PFT PFT RITMO User manual

PFT RITMO powercoat 110V Operating Instructions Last updated 12.2006
Knauf PFT GmbH & Co. KG
1
OPERATING INSTRUCTIONS
(item number of the operating instructions 00 09 93 39)
(item number of the machine 00 09 90 64)
MIXER PUMP
PFT RITMO powercoat 110V
WE KEEP THINGS FLOWING

PFT RITMO powercoat 110V Operating Instructions Last updated 12.2006
Knauf PFT GmbH & Co. KG
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PFT RITMO powercoat 110V Operating Instructions Last updated 12.2006
Knauf PFT GmbH & Co. KG
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PFT RITMO powercoat 110V Operating Instructions Last updated 12.2006
Knauf PFT GmbH & Co. KG
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Contents
Contents 4
Please note ! 6
Inspection confirmation / type plate 7
Basic safety instructions 8
Basic safety instructions 9
Operating principle 10
General view of the RITMO powercoat: View from behind 11
General view of the RITMO powercoat: View from the front 12
Overview of the RITMO powercoat 110V control box, item number 00097590 13
Overview of the RITMO powercoat water manifold, item number 00097921 14
Setting values 15
Technical specifications 15
Assembly – rotor/stator/mortar pressure gauge 16
Mortar pump 17
Operation as pump (for pastes) 18
Operation as mixing pump (for filler in powder form) 19
Interruption of work 21
Measures to be taken when work is finished or interrupted 22
Clearing hose blockages 23
Measures to be taken in the event of a power failure 23
Measures to be taken in the event of a water supply failure 23
Measures to be taken if there is a risk of frost 24
Transport 24
Maintenance 25
Fault – Cause – Remedy 26
Accessories 28
Accessories 29
Spare parts drawing for motor and protection grille, RITMO powercoat 30
Spare parts list for motor and protection grille, RITMO powercoat 31
Spare parts drawing for material hopper, RITMO powercoat 32
Spare parts list for material hopper, RITMO powercoat 33
Spare parts drawing for pump unit, RITMO powercoat 34
Spare parts list for pump unit, RITMO powercoat 35
Spare parts drawing for frame, RITMO powercoat 36
Spare parts list for frame, RITMO powercoat 37
Spare parts drawing for control box, RITMO item number 00 09 75 90 38
Spare parts listfor control box, RITMO item number 00 09 75 90 39
Spare parts drawingfor water manifold, RITMO powercoat 40
Spare parts listfor water manifold, RITMO powercoat 41
Circuit diagram 42
Circuit diagram 43
Program Group Parameters Frequency Power Flex RITMO 110V 1Phase 44
Check list for annual inspection by specialist (master copy) 47

PFT RITMO powercoat 110V Operating Instructions Last updated 12.2006
Knauf PFT GmbH & Co. KG
5
Congratulations on your purchase! You have made a wise choice as you clearly value the quality
that comes with a brand name product from a reputable company.
The PFT RITMO powercoat mixing pump uses state-of-the-art technology. It has been designed in
such a functional manner as to be a reliable aid in rough construction site conditions.
These operating instructions should always be kept at the site of the machine so that they are
always readily available. They contain information on the various functions of the machine. Study
the operating instructions thoroughly before putting the machine into service, since we assume no
liability for accidents or damage caused by incorrect operation.
The PFT RITMO powercoat mixing pump will be a trustworthy aid, if it is operated correctly and
handled with care.
It is prohibited to forward this document, even excerpts, without our written authorisation. All
technical specifications, diagrams etc. are subject to copyright law. All rights, errors and
modifications are reserved.
Initial inspection after delivery
An important task of all technicians delivering the PFT RITMO powercoat mixing pump is the
inspection of the machine settings at the end of the first working operation. The factory settings
may change during the initial cycle. If these changes are not corrected in time – immediately after
start-up – malfunctions may well be the result.

PFT RITMO powercoat 110V Operating Instructions Last updated 12.2006
Knauf PFT GmbH & Co. KG
6
Please note !
WARNING!
If additional parts that are not specified in these operating instructions
are installed for special procedures, it is necessary to keep to the
utilisation, safety and maintenance regulations.
WARNING!
It is forbidden to use the machine for purposes other than those for
which it is intended.
WARNING!
It is forbidden to use the machine in explosive environments.
WARNING!
The machine must always be used in a perfect condition and in
accordance with these instructions, while observing the safety
instructions and danger warnings. Any damage that could impai
r
operational reliability must be repaired immediately.
WARNING!
The user must be aware of the risk of getting one’s clothes or long hair
caught in moving parts.
Chains, bracelets and rings can also pose a risk.
WARNING!
The workplace of the user must be clean, tidy and free from objects that
could restrict one's freedom of movement.
WARNING!
The workplace must be lit appropriately for the particular work you are
doing.

