ASE SM 5 User manual

OPERATION MANUAL

ASE SM 5

MIXING PUMP

ASE MAKINE İNŞ. ELEKTRİK. SAN VE TİC A.Ş.

ADDRESS : IVEDIK OSB MH. 1372 SK. NO:20, YENIMAHALLE, 06210 ANKARA - TURKEY

TEL : +90 312 256 56 33 FAX : +90 312 256 61 50 WEB: www.ase-co .com

OPERATION MANUAL

Dear Customer,

We congratulate you on your choice of our SM 5. This machine is a continuous

plaster mixing and spraying machine for all kind of ready-mixed materials both cement

basis and gypsum basis plasters and renders.

Before applying the energy to the machine please read this manual carefully.

In this operation manual you will find all information of operation and maintenance

of SM 5. If you need further information please do not hesitate to contact with our office.

This manual supplied with the machine. Therefore, it may only be used for the

purpose of operation of SM 5. It is forbidden to pass it on to third parties or to copy

without permission.

1) OPERATING PRINCIPLE OF MACHINE:

The dry premixed material in bags filled into the hopper by the motor driven star

wheel. The material is fed into the mixing chamber through a trap door. A constant

stream of water adjustable according to the requirements is injected into the mixing

chamber where the mixing shaft driven by an electric geared motor mixes material

and water homogeneously to a useable plaster. At the same time, the mixing shaft

drives a rotor/stator pump. The pump transports the material through high-pressure

hoses to the spraying gun. With the help of compressor, the plaster is being

sprayed onto walls and ceilings.

2) OPERATION OF MACHINE:

1. Before running the machine, be sure about undistorted power supply and

undistorted water supply (remember that it needs 380 V 50 Hz. 3-phase power

supply to work and water supply with the pressure min. 3.5 bars).

2. In the case of low water pressure, the water pump can be used to obtain the

sufficient water pressure from direct connection to water supply. It is suggested to

use big barrel and supply water directly from the barrel by water pump.

3. Place pump unit (mixing chamber and pump motor with rotor/stator pump) into the

machine and connect pump motor cable to switch case. Connect water hose to

pump unit.

4. Connect cable of compressor to switch case. Turn on compressor. Connect

pneumatic remote control hose to outlet of compressor.

5. Connect ¾” water hose to machine and observe manometer reading. If pressure is

below 3.5 bar, check the water pump is working properly otherwise machine works

unevenly.

6. Fix the spray gun and connect both air and plaster hoses to machine. Check the

gasket in the plaster hose coupling. Open air tap at the spray gun.

7. Connect the 3 phase electric power to the switch case with 5 core CEE plug. Ensure

earth is connected. Mind all 3 phases are supplied.

8. Turn on machine by rotating the main red commutator to any position other then ‘0’.

To find the correct direction of rotation turn the direction of rotation commutator (red

switch) on the cabinet to any one of the two positions and observe the lamp indicator

of direction of rotation on panel is not lighted on. If this yellow lamp is lighted on the

direction of rotation is wrong. In that case, rotate the direction of rotation commutator

to other position and again observe the warning indicator lamp of direction. This is

done to protect the rotating shaft. Otherwise consistency may not be correct.

9. There are two more three-state commutators on cabinet door other than main red

switch. One is water pump commutator; other is the star wheel commutator. Both

have ‘MANUAL’, ‘0’, ‘AUTO’ positions. In the ‘MANUAL’ position water pump works

by the electric supply directly; star wheel turns by the Start of machine. In ‘0’

position, both water pump and star wheel do not work. In ‘AUTO’ position both water

pump and star wheel works by working of the mixing pump. To get pressurized

water supply turn on the water pump to ‘MANUAL’ position when you have water line

with low pressure in the site. If the water line is proper then you can use the machine

with ‘AUTO’ or ‘0’ position. Remember that you may read 3.5 bars in the water

manometer when machine is not working, the supplying the water to machine may

decrease this water pressure. Put the star wheel commutator to ‘0’ positions initially

when you starts the machine to avoid the dry feed of the rotor/stator pump.

