PICOTE MINI PUMP Owner'S Operation & Safety Manual Download Page 1

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These instructions are for your personal safety. Always ensure that you have

read and understood these instructions before using any of the Picote Brush

Coating

™

System Range.

PICOTE BRUSH

COATING™

SYSTEM

MINI PUMP

OPERATION

& SAFETY

MANUAL

Summary of Contents for MINI PUMP

Page 1: ...ons are for your personal safety Always ensure that you have read and understood these instructions before using any of the Picote Brush Coating System Range PICOTE BRUSH COATING SYSTEM MINI PUMP OPERATION SAFETY MANUAL ...

Page 2: ... THE RESIN OPERATING THE COATING SYSTEM CLEANING UP THE COATING SYSTEM CURING ADDITIONAL COATS PICOTE EPOXY RESIN INFORMATION MAINTENANCE ERROR CODE LIST WARRANTY POLICY PROCEDURE Topic Page To watch practical demonstration videos or to download an electronic copy of these Instructions please visit www picotesolutions com Please note that videos are not intended as a replacement or alternative to ...

Page 3: ... System to prevent any skin irritations Any open injuries or skin irritations should be covered at all times to avoid contact with resin or dust Always wear a suitable ventilation mask when using the Coating System to prevent any resin dust or vapors being inhaled or consumed which can cause occupational asthma or resin dermatitis as well as eye irritation Always Remember Always ensure that the ma...

Page 4: ...f Mini Coating Pump will be stored in colder environment than 10 o C 50 o F the pump should be stood at room temperature for 24hours before use If Mini Coating Pump has been stored for long periods of time over 2 3 months it should be checked and tested according to maintence program before use DISPOSAL Mini Coating Pump motor control box pumping assembly and electric wires can be disposed in Euro...

Page 5: ...d representative in Europe who is Picote Solutions Oy Ltd Pienteollisuustie 24 06450 Porvoo Finland 1st January 2017 Katja Lindy Wilkinson C E O Picote Solutions Oy Ltd Pienteollisuustie 24 06450 Porvoo Finland Picote Brush Coating System TM has been granted with WRc Product Certificate for non potable and waste water application for pipe diameters DN32 11 4 to DN300 12 Certificate Number PT 431 0...

Page 6: ...essories SIZE HOSE RANGE ROTATING SPEED OUTPUT kw POWER SOURCE WEIGHT 41x42x54 4 cm 8 10mm Max 22m Depends on pipe diameter 0 18 110v or 230v 16kg 16 2 2x16 5x21 5 Max 75ft 35 5 lb Ensure that the supply voltage is correct The voltage of the power source must match the value given on the nameplate of the machine Available in 230v and 110v The machine should be connected only to a power supply of t...

Page 7: ...GHT 752x519x389 8mm 17m 500 2900rpm 110V 1 1kW 110v or 230v 27kg 29 6x20x15 3 1 3 55ft 230V 1 2kW 59 5lb When is use always lay the machine down horizontally on the floor as shown above When not in use some non hazardous Picote Flexible Shaft Lubricant might leak from the hand guard 1 2 3 4 5 6 9 8 7 VOLTAGE Ensure that the supply voltage is correct The volt age of the power source must match the ...

Page 8: ...3540000817US Mini Miller 230v 17m range Mini Miller 110v 17m range Mini Miller 110v 55ft range 8mm Shaft 3 HOSES SHAFT 2220100004 2220100003 1312030085017 9123050001 2220100007 93212321085 Resin Supply Hose Resin Delivery Hose Mni Miller spare shaft 8mm with thick outer casing Shaft connector Hose Connector with two hose clamps 11 13mm Sleeve 2 Plastic for 8mm thick casing Supplied in 25m 82ft len...

Page 9: ...Special Lubricant designed to reduce friction 6 Cartridge Kit 3 White 3 Dark Grey with 8 Tips 3 Nuts More information on p 37 1 quart hose lubricant 6 PICOTE SMART MIXER 2130001001 Picote Smart Mixer Battery powered cartridge case with spare battery charger and additional 600ml piston Please see the Smart Mixer operating manual for more information 7 DRAIN CAMERA Use your own mini camera Mini came...

