Re ROCKCRETER OPTIMIX 1.5 User manual

OPERATORS MANUAL
FOR
ROCKCRETER OPTIMIX 1.5
SOUTH AFRICAN SHOTCRETE TECHNOLOGY
Designed to perform, the power to succeed!
P. O. Box 18924 Sunward Park 1470●361 Crocker Road, Wadeville, Germiston, South Africa
Co. Reg. no: 1947/24677/07
TEL: [phone]
e-mail: [email protected]
www.rockcrete.co.za
As part of our policy of constant product development and improvement information and
specifications contained in this document are liable to change.

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CONTENTS LIST
Figure Description Page
No
1. SAFETY PROCEDURES 1
2. TECHNICAL SPECIFICATIONS 2
3. PRINCIPLES OF OPERATION 2
3.1 Materials 3
3.2 Flow 3
3.3 Setting Time 3
3.4 Pumping Distance 3
3.5 General Procedures 4
4. OPERATING PROCEDURES 6
4.1 Set-Up 6
4.2 Priming with Water 6
4.3 Prime with Material 7
4.4 Prevent Blocking 8
4.5 Spraying 8
4.6 Pressure Relief Procedure 9
4.7 Flush 9
4.8 Shutdown 11
5. TROUBLESHOOTING 12
PRE USE CHECK LIST 14
6. ILLUSTRATED PARTS CATALOGUE 15
.

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OPERATORS MANUAL
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1. SAFETY PROCEDURES
Recommended items to keep pumping safe:
a. Hard hats.
b. Safety goggles.
c. Dust masks in confined spaces or unventilated areas.
d. Good lighting.
e. Whip check cables and chain safety couplings on air supply
hoses.
f. Rubber gloves to protect workmen with skins sensitive to cement
burns (also use barrier cream).
g. Sturdy and safe lifting devices, platforms and scaffolding for
those many pumping operations that are performed off the
ground. All platforms should be equipped with safety rails.
h. A qualified electrician must do all electrical connections.
i. Do not remove the screen/sieve supplied on the hopper whilst the
machine is in operation.
j. Do not carry out any maintenance whilst the air or electrical
connections are connected to the machine.
k. Do not poke or prod any instrument of any sort into the hopper
whilst the machine is in operation.
l. Use safety straps on all grout hose connections.
m. Keep arms, hands, fingers etc away from moving parts.
n. Disconnect power/air before attempting to clean or repair
equipment.

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PAGE 2
2. TECHNICAL SPECIFICATIONS
ROCKCRETER OPTIMIX 1.5
Dimensions
Length 1780 mm
Width 580 mm
Loading Height 970 mm
Weight 105 kg
Output Up to 1,5m3/Hr
Aggregate size Up to 4mm
Outlet 32mm
Conveying Distance
Horizontally Up to 30m – material dependant
Vertically Up to 15m
Electric drive – 3kW. 220V/380V/525V
3. PRINCIPLES OF OPERATION
NOTE:
The principles of operation offered herein are intended as an aid to
help the operator identify some of the factors that need to be taken
into consideration when mixing and pumping cementitious grouts.
Because wide varieties of materials are available for many
different applications, it is important the operator becomes familiar
with the specific characteristics of the material he intends using.

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3.1 Materials
1. Among the commercially manufactured materials available in today’s
market are materials for structural repairs, floor toppings, high strength
non-shrink grouts, special linings and other specialty materials.
2. Each of these materials has unique characteristics, which must be well
understood to insure a successful application.
3.2 Flow
1. In general, most materials need to be a flowable or pourable
consistency for successful pumping. This means that if the material can
be poured out of a pail or bucket, it can likely be pumped.
2. The exception to this requirement is repair mortars, which tend to be
mixed in a thicker consistency and require special pumping techniques.
3. Materials that contain aggregates pump best and perform best when
the consistency is kept to the lower range of pourable, that is, not too
wet.
3.3 Setting Time
1. Some materials contain accelerating admixtures to reduce the setting
time. This is particularly true of repair mortars and other spray applied
materials so that strength gain can be fairly rapid. It is important to
keep moving when using these types of materials.
2. Once the material is mixed, it must be pumped immediately and kept
in motion and subsequent batches must be mixed and pumped as
rapidly as possible. Any delays in the application process could result
in plugged hoses and equipment.
3. Temperature also has an effect upon these materials to the extent that
exposure of the hose to the sun on a hot day will accelerate the set
time even more, therefore this should be avoided. It may even be
necessary in some cases to cool the material, the mix water, or even
the hose itself.
3.4 Pumping Distance
1. Pumping distances should always be kept to a minimum, and hoses
should run as straight as possible no matter what material is being
used.
2. Sometimes circumstances require longer than usual hose lengths,
when this occurs, every effort should be made to use every advantage
possible to insure a successful application. Some materials simply
cannot be pumped for long distances, so it’s best to know the