PFT RITMO powercoat 110V Operating Instructions Last updated 12.2006
Knauf PFT GmbH & Co. KG
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Inspection confirmation / type plate
Sticker above the control box.
Confirmed according to EU directives.
Serial number.
Inspection date.
Inspection / signature.
Sticker above the control box.
PFT type plate.

PFT RITMO powercoat 110V Operating Instructions Last updated 12.2006
Knauf PFT GmbH & Co. KG
8
Basic safety instructions
1. The safety instructions and danger warnings on the machine must be observed and kept in a
legible condition.
2. All procedures for switching the machine on and off and control indicators and signal lamps
should be in compliance with the operating instructions.
3. Install the machine on stable and even ground and secure it against accidental movements. It
may neither tilt nor roll away. The machine must be installed in such a way that it cannot be hit
by any falling objects. The controls must be freely accessible.
4. Inspect the machine for visible damage and defects at least once every shift. When doing so,
pay special attention to electrical power cables, couplings, plugs and air, water and conveying
lines. Any visible defects must be eliminated immediately.
5. Spare parts must comply with the technical requirements of the manufacturer. This is
guaranteed for all original PFT parts.
6. The machine may only be connected to a worksite switchgear assembly with an earth-leakage
circuit breaker (30 mA). If the control system of the machine has a 3-phase frequency
converter, the 30 mA earth-leakage circuit breaker of the worksite switchgear assembly must
be sensitive to all currents.
7. The machine may only be put into service by trained or instructed personnel. Clearly define the
responsibilities of the personnel for operation, setup, maintenance and repairs.
8. Personnel undergoing training should only be allowed to operate the machine under the
supervision of experienced personnel.
9. Work on the electrical equipment of the machine may only be carried out by qualified
electricians or by trained personnel under the supervision of a qualified electrician in
accordance with electro-technical regulations.
10. The machine must be completely switched off for maintenance and repairs and secured
against being accidentally switched back on again (lock the main switch and pull the key, for
example, or attach a warning sign to the main switch).
11. If work has to be carried out on live components, a second person should be present to
disconnect the power in the event of an emergency.
12. Depressurise all conveying systems before opening conveying lines.
13. Before cleaning the machine with a water jet, seal all openings through which water could enter
and impair the safety and functions of the machine (e.g.: electric motors and control boxes).
Remove all covers after cleaning.
14. Only use original fuses of the prescribed amperage.
15. Disconnect the machine from any external power supply before relocating it, even it is only to
be moved a short distance. The machine should be connected properly to the mains before
being put back in operation.
16. The machine may only be moved by a crane if it is firmly strapped to a Euro pallet. All
removable parts must be removed first. Make sure nobody enters the danger area of the crane.
All precautions must be taken to prevent parts from falling down.
17. Safety devices such as inclination switches, protection grilles etc. may not be manipulated. The
safety devices should be checked separately before beginning with work.
18. Longer work breaks can cause the mortar to set, resulting in malfunctions during operation.
This is why the machine should always emptied and cleaned (incl. spray gun and conveying
hoses) during long breaks.
19. Never put any objects in the dry material hopper or pump container.
20. Appropriate noise insulation devices must be provided if the permanent noise level exceeds
85 dB (A).

