ASE SM 5 User manual

OPERATION MANUAL
ASE SM 5
MIXING PUMP
ASE MAKINE İNŞ. ELEKTRİK. SAN VE TİC A.Ş.
ADDRESS : IVEDIK OSB MH. 1372 SK. NO:20, YENIMAHALLE, 06210 ANKARA - TURKEY
TEL : [phone] FAX : [phone] WEB: www.ase-co .com

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OPERATION MANUAL
Dear Customer,
We congratulate you on your choice of our SM 5. This machine is a continuous
plaster mixing and spraying machine for all kind of ready-mixed materials both cement
basis and gypsum basis plasters and renders.
Before applying the energy to the machine please read this manual carefully.
In this operation manual you will find all information of operation and maintenance
of SM 5. If you need further information please do not hesitate to contact with our office.
This manual supplied with the machine. Therefore, it may only be used for the
purpose of operation of SM 5. It is forbidden to pass it on to third parties or to copy
without permission.

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1) OPERATING PRINCIPLE OF MACHINE:
The dry premixed material in bags filled into the hopper by the motor driven star
wheel. The material is fed into the mixing chamber through a trap door. A constant
stream of water adjustable according to the requirements is injected into the mixing
chamber where the mixing shaft driven by an electric geared motor mixes material
and water homogeneously to a useable plaster. At the same time, the mixing shaft
drives a rotor/stator pump. The pump transports the material through high-pressure
hoses to the spraying gun. With the help of compressor, the plaster is being
sprayed onto walls and ceilings.

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2) OPERATION OF MACHINE:
1. Before running the machine, be sure about undistorted power supply and
undistorted water supply (remember that it needs 380 V 50 Hz. 3-phase power
supply to work and water supply with the pressure min. 3.5 bars).
2. In the case of low water pressure, the water pump can be used to obtain the
sufficient water pressure from direct connection to water supply. It is suggested to
use big barrel and supply water directly from the barrel by water pump.
3. Place pump unit (mixing chamber and pump motor with rotor/stator pump) into the
machine and connect pump motor cable to switch case. Connect water hose to
pump unit.
4. Connect cable of compressor to switch case. Turn on compressor. Connect
pneumatic remote control hose to outlet of compressor.
5. Connect ¾” water hose to machine and observe manometer reading. If pressure is
below 3.5 bar, check the water pump is working properly otherwise machine works
unevenly.
6. Fix the spray gun and connect both air and plaster hoses to machine. Check the
gasket in the plaster hose coupling. Open air tap at the spray gun.
7. Connect the 3 phase electric power to the switch case with 5 core CEE plug. Ensure
earth is connected. Mind all 3 phases are supplied.
8. Turn on machine by rotating the main red commutator to any position other then ‘0’.
To find the correct direction of rotation turn the direction of rotation commutator (red
switch) on the cabinet to any one of the two positions and observe the lamp indicator
of direction of rotation on panel is not lighted on. If this yellow lamp is lighted on the
direction of rotation is wrong. In that case, rotate the direction of rotation commutator
to other position and again observe the warning indicator lamp of direction. This is
done to protect the rotating shaft. Otherwise consistency may not be correct.
9. There are two more three-state commutators on cabinet door other than main red
switch. One is water pump commutator; other is the star wheel commutator. Both
have ‘MANUAL’, ‘0’, ‘AUTO’ positions. In the ‘MANUAL’ position water pump works
by the electric supply directly; star wheel turns by the Start of machine. In ‘0’
position, both water pump and star wheel do not work. In ‘AUTO’ position both water
pump and star wheel works by working of the mixing pump. To get pressurized
water supply turn on the water pump to ‘MANUAL’ position when you have water line

