PFT LOTUS XS 230 V User manual

Operating manual
LOTUS XS 230 V horizontal continuous mixer
Part 2 Overview, operation and service
Item no. of the operating manual: 00414358
LOTUS XS, 230 V, 1 Ph, 50 Hz Item no.: 00246057
LOTUS XS, 230 V, 1 Ph, 50 Hz with AVO 500 Item no.: 00266950
LOTUS XS, 230 V, 1 Ph, 50 Hz with pressure gauge Item no.: 00282613
LOTUS XS, 230 V, 1 Ph, 50 Hz for spatula applications Item no.: 00754070
LOTUS XS r (rubber mixing tube), 230 V, 1 Ph, 50 Hz for
spatula applications
Item no.: 00754071
LOTUS XS r (rubber mixing tube), 230 V, 1 Ph, 50 Hz for
mortar applications
Item no.: 00754072
Read the operating manual prior to starting any work!

LOTUS XS 230 V horizontal continuous mixer / 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 00414358_2.0_GB
Translation of the original operating manual (DE)
Date of first issue 06.2022
Date of change
Copyright The distribution or reproduction of this document, exploitation or
communication of its contents are prohibited unless expressly autho-
rised. Violations may lead to damage compensation.
All rights are reserved in the event of patent, utility model or design
registration.
Notes All rights, technical changes, printing errors and mistakes reserved.
Our guarantee only relates to the perfect quality of our machines.
Consumption, quantity, execution details and performance data
are empirical values, which cannot be transferred readily in case of
different circumstances.
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LOTUS XS 230 V horizontal continuous mixer / Part 2 Overview, operation and service
Table of contents
Table of contents
1 General information................................... 5
1.1 Information regarding the operating
manual.............................................. 5
1.2 Division............................................. 5
1.3 Keep the manual for future refer-
ence.................................................. 5
1.4 Display of safety and warning
notices.............................................. 6
1.5 Name plate....................................... 6
1.6 EC Declaration of Conformity........... 7
1.7 Quality Control sticker...................... 8
1.8 Intended use.................................... 8
1.8.1 Purpose of fitting block..................... 8
1.8.2 Purpose of flowmeter....................... 9
1.8.3 Purpose of solenoid valve................ 9
2 Technical data............................................. 10
2.1 General information.......................... 10
2.2 Connection values of water.............. 11
2.3 Operating conditions........................ 11
2.4 Sound power level............................ 11
2.5 Vibrations.......................................... 11
3 Transport, packing and storage................ 12
3.1 Safety instructions for transport........ 12
3.2 Transport inspection......................... 13
3.3 Packaging......................................... 13
3.4 Transport in individual parts............. 14
3.5 Transporting a running machine....... 14
4 Description.................................................. 15
4.1 Overview........................................... 15
4.2 Brief description of the Lotus XS...... 16
4.3 Fields of application......................... 16
4.4 Description of assemblies................ 16
4.4.1 Material hopper with frame............... 17
4.4.2 Mixing tube....................................... 17
4.4.3 Mixing shaft...................................... 18
4.4.4 Water manifold................................. 18
4.5 Connections...................................... 19
4.6 Accessories...................................... 20
5 Operation..................................................... 24
5.1 Safety............................................... 24
5.1.1 Safety rules...................................... 24
5.1.2 Hazardous dusts.............................. 25
5.2 Inspection by machine operator....... 25
5.3 Preparing the machine..................... 25
5.3.1 Risk of injury due to rotating dosing
shaft.................................................. 25
5.3.2 Positioning machine......................... 26
5.3.3 Connecting the power supply........... 26
5.3.4 Connecting the water supply............ 27
5.3.5 Setting pressure reducer.................. 28
5.3.6 Setting the water quantity................. 29
5.3.7 Feeding dry material to the machine 29
5.4 Shutdown in case of emergency...... 29
5.5 Putting the machine into operation... 30
5.5.1 Feeding material to the machine...... 30
5.6 Applying mortar................................ 31
5.7 Interruption of work.......................... 31
5.8 Switching off the machine................ 31
5.9 Action in case of power failure......... 32
5.10 Measures in case of risk of frost....... 32
5.11 Measures to be taken in case of
water outage.................................... 33
5.12 Ending work / cleaning the machine. 33
5.12.1 Cleaning........................................... 33
5.12.2 Secure against restarting................. 33
5.12.3 Removing the mixing tube................ 33
5.12.4 Cleaning the material hopper........... 35
5.12.5 Cleaning the dosing shaft................. 35
