PFT CMP 30 4.0 User manual

Contents
2021-02-10
Operating Manual
Container Mixing Pump CMP 30 4.0
Part 2: Overview – Operation – Spare Part Lists
Item number of operating manual: 00686687
Item number of the machine parts list: 00627857
Read the operating manual prior to beginning any work!

2 2021-02-10
© Knauf PFT GmbH & Co. KG
Postfach 60 97343 Iphofen
Einersheimer Straße 53 97346 Iphofen
Germany
Tel. [phone]
Fax [phone]
Technical hotline: [phone]
[email protected]t
www.pft.net

Container Mixing Pump CMP 30 4.0 Part 2: Overview – Operation – Spare Part Lists
Contents
2021-02-10 3
1 Testing............................................................... 7
1.1 Testing by machine operator ................... 7
1.2 Periodic inspection................................... 7
2 General information ......................................... 8
2.1 Information regarding the operating
manual ................................................. 8
2.2 Keep the manual for later use.................. 8
2.3 Layout ...................................................... 8
3 Equipment or accessories............................... 9
4 Technical data................................................. 10
4.1 General specifications ........................... 10
4.2 Connected load...................................... 10
4.3 Operating requirements ......................... 11
4.4 Output values......................................... 11
5 Sound power level.......................................... 11
6 Vibrations ........................................................ 11
7 Dimensions ..................................................... 12
8 Type plate ........................................................ 12
9 Quality control sticker.................................... 12
10 Overview CMP 30 4.0.................................... 13
11 Description of assemblies ........................... 15
11.1 Description of control box module ....... 15
11.2 Pump motor with tank and pump ......... 16
11.3 Geared motor with sealing unit ............ 17
11.4 Pump container.................................... 17
11.5 Frame CMP30...................................... 17
11.6 Overview water/air fitting ..................... 18
12 Operating modes step switch ..................... 19
13 Function description and operating
sequence .................................................... 20
13.1 Areas of application ............................. 20
14 Basic equipment........................................... 20
15 Safety regulations ........................................ 20
16 Transport, packaging and storage ..............21
16.1 Safety instructions for transport ...........21
16.2 Transport checklist ...............................22
16.3 Transport by car or truck ......................22
16.4 Transport ..............................................22
16.5 Transport safety ...................................23
16.6 Transport with a forklift truck ................23
16.7 Transportation of operational
machines ............................................24
17 Packaging ......................................................25
18 Safety .............................................................25
19 Set up silo with CMP.....................................26
20 Safety device .................................................26
20.1 EMERGENCY OFF pushbutton ...........26
20.2 Position switch for pump unit................27
20.3 Position switch for mixing tube .............27
20.4 Hinge safety switch on the protective
grille....................................................27
21 Intended use of fitting block ........................28
21.1 Purpose of fitting block .........................28
21.2 Purpose of solenoid valve ....................28
21.3 Purpose of flowmeter ...........................28
22 Intended use of air compressor ..................29
22.1 Purpose of air compressor ...................29
22.2 Safety devices of air compressor .........30
22.3 General setup of the air compressor....30
22.4 Hot surfaces on the air compressor .....30
23 Description of the PFT water pump
(accessories)...............................................31
23.1 Application field of water pump ............31
23.2 Proper use of the machine ...................31
24 Water pump preparation (accessories) ......32
25 Initial start-up of water pump.......................32
25.1 Commissioning the water pump ...........32
26 Material...........................................................34
26.1 Flow characteristics..............................34

