PFT ZP 3 M User manual

Operating manual
ZP 3 M delivery pump
Part 2 Overview, operation and service
Item no. of the operating manual: 00544586
Read the operating manual prior to starting any work!

ZP 3 M delivery pump / Part 2 Overview, operation and service
This operating manual applies to the following items:
ZP 3 M FC-400V, 3 Ph, 50 Hz, 4 kW without accessories Item no. 00531449
ZP 3 M FC-230V, 1 Ph, 50 Hz, 4 kW without accessories Item no. 00531450
ZP 3 M pole-changing, 400 V, 3 Ph, 50 Hz, 3,7 kW without accessories Item no. 00531452
ZP 3 M FC-230V, 1 Ph, 50 Hz, 4 kW with accessories Item no. 00542526
ZP 3 M FC-400V, 3 Ph, 50 Hz, 4 kW with accessories Item no. 00542527
ZP 3 M pole-changing, 400 V, 3 Ph, 50 Hz, 3,7 kW with accessories Item no. 00542528
ZP 3 M FC-400V, 3 Ph, 50 Hz, 4 kW screed without accessories Item no. 00543560
ZP 3 M FC-400V, 3 Ph, 50 Hz, WILCOWA Item no. 00550671
ZP 3 M FC-400V, 3 Ph, 50 Hz, 4 kW with vibrating screen and accessories Item no. 00594140
ZP 3 M, 230 V, 3 Ph, 60 Hz, 4,5 kW RAL1006 Item no. 00617978
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ZP 3 M delivery pump / 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 00544586_1.0_GB
Translation of the original operating manual (DE)
Date of first issue 07.2023
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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ZP 3 M delivery pump / Part 2 Overview, operation and service
Table of contents
Table of contents
1 General information................................... 6
1.1 Information regarding the operating
manual.............................................. 6
1.2 Division............................................. 6
1.3 Display of safety and warning
notices.............................................. 6
1.4 Keep the manual for future refer-
ence.................................................. 7
1.5 Name plate....................................... 7
1.6 EC Declaration of Conformity........... 8
1.7 Quality Control sticker...................... 9
1.8 Intended use.................................... 9
1.8.1 Purpose of air compressor............... 9
1.8.2 Safety devices of air compressor..... 10
1.8.3 General setup of the air compressor 10
1.8.4 Hot surfaces on the air compressor.. 10
2 Technical data............................................. 11
2.1 General information.......................... 11
2.2 Operating conditions........................ 11
2.2.1 Operating conditions FC-230V 50Hz 12
2.2.2 Operating conditions 230V 60Hz...... 12
2.2.3 Operating conditions FC-400V......... 13
2.2.4 Operating conditions 400V pole-
changing........................................... 13
2.3 Performance values pump unit 2L6
RENDER STAR................................ 13
2.4 EMC test.......................................... 14
2.5 Sound power level............................ 14
2.6 Vibrations.......................................... 14
3 Transport, packing and storage................ 15
3.1 Safety instructions for transport........ 15
3.2 Transport inspection......................... 16
3.3 Packaging......................................... 16
3.4 Transport.......................................... 17
3.5 Crane transport................................ 17
3.6 Transport by car or truck.................. 17
3.7 Transporting a running machine....... 18
4 Description.................................................. 19
4.1 Overview - ZP 3 M........................... 19
4.2 Functional description ZP 3 M.......... 19
4.3 Fields of application......................... 20
4.4 Description of assemblies................ 20
4.4.1 Material hopper................................ 21
4.4.2 Control cabinet item no. 00531100... 21
4.4.3 Control cabinet item no. 00531101... 22
4.4.4 Control cabinet item no. 00531102... 22
4.4.5 Control cabinet item no. 00617410.. 23
4.4.6 Pump unit......................................... 23
4.4.7 Vibrating screen............................... 23
4.4.8 Air compressor................................. 24
4.4.9 Mortar pressure gauge..................... 24
4.5 Operating modes.............................. 25
4.6 Accessories...................................... 26
5 Operation..................................................... 30
5.1 Safety............................................... 30
5.1.1 Safety rules...................................... 30
5.1.2 Monitoring the machine.................... 31
5.1.3 Hazardous dusts.............................. 31
5.1.4 Safety system................................... 31
5.1.5 Mortar pressure gauge..................... 32
5.2 Inspection by machine operator....... 32
5.3 Preparing the machine..................... 32
5.3.1 Risk of injury due to rotating pump
shaft.................................................. 32
5.3.2 Setting up the machine.................... 33
5.3.3 Connecting the power supply........... 33
5.3.4 Checking the direction of rotation..... 35
5.3.5 Mortar hoses.................................... 37
5.3.6 Drain residual water......................... 39
5.3.7 Compressed air supply.................... 39
5.3.8 Feeding material to the machine...... 41