5.13 Reaction in the event of faults.......... 36
5.13.1 Safety............................................... 36
5.13.2 Faults................................................ 36
5.13.3 Table of faults................................... 37
6 Maintenance................................................ 38
6.1 Safety............................................... 38
6.1.1 Remove connection cable................ 39
6.2 Environmental protection.................. 39
6.3 Maintenance plan............................. 40
6.4 Maintenance work............................ 40
6.4.1 Implementation by a service techni-
cian................................................... 40
6.4.2 Strainer screen in the water inlet...... 41
6.5 Actions after completed mainte-
nance................................................ 41
6.6 Periodic inspection/expert inspec-
tion.................................................... 41
6.7 Spare parts lists............................... 42
6.8 Accessories...................................... 42
7 Disassembly................................................ 43
7.1 Safety............................................... 43
7.2 Disassembly..................................... 44
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LOTUS XS 230 V horizontal continuous mixer / Part 2 Overview, operation and service
Table of contents
8 Disposal....................................................... 45
9 Assembly instructions............................... 46
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LOTUS XS 230 V horizontal continuous mixer / Part 2 Overview, operation and service
General information
1 General information
1.1 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.
Furthermore, the local accident prevention guidelines and general
safety instructions for the application area of the device are to be
adhered to.
Read the operating manual thoroughly before starting any work!
It is a part of the product and has to be kept near the device and
easily accessible to the personnel at all times.
If the device is given to third parties, also include the operating
manual.
The figures in this manual are for presentation purposes of facts,
not necessarily to scale and may slightly differ from the actual
model of the device.
1.2 Division
The operating manual is divided into 2 books:
Part 1 Safety/drinking water protection
General safety instructions horizontal continuous mixer/compulsory
mixer
Item no.: 00146378
Part 2 Overview, operation and service (this manual).
WARNING
Danger of injury due to incorrect operation!
Improper operation may lead to serious damage to
persons and property.
To ensure safe and proper operation of the machine,
all parts of the operating manual must be read before
starting work; all parts together are considered to be a
single operating manual.
1.3 Keep the manual for future reference
The operating manual has to be available during the whole service life
of the product.
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LOTUS XS 230 V horizontal continuous mixer / Part 2 Overview, operation and service
General information
1.4 Display of safety and warning notices
In this manual, safety and warning notices are used in conjunction
with signal words to raise safety awareness, indicate degrees of
danger and explain safety measures.
Such safety and warning information may also be attached to the
product in the form of signs, stamps or stickers.
Structure of the safety and warning
notices
All safety and warning notices consist of:
The danger sign and signal word
Information on the nature of the hazard
Information on the source of the hazard
Information on possible consequences of disregarding the hazard
Measures to avert the hazard
Danger sign Signal word Significance
Danger Death or serious injury will occur if you do not take the precautions
described.
Warning Death or serious injury may occur if you do not take the precautions
described.
Caution Minor injury may occur if you do not take the precautions described.
Note Property damage may occur if you do not take the precautions
described.
Tip An important piece of information about the product or the particular
section of the manual to which special attention is to be drawn.
1.5 Name plate
Figure 1: Name plate
The following details can be found on the name plate:
Manufacturer
Type
Year of manufacture
Machine number
Permissible operating pressure
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LOTUS XS 230 V horizontal continuous mixer / Part 2 Overview, operation and service
General information
1.6 EC Declaration of Conformity
Company: Knauf PFT GmbH & Co. KG
Einersheimer Straße 53
97346 Iphofen
Germany
declares under our sole responsibility that the machine:
Type of machine: LOTUS XS
Type of equipment: Horizontal mixers
Serial number:
Guaranteed sound power level: 78 dB
is in conformity with the following CE directives:
– Outdoor Directive (2000/14/EC),
– Machinery Directive (2006/42/EC),
– Electromagnetic Compatibility Directive (2014/30/EU).,
Operative Conformity Assessment according to Outdoor Directive 2000/14/EC:
Internal production control as per article 14 paragraph 2 in connection with annex V.