Page 10: ...hly with Picote Smart Cutter TM grinding panels WARNING STEP 1 Clean the host pipe very well Use Original a or Cyclone b grinding chains with carbides for cast iron pipes and flush with water For PVC pipes use the special PVC chains c Use a wire brush d to remove final dust and other remaining particles OPTIONAL STEP For pipe with excessive build up of fats oils or grease FOG a degreaser may be ne...

Page 11: ...ing panels through the pipe to create a rough surface and allow for the resin to have the best possible bond to the pipe wall The pipe MUST be dry before continuing with the coating setup Use the Picote Heater to expedite the process Once the original pipe is clean move on to the Coating System Pump Assembly ...

Page 12: ...1mm 13mm HOSE CLAMPS BEFORE BEGINNING ASSEMBLY DANGER Risk of serious injury from rotating parts Have plenty of rubber gloves and towels available Wearing a double layer of rubber gloves is useful when applying lubricant Be sure that all machines have the required power supply Test machines and power source to ensure adequate and safe operation ...

Page 13: ... inserted into Resin Supply Hose There are 2 small hose clamps for black hose 10mm and 2 larger hose clamps for red hose 13mm Insert hose connectors and rotate notched surface up while following the natural curve of the hose Ensure hose clamps are facing outward and inward Once positioned properly tighten the hose clamps This is important when installing into the pump housing 248mm to 254mm 9 to 1...

Page 14: ...nto bottom of the housing key way Push hose into housing and slowly rotate the pump rotor clockwise manually while feeding the hose into place Tip Silicone grease will make the process easier Slide second connector into the top key way Note light pressure will be needed to pull the top connector into the key way ...

Page 15: ...quired STEP 8 Apply a small amount of a silicone grease to the underside of the hose at the bottom of the housing This allows the hose to always return to the center after the rollers pass over it STEP 9 Close housing door to secure connectors Pump door should remain closed at all times during the coating process ...

Page 16: ...upply hose extension One end will require a 45 degree angle and the other should be a square cut Attach the square end of the hose to the top hose connector on pump using a small hose clamp Take the 45 degree end and place in the resin cup at the back of the pump Run the hose through the retaining holes on the back of the pump ...

Page 17: ...S 1 or 2 BRUSH STOPPER SLEEVE BEARING ALLEN KEY 2 5 ADJUSTABLE WRENCH Before Beginning Assembly Have extra brush stoppers and hose connectors available Use angle grinder or portable band saw to cut Mini Miller shaft if necessary Have a roll of duct tape available ...

Page 18: ...shaft Attach the smaller brush against the sleeve leaving roughly 6mm 1 4 between the brush hub and sleeve and secure the two 2 5mm set screws DO NOT OVER TIGHTEN OR SCREWS MAY STRIP THE NYLON HUB Recommended Coating Brush Diameters Host Pipe Diameter Front Coating Brush Diameter Straight Front Coating Brush Diameter Multiple Bends Rear Coating Brush DN32 1 1 4 40mm 1 1 2 50mm 2 40mm 1 1 2 DN40 1 ...

Page 19: ... or 4 between the brushes with no need for casing over the shaft This will allow for flexibility around bends Once the brushes are assembled move on to the Delivery Hose and Camera set up The larger of the two brushes will be the brush at the tip of the shaft and is used for ﬁnishing the resin The closest brush helps to spread the resin and stabilize the brush set during coating ...

Page 20: ...20 COATING SYSTEM ASSEMBLY Delivery Hose Camera Required Tools Parts DELIVERY HOSE DUCT TAPE CAMERA NUT DRIVER SCISSORS 11mm CLAMP ...

Page 21: ...second piece of tape securing the delivery hose to the shaft Attach the camera head 10 15cm 4 6 behind the sleeve bearing Watch your camera screen to ensure that you have full view of the brush Coating System Assembly Delivery Hose Camera When you are pulling the delivery hose from the roll always pull from the center This will keep the hose from getting tangled and messy ...