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proposed material characteristics before attempting a production
procedure.
3.5 General Procedures
1. Before attempting to mix and pump production materials, it is important
to rinse and charge the pump hopper with sufficient water to
thoroughly flush the pump and all grout lines. This is to purge the
grouting system of any residual materials or scale that may exist.
2. Once that is completed, remove the grout hose from the pump and
drain out all water by elevating one end, or by progressively elevating
the entire hose, at one end and proceeding to the other.
3. Mix slurry composed of Portland cement in approximate proportions of
25 litres of water to ½ a bag of cement, and pump this through the
grouting system. This is to remove any residual water from the hose,
lubricating it for the production material to follow. Now the production
grout may be mixed and pumped immediately behind the slurry mix.
4. The slurry mix may be retrieved in a bucket.
NOTE: DO NOT attempt to pump production material through a dry
hose. Occasionally, no matter how conscientious an operator may
be, a hose will get plugged. Once this happens, the only sure way to
remove the plug is to empty it of material. Beating on it with a
hammer or running over it with a vehicle will not usually be
successful. A prudent operator will be prepared for such
eventuality.

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Figure 1

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4. OPERATING PROCEDURES
4.1 Set- Up
1. Insert the drive/mix shaft into the hopper and engage the flat end into
the slot of the rotor.
2. Slowly swing the motor assembly into the closed position, stopping
before the motor shaft adapter and drive/mix shaft touch.
3. Align the shaft adapter and drive/mix slots so that they engage, If they
do not align then rotate until correct position is achieved.
4. Swing the motor completely shut and secure in place with motor latch.
5. Secure the hopper gate onto the top of the hopper.
6. Connect the motor cable to the power out connector.
7. Connect the power cable to the main power in connector.
8. Connect the power cable to an appropriate power source.
4.2 Priming with Water
1. Attach a water feed hose to the water inlet.
2. Attach the main hose to the water system bypass outlet and attach the
spay nozzle to the hose outlet.
3. Place the nozzle into a waste container.
4. Turn the main power disconnect switch to the “ON” position.
5. Open the ball valve directly before the water system bypass outlet.
6. Press the water drain button to turn on.
7. Run the water until water flows from the end of the nozzle.
8. Press the water drain button to stop the water and close the ball valve
directly before the water pump bypass outlet.
NOTE: Do not run the water pump without water. The water pump
will overheat and cause damage.
9. Run clean-out ball(s) to coat the inside of the hoses:
a. Remove the nozzle from the end of the hose.
b. Remove the hose inlet from the water system bypass outlet and
insert a clean-out ball into the hose inlet (The ball must be soaked in
water before inserting).
c. Attach the hose to the water system bypass outlet, open the ball
valve and press the water drain button to resume flushing the hose.
d. The clean-out ball will be pushed out of the hose after several
minutes.
e. When the task is complete, close the ball valve, remove the hose
inlet from the water system bypass outlet.

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f. Add dish soap or a slicking agent to the water and pour into the
hose using a funnel. Once complete, connect hose to machine
outlet.
NOTE: When priming with water, add dish soap or a slicking agent
to help lubricate the pump. Priming with water only may cause
excessive pump friction, producing a high pitch noise and
premature pump wear.
10. Turn the FWD/REV selector knob to FWD. If the pump does not turn
within five seconds, press the STOP button.
11. If the pump does not turn within five seconds, perform the steps
below
a. Press the START button and quickly turn the pump direction switch
between forward and reverse.
b. If the rotor still does not turn freely in the pump assembly then refer
to Troubleshooting page.
NOTE: The pump direction switch is normally in the Neutral
position. The switch must be held in the REV position to reverse the
pump direction. The switch will return to the Neutral position when
released.
If the pump has not broken free after five seconds, press the STOP
button or the motor could encounter an overload error. After
multiple attempts to free the pump, allow the motor to cool for one
minute.
4.3 Prime with Material
1. Prime the system with water (Refer to 4.2).
2. Remove the nozzle.
3. Remove the hose inlet from the pump outlet and place a waste tray
below the pump outlet.
4. Add dry material:
a. Place the bag of material on the center of the hopper grate so the
serrated teeth are in the middle of the bag.
b. Twist the bag 15 degrees in both directions to tear the bag.
c. Lift both ends of the bag so the material falls into the hopper.
d. Dispose of the bag.
NOTE: Keep the hopper filled with dry material when priming with
material and spraying.
5. Press the START button. Material should start to flow from the pump
outlet.