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with low pressure in the site. If the water line is proper then you can use the machine
with ‘AUTO’ or ‘0’ position. Remember that you may read 3.5 bars in the water
manometer when machine is not working, the supplying the water to machine may
decrease this water pressure. Put the star wheel commutator to ‘0’ positions initially
when you starts the machine to avoid the dry feed of the rotor/stator pump.
10.There are four push buttons on the side of the switch box just above the mains CEE
plug. They are ‘START’, ‘STOP’, ‘WATER’, and ‘REVERSE’ buttons. ‘START’ button
starts the machine after the turning on the machine if the direction of rotation is
correct and water pressure is proper and the remote control valve of spray gun is on.
When the start conditions are O.K. then the green lamp indicator lights on in the
START button. ‘STOP’ button stops the machine whenever you want to stop the
machine. Then the green lamp lights off. ‘WATER’ button supplies the water to the
pump unit by opening the water solenoid valve. Use this button to fill the mixing
chamber with the water and to adjust the water flow rate with the flow meter if you
start the machine first time after the cleaning procedure. To avoid dry operation of
rotor/stator pump. ‘REVERSE’ button has two different functions. First function is to
allow pump motor to turn reverse direction when the direction of the rotation is wrong
(Direction of rotation warning indicator lights on). In some cases, you may want to
rotate the pump motor to reverse direction in very short time then use this button
after start button. Second function of this button is degassing the water pump. When
the direction of rotation is correct, you may need to operate the water pump only to
remove the air from the water pump.
11.Before charging dry material to pump unit, press the WATER button and wait until
mixing unit is filled with water. Don’t operate pump with dry material only.
12.When the machine starts running, regulate the water about 10 % above the nominal
settings (for initial uses read minimum 800 on flow meter). Then start to change the
dry material to the pump unit by rotating the STARWHEEL commutator to ‘AUTO’
position. During the initial running period it may prove necessary to adjust the
amount of water fed into the mixing unit, in order to obtain the correct consistency.
13.Mixed material is applied on the wall with 30 bars at the outlet of hose. Consistency
of plaster is adjusted by adjusting the water flow rate with flow meter. Mind that at
first, rather a liquid plaster will appear at the nozzle of the spraying gun then users
have to adjust correct plaster consistency.

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14.Correct plaster consistency is reached when the plaster flows smoothly on the
surface sprayed. Insufficient water supply to the mixing unit will result in uneven
mixing and spraying which again leads to considerable wear of both stator and rotor.
15.For the star wheel at MANUAL position dry material can be charged while the pump
remains stationary and at ‘0’ position star wheel is switched off and material supply
is interrupted.
16.Interruptions more than 30 min. is avoided, otherwise there is the danger of plaster
hardening in the hose and machine. Every break in the spraying process causes a
slight irregularity of the consistency. This however corrects itself as soon as the
machine has been running again for a few minutes. Therefore do not alter the water
supply at every irregularity but wait until the consistency of plaster coming out of the
spraying gun becomes normal again.
17.In the case of long breaks hose and machine should be cleaned according to the
Cleaning Procedure.

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3) DURING OPERATION PAY ATTENTION TO:
1- Don’t stop and add the material into the mixing chamber in the case that there exists
material in the pump unit.
2- Every time after the change of mains plug, control the rotation direction of motor.
Determine the warning indication lamp on the control cabinet.
3- After the operation, if the machine will not work close the main switch.
4- After turn on the machine, if the machine do not work control :
a- Main Switch
b- Fault indication lamp (red lamp) on the control cabinet
c- Pneumatic valve at the spraying gun whether it is closed or open
d- Water supply. There may remain air in the water hose. If so, open the auxiliary
water tap on the machine, operate water pump and try to get away the air. If
there is still air in the water hose and there is no water supply disconnect the
hose on the machine and again try to get away the air in the hose. If it is not
succeeded, control the hose whether there is any broken part or any blockage.
e- If the air remains in the hose machine will not work properly. In that case press
the WATER button for a few seconds to get the air out off.
5- Before operating the machine, control the power supply on three phase and neutral
6- Control the fuses, main switch and motor protection switch.
7- Don’t operate the machine with only dry material.
8- Don’t remove guard of hopper during operation.
9- Soaking is recommended with coarse material.
10-Do not press your hands through the guard while the machine is running.
11-Interruptions more than 30 min. is avoided otherwise there is the danger of plaster
hardening in the hose and machine.

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4) CLEANING THE MACHINE:
1- When spraying is finished, turn the star wheel commutator to position ‘0’. Then the
pump should left to run until water comes out of the spraying gun. Then turn off the
main switch.
2- Tilt and lift pump motor, take out mixing shaft and clean it thoroughly.
3- Insert cleaning shaft and cleaner into the pump unit and close the motor bracket.
Leave the star wheel commutator in “0” position. Turn on main switch. After a short
run (5-10 seconds) the mixing unit is clean. Remove the cleaning device and
reassemble the mixing shaft.
4- Clean plaster hose with sponge balls after each spraying periods. Push wetted ball
into pressure plate outlet. Tighten hose to outlet and start machine. Wait until
sponge ball comes out of the spraying gun end of the hose. If hoses are still dirty
repeat the process.
5- The compressor filter has to be clean from time to time. If very dirty it may be
removed.
6- Dirt collector in the water filter of the machine should be taken out and cleaned at
intervals of two weeks. And changed when necessary.
7- Turn off main switch then open the lid at the bottom of the hopper and remove star
wheel.
8- In the case of power cut you may clean hose at once by attaching fitting to water
tap and fixing hose. Then open tap. Repeat this until clean water emerges at the
end of the spray gun. Repeat this by sponge ball.
9- After cleaning the machine should be emptied as follows:
a) Close main water tap.
b) Decrease water pressure by closing water valve.
c) Disconnect and empty water hose.
d) Disconnect air hose from spraying gun and connect it to main water inlet.
e) Disconnect water hose from pump unit.
f) Turn on compressor.
g) Press water button outside switch cabinet, the remaining water is now blown
out of the system.
h) Tilt pump and clean mixing unit.
i) Disconnect and empty plaster hoses as described above.
Although the entire machine is empty and clean, there is a small residue in the
rotor/stator. Therefore, run the machine carefully when next time use.