Page 22: ...era spring and con nectors inside stay clean during the process Once the camera is secure insert the brushes in to the pipe opening Push in about 1 meter 3ft and tape camera delivery hose and miller cable all together Continue taping every 1 meter 3ft and pushing into the pipe until the end of the pipe to be coated has been reached Coating System Assembly Delivery Hose Camera ...

Page 23: ...lose to the opening as possible cut off the delivery hose square cut and attach to the bottom connector on the pump Secure with a hose clamp Coating System Assembly Delivery Hose Camera Once the Delivery Hose Camera are set up begin preparing the Resin ...

Page 24: ...tallation it is recommended to chill the resin slightly If too cold the resin may become difficult to pump Room temperature 18 27 o C 65 80F is always recommended Before Beginning Preparation In case of spills or accidents have plenty of rubber gloves towels chemical spill kit and acetone readily available Be sure to prepare all cartridges before pumping any resin This will allow you to have more ...

Page 25: ...sing High Pressure Water Jetting Maximum Water Jetting Pressure is 2600 PSI or 180 Bar A minimum of 3 coats need for abrasion resis tance STEP 1 Before you begin preparing the resin for application verify the following A The Mini Miller and Pump are ON B The Speed of the Mini Miller is set to 950 to 1100 rpm speed dial 2 3 C The Speed of the Pump is set to full speed D The Pump is set to rotate cl...

Page 26: ...eakage and possible mixing of resin Choose the desired color of resin for the first application Choose a color that gives the most contrast to the original pipe color If you are coating a light pipe use the dark gray first or in dark pipe use the white resin to start with Remove the nut 1 and cartridge cap 2 and set aside for later A B Preparing The Resin C Cut the mixer tip back two notches This ...

Page 27: ...w change the speed dial on the Smart Mixer to the 4th setting Preparing The Resin STEP 5 Feather the trigger to allow the pistons to seat properly and evenly on the back of the car tridge Once resin flows into the tip slowly dose a small amount of resin no more than 30g 1 oz into a cup or cartridge bag and dispose of it This will ensure the resin is mixed properly ...

Page 28: ... specialized and designed to be absorbed into the coating resin without causing negative effects Any other lubricant WILL cause negative effects and can prevent the epoxy from bonding or curing properly Excessive use is not needed or recommended TIP After priming the static mixing tip allow the resin to begin filling the resin cup to no more than full Filling the cup too full will generate hear to...

Page 29: ...in can be seen flowing stop the pump and turn the variable speed dial down to the appropriate speed for the pipe diameter Normally the pump is set to full speed and the Mini Miller in between 950 1100 rpm speed dial 2 3 STEP 4 Start the coating from the far end Pump out resin and brush it on Pay close attention to the flow of resin and lay a consistent bead into the pipe Also watch the bead of the...

Page 30: ...sections until the pipe is fully coated STEP 6 Average coat thickness is 0 7 to 0 8 mm Carefully inspect that the resin covers the pipe everywhere Be especially careful around bends STEP 7 Once first coat is complete apply heat after 20 minutes Picote Heater to the pipe before starting the next coat to speed up dry time Please have a look at page 36 for more information about additional coats ...

Page 31: ...ed to be abraded with a Smart CutterTM first to make sure that the layers bond well Dual Color Method Apply over existing color with new color Verify that resin has been applied everywhere The Dual Color Method allows for clear visual verification during application that resin has been evenly distributed everywhere ...

Page 32: ...m DRILL BIT NUT DRIVER Before Beginning Cleaning Process In case of spills or accidents have plenty of rubber gloves towels chemical spill kit and acetone readily available Have buckets ready for cleaning the brush es and camera Have a roll of duct tape and large waste bin nearby ...

Page 33: ...during the cleaning process When the resin stops dripping put the brushes in a bucket of Acetone Cover the opening and run brushes for a short time to rinse off resin Brushes and cable should now be clean enough for reuse later Wipe the camera head and the Mini Miller shaft clean with an acetone soaked rag Cut away tape and recoil the cleaned camera and miller cables into their holders ...