Container Mixing Pump CMP 30 4.0 Part 2: Overview – Operation – Spare Part Lists
Contents
4 2021-02-10
27 Mortar pressure gauge................................. 34
28 Safety regulations......................................... 34
29 Preparation .................................................... 35
29.1 Connection to the 400 V power supply 35
29.2 Checking the individual connector
plugs .................................................. 36
29.3 Water supply connection...................... 36
29.4 Water from water barrel connection..... 37
30 Switching on CMP 30 4.0 ............................. 37
30.1 Setting the water volume ..................... 37
30.2 Switching off the machine .................... 38
30.3 Coupling the water hose to the mixing
tube .................................................... 38
30.4 Switching over the step switch............. 38
31 Mortar pressure gauge................................. 38
32 Hazardous dust ............................................. 39
33 Switching on the horizontal mixer .............. 39
33.1 Releasing the fuses for the pump unit . 39
33.2 Switching on the mixer......................... 40
33.3 Switching off the mixer ......................... 40
33.4 Level probe in the mixer....................... 40
33.5 Pulling the pump unit out of the frame . 40
34 Mortar hoses ................................................. 41
34.1 Preparing the mortar hoses ................. 41
34.2 Turning the step switch pump to
manual operation ............................... 41
34.3 Draining residual water from the
pump tank .......................................... 41
34.4 Filling the pump container .................... 42
34.5 Level probe in the pump container....... 42
35 Compressed air supply ................................ 43
35.1 Connecting the air hose ....................... 43
35.2 Connecting the spray gun .................... 43
35.3 Switching on the air compressor.......... 43
36 Applying mortar ............................................ 43
36.1 Switching to automatic mode ............... 44
36.2 Opening the air tap on the spray gun... 45
36.3 Interruption of work .............................. 45
36.4 In the event of a work stoppage /
pause................................................. 46
36.5 Switching off the air compressor ......... 46
37 Remote control ............................................. 46
37.1 Using the remote control without
spray gun........................................... 46
38 Measures to be taken in the event of a
water supply failure ................................... 47
39 Switching off in an emergency ................... 47
39.1 Emergency OFF button ....................... 47
39.2 Emergency OFF switch ....................... 47
40 Measures to be taken in the event of a
power failure .............................................. 48
40.1 Turning the main switch to position “0” 48
40.2 Discharging mortar pressure ............... 48
40.3 Discharging mortar pressure ............... 49
40.4 Switching on the machine again after
a power failure ................................... 49
41 Troubleshooting ........................................... 50
41.1 Dealing with malfunctions.................... 50
41.2 Fault displays....................................... 50
41.3 Malfunctions......................................... 50
41.4 Safety................................................... 51
41.5 Table of malfunctions........................... 51
41.6 Pumping stopped / blockage ............... 53
41.7 Indications of clogged hoses: .............. 53
41.8 Possible causes:.................................. 54
41.9 Pre-existing damage on mortar hose .. 54
42 Clearing hose blockages ............................. 54
42.1 Changing the direction of rotation of
the mixing pump motor in case of
hose blockage ................................... 55
42.2 Stopper will not come loose................. 55
42.3 Switching on the machine after
removing a blockage ......................... 56
43 End of work / Cleaning the machine .......... 56
43.1 Running the machine empty................ 56
43.2 Securing against restarting.................. 57
43.3 Cleaning the CMP 30 4.0 .................... 57
43.4 Disconnect mortar hose....................... 57
43.5 Cleaning the mortar hose .................... 58