10.There are four push buttons on the side of the switch box just above the mains CEE

plug. They are ‘START’, ‘STOP’, ‘WATER’, and ‘REVERSE’ buttons. ‘START’ button

starts the machine after the turning on the machine if the direction of rotation is

correct and water pressure is proper and the remote control valve of spray gun is on.

When the start conditions are O.K. then the green lamp indicator lights on in the

START button. ‘STOP’ button stops the machine whenever you want to stop the

machine. Then the green lamp lights off. ‘WATER’ button supplies the water to the

pump unit by opening the water solenoid valve. Use this button to fill the mixing

chamber with the water and to adjust the water flow rate with the flow meter if you

start the machine first time after the cleaning procedure. To avoid dry operation of

rotor/stator pump. ‘REVERSE’ button has two different functions. First function is to

allow pump motor to turn reverse direction when the direction of the rotation is wrong

(Direction of rotation warning indicator lights on). In some cases, you may want to

rotate the pump motor to reverse direction in very short time then use this button

after start button. Second function of this button is degassing the water pump. When

the direction of rotation is correct, you may need to operate the water pump only to

remove the air from the water pump.

11.Before charging dry material to pump unit, press the WATER button and wait until

mixing unit is filled with water. Don’t operate pump with dry material only.

12.When the machine starts running, regulate the water about 10 % above the nominal

settings (for initial uses read minimum 800 on flow meter). Then start to change the

dry material to the pump unit by rotating the STARWHEEL commutator to ‘AUTO’

position. During the initial running period it may prove necessary to adjust the

amount of water fed into the mixing unit, in order to obtain the correct consistency.

13.Mixed material is applied on the wall with 30 bars at the outlet of hose. Consistency

of plaster is adjusted by adjusting the water flow rate with flow meter. Mind that at

first, rather a liquid plaster will appear at the nozzle of the spraying gun then users

have to adjust correct plaster consistency.

14.Correct plaster consistency is reached when the plaster flows smoothly on the

surface sprayed. Insufficient water supply to the mixing unit will result in uneven

mixing and spraying which again leads to considerable wear of both stator and rotor.

15.For the star wheel at MANUAL position dry material can be charged while the pump

remains stationary and at ‘0’ position star wheel is switched off and material supply

is interrupted.

16.Interruptions more than 30 min. is avoided, otherwise there is the danger of plaster

hardening in the hose and machine. Every break in the spraying process causes a

slight irregularity of the consistency. This however corrects itself as soon as the

machine has been running again for a few minutes. Therefore do not alter the water

supply at every irregularity but wait until the consistency of plaster coming out of the

spraying gun becomes normal again.

17.In the case of long breaks hose and machine should be cleaned according to the

Cleaning Procedure.

3) DURING OPERATION PAY ATTENTION TO:

1- Don’t stop and add the material into the mixing chamber in the case that there exists

material in the pump unit.

2- Every time after the change of mains plug, control the rotation direction of motor.

Determine the warning indication lamp on the control cabinet.

3- After the operation, if the machine will not work close the main switch.

4- After turn on the machine, if the machine do not work control :

a- Main Switch

b- Fault indication lamp (red lamp) on the control cabinet

c- Pneumatic valve at the spraying gun whether it is closed or open

d- Water supply. There may remain air in the water hose. If so, open the auxiliary

water tap on the machine, operate water pump and try to get away the air. If

there is still air in the water hose and there is no water supply disconnect the

hose on the machine and again try to get away the air in the hose. If it is not

succeeded, control the hose whether there is any broken part or any blockage.

e- If the air remains in the hose machine will not work properly. In that case press

the WATER button for a few seconds to get the air out off.

5- Before operating the machine, control the power supply on three phase and neutral

6- Control the fuses, main switch and motor protection switch.

7- Don’t operate the machine with only dry material.

8- Don’t remove guard of hopper during operation.

9- Soaking is recommended with coarse material.

10-Do not press your hands through the guard while the machine is running.

11-Interruptions more than 30 min. is avoided otherwise there is the danger of plaster

hardening in the hose and machine.

4) CLEANING THE MACHINE:

1- When spraying is finished, turn the star wheel commutator to position ‘0’. Then the

pump should left to run until water comes out of the spraying gun. Then turn off the

main switch.

