coats to apply.
  • Page 43 Industrial Safety: Mixed product should not be allowed to come into contact with skin (it adheres). Gas Emissions / VOC: No harmful VOCs (Zero VOCS) released during mixing or after hardening. Safety Data Sheet (SDS): Available via QR code on resin buckets, as well as at Picote Institute (picoteinsitute.com) RESIN SDS AND OPERATOR CHECKLISTS ARE AVAILABLE TO DOWNLOAD FROM THE PICOTE INSTITUTE.
  • Page 44 See relevant Miller operating manual, available from the Picote Institute. The flexible shaft is pre-treated with Picote Flexible Shaft Lubricant and the casing replaced prior to shipping. Always inspect the condition and apply oil between flexible shaft and its outer casing when required.
  • Page 45 Reservoirs. If the lubricant level has gone over MAX level without adding any oil, that means the seals are leaking and need to be serviced. Contact Picote Solutions, your reseller or a Picote Authorized Service Center. If the lubricant level has dropped, add lubricant. If the lubricant level drops quickly after use check that the pistons are not retracted while the reservoir valves are closed.
  • Page 46 US PRODUCTS, PARTS & ACCESSORIES SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE Picote Solutions Oy Ltd www.picoteinstitute.com...
  • Page 47 US PRODUCTS, PARTS & ACCESSORIES SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE Picote Solutions Oy Ltd www.picoteinstitute.com...
  • Page 48 UK/EU/ROW PRODUCTS, PARTS & ACCESSORIES SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE Picote Solutions Oy Ltd www.picoteinstitute.com...
  • Page 49 UK/EU/ROW PRODUCTS, PARTS & ACCESSORIES SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE Picote Solutions Oy Ltd www.picoteinstitute.com...
  • Page 50 TROUBLESHOOTING FLOWCHART SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE If there is problem that you cannot resolve with this manual, please consult your Picote Reseller or Picote Solutions at claims@picotesolutions.com Picote Solutions Oy Ltd www.picoteinstitute.com...
  • Page 51 Actuator movement without user command. Avoid vibrating surfaces. Restart the system. Parameter Flag Parameters not within specified range. Parameter file might be corrupted. Contact Picote Solutions or reseller. E-code 1 Communication error. Check the error and continue working. If the problem persists, restart the system and connect the system to AC power.
  • Page 52 SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE Limited Warranty: Picote warrants to the original End User that the Product purchased by such End User will operate in accordance with, and substantially conform to their published specifications when shipped or otherwise...
  • Page 53 30-50 years. When you successfully complete Picote Certified Installer Training for Picote Xpress Coating System you will be able to offer a 10 year warranty on the Picote 100% Solids Epoxy Resin when you meet the outlined criteria. This provides assurance for the end-user as well as an advantage when you tender for work.
  • Page 54 Revision Date: March 2025 Revision number: 6 Accepted: Ryan Boldan: March 2025 Please Contact: Your Reseller / Salesperson or Picote www.picotegroup.com Production & R&D International Offices Technical Support Pienteollisuustie 24 Finland. United Kingdom. USA. support@picotesolutions.com 06450 Porvoo, Finland support@picotesolutions.com E-Learning...