This declaration only refers to the machine in the state in which it has been placed on the market. Parts
subsequently added by the user and/or subsequent interventions are not covered. This declaration ceases to
be valid if the product is converted or changed without consent.
Person authorised to compile the relevant technical documentation:
– (Dipl. in Industrial Engineering, University of Applied Sciences) 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
Managing Director
Town/city Name and signature Details of signatory
page 7 / 48

LOTUS XS 230 V horizontal continuous mixer / Part 2 Overview, operation and service
General information
1.7 Quality Control sticker
Figure 2: Quality Control sticker
The following details can be found on the Quality Control sticker:
CE confirmed as per EU directives
Serial no / serial number
Controller / signature
Date of control
1.8 Intended use
1.8.1 Purpose of fitting block
The fitting block has been designed and constructed only for the
intended use described below.
NOTE
Application range!
Primary use for water and neutral, non-adhesive liquids.
Also suitable for air and neutral non-flammable gases.
Maximum operating pressure (initial pressure) 16 bar.
After-pressure infinitely adjustable from 1.5 to 6 bar.
Smallest possible initial pressure 2.5 bar.
Minimum pressure gradient (initial/after-pressure) 1
bar.
Maximum media and ambient temperature 75 °C.
Assembly position as desired, preferable vertical.
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LOTUS XS 230 V horizontal continuous mixer / Part 2 Overview, operation and service
General information
1.8.2 Purpose of flowmeter
NOTE
Application range!
The flowmeter serves for measuring the volume of trans-
parent liquid and gas flows in closed pipes. Optionally, the
flowmeter can also be used for flow monitoring.
CAUTION
Danger due to improper use!
Any use beyond the specified purpose of use and/or any
other form of use of the flowmeter can lead to dangerous
situations.
Therefore:
Only use the flowmeter as intended.
Always adhere to the usage directives of the material
manufacturer.
Strictly follow all instructions in this operating manual.
We accept no responsibility for damages caused by improper or unau-
thorised use.
The operator of the device is solely responsible for any damage
arising from improper use.
1.8.3 Purpose of solenoid valve
NOTE
Application range!
Solenoid valves for liquid and gaseous media, aggressive
or neutral, can be used in various temperature and pres-
sure ranges
Type 6213 is a 2/2 way solenoid valve with straight
passage, normally closed, with a permanently coupled
membrane system. It switches from 0 bar and is universal
in use for liquids. A minimum differential pressure of 0.5
bar is necessary for complete opening.
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LOTUS XS 230 V horizontal continuous mixer / Part 2 Overview, operation and service
Technical data
2 Technical data
2.1 General information
1.240 500
513
1.218 635
1.010 - 1.150
Figure 3: Dimension sheet in mm
Detail Value Unit
Empty weight approx. 66 - 74 kg
Length 1,218/1,240 mm
Width 500/635 mm
513 mm
Height 1,010 - 1,150 mm
Maximum grain size 4 mm
Material hopper dimensions Detail Value Unit
Filling height 1,010 - 1,150 mm
Outlet height 570 - 710 mm
Material hopper volume 50 l
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LOTUS XS 230 V horizontal continuous mixer / Part 2 Overview, operation and service
Technical data
2.2 Connection values of water
Figure 4: Water connection
Detail Value Unit
Operating pressure, min. 2.5 bar
Connection ½ inch
2.3 Operating conditions
Environment Detail Value Unit
Temperature range 2 - 45 °C
Relative humidity, max. 80 %
Duration Detail Value Unit
Max. operating time at a stretch 8 hours
Electrical details Detail Value Unit
Voltage, alternating current 50 Hz 230 V
Power consumption, max. 8.2 A
Fuse protection 16 A
Power input, max. 1.3 kW
Mixer motor speed 280 Rpm
2.4 Sound power level
Guaranteed sound power level LWA
78 dB(A)
2.5 Vibrations
Weighted effective value of acceleration to which the upper body parts
are exposed <2.5 m/s²
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LOTUS XS 230 V horizontal continuous mixer / Part 2 Overview, operation and service
Transport, packing and storage
3 Transport, packing and storage
3.1 Safety instructions for transport
Improper transport NOTE
Damage from improper transport!