Container Mixing Pump CMP 30 4.0 Part 2: Overview – Operation – Spare Part Lists
Contents
2021-02-10 5
43.6 Cleaning the mixer............................... 58
43.7 Cleaning the pump container............... 59
43.8 Cleaning the level probe ...................... 59
43.9 Cleaning the pump............................... 60
44 Pump replacement ....................................... 60
45 Switching off the CMP 30 4.0 ...................... 61
46 Measures to be taken if there is a risk of
frost ............................................................. 61
46.1 Uncoupling the water hose .................. 61
46.2 Draining the water fitting ...................... 62
47 Maintenance .................................................. 62
47.1 Safety................................................... 62
47.2 Removing the connection cable .......... 63
47.3 Environmental protection ..................... 63
47.4 Maintenance plan ................................ 64
47.5 Maintenance tasks............................... 64
47.6 Removing the air compressor from
the holder........................................... 65
47.7 Strainer screen in pressure reducer .... 65
47.8 Safety valve air compressor ................ 66
47.9 Checking the sealing unit..................... 66
47.10 Lubricating the mixing motor.............. 66
47.11 Cleaning the filter insert for the
frequency converter ........................... 67
47.12 After performing maintenance ........... 67
48 Setting values / settings .............................. 68
48.2 Adjusting the level probe ..................... 68
49 Disassembly.................................................. 69
49.1 Safety................................................... 69
49.2 Disassembly......................................... 70
50 Disposal......................................................... 70
51 Spare parts drawings, spare parts list ....... 72
51.1 Motor flange swivelling Art. No.
00628865........................................... 72
51.2 Spare parts list for pivoting motor
flange Art. No. 00628865................... 73
51.3 Rubber mixing tube Art. No.
00628868........................................... 74
51.4 Spare parts list for rubber mixing tube
Art. No. 00628868 ............................. 75
51.5 Frame CMP 30 4.0 Art. No. 00628863.76
51.6 Spare parts list for frame CMP 30 4.0
Art. No. 00628863 ..............................77
51.7 Dosing tube CMP 30 4.0 ......................78
51.8 Spare parts list for dosing tube CMP
30 4.0 .................................................79
51.9 Bag insertion cover CMP 30 4.0 ..........80
51.10 Bag insertion cover CMP 30 4.0 ........81
51.11 Gear motor with sealing unit CMP 30
4.0 cpl.................................................82
51.12 Spare parts list gear motor with
sealing unit CMP 30 4.0 cpl. ..............83
51.13 Pump container with pump shaft
CMP 30 4.0 cpl. Item Number
00628859 ...........................................84
51.14 Spare parts list for pump container
with pump shaft CMP 30 4.0 plus
cpl. Item Number 00684014...............85
51.15 Pump unit CMP 30 4.0 Item Number
00628862 ...........................................86
51.16 Spare parts list for pump unit CMP
30 4.0 Item Number 00628862 ..........87
51.17 Control box CMP 30 4.0 VA ...............88
51.18 Spare parts list for control box CMP
30 4.0 VA............................................89
51.19 Air fitting CMP 30 4.0 .........................90
51.20 Spare parts list for air fitting CMP 30
4.0 ......................................................91
51.21 Water fitting CMP 30 4.0 Item
Number 00628081 .............................92
51.22 Spare parts list for water fitting CMP
30 4.0 Item Number 00628081 ..........93
51.23 Water fitting CMP 30 4.0 Item
Number 00628081 .............................94
51.24 Switch cabinet CMP 30 4.0 Item
Number 00627311 .............................96
51.25 ET list for control box CMP 30 4.0
Item Number 00627311 .....................97
51.26 Switch cabinet CMP 30 4.0 Item
Number 00627311 .............................98
51.27 ET list for control box CMP 30 4.0
Item Number 00627311 .....................99
51.28 Switch cabinet CMP 30 4.0 Item
Number 00627311 ...........................100
51.29 ET list for control box CMP 30 4.0
Item Number 00627311 ...................101
51.30 Switch cabinet CMP 30 4.0 Item
Number 00627311 ...........................102

Container Mixing Pump CMP 30 4.0 Part 2: Overview – Operation – Spare Part Lists
Contents
6 2021-02-10
52 EC Declaration of Conformity.................... 103
53 Circuit diagram ........................................... 104
54 Index ............................................................ 116

Container Mixing Pump CMP 30 4.0 Part 2: Overview – Operation – Spare Part Lists
Testing
2021-02-10 7
1 Testing
1.1 Testing by machine operator
Before the start of each work shift, the machine operator must test
the effectiveness of the control and safety devices as well as check
the proper attachment of all protective devices.
During operation, the machine must be tested by the machine
operator for its operational safety.
If defects are found in the safety devices or any other area that
could impair safe operation, the supervisor must be notified
immediately.
For defects posing a hazard to persons, the operation of
the machine must be halted until the defect is eliminated.
1.2 Periodic inspection
Construction machines must be tested for safe operation by
a specialist as the usage conditions and operating circumstances
require, but at least once a year.
Pressure vessels must undergo the prescribed inspections by
authorised experts.
The inspection results are to be documented and must be stored
at least until the next inspection.
This heading contains test suggestions for the annual by a specialist according to BGR 183 for
the container mixing pump.
http://www.pft.de/www/de/information_service/recurrent_checks/recurrent_checks.php