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6. Adjust the water flow meter until the desired material consistency is
achieved.
7. Press the STOP button and water pump button.
8. Attach the hose to the pump outlet.
9. Press the START button. Pump until any remaining water is purged
out of the hose and a steady stream of material flows from the hose
outlet.
10. To stop dispensing, press the STOP button.
11. Install the nozzle.
NOTE: For materials prone to packing out, before installing the
nozzle, prime the larger ID hose, then install and prime the
transition fitting and whip hose
12. Press the START button to start dispensing and pump until material
exits the nozzle.
13. Press the water pump button and STOP button to stop dispensing.
14. Install the air line and a tip onto the nozzle. The system is now primed
and ready to spray.
4.4 Prevent Blocking
1. To prevent “Blocking” in the pump or hose follow the steps below:
a. Use the lowest pressure and largest nozzle size that provides an
acceptable spray pattern. This will also result in wear parts lasting
longer.
b. Do not use any more material hose than is necessary (minimum
15m).
NOTE: Before starting or stopping material flow, always have the
atomizing air turned on at the applicator before and after spraying
fluid.
4.5 Spraying
1. Prime with material (Refer to 4.3).
NOTE: Failure to flush prior to material curing in the system will
result in damage to the system and may require replacement of all
system parts in contact with material.
2. Turn on atomizing air and adjust the air output to the required level.
3. Turn the main power disconnect switch to ON and press the water
pump button and START button to spray material.
4. If the system is approaching its cure time, or if the system will be idle
for enough time for material to begin curing in the system then flush
the system.

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ROCKCRETER OPTIMIX 1.5
PAGE 9
4.6 Pressure Relief Procedure
NOTE: The equipment stays pressurized until pressure is manually
released. To help prevent serious injury from pressurized fluid,
such as splashing fluid and moving parts, follow the “Pressure
Relief Procedure” when you stop dispensing and before cleaning,
checking, or servicing the equipment.
1. Push the STOP button.
2. Remove the applicator tip, and hold the applicator firmly against a
bucket.
3. Hold the pump direction switch in the REV position.
4. Allow the pump to run in reverse for several seconds while holding the
direction switch in the REV position.
NOTE: If the pump is stalled, do not run the pump for more than five
seconds at a time or the motor could encounter an overload error.
After multiple attempts to free the pump, allow the motor to cool for
one minute.
5. Push the STOP button after five seconds and release the pump
direction switch. The switch will return to its normal position.
6. Turn the main power disconnect switch to OFF.
7. Allow time for material to drain to relieve any remaining pressure.
8. If you suspect the applicator or hose is still clogged or that pressure
has not been fully relieved, proceed with the following steps:
a. Starting at the applicator, VERY SLOWLY open the coupling while
maintaining control of both the applicator and hose.
b. Clear the hose or tip obstruction. If there is still pressure trapped
down the line, work your way back to the pump by individually
opening each coupling between each hose connection. Maintain
control of each hose section and VERY SLOWLY open each coupling
until pressure has been fully relieved.
4.7 Flush
NOTE: Failure to flush prior to material curing in the system will
result in damage to the system and may require replacement of all
system parts in contact with material.
1. Remove the applicator tip and retainer.
2. Place the applicator outlet in a waste container.
3. Follow the steps below to flush material from the hopper and mixing
chamber:

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a. Press the START button to begin flushing out any remaining
material until the hopper is empty.
b. Once the hopper is empty of all material, press the STOP button to
stop the pump.
c. Rinse the hopper with the attached water wash-down hose.
d. Press the START button and run the pump until no water is left
inside the hopper.
4. If there is still material left in the mixing chamber after flushing with
water, then use the clean-out shaft as follows:
a. Turn the main power disconnect switch to OFF.
b. Undo the motor latch and swing the motor assembly open.
c. Remove the drive/mix shaft and replace with the clean-out shaft.
NOTE: Only use the clean-out shaft if material cannot be cleaned
using normal flushing means. Excessive use of the clean-out shaft
can cause premature wear to the system.
d. Slowly swing the motor assembly toward its closed position,
stopping before the motor shaft adapter and clean-out shaft touch.
e. Make sure the motor shaft adapter and clean-out shaft are aligned
so the clean-out shaft slides into the motor shaft adapter slot. If the
do not align, rotate them into position.
f. Swing the motor completely shut and lock it in place with motor
latch.
g. Turn the main power disconnect switch to ON and press the drain
button.
h. Fill the hopper with water and slicking agent or dish soap.
i. Press the START button and run the pump until no water is left in
the hopper. Press the STOP button to stop the pump.
j. Make sure the mixing chamber is clean. If not, repeat steps 5(h)
and 5(i) until clean.
k. Repeat steps 5(a) to 5(f), but replace the clean-out shaft with the
drive/mix shaft.
5. Once the hopper and mixing chamber are clean, remove the hose inlet
from pump outlet and attach the hose to the water system bypass
outlet.
NOTE: The rotor/stator pump should be used as little as possible
when flushing. Once the system is clean, it is important to use the
direct output from the water pump during the remaining flushing
procedure to increase the life of the rotor and stator.