Improper transport may cause substantial property
damage.
Therefore:
When unloading the packages on delivery, as well
as transport within the company, pay attention and
observe the symbols and instruction on the package.
Use only the specified anchorage points.
Remove packaging only shortly before the assembly.
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:
Never step under suspended loads.
Observe the instructions regarding the provided
anchorage points.
Do not attach to projecting machine parts or eyelets of
attached components and ensure safe fit of the sling
gear.
Only use approved lifting gear and accessories with a
sufficient load-bearing capacity.
Do not use torn or frayed ropes and belts.
Do not lay ropes and belts over sharp edges and
corners, do not knot or twist.
When ropes and chains are used in construction
operations, the provisions contained in the accident
prevention regulation "Load suspension devices in
lifting gear operations" (VBG 9a) should be complied
with. The following sections contain instructions for
scenarios in which ropes and chains are used as lifting
means.
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LOTUS XS 230 V horizontal continuous mixer / Part 2 Overview, operation and service
Transport, packing and storage
3.2 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.
Note the extent of damage on the transport documentation or on
the delivery note of the carrier.
Initiate complaint process.
NOTE
Report any defect as soon as it is detected. Claims for
damages can be asserted only within the valid warranty
period.
3.3 Packaging
For packaging The individual packages have to be packed in accordance with the
transport conditions to be expected. Only environmentally-friendly
materials were used for the packaging.
The packaging should protect the individual components until the
assembly from transport damage, corrosion and other damage. There-
fore do not destroy the packaging and remove only shortly before the
assembly.
Handling packaging materials If no agreement for the recovery of the packaging has been made,
separate materials according to type and size and reuse or recycle.
NOTE
Environmental damage due to incorrect disposal!
Packaging materials are valuable raw materials and in
many cases they can be reused or reconditioned and
recycled.
Dispose of packaging materials in an environmen-
tally-friendly way.
Observe the applicable local disposal regulations. If
required hand over the disposal to a specialist.
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LOTUS XS 230 V horizontal continuous mixer / Part 2 Overview, operation and service
Transport, packing and storage
3.4 Transport in individual parts
Figure 5: Individual parts
To make transport easier, disassemble the machine into its individual
components:
1. The mixing tube and mixing shaft units.
2. Material hopper with support feet and frame.
3. Remove the support feet from the frame.
3.5 Transporting a running machine
CAUTION
Danger of injury from discharged mortar!
Injuries to face and eyes can occur.
Therefore:
Before opening the couplings ensure that there is no
more pressure on the hoses (observe display at mortar
manometer).
Carry out the following steps before beginning the transport:
1. First unplug the mains cable.
2. Undo all other cable connections, water supply lines and hoses.
3. Remove loose parts during crane transport.
4. Start transport.
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LOTUS XS 230 V horizontal continuous mixer / Part 2 Overview, operation and service
Description
4 Description
4.1 Overview
1
2
3
4
5
6
7
8
9
10
12
13
14
11
Figure 6: Table of the assembly groups
[1] Protective grille with sack opener [2] Motor cover
[3] Mixer motor [4] Material hopper
[5] Water manifold [6] Water inlet
[7] Support foot with wheel [8] Wheel
[9] Support foot with foot plate [10] Mortar outlet
[11] Mixing tube [12] Slider handle
[13] "ON/OFF" pushbutton, is also emergency stop
switch
[14] Main terminal
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LOTUS XS 230 V horizontal continuous mixer / Part 2 Overview, operation and service
Description
4.2 Brief description of the Lotus XS
The PFT LOTUS XS can be operated via a standard household grounded socket, thanks to the 230 V
connection.