5.4 Shutdown in case of emergency...... 41
5.5 Putting the machine into operation... 42
5.5.1 Checking the mortar consistency..... 42
5.5.2 Feeding material to the machine...... 43
5.6 Remote control................................. 44
5.7 Applying mortar................................ 44
5.7.1 Opening the air tap on the spray
gun.................................................... 44
5.8 Pump screed or masonry mortar...... 45
5.9 Interruption of work.......................... 45
5.9.1 In case of longer interruption of
work / break...................................... 46
5.10 Switching off the air compressor...... 47
5.11 Switching off the air compressor...... 47
5.12 Switching off the machine................ 47
5.13 Action in case of power failure......... 48
5.13.1 Discharging mortar pressure............ 49
5.13.2 Switching on the machine again
after a power failure......................... 49
5.14 Measures in case of risk of frost....... 50
5.15 Ending work / cleaning the machine. 51
5.15.1 Cleaning........................................... 51
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ZP 3 M delivery pump / Part 2 Overview, operation and service
Table of contents
5.15.2 Secure against restarting................. 51
5.15.3 Running the machine empty............ 51
5.15.4 Disconnecting and cleaning the
mortar hose...................................... 52
5.15.5 Cleaning the material hopper........... 53
5.15.6 Drain residual water......................... 54
5.15.7 Cleaning the pump........................... 54
5.16 Reaction in the event of faults.......... 55
5.16.1 Safety............................................... 55
5.16.2 Faults................................................ 55
5.16.3 Fault displays................................... 56
5.16.4 Table of faults................................... 57
5.16.5 Hose blockages................................ 58
5.16.6 Removal of clogging in hoses.......... 59
6 Maintenance................................................ 63
6.1 Safety............................................... 63
6.1.1 Remove connection cable................ 64
6.2 Environmental protection.................. 64
6.3 Maintenance plan............................. 65
6.4 Maintenance work............................ 65
6.4.1 Implementation by a service techni-
cian................................................... 65
6.4.2 Air filter compressor......................... 66
6.4.3 Setting value pressure switch air
compressor....................................... 66
6.4.4 Safety valve air compressor............. 66
6.4.5 Clean the filter cartridge for the
frequency converter.......................... 66
6.5 Actions after completed mainte-
nance................................................ 67
6.6 Periodic inspection/expert inspec-
tion.................................................... 67
6.7 Spare parts lists............................... 68
6.7.1 Accessories...................................... 68
7 Disassembly................................................ 69
7.1 Safety............................................... 69
7.2 Disassembly..................................... 70
8 Disposal....................................................... 71
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ZP 3 M delivery pump / 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 mixing pumps/conveying pumps
Item no.: 00172709
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 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.
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ZP 3 M delivery pump / Part 2 Overview, operation and service
General information
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.
1.4 Keep the manual for future reference
The operating manual has to be available during the whole service life
of the product.
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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ZP 3 M delivery pump / 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: ZP 3 M
Type of equipment: Delivery pump
Serial number:
Guaranteed sound power level: 95 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
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ZP 3 M delivery pump / 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 air compressor
The air compressor has been designed and constructed only for the
intended use described in this document.
NOTE
The air compressor is only intended for generating
compressed air and may only be used with connected
work devices. Any other use or use beyond what is spec-
ified, such as with freely accessible and/or open hoses
and pipelines, is deemed to be not for the intended
purpose. Connected implements or components are to be
designed for the maximum generated pressure of 5.5 bar.
The air compressor is to be used only in technically
perfect condition, as well as for its intended use and while
taking into account the safety and hazard information in
the operating manual!
In particular faults that can impair safety must be rectified
immediately before the compressor is put back into opera-
tion.