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4) ADJUSMENT DATA:
a) Water pressure safety switch:
At minimum 2.2 bars machine starts to work. At the pressure lower than 2.0 bar
machine stops itself automatically.
b) Water pressure reduction valve:
1.7 Bar, 800 liter /hour
c) Pneumatic remote control switch:
0.9 Bar: Machine Starts
1.2. Bar: Machine Stops
d) Compressor security valve:
3.5Bar against closed air tap.
e) Motor Protection switch unit:
5.5KW motor 12.5A in case of 380VAC
f) Motor protection switch unit (star wheel):
0.55 KW motor 1.95 A 380 V AC.
g) Star wheel:
Distance wheel bottom: 1.5 times grain size of plaster used.
If necessary place washers under wheel.
h) Conveying pump (Rotor/Stator Pump)
For each meter length of hose there is a pressure of 0.9 bar. When machine is
stopped pressure will drop by about 30 % to approx. 8 bar.
The pressure and the granule size of the rotor/stator pump are depending on the
type of it. As the granule size increases the pressure will decrease. Control and
adjustment of consistency can be achieved by the manometer. So life of pump will be
longer, loss of plaster / rendering will be decrease, full utilization of motor characteristics
can be achieved.
i) Spraying Gun:
The diameter of the nozzle must correspond to the distance nozzle-air tube.
Example: Diameter nozzle: 14mm
Distance nozzle-air tube: 14mm
j) Rotation of star wheel: No particular direction is required except connecting to
pneumatic equipment. In that case counter clockwise direction of rotation is required.

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6) TECHNICAL DATA:
1- Power: 2 transmission motors:
Pump motor: 5.5 KW, 12.5 A, 380 V, 400 rpm
Star wheel motor: 0.55 KW, 1.95 A, 380V, 28 rpm
2- Conveying pressure: 5-40 bar depending on type of plaster / rendering and pump
used.
3- Conveying distance: Up to 40 meters depending on type of plaster / rendering and
pump used.
4- Conveying hose : 25 mm /1” or 35 mm / 1 ½”
5- Air hose : 13 mm / ½”
6- Compressor output : 0.9 KW Nm3/ min max 6 bar
7- Water connection: max 2.5 bar when in operation.
8- Water connection hose :3/4”
9- Current connection: 380 V, 3 phase, 5 core cable, 32 A fuses.
10- Machine output: 6-45 l / min depending on motor, type of plaster / rendering and
pump used.
14-Remote control: by air or 24 V safeties current.

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7) TROUBLE AND SHOOTING:
1- Machine does not start although power and water are connected.
Reasons: Insufficient water pressure. Manometer shows less than 2 bars.
Remedies: Clean dirt collector and check air in the water pump. If so press the water
button for a few seconds to remove the air.
2- Machine does not start although mains switched turn on and water pressure
sufficient.
Reasons: Start button is not pressed and direction of rotation is wrong.
Remedies: Determine and switched to correct direction of rotation by checking the
yellow warning indicator, then press start button and observe green light in start button.
3- Machine doesn’t start although water pressure is correct and compressor switched
on.
Reasons: Insufficient air pressure drop in the remote control system because of blocked
up nozzle or closed air tap at spray gun.
Remedies: Open-air tap, clean air nozzle pipe.
4- Mortar comes out of spray gun irregularly (bubbles)
Reasons: Inadequate mixing in mixing unit.
Remedies: Increase water supply. If this fails, clean pump thoroughly and start again.
Ensure that inlet for dry material into pump unit, is dry.
5- Irregular plaster inconsistency.
Reason: Insufficient water produces thick plaster mix resulting in high pressure and less
quantity delivered. Then follows a thinning of material because of the constant flow of
water into pump unit, does it goes from one extreme to the other.
Remedies: Increase water supply for about ½ min, by approximately 10 % then slowly
reduce to nominal settings. Tighten clamp of stator or replace entire pump.
6- Motor or star wheel does not start.
Reason: Hopper or mixing unit blocked by surplus material.
Remedy: Empty hopper and /or mixing unit. Start again.