PFT RITMO powercoat 110V Operating Instructions Last updated 12.2006
Knauf PFT GmbH & Co. KG
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21. The machine must be inspected by a specialist once a year. This inspection must be
documented and include: a visual inspection for damage, a functional check, an inspection of
the safety devices and a high-voltage check of the control box.
22. Safety-relevant components may be damaged by frost. Drain the machine whenever there is a
danger of frost.
23. The machine’s lubrication and maintenance schedule must be complied with, since otherwise
the warranty will lose its validity.
24. Changes to the machine are not permitted. Knauf PFT GmbH & Co. KG will not accept any
liability for claims if changes are made.
25. The following safety instructions must also be observed for pumps and mixer pumps: Wear
appropriate protective clothing during spraying work: safety goggles, safety shoes, safety
clothing, gloves, protective skin cream and respirator mask.
When removing blockages, the person undertaking the task must stand in such a way that
he/she cannot be hit by discharged mortar. In addition, safety goggles should be worn. No
other persons may be within the immediate vicinity of the machine while this job is being done.
Only conveying hoses with a permissible operating pressure of at least 40 bar may be used.
The burst pressure of the conveying hose must be at least 2.5 times the operating pressure.
The machine may not be operated without a mortar pressure gauge.
Depressurise all conveying systems before opening any mortar pressure hoses. The machine
can be switched on and off at any time without anyone working directly at the machine if it is
remote-controlled by means of a spray gun or remote control.
Basic safety instructions
The following terms and symbols are used in these operating instructions for particularly important
information:
NOTE:
Special information for running the machine efficiently.
WARNING!
Special information, regulations and restrictions for the prevention of damage.
WARNING!
The machine should only be used if it is in technically perfect condition and in compliance with the
regulations. Pay attention to safety and the operating instructions. It is especially important to
immediately correct any faults that could impair safety.
In order to make the operation of our machines as easy as possible for you, we would like to briefly
inform you of the most important safety regulations. If you comply with these regulations, you will
be able to use our machine in a safe and quality-assuring manner for a long time to come.

PFT RITMO powercoat 110V Operating Instructions Last updated 12.2006
Knauf PFT GmbH & Co. KG
10
Proper use of the machine
The PFT RITMO powercoat is a continuously operating mixing pump for pre-mixed machineable
filler in the form of powder.
The machine was designed for a permanent operating pressure of max. 20 bar.
Observe all processing guidelines from the material manufacturer.
The PFT RITMO powercoat may only be used for filler and pastes without granulation.
If material with granulation is used, PFT assumes no guarantee for the pump system with agitator.
Operating principle
The PFT RITMO powercoat is designed for being filled with material from bags. The mixing shaft
and the pump are driven by a gear motor.
The rotary speed of the pump motor is continuously adjustable within the range of 140-575 rpm.
However, the machine should always be started at maximum speed.
Water is added to the dry material in the mixing area where it is then mixed. The water flow rate
needs to be set manually at the needle valve.
The water flow rate may be checked using the water flow meter.
A water safety switch monitors the water flow pressure. If it falls below 1.6 bar, the machine shuts
down automatically. This problem is prevented by installing a high pressure pump upstream
(accessory).
The mixed putty coat is pumped away by a screw pump with agitator installed behind the mixing
shaft.
The agitator is for grinding and crushing lumps that have passed the pump system.
The powercoat 1500lg spray gun or the powercoat spray gun are mounted offset at the end of the
conveying hose. The compressed air required for spraying must be supplied by a compressor.
The RITMO can also be used for pumping pastes. A water connection is not required. The water
safety switch is then bypassed by an electrical control.
Applications:
Filling of large surfaces on dry walls
Filling of primed raw ceilings
Finish filling of walls
Filling as preparation for high-quality painting
The machine consists of portable individual components of small, handy dimensions and light
weight that allow fast, convenient transport.
The following points should be observed during operation:
9Connection mains – control box
9Connection control box – motor
9Connection water supply – water manifold
9Connection water manifold – rubber mixing zone
9Connection pressure gauge – material hose
9Connection material hose – spray gun
9Connection compressor – spray gun
9Connection control box – spray gun

PFT RITMO powercoat 110V Operating Instructions Last updated 12.2006
Knauf PFT GmbH & Co. KG
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General view of the RITMO powercoat: View from behind
1. Gear motor, 1.5 KW 2. Gear motor power supply
3. Control box 4. Water manifold
5. Water manifold – needle valve 6. Main power supply
6
2
1
4
3
5

PFT RITMO powercoat 110V Operating Instructions Last updated 12.2006
Knauf PFT GmbH & Co. KG
12
General view of the RITMO powercoat: View from the front
1. Protection grille with bag opener 2. Material hopper
3. RITMO powercoat mixing shaft 4. Water outlet valve
5. Pump, A2 – 2.5 L ( rotor / stator ) 6. Pressure gauge, 0 – 40 bar 1/2“
7. Coupling,13M part 1/2“ male thread 8. Water supply, rubber mixing zone
9. Nozzle 10. Air supply for spray gun
11. Water supply 12. Powercoat agitator
8
9
11
7
6
5
1
2
3
4
10
12