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ZP 3 M delivery pump / 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. Safety is only
assured when the safety devices are intact.
Therefore:
Check that the safety devices and functional and
correctly installed before starting work.
Use safety equipment at all times.
Do not obstruct access to safety systems such as
EMERGENCY STOP pushbuttons, emergency off
buttons, pull cords etc.
1.8.3 General setup of the air compressor
The air compressor corresponds to the national and international
safety regulations and can therefore also be used in damp rooms or
in the open air. Areas with as clean and dry air as possible should be
preferred. Make sure that the air compressor can suck in the air unim-
peded. This applies in particular when an installation is intended.
The air compressor must be set up so that no hazardous admixtures,
such as solvents, vapours, dusts or other harmful substances, can be
sucked in. The device should be positioned only in rooms where the
hazard of a potentially explosive atmosphere is not given.
1.8.4 Hot surfaces on the air compressor
General information WARNING
Risk of injury due to hot surface!
Surface temperatures can reach up to 100 °C during
operation of the air compressor.
Therefore, always ensure that the air compressor does
not come into contact with exposed body parts during
use as well as for some time after use, depending on
the temperature.
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ZP 3 M delivery pump / Part 2 Overview, operation and service
Technical data
2 Technical data
2.1 General information
680 1.800
670
Figure 3: Dimension sheet in mm
Detail Value Unit
Empty weight approx. 155 - 253 kg
Length 1,800 mm
Width 680 mm
Height 670 mm
Material hopper dimensions Detail Value Unit
Filling height 640 mm
Material hopper volume 85 l
2.2 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
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ZP 3 M delivery pump / Part 2 Overview, operation and service
Technical data
2.2.1 Operating conditions FC-230V 50Hz
Electrics FC-230V 50Hz Detail Value Unit
Voltage, alternating current 50 Hz 230 V
Power consumption, max. 16 A
Fuse protection, minimum 16 A
Pump motor current consumption 13.9 A
Pump motor speed range 40 - 190 Rpm
Power input, max. 5 kW
Drive pump motor 4 kW
Air compressor *0.9 kW
Vibrating unit *0.045 kW
*Optional accessories
2.2.2 Operating conditions 230V 60Hz
Electrics 230V 60Hz Detail Value Unit
Voltage, alternating current 60 Hz 230 V
Power consumption, max. 15.5 A
Fuse protection, minimum 16 A
Pump motor current consumption 15.5 A
Pump motor speed range 144 Rpm
Power input, max. 4.5 kW
Drive pump motor 4.5 kW
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ZP 3 M delivery pump / Part 2 Overview, operation and service
Technical data
2.2.3 Operating conditions FC-400V
Electrics FC-400V Detail Value Unit
Voltage, three-phase current 50
Hz
400 V
Power consumption, max. 16 A
Fuse protection, minimum 16 A
Pump motor current consumption 8.5 A
Pump motor speed range 40 - 190 Rpm
Power input, max. 5 kW
Drive pump motor 4 kW
Air compressor *0.9 kW
Vibrating unit *0.045 kW
*Optional accessories
2.2.4 Operating conditions 400V pole-changing
Electrics 400V pole-changing Detail Value Unit
Voltage, three-phase current 50
Hz
400 V
Power consumption, max. 16 A
Fuse protection, minimum 16 A
Pump motor current consumption 7.9/9.6 A
Pump motor speed range 106/215 Rpm
Drive pump motor 3.7/4.4 kW
Air compressor *0.9 kW
Vibrating unit *0.045 kW
*Optional accessories
2.3 Performance values pump unit 2L6 RENDER STAR
Pump performance 2L6 RENDER
STAR
Detail Value Unit
Delivery rate infinitely adjustable 8 - 33 l/min
Operating pressure, maximum 20 bar
Maximum grain size 6 mm
Delivery distance *, maximum
with 35 mm Ø
60 m
*Reference value depending on conveying height, pump condition
and version, mortar quality, composition and consistency
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ZP 3 M delivery pump / Part 2 Overview, operation and service
Technical data
Compressor output DELTA 2 Detail Value Unit
Compressor output 0.180 Nm³/min
Compressor output for COMP
M-250
Detail Value Unit
Compressor output 0.250 Nm³/min
2.4 EMC test
The machine has been EMC tested and complies with the strict
requirements of EMC Directive filter class B.