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7- Water level in pump rises in the mixing chamber during work.
Reasons: Holding pressure in plaster hose is higher than pump pressure. Rotor or
stator are worn out or damaged. Blockage in plaster hose is due to insufficient water
supply.
Remedies: Tighten clamp of stator or replace it. If necessary also replace rotor.
8- Machine stops or does not start.
Reasons: Overloading
1- At pump motor:
a) By blocking the rotor with dry material.
b) Due to insufficient water supply.
2- At star wheel motor, due to excessive charging of hopper.
Remedies: Release security button and
1- Increase water supply
2- Clean hopper, mixing chamber and star wheel.
9- Power Failure:
Reason: Plaster hoses are dirty.
Remedies: Plaster hoses must be cleaned immediately. This can be done at the water
valve. Before disconnecting hose make sure those are not under pressure.
10- Water Failure:
Reason: Pressure is below the recommended value.
Remedies: Feed water into machine from container by using suction basket and extra
pump to increase pressure.
11- Hose blockage:
Stop star wheel motor tilt pump unit and run motor via the pole turning switch forward
and backward until motor pressure indicator indicates no pressure. Loosen ring nuts of
pressure plate. Disconnect hose and clean.
12- Water pump and compressor don’t work.

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Reason: Water pump and compressor of machine work at 220 V AC. So although the
380 V AC supply exist if there is no neutral line 220 V AC supply will not exist so water
pump and compressor don’t work.
Remedies: Control power supply lines and neutral line.
13-Machine works normally but there is an undesired noise during working.
Reason: Pneumatic remote control switch is not adjusted to normal pressure value.
Remedies: Adjust pneumatic remote control switch to normal value
14- Flow meter reading is changing continuously.
Reason: Pressure regulator is not adjusted to normal value.
Remedies: Adjust pressure regulator to desired value.
15- Although power supply exist if the machine does not work.
Reason: Motor protect switch and fuses may be switched off.
Remedies: Switch on motor protects switch and fuses. If necessary change them.
16- During working of machine heat increases too much.
Reason: There may be particles inside plaster or plaster which has a diameter more
than 3 mm and it may squeeze rotor/stator pump.
Remedies: Clean mixing shaft and rotor / stator
17-Motor stops suddenly during working operation or machine do not start.
Reason: Overloading of pump motor (blocking of rotor by dry material or insufficient
water supply may cause this)
Remedies: Stop motor, empty water inside, clean hopper and mixing shaft.

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8) TROUBLES DUE TO MISUSAGE OF OPERATOR ARE NOT GUARANTEED:
1- In any way waters inside electricity panel.
2- Damaging and breaking in some parts of machine because of stroke
3- Damaging of some parts of machine (motor, compressor etc.) because of using
power supply other than considered in instruction manual.
4- Breaking of motor because of forcing motor by surplus materials with more than 3
mm in plaster or plaster.
5- Faults caused by electrical or mechanical parts of machine, which are changed by
user with different than original parts.
6- Faults caused by calibrations different from factory settings.
7- Damaging caused by natural disasters as fire, flood, earthquake etc.

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General view
A B C D E
A:
CONTROL PANEL
D:
DRY MATERIAL BUNKER
B:
MIXING–PUMPING CHAMBER
E:
COMPRESSOR
C:
WATER- AIR SYSTEM

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General view
76
5
4
32
18 9 10

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General view
NR.
PART NAME
1
PUMPING MOTOR
2
MIXING CHAMBER
3
AIR –WATER REGULATOR
4
PUMP
5
COMPRESSOR
6
MALZEME KA DRY MATERIAL BUNKER
7
PROTECTIVE GRID WITH BAG CUTTER
8
STARWHEEL MOTOR
9
CONTROL PANEL
10
WATER PUMP

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Air –Water Regulator

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Air –Water Regulator
Nr.
1
Air to the spray gun
2
Pressure reducer
3
Solenoid valve
4
Air from compressor
5
Emptying tap
6
Water regulating tap
7
Water to the mixing chamber
8
External water tap
9
Flow meter
10
Water from net or barrel
11
Air-water block

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ÇALIŞTIRMA ve UYARI ELEMANLARI
1. Main torque switch
2. Star wheel(manual/automatic)
3. Water pump manual-automatic
4. Green led
Sign for mortar flow
5. Red led / problem
6. Panel socket
7. R-Reverse
Reverse pumping motor backward
8. Water flow button
9. Start
10.Stop
11.Cable socket
12.Cable socket
13.Cable socket
14.Socket (220 V)
15.Socket (Compressor)
16.Socket (Pumping)