It is particularly suitable for processing small quantities of premixed bagged material. The PFT LOTUS XS
continuously and fully automatically mixes all premixed dry mortar with a lime/cement base up to a maximum
4 mm grain size. The innovative special mixing shaft ensures homogeneous blending with a low motor
output.
The optimally placed water inlet prevents most deposits from forming inside the machine, making the mixer
virtually self-cleaning.
The organised layout of the operating elements makes work with the PFT mixer extremely straightforward.
The special tamper-proof mortar outlet is designed without deep-drawn outlet connection, so that a down-
stream PFT feed pump or mortar bucket can be pushed underneath without difficulty. Furthermore, the small
continuous mixer is height-adjustable - firstly so that the processor can be set at a convenient height for
filling, and secondly so that a range of different feed pumps can be placed underneath for the further trans-
port of the material mixed by the PFT LOTUS XS.
4.3 Fields of application
For all dry mortars with a maximum granulation of 4 mm, such as:
Masonry mortar
Light masonry mortar
Adhesive and reinforcement mortar
Sgraffito
Cement plasters
Insulation plasters
Screed mortar
Levelling compounds
Smoothing cement
Facing mortar
Textured plaster
Lime plaster
Reconstruction plaster
Finishing plaster
Tiling and grouting mortar
.... and many more
4.4 Description of assemblies
The PFT LOTUS XS horizontal mixer consists of the main compo-
nents described in the following chapters.
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LOTUS XS 230 V horizontal continuous mixer / Part 2 Overview, operation and service
Description
4.4.1 Material hopper with frame
Figure 7: Material hopper assembly
Material hopper with frame and gear motor.
4.4.2 Mixing tube
Figure 8: Steel mixing tube assembly
Steel mixing tube
Figure 9: Rubber mixing tube assembly
Rubber mixing tube
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LOTUS XS 230 V horizontal continuous mixer / Part 2 Overview, operation and service
Description
4.4.3 Mixing shaft
Figure 10: Mixing shaft assembly
Mixing shaft
4.4.4 Water manifold
5
4
1
3
2
Figure 11: Water tap assembly
Water manifold for LOTUS XS item no.: 00246057 & 00754072
1. Solenoid valve
2. Pressure reducer
3. Water connection from water supply
4. Water to mixing tube
5. Needle valve water quantity
6
7
Figure 12: Water tap assembly
Water manifold for LOTUS XS item no.: 00266950
1. Pressure booster pump
2. Water connection from water supply
1
2
3
4
5
6
7
Figure 13: Water tap assembly
Water manifold for LOTUS XS item no.: 00282613
1. Water inlet pressure gauge
2. Water connection from water supply
3. Water to mixing tube
4. Water operating pressure gauge
5. Needle valve water quantity
6. Solenoid valve
7. Pressure reducer
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LOTUS XS 230 V horizontal continuous mixer / Part 2 Overview, operation and service
Description
6
1
2
3
5
4
Figure 14: Water tap assembly
Water manifold for LOTUS XS item no.: 00754070 & 00754071
[1] Solenoid valve
[2] Pressure reducer
[3] Water connection from water supply
[4] Needle valve water quantity
[5] Water to the mixing tube or flow meter
[6] Flow meter
4.5 Connections
1
Figure 15: Power connection
1. Power supply connection
2
Figure 16: Water connection without a
booster pump
2. Water supply connection (2) from water supply network or water
barrel, without booster pump
2
Figure 17: Water connection with a
booster pump
3. Water supply connection (2) from water supply network with
booster pump
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LOTUS XS 230 V horizontal continuous mixer / Part 2 Overview, operation and service
Description
4.6 Accessories
Extension cable 3 x 2.5 mm², BLA 2-16 A - 25 m (230 V, 1 Ph)
Item no. 20423400
Water hose/air hose DN19 Geka | Geka - 40 m
Item no. 20212100
Water pump as standalone suction pump AV 1000 with integrated
pressure cut-off and flow monitor, 230 V, 1 Ph, 50 Hz, 0.6 kW
Item no. 00493686
Inlet strainer complete with stainless steel filter screen
Item no. 00136619
page 20 / 48