2- Tilt and lift pump motor, take out mixing shaft and clean it thoroughly.

3- Insert cleaning shaft and cleaner into the pump unit and close the motor bracket.

Leave the star wheel commutator in “0” position. Turn on main switch. After a short

run (5-10 seconds) the mixing unit is clean. Remove the cleaning device and

reassemble the mixing shaft.

4- Clean plaster hose with sponge balls after each spraying periods. Push wetted ball

into pressure plate outlet. Tighten hose to outlet and start machine. Wait until

sponge ball comes out of the spraying gun end of the hose. If hoses are still dirty

repeat the process.

5- The compressor filter has to be clean from time to time. If very dirty it may be

removed.

6- Dirt collector in the water filter of the machine should be taken out and cleaned at

intervals of two weeks. And changed when necessary.

7- Turn off main switch then open the lid at the bottom of the hopper and remove star

wheel.

8- In the case of power cut you may clean hose at once by attaching fitting to water

tap and fixing hose. Then open tap. Repeat this until clean water emerges at the

end of the spray gun. Repeat this by sponge ball.

9- After cleaning the machine should be emptied as follows:

a) Close main water tap.

b) Decrease water pressure by closing water valve.

c) Disconnect and empty water hose.

d) Disconnect air hose from spraying gun and connect it to main water inlet.

e) Disconnect water hose from pump unit.

f) Turn on compressor.

g) Press water button outside switch cabinet, the remaining water is now blown

out of the system.

h) Tilt pump and clean mixing unit.

i) Disconnect and empty plaster hoses as described above.

Although the entire machine is empty and clean, there is a small residue in the

rotor/stator. Therefore, run the machine carefully when next time use.

4) ADJUSMENT DATA:

a) Water pressure safety switch:

At minimum 2.2 bars machine starts to work. At the pressure lower than 2.0 bar

machine stops itself automatically.

b) Water pressure reduction valve:

1.7 Bar, 800 liter /hour

c) Pneumatic remote control switch:

0.9 Bar: Machine Starts

1.2. Bar: Machine Stops

d) Compressor security valve:

3.5Bar against closed air tap.

e) Motor Protection switch unit:

5.5KW motor 12.5A in case of 380VAC

f) Motor protection switch unit (star wheel):

0.55 KW motor 1.95 A 380 V AC.

g) Star wheel:

Distance wheel bottom: 1.5 times grain size of plaster used.

If necessary place washers under wheel.

h) Conveying pump (Rotor/Stator Pump)

For each meter length of hose there is a pressure of 0.9 bar. When machine is

stopped pressure will drop by about 30 % to approx. 8 bar.

The pressure and the granule size of the rotor/stator pump are depending on the

type of it. As the granule size increases the pressure will decrease. Control and

adjustment of consistency can be achieved by the manometer. So life of pump will be

longer, loss of plaster / rendering will be decrease, full utilization of motor characteristics

can be achieved.

i) Spraying Gun:

The diameter of the nozzle must correspond to the distance nozzle-air tube.

Example: Diameter nozzle: 14mm

Distance nozzle-air tube: 14mm

j) Rotation of star wheel: No particular direction is required except connecting to

pneumatic equipment. In that case counter clockwise direction of rotation is required.

6) TECHNICAL DATA:

1- Power: 2 transmission motors:

Pump motor: 5.5 KW, 12.5 A, 380 V, 400 rpm

Star wheel motor: 0.55 KW, 1.95 A, 380V, 28 rpm

2- Conveying pressure: 5-40 bar depending on type of plaster / rendering and pump

used.

3- Conveying distance: Up to 40 meters depending on type of plaster / rendering and

pump used.

4- Conveying hose : 25 mm /1” or 35 mm / 1 ½”

5- Air hose : 13 mm / ½”

6- Compressor output : 0.9 KW Nm3/ min max 6 bar

7- Water connection: max 2.5 bar when in operation.

8- Water connection hose :3/4”

9- Current connection: 380 V, 3 phase, 5 core cable, 32 A fuses.

10- Machine output: 6-45 l / min depending on motor, type of plaster / rendering and

pump used.

14-Remote control: by air or 24 V safeties current.

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