PFT RITMO powercoat 110V Operating Instructions Last updated 12.2006
Knauf PFT GmbH & Co. KG
13
Overview of the RITMO powercoat 110V control box, item number 00097590
1. Motor connection cable 2. Inspection window for FU
3. Outlet filter for control box 4. Remote control connection
5. Blind plug 6. Main power cable
7. Plug for water safety switch 8. Plug for solenoid valve
9. Speed control / material quantity 10. Motor rotation direction LEFT/RIGHT
11. Operation as pump or mixing pump 12. Water flow button
13. Main switch 14. Machine ON / OFF operating switch

PFT RITMO powercoat 110V Operating Instructions Last updated 12.2006
Knauf PFT GmbH & Co. KG
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Overview of the RITMO powercoat water manifold, item number 00097921
1. Water to mixing tube 2. Water pressure switch
3. Connection to water supply 4. Water outlet Open – Closed
5. Water supply for cleaning the mortar
pressure hose
6. Primary water pressure gauge
7. Antifreeze outlet tap 8. Needle valve water quantity
9. Solenoid valve 10. Water flow meter 31.5 – 315 l/h
11. Pressure reducer

PFT RITMO powercoat 110V Operating Instructions Last updated 12.2006
Knauf PFT GmbH & Co. KG
15
Setting values
Water pressure release:
Machine starts at 1.9 bar
Machine stops at 1.6 bar
The values are permanent and may not be adjusted.
Pressure reducing valve:
1.5 bar at maximum flow rate
Technical specifications
Drive Three phase motor 1.5 kW
Speed range 140 – 575 rpm, continuously adjustable
Control box power supply 110 V alternating current, 50 Hz
Max. power consumption 5.8 A gear motor
Fuse protection 16 A
Power unit Min. 6 kVA
Water supply 1/2 inch, min. 2.5 bar when the machine is
running
Pump output Approx. 0.8 – 3 l/min, continuously adjustable
Pumping distance* Up to 15 m, mineral fillers
Operating pressure Max. 20 bar
Material hopper filling height 900 mm
Material hopper capacity 45 litres
Overall length 750 mm
Overall width 600 mm
Overall height 1,350 mm
Weight of hopper unit 19 kg
Weight of drive with protection grille 25 kg
Weight of frame with control box 40 kg
Weight of mixing shaft 2 kg
Total weight 86 kg
Permanent noise pressure level 77±1 dB(A)
EMC inspection The machine has been EMC-inspected and
complies with the strict requirements of
protection class B. The control box is equipped
with a line filter.
* Approximate value depending on conveying height, material quality, composition and
consistency, pump version and condition.

PFT RITMO powercoat 110V Operating Instructions Last updated 12.2006
Knauf PFT GmbH & Co. KG
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Assembly – rotor/stator/mortar pressure gauge
Rotor/stator
The PFT RITMO powercoat mixing pump is standard-equipped with the A2
2.5 L pump system with agitator.
The rotor and stator are subject to wear and must be checked regularly.
New pump components with a conveying hose of 15 m should achieve a
pressure of approx. 15 bar (approx. 20 bar if water is the conveying
medium, approx. 15 bar for mortar) before and after initial spraying.
Pressure gauge
The PFT pressure gauge may be used used to monitor the consistency
quickly and easily.
The pressure gauge is part of the scope of delivery.
Some benefits of the mortar pressure gauge:
¾Constant monitoring of the correct conveying pressure
¾Early detection of clogging or overloading of the pump motor
¾Establishment of zero pressure
¾Significant contribution to the safety of the operating personnel
¾Durability of the pump components
WARNING!
Before installing/removing the mortar pump, make sure that the machine
has been disconnected from the power supply (1).
None of the control lamps on the control box may be on (2).
1
2

PFT RITMO powercoat 110V Operating Instructions Last updated 12.2006
Knauf PFT GmbH & Co. KG
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Mortar pump
Furthermore, observe that:
¾A new rotor and new stator need to be run in; actual pressure values can only be determined
after the first spraying cycle.
¾Pump components that do not achieve the specified operating pressure (15 bar) are worn out
and must be replaced.
¾An operating pressure of 20 bar should not be exceeded.
¾The minimum conveying distance depends mainly on how the material flows. It is
recommended to check and possibly change the consistency of the material if you exceed an
operating pressure of 20 bar.
¾To avoid machine breakdowns and excessive wear to pump motor, mixing shaft and pump,
always use original PFT parts, such as e.g.
PFT rotors with agitator
PFT stators
PFT mixing shaft
PFT pressure hoses.
These wearing components are compatible with one another and form a single construction unit
together with the machine.

