The Monolithic EHP 1500--Peristaltic Carrousel Pump

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Start up Instructions

The Monolithic EHP 1500 is designed for use with small aggregate mortars, pastes, heavy bodied paints, mud, and other thick viscous materials. It works as an excellent small line shotcrete pump for stuccos and concrete. It is made from the toughest materials available at an affordable price. The unit is designed for maximum capacity and minimum maintenance.

Assembling Instructions

Testing Power Unit Prior to Installation of Pumping Line

1. Connect carrousel pump to air supply. For the pump only the air supply should be at least 80-100 cfm at 100 psi (Note: for shotcrete applications the air compressor must be able to supply both the pump and the nozzle. Therefore at least 185 cfm at 100 psi must be available for both functions). The air supply hose should be 1" I.D.
2. The carrousel pump is controlled with an air direction valve. Center position of off, the right (up) is forward and to the left (down) is reverse. The speed of the carrousel pump is controlled by the faucet type air regulator on the exhaust line.
3. Connect 3/4" air line (red hose) with quick coupling & Chicago coupling to spray gun from pump.
4. To start the pump, move lever on air direction valve to "on" position. Opening the faucet-type air regulator on the exhaust line will increase the pump speed. By putting the pump in reverse, you can bring a lump back into the hopper to be removed. The pressure on a line pack can also be reduced by reversing the pump.This relieves pressure in case of "build-up."

After having tested the pump and control unit, the pumping line can be installed

1. Lubricate the outside of the elbow end at the bottom of the hopper and the inside of the hose with pump line lubricant or a heavy soap solution. The wetness and slipperiness will help to force the rubber pumping line over the tube.
2. Lubricate the internal pump line and feed it into the carrousel by slowly reversing the pump. The pumping action in reverse should draw the pump line into and around the carrousel to the hose connection at the hopper bottom elbow.
3. After the pumping line has been slipped over the tube at the elbow, attach the hose clamp. The pumping line has a soft internal line and because of this softness, it is virtually impossible to keep the hose from separating unless the hose clamp and the hopper are connected by an external bolt-on strap.

IMPORTANT

Should the material line become disconnected from the bottom of the hopper, the bolt-on clamp will prevent the metal clamp from being pulled into the pump. Failure to attach the bolt-on clamp may result in damage to the pump and to the squeeze rollers.

IMPORTANT

Coating the outside of the pumping line with lubricant will greatly speed the installation of the pumping line into the carrousel. The lubricant will also greatly reduce the wear and tear on the exterior of the pumping line. Lubricant can be applied to the pumping line after assembly. Lubricant should be applied at least once a week especially before use after sitting.

1. Rotating the pump line regularly will greatly increase the working life. Rotate it once a day or after each 10 yards of concrete is pumped.
2. The material line can now be attached to the pumping line.
   1. The internal tube with the male quick coupling
   2. The exterior U-clamp
   3. The connecting strap between the clamp and coupling

The external hose clamp and joining metal strap must be used to prevent the pumping line and the material line from separating.

Operating instructions for Shotcreting

1. After the pump is fully assembled, (do not connect material line to the spray gun) pour water into the hopper. Turn on the unit by moving the air valve control lever to the forward position. After the water is pumped from the hopper, add mixed material to the hopper. Pump the material through the material line until a uniform consistency of material is flowing. The air line should be attached to the spray gun. A small amount of air should always be bleeding through the spray gun air jets to keep the material from backing up in the air jets.
2. The material is now being pumped into the material line pushing the lubricating water if front. At the point where the mixed material comes in contact with the lubricating water, there will be some material separation. Should a line pack occur, reverse pump to reduce pressure. The line pack will be where the hose is still hard. Insert a metal rod or a small water line to break up the pack. It is advisable not to put the spray gun on the material line until properly mixed material is extruded from the material line.
3. The operator stops the pump, washes the end of the material line and attaches spray gun.
4. Hold spraying air supply and start pump. You are now spray applying material. Move the spray in the uniform circular manner to achieve a consistent thickness of application.
5. When the spray man wishes to stop spraying, he should anticipate and stop the pump. Material will continue to spray for approximately fifteen seconds, as the pressure of the material in the material line dissipates. If the spray man is using the Monolithic nozzle, he will be unable to completely stop the dribbling of material to the spray gun, and should position they spray gun in a manner that it will not spray an undesirable area. Reducing the air supply to the spray gun to a minimum will allow the excess material to dribble from the end of the spray gun. The slight flow of air to the spray gun will keep material from entering and plugging the air jets.
6. To clean — Wash hopper and spray gun thoroughly. The material line can be cleaned by pumping sponges and clean water through the pump and the material line. Sponges should be approximately 1 1/2" cube, and can be easily cut from a cellulose sponge.