The control box is equipped with a network filter.
2.5 Sound power level
Guaranteed sound power level LWA
95 dB(A)
2.6 Vibrations
Weighted effective value of acceleration to which the upper body parts
are exposed <2.5 m/s²
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ZP 3 M delivery pump / 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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ZP 3 M delivery pump / 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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ZP 3 M delivery pump / Part 2 Overview, operation and service
Transport, packing and storage
3.4 Transport
Figure 4: Transport without pump unit
The pump unit can be disassembled in order to make it
easier to transport the machine.
3.5 Crane transport
1
2
Figure 5: Attachment points
Attachment points
For transport by crane, attach the machine to the stop eyelets (1) and
attach round slings in the area of the brackets (2).
Observe the following conditions:
The crane and lifting equipment have to be designed for the weight
of the packages.
The operator has to be authorised to operate the crane.
Attachment:
1. Anchor the hooks to the crane hooks accordingly.
2. Ensure that the package is straight, possibly observe eccentric
centre of gravity.
3.6 Transport by car or truck
CAUTION
Risk injury due to unsecured load!
All persons involved in the loading are responsible for
securing the load properly during road transport. The
relevant vehicle driver is responsible for the operational
loading.
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ZP 3 M delivery pump / Part 2 Overview, operation and service
Transport, packing and storage
3.7 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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ZP 3 M delivery pump / Part 2 Overview, operation and service
Description
4 Description
4.1 Overview - ZP 3 M
1
2
3
4
5
7
8
9
11
12
14
15
16
17
6
10
13
Figure 6: Table of the assembly groups
[1] Plastic cover [2] Impact screen (accessory)
[3] Vibrating unit (accessory) [4] Crane eyes
[5] Hinged handle [6] Main terminal
[7] Carrying handle [8] Mortar pressure gauge
[9] Connection for mortar hose [10] Pump unit
[11] Compressed air connection for the spray gun [12] Puncture-proof tyre
[13] CEE mounted socket for connection of
vibrating unit
[14] Pump motor
[15] Air compressor (accessory) [16] CEE mounted socket for connection of air
compressor
[17] Control cabinet
4.2 Functional description ZP 3 M
The delivery pump PFT ZP 3 M is characterised by its compact design, low weight and optimum delivery of
almost all materials. The ZP 3 M is used for processing building site mixtures, screed mortar and cement
plasters. The conveying output can be steplessly adapted to the material requirements. The delivery pump
has an integrated pressure control for the compressor and has a remote control for switching on and off.
The machine is made up of portable components, which facilitate speedy and convenient transport when the
dimensions are manageable and the weight is at a low level.
The feed pump can be fed in a universal manner. Consequently, it can be fed from buckets, horizontal
mixers, pug mill mixers or concrete mixers. Fluid, pumpable and solvent-free materials up to a maximum of 6
mm granulation can be pumped, grouted and sprayed.
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ZP 3 M delivery pump / Part 2 Overview, operation and service
Description
4.3 Fields of application
Figure 7: ZP 3 M and MULTIMIX
For fields of application such as:
Building site mixture
Screed mortar
Cement plaster
Lime-cement render
Adhesive mortar
Frame grouting mortar
Loam plaster, dry
Loam plaster, earth-moist
Masonry mortar
Fire protection mortar
Concrete restoration mortar
Floor screed 35 l
Thin screed
Floor fillers
Building site mixture
Flowability / flow characteristics The 2L6 RENDER STAR pump can be used with an
operating pressure of up to 20 bar.
The possible conveying distance depends mainly on
the flowability of the material.
Runny materials, fillers, paints etc. have good flow
characteristics.
If 20 bar operating pressure are exceeded the mortar
hose length has to be reduced.
In order to avoid machine faults and increased wear of
the pump motor, pump shaft and the pump itself, only
original PFT spare parts must be used, such as:
– PFT rotors
– PFT stators
– PFT pump shafts
– PFT mortar hoses
These are compatible with each other and form a
constructive unit with the machine.
Non-compliance does not only cause loss of guar-
antee, but also bad mortar quality is to be expected.
4.4 Description of assemblies
The PFT ZP 3 M delivery pump consists of the main components
described in the following chapters.
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