PFT RITMO powercoat 110V Operating Instructions Last updated 12.2006
Knauf PFT GmbH & Co. KG
18
Operation as pump (for pastes)
Turn all switches to “0”
Electrical connection:
Plug the 10-pin motor connecting cable (A) into the designated socket (B)
on the motor.
Connect the control box (C) to a distributor box with approved FI safety
switch (30 mA).
The 10 m 3-pin connection cable with CEE plug is part of the scope of
delivery.
Turn the main switch (1) to ON.
Set the operation switch (2) to ON. The operation switch lights up.
Turn the “Operate with water flow / without water flow” selection switch (3)
to the right, to without water.
Disconnect the water hose from the mixing tube and close both water inlets
with a Geka blind cover.
The paste can now be filled into the material hopper.
The machine is now ready for operation.
Pre-lubricate the material hose with wallpaper paste and then connect it to
the pump unit (4).
Connect the material hose to the airless spray gun (6).
Connect the remote control cable to the remote control box and to the
airless spray gun (7).
Switch on the machine (1).
Turn the selection switch to the right (forwards) (5).
Press the spray gun switch, the machine runs.
Warning:
If the spraying process is interrupted, press the button (8) to prevent any
unintentional operation of the switch.
WARNING!
The protection grille may not be removed while preparing or operating the
machine.
Always wear safety goggles during operation.
4
A B
2
1
C
3
6 7
8
5

PFT RITMO powercoat 110V Operating Instructions Last updated 12.2006
Knauf PFT GmbH & Co. KG
19
Operation as mixing pump (for filler in powder form)
Turn all switches to “0”
Electrical connection:
Plug the 10-pin motor connecting cable (A) into the designated socket (B)
on the motor.
Connect the control box (C) to a distributor box with approved FI safety
switch (30 mA).
The 10 m 3-pin connection cable with CEE plug is part of the scope of
delivery.
Water supply
Connect a ½“ water hose to the water supply. Open the supply valve and
flush the water hose with water to remove any dirt. After bleeding the hose,
the supply valve can be closed again.
Then connect the water hose to the machine’s water manifold (1). Then
connect the water hose to the water manifold at the mixing tube’s lower
water inlet.
Make sure that the nozzle (2) is in the water connection of the rubber
mixing zone.
If the water’s flow pressure is below 1.9 bar, then a high-pressure pump
needs to be connected upstream.
WARNING!
The RITMO can also be supplied with water from a water barrel. If this is
done, observe that a suction inlet with filter (item no. 00 00 69 06) and a
high-pressure pump need to be connected upstream.
Watering the mixing area
Turn the “Operate with water flow / without water flow” selection switch (3)
to the left, to with water.
Set the operation switch (2) to ON, then press the water flow button (1) until
there is a maximum of 1 cm of water in the mixing zone (pay attention to
any loss of water; the screw pump might be defective or the position of the
screw pump needs to be changed).
Make sure that the upper mixing zone is dry in the material hopper.
1
2
2
1
A
B
C
3

PFT RITMO powercoat 110V Operating Instructions Last updated 12.2006
Knauf PFT GmbH & Co. KG
20
Setting the water factor
Set the expected water volume (approx. 90 litres) at the needle valve (4).
To do this, press the water flow button (1) and keep it pressed.
Observe the specifications of the material manufacturer.
The material can now be filled into the material hopper.
(fill slowly)
During operation: Every interruption of the spraying procedure results in
minor irregularities of the material consistency. This normalises, however,
automatically as soon as the machine has been working for a while.
Therefore do not change the water quantity each time you detect
irregularities, but instead wait until the consistency of the material emerging
at the spray gun has self-adjusted.
Settings
Adjust the rotary speed (5) (left position = min. rotary speed, right position
= max. rotary speed).
Maximum speed for putty coat.
Insert the remote control blind plug (6). The machine is ready for operation.
Switch on the machine (7). The mortar consistency can now be checked at
the outlet of the pressure gauge. If required, change the setting of the
needle valve.
If you change the machine’s rotary speed, you must adjust the needle
valve’s setting accordingly. A higher rotary speed means more water, a
lower rotary speed means less water. When the correct mortar consistency
is set, the mortar hose can be connected.
Connecting the mortar hose
Pre-lubricate the mortar hoses with wallpaper paste and then connect them
to the pump unit (8).
Connect the air compressor to the external power supply.
Warning:
The air compressor may not be connected to the Ritmo powercoat control
box.
Connect the air hose from the compressor to the spray gun (1).
Connect the material hose (2) to the spray gun.
5
8
6
7
2
1
4
1