Page 34: ...supply Remove cartridge from the Smart Mixer Recap for later if there is unused material in the cartridge STEP 5 Wipe down the delivery hose so as not to make a mess and remove the pump hose from the housing STEP 6 Carefully remove the suction hose from the cup and wipe down the end Watch for drips and tape the end closed if necessary ...

Page 35: ...om the pump cut away the hose connectors and clamps for reuse STEP 8 Remove hose clamps and carefully cut away hoses and dispose of them STEP 9 Hose connectors can be cleaned with acetone and a small wire brush or cotton swab or they can be allowed to cure and drilled out later ...

Page 36: ... Cleaning Up The Coating System STEP 12 Collect all the contained waste including used gloves delivery hose rags etc into thick waste bags and seal properly If large amounts of mixed coating resin was left let it harden separately for example in the resin cup Dispose according to waste laws and regulation Follow instructions from coating resin MSDS Note Mixed resin will generate heat while curing ...

Page 37: ...coats to apply Additional coats should always be applied in contrasting layers This will give a visual verification to each coat that is applied If the previous coat sits lon ger than 24 h before coated again the pipe will need to be abraided with Smart CutterTM A minimum number of 4 coats needs to be applied to the pipes that will be cleaned using high pressure water jetting Maximum water jetting...

Page 38: ...ust be used after 24hrs Installation 50F 10 C 140F 60 C Storage Room Temp 60F 15 5 C 85F 29 C Finished product up to 250F 121 C constant Minimum Storage Temperature Room Temp 60F 15 5 C 85F 29 C Shelf life 2 years from packaging when kept in accordance with storage instructions included in MSDS and Technical Data Sheet Industrial safety Ready measured product must not be in contact with skin it ad...

Page 39: ...ER SCREWS FOR THE SMART CUTTER HUB If you are unable to tighten the fastener screws properly due to worn out hex socket heads replace the fastener screws immediately Otherwise a brush or other tool can detach from the shaft during use and fall into the pipe PUMP MILLER PARTS Keep parts clean Where possible remove resin from the Coating Pump brushes Miller and other parts care fully with acetone Se...

Page 40: ...on of frame quick locks I I Condition of electric components I I I I Clean resin stains P P P P Operation of Smart Mixer I I I I Condition of hose clamps R R R R Condition of hose connectors I I R R I Inspect fix or replace if needed P Perform replace if needed R Replace WARRANTY PERIODS Service Period 3 months 6 months 1a A B C A Milling machine spare parts except B Electric motors C Service Cent...

Page 41: ...t pump resin No Yes Change pump hose Did it help Coating Pump is OK Yes Check ON OFF Switch of Control Box Test in different power source Yes No Does the Control Box power up Does the Control Box give error code Change the Control Box Check the Control Box error code list and make correcti ons according to instructions Yes No No Change pump rollers Did it help No Yes Troubleshooting flowchart Mini...

Page 42: ... Check the ambient temperature around the drive is within the drive specifi cation 50 C 122F Ensure sufficient cooling air is free to circulate around the drive Increase the panel ventilation if required Ensure sufficient cooling air can enter the drive and that the bottom entry and top exit vents are not blocked or obstructed U t Under temperature Trip occurs when ambient temperature is less than...

Page 43: ...ries or third party products when using the Products or 6 the use of the Products not in compliance with their respective Documentation user manuals safety and maintenance instructions and any usage restrictions contained therein or 7 accident fire power failure power surge or other hazard Otherwise the Products are sold AS IS End User is responsible for using the Products within their specificati...

Page 44: ...rld wide Training Centers in Anderson SC USA Finland and in our new training center in UK Contact your reseller or Picote Solutions for details INNOVATIVE THINKING In Finland Picote is a very well established contracting company succesfully rehabilitating thousands of drains and sewer pipes with trenchless methods since 2008 By focusing on in house research and development our company also offers ...

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