Controlling speed of application

The speed of the carrousel pump is controlled by the air valve on the exhaust air line. At maximum flow, the free flow rate is approximately six gallons per minute and will achieve an application rate in excess of 2 plus cubic yards per hour.

Trouble shooting problems

Most of the problems encountered will be in the mix of the material.

1. Improper mixing can cause lumping, resulting in plugging at the material hopper. These plugs are easily and quickly remove by momentarily reversing the pump. The pump will now pump material backwards and the operator will be able to remove the lumps from the bottom of the hopper. Use reverse only momentarily as continued reverse operation will pull the coupling back into the pump causing damage.
2. Material lumps can be caused by exposure to moisture during storage. Overaged material will generally result in a lump at the filling spout of the bag.
3. The unique design of the carrousel pump and material line fittings will pass any smaller lumps directly to the spray gun. Most lumps will pass and be sprayed on the wall.
4. Air motors can freeze or rust up due to moisture in the air. Keep the lubricator filed with oil for proper lubricating of the motors. If a lubricator is not fitted to the air supply line, a few periodic squirts of oil will suffice. An excess amount of lubrication will flood the air motor resulting in stalling and slow speeds. To correct, remove exhaust filter and screen, run motor to clear excess oil. If air motors seize and will not turn, disassemble, clean, and oil the air motors. Drain moisture extractors as needed.

IMPORTANT

Do not operate the Monolithic EHP 1500 in reverse while unattended. Explanation: The pumping line will double up inside of the pump and cause damage and/or the coupling between the material in and the pumping line will be pulled into the pump and cause immediate damage.

After the carrousel pump has been completely cleaned, apply oil on the outside of the pump

with a sprayer or a saturated rag. This prevents cement from bonding to the surface of the pump.

CAUTION: Only use Monolithic Internal pump line! This hose is manufactured specially to Monolithic specifications (Rubber Durometer & Dimensions). Failure will occur with any other product and warranty will be nullified.

Instructions for removing internal carrousel housing

Remove internal pumping line.

Remove motor and gearbox by removing four bolts holding the gearbox to the carrousel frame. The drive chain does not have to be separated.

1. Now that the motor and gearbox has been removed, the carrousel (two squeeze wheel unit) can be removed as follows:
2. Loosen the two allen screws in each of the top and bottom flange bearings. (1/8" allen wrench size).
3. One large 3/8" square head set screw locks the carrousel to the 1" center shaft. Position the carrousel where the lock screw can be seen between two of the squeeze rollers. By using and 8 or 12 sided 7/16" socket with an extension, back the screw loose from the center shaft.
4. The center shaft is tapped 3/8" x 16 at both ends. Remove bolts retaining top and bottom washers. Replace bolts in tapped ends before attempting to loosen shaft by light tapping.
5. Before removing carrousel from housing, record the number of steel spacers on the top and bottom of the carrousel. A plastic spacer is always on the very top and the very bottom of the steel spacers.
6. To disassemble the carrousel, remove the bolts on the drive sprocket and the bolts at the end of each squeeze wheel. Now separate two halves of the carrousel by light tapping on the top and bottom plates. Alternate tapping from side to side. After separating, remove damaged wheel and bearing. Replace with new and reassemble with code numbers on the top and bottom plates in line using "locktite" on all bolt threads. Replace drive chain on sprocket and hold in place by shortening the chain with string or light wire. A wood dowel almost 1" in diameter cut to just under 6 1/2" will help in reassembling the carrousel. Place wood dowel in center hold of carrousel, and place the proper number of spacers on top of the dowel and on the bottom of the dowel. Lubricate the individual spacers as well as the inside of the housing top and bottom. Slide carrousel into position in the housing. Before replacing the 1' steel center shaft, remove all burrs by light filing. Insert steel shaft in proper position. DO NOT USE EXCESSIVE FORCE. Position flats on the center shaft and retighten the center lock screw and two set screws in both the top and bottom flange bearings. To complete assembly of unit follow disassembly in reverse.

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September 25, 2001

177 Dome Park Place - Italy, TX 76651
Tel (972)483-7423 - Fax (972)483-6662
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