Container Mixing Pump CMP 30 4.0 Part 2: Overview – Operation – Spare Part Lists
General information
8 2021-02-10
2 General information
2.1 Information regarding the operating manual
This manual provides important information and instructions on
the correct use of the equipment. Adherence to all defined safety and
handling instructions is a prerequisite for a safe working environment.
Additionally, the on-site accident prevention regulations and general
safety guidelines for the equipment must be followed at all times.
Read the manual carefully before starting any work! It is an integral part
of the product and must be kept near the machine and accessible to
operators at all times.
Always include the operating manual when transferring the machine to
third parties.
The diagrams and illustrations shown in the manual are intended for
better understanding of tasks and descriptions. They are not necessarily
shown to the correct scale and may vary slightly from the actual
equipment used.
2.2 Keep the manual for later use
The operating manual must be available during the entire service life of
the product.
2.3 Layout
The operating manual is comprised of three booklets:
Part 1: Safety
General safety instructions for mixing pumps/conveying pumps
Item number: 00172709
General safety instructions for the horizontal screw mixer
Item number: 00146378
Part 2 Overviews, Operation (this book).
All three parts must be adhered to in order to ensure safe operation of
the equipment. Together, they are valid as one operating manual.

Container Mixing Pump CMP 30 4.0 Part 2: Overview – Operation – Spare Part Lists
Equipment or accessories
2021-02-10 9
3 Equipment or accessories
You can find equipment or accessories for the machine in the Internet at
www.pft.net.
1
2

Container Mixing Pump CMP 30 4.0 Part 2: Overview – Operation – Spare Part Lists
Technical data
10 2021-02-10
4 Technical data
4.1 General specifications
Part number CMP 30 4.0 00627857
Silo / container connection
Specification Value Unit
Flange connection D = 250 mm
4.2 Connected load
Electrical
Specification Value Unit
Voltage, three-phase current 50
H
400 V
Max. current consumption 32 A
Max. power consumption 15 kW
Connection 32 A
Fuse At least 3 x 25 A
Motor protection switch
Fig. 1: Motor protection switch
Specification
Service
Setting value
Designation
Pump motor 7.5 kW 15 A
Mixer motor 4.0 kW 8.3 A Q2
Water pump 1.1 kW 0.37 A Q4
Compressor 0.9 kW 1.8A Q6
Vibrator Q6
Water connection
Specification Value Unit
Operating pressure, min. 2.5 bar
Connection 3/4 inches
Specification
Value
Unit
Weight 507 kg
Length 1940 / 2620 mm
Width 940 mm
Height 1230 mm

Container Mixing Pump CMP 30 4.0 Part 2: Overview – Operation – Spare Part Lists
Sound power level
2021-02-10 11
4.3 Operating requirements
Ambient conditions
Specification Value Unit
Temperature range 2–45 °C
Relative humidity (maximum) 80 %
Operating period
Specification Value Unit
Maximum continuous
operating period
8
hours
4.4 Output values
Pump output R7-3S
Specification Value Unit
Pumping capacity, approx. 7-26 l/min
Max. operating pressure 30 bar
Pumping distance*,
max. at 50 mm Ø
50
m
* Recommended value, depending on conveying height, condition and version of
pump, mortar quality (composition and consistency)
5 Sound power level
Sound power level LWA 95 dB(A)
6 Vibrations
Weighted effective acceleration value to which the upper limbs are exposed = < 2.5 m/s²

Container Mixing Pump CMP 30 4.0 Part 2: Overview – Operation – Spare Part Lists
Dimensions
12 2021-02-10
7 Dimensions
Fig. 2: Dimensions
8 Type plate
Fig. 3: Type plate
The type plate is found in the control box and contains
the following details:
Manufacturer
Type
Year built
Machine number
Permissible operating pressure
9 Quality control sticker
Fig. 4: Quality control sticker
The quality control sticker contains the following information:
CE confirmed in compliance with EU directives
Serial no. / serial number
Controlled by / signature
Date of control
1940 940
1240
910