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6. Open the water outlet ball valve and press the drain button. Run until
heavy sediment has been flushed and clean water begins to exit the
applicator outlet.
7. Press the water drain button to stop dispensing and close the ball
valve.
8. Remove the applicator and clean/flush separately as follows:
9. Make sure all parts are free of residual material.
10. Turn on air to make sure air lines are free of obstructions.
11. Remove the remaining material in the hoses with a clean-out ball as
follows:
a. Place the hose outlet into a waste container.
b. Remove the hose inlet from the water outlet and place a hose
clean-out ball within the hose inlet. The ball must be wetted down
before inserting. If using a 1 in. (25 mm) whip hose, begin with the
smallest clean-out ball.
c. Attach the hose to the water system bypass outlet, open the ball
valve and press the drain button to resume flushing the hose.
d. The hose clean-out ball will be pushed out of the hose after several
minutes. Once the ball is pushed through the hose, press the water
pump button. Repeat until all sediment is removed from the hose.
e. If using a 1 in.(25 mm) whip hose, remove the hose and transition
fitting and repeat the process using the large clean-out ball on the
remaining hoses. Once the ball is pushed out, stop the water pump
and attach the fitting and whip hose.
12. Turn the main power disconnect switch to OFF.
13. Dispose of all waste material in accordance with local rules and
regulations.
4.8 Shutdown
1. To shutdown, flush the system (Refer to 4.7).
2. Disconnect from the power supply.
NOTE: In cold environments, water left in the pump system could
freeze and damage the equipment. When working in cold
environments, drain all water from the pump system to avoid
damage.

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5. TROUBLESHOOTING
Fault Cause Solution
The rotor/stator pump
operates, but output is low.
Pump pressure is too low,
stator is too loose.
Tighten stator to achieve suitable pumping
pressure.
Pump pressure is too high,
Stator is too tight.
Loosen stator to achieve suitable pumping
pressure.
Stator is worn or damaged. Tighten stator. If low output continues,
replace stator.
Rotor is worn or damaged. Tighten rotor. If low output continues,
replace rotor.
Material hose is clogged. Clean or replace the material hose.
Applicator or tip is dirty or
clogged.
Clean or replace the applicator or tip.
Large pressure drop in
material hose.
Reduce hose length and/or increase
diameter.
Pump does not operate. Material hose or applicator is
obstructed.
Clean or replace the hose or applicator.
Dried material in pump
assembly.
Clean or replace the pump assembly.
Poor finish or irregular spray
pattern.
Inadequate air assist air
pressure
Adjust the air assist air pressure output on
the applicator.
Pump is noisy when
pumping.
Pumping water without dish
soap or a slick agent.
Add dish soap or a slicking agent to the
water.
Pump is running with no
material or fluid in the hopper.
Add material to hopper or shut off pump.
Erratic accelerated speed. Material supply exhausted. Refill the hopper and prime pump with
material.
Motor is powered but nothing
comes out of the hose.
Pump is packed out with dry or
cured material.
Disassemble and clean the pump.
Hose is packed out with dry or
cured material.
Clean or replace the material hose.
Material is too thick to push
through the hose without
packing out.
Hose is too restrictive. Thin the mix material thoroughly to a lower
viscosity if material supplier allows.
Use a pump system priming fluid (dish
soap or slicking agent) to wet out the
system.
Reduce length and/or increase diameter of
hose.

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Fault Cause Solution
Electric motor will not start or
stops during operation.
Loose connections. Check connections in electrical enclosure.
Check for correct voltage supply at the
disconnect voltage supply at the disconnect
and VFD terminals L1, L2 and L3.
Motor overload relay trips. Turn power disconnect switch to OFF and
wait one minute for the VFD to reset. Allow
the motor to cool if conditions occur
frequently.

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ILLUSTRATED PARTS CATALOGUE
CONTENTS LIST
Figure Description Page
No
1. BODY ASSEMBLY 16
2. HOSE AND NOZZLE ASSEMBLY 18

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1. BODY ASSEMBLY