Container Mixing Pump CMP 30 4.0 Part 2: Overview – Operation – Spare Part Lists
Overview CMP 30 4.0
2021-02-10 13
10 Overview CMP 30 4.0
1 2 3 4 5 6 5 7 8 9 10
19 18 17 16 15 14 13 12 11
Fig. 5: Overview CMP 30 4.0
1. Motor flange pivoting 2. Mixer motor
3. Sack insertion 4. Filter hose / rain protection
5. Transport lock for welding to the Sio 6. Silo connection
7. Water inlet into the mixing tube 8. Emergency OFF button
9. Rubber mixing pipe 10. Square outer bearing
11. Plaster piece for cleaning the mortar hoses 12. Connection of the mortar hoses to the pump unit
13. Mortar pressure gauge 14. Pump unit R7-3S
15. Control box 16. Pump container
17. Oil sealing unit 18. Main power supply
19. Pump motor

Container Mixing Pump CMP 30 4.0 Part 2: Overview – Operation – Spare Part Lists
Overview CMP 30 4.0
14 2021-02-10
1 2 3 4 5 6
13 12 10 11 10 9 8 7
Fig. 6: Overview CMP 30 4.0
1. Rubber mixing pipe 2. Emergency OFF button
3. Water inlet into the mixing tube 4. Water connection from water fitting to mixing tube
5. Position switch for mixing tube 6. Capacitive level probe
7. Pump motor 8. Oil sealing unit
9. Pivot pin for transportation lock 10. Snap lock with catch
11. Position switch for pump unit 12. Connection of the mortar hoses to the pump unit
13. Water connection from mains or water barrel

Container Mixing Pump CMP 30 4.0 Part 2: Overview – Operation – Spare Part Lists
Description of assemblies
2021-02-10 15
11 Description of assemblies
11.1 Description of control box module
Fig. 7: Control box module
Control box
1. Relieve the pump
(reverse running).
2. Control voltage ON / OFF
3. Main switch, also functions as
Emergency OFF switch.
4. Hinges for switch cabinet door.
5. Socket (230 V),
continuous current.
6. Step switch, operating modes.
7. Water inlet button.
8. Control lamp fault.
9. Speed controller for pump motor
.
10. Pump OFF indicator light.
11. Filter fan for switch cabinet.
12. Connection remote control
pump motor.
13. Main power supply.
14. Outlet filter for control box.
15. Reserve.
16. Vibrator connection.
17. Mixer motor connection.
18. Emergency OFF button
19. Indicator lamp (no material)
20. Control lamp no water pressure.
21. Vibrator manual operation.
22. Control box lock.
1
2
3
4
5
6
7
8
9
10
11
12
13
22
12
21
13
20
19
18
17
16
15
14

Container Mixing Pump CMP 30 4.0 Part 2: Overview – Operation – Spare Part Lists
Description of assemblies
16 2021-02-10
11.2 Pump motor with tank and pump
1 2 3 4 5 6
13 12 11 10 9 8 7
Fig. 8: Overview of pump motor with tank and pump
1. Pump motor 2. Oil sealing unit
3. Level probe KPS1 for pump container 4. Wheel for pump container
5. Safety switch for protective grids 6. Protective grille
7. Mortar pressure gauge 8. Connection for the mortar hoses
9. Pump unit R7-3S 10. Tie rod M16
11. Snap lock with catch 12. Pump shaft
13. Cleaning nozzle for draining residual material
from the pump container

Container Mixing Pump CMP 30 4.0 Part 2: Overview – Operation – Spare Part Lists
Description of assemblies
2021-02-10 17
11.3 Geared motor with sealing unit
Fig. 9:Geared motor with sealing unit
1. Gear motor, 7.5 KW.
2. Sensor cover.
3. Gearbox 175 rpm.
4. Sealing unit.
11.4 Pump container
Fig. 10:Pump container
1. Level probe KPS1 for pump container.
2. Wheel for pump truck.
3. Safety switch for protective grids.
4. Cleaning nozzle for draining residual material from
the pump container.
11.5 Frame CMP30
Fig. 11:Frame CMP30
1. Connection to silo or container.
2. Position switch.
3. Capacitive level probe.
4. Pivot pin for transport security.
5. Quick fastener.
1
2
3
4
1
2
3
4
5
1
2
3
4
5

Container Mixing Pump CMP 30 4.0 Part 2: Overview – Operation – Spare Part Lists
Description of assemblies
18 2021-02-10
11.6 Overview water/air fitting
1 2 3 4 5 6 7 8
18 17 16 15 14 13 12
Fig. 12: Overview water/air fitting
1. Socket (230 V), continuous current 2. Compressor pressure switch switch off
3. Pressure switch air / pump stops / mixer continues to run 4. Air compressor
5. Water safety switch 6. Pressure reducer
7. Solenoid valve 8. Water flow meter
9. Needle valve for water quantity 10. Water tap cleaning hose
11. Water connection from water supply 12. Air connection to spray gun
13. Water connection for cleaning the mortar hose 14. Water pressure gauge
15. Water primary-pressure gauge 16. Water pump
17. Drain valve Water flow meter 18. Drainage valve for water fitting
19. Stopcock / continuous operation for air compressor
19
9
10
11

Container Mixing Pump CMP 30 4.0 Part 2: Overview – Operation – Spare Part Lists
Operating modes step switch
2021-02-10 19
12 Operating modes step switch
Fig. 13:Step switch “0”
The step switch can be switched in five different operating modes:
Position “0”
Machine is ready for operation, no function.
Fig. 14: Step switch “1”
Position “1”
Water pump is in operation (e.g. for cleaning the machine or
the mortar hoses)
Fig. 15: Step switch “2”
Position “2”
In switch position “2” the mixer motor runs.
Mixer and water pump run in manual mode.
The mixer is switched off by the level probe in the pump material
container when the signal is full.
Fig. 16:Step switch “3”
Position “3”
In switch position “3” the pump motor runs.
Pump runs in manual mode.
NOTE!
Never allow the pump to run dry.
Fig. 17:Step switch “4”
Position “4”
Container mixing pump runs in automatic mode.
NOTE!
Water factor m
ust be set to the prescribed value.
Fig. 18:Step switch “5”
Position “5”
In switch position “5” and by pressing the blue pushbutton
the pump is released (reverse operation).
Fig. 19:Step switch “6”
Position “6”
Forced drainage of the water fitting.

Container Mixing Pump CMP 30 4.0 Part 2: Overview – Operation – Spare Part Lists
Function description and operating sequence
20 2021-02-10
13 Function description and operating sequence
The machine combination PFT CMP 30 4.0 is a continuously operating mixing and conveying pump for the
processing of plaster mortar. The machine is directly attached to a stationary silo with a 250 capacity outlet.
A horizontal continuous mixer mixes the ready-mixed dry mortar with water and transfers it to the storage
tank of the feed pump. The feed pump can variably pump 7-26 litres of mortar per minute into the mortar
hoses.
Due to the “open mixing pump system”, the consistency check can be carried out at any time after mixing
and not only at the end of the hose. The worm pump can also be retracted in order to fill mortar buckets,
for example.
The system is automatically controlled by an integrated switch cabinet in connection with the remote control
and the water supply.
The horizontal mixer, pump and water pump on the control box can be operated manually for starting up
the plant and also for cleaning at the end of work.
For a trouble-free operation of the system an appropriate water pressure is necessary. With the integrated
water pump it is also possible to feed water from a reservoir (water barrel) if there is not enough water.
If the water pressure is too low, the pressure switch built into the water supply automatically switches off
the PFT CMP 30 4.0 to prevent malfunctions of the system.
13.1 Areas of application
The PFT CMP 30 4.0 has been specially designed for the thermal insulation and composite system and
the entire plaster mortar sector. Due to the variable pump drive, e.g. adhesive and reinforcing mortar as
well as finishing or fine plaster can be optimally processed.
14 Basic equipment
The basic equipment of the mixing and pumping unit consists of the following assemblies, depending on
the construction site and application:
Frame CMP 30 4.0
Mixing tube with dosing and mixing shaft
Capacitive level probe
Control box
Water fitting CMP 30 4.0
Material container with pump
Pump shaft
Pressure flange with diaphragm seal and pressure gauge
Level probe KPS1
15 Safety regulations
Important!
When performing any work, observe the locally applicable safety regulations for mortar
conveying and spraying machines!