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Continuous-Flow Mixer
calypso D30
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calypso D30
43
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Technical development:
The manufacturer reserves the right to adapt technical data without notification in order to reflect the current state of
technical development. For information regarding the current status, alterations or additions to these operating
instructions, please contact m-tec.
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Copyright in these operating instructions remains with m-tec mathis technik gmbh. These operating instructions are
intended for the use of installation, operating and maintenance personnel. They contain technical regulations and
drawings which may not be copied, distributed, used for advertising purposes, or communicated to third parties
either in whole or in part without authorisation.
calypso D30
Dear Customer,
this machine represents the most up to date technology and complies fully with
general standards and EEC guidelines. This is indicated by the CE symbol and
the enclosed declaration of conformity in the pocket on the machine.
Before starting the machine for the first time, please remove the
declaration of conformity from the pocket and keep it in a safe
place.
Before commissioning the machine, please complete the form below. This is the
easiest way to familiarize yourself with the most important machine data, and to
have them ready at all times without having to refer to the rating plate on the
machine. If you wish to contact us at any time, please have the information on
this page ready. The data you require can be found on the machine plate.
Type ________________________________________
Machine no. _________________________________
Year of manufacture __________________________
Power supply ________________________________
Rated current (total) _________________________
Date of commissioning _______________________
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Application _________________________________
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Circuit diagram
calypso D30
Safety ........................................................................................................................................... 6
1.1 Warning Symbols and Hazard Categories ....................................................................... 6
1.2 General Safety Instructions .............................................................................................. 8
1.3 Intended Use ..................................................................................................................... 10
1.4 Target Group ..................................................................................................................... 10
1.5 Qualified Personnel .......................................................................................................... 11
1.6 Instructions Book ............................................................................................................. 11
1.7 Safety at Work .................................................................................................................. 12
1.8 Personal Safety Equipment ............................................................................................. 14
Start-up ...................................................................................................................................... 24
4.1 Electrical connections ..................................................................................................... 24
4.2 Water connection ............................................................................................................. 25
4.3 Rotary direction ................................................................................................................ 26
4.4 Adjusting water flow ....................................................................................................... 27
Operation .................................................................................................................................. 28
5.1 Using bagged material .................................................................................................... 28
5.2 Using material from a hopper ........................................................................................ 29
5.3 Work interruptions ........................................................................................................... 30
5.4 Operation in winter .......................................................................................................... 30
5.5 Work termination ............................................................................................................. 31
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Table of contents
41
40
Table of contents
calypso D30
10 Circuit diagram
Cleaning .................................................................................................................................... 32
6.1 Cleaning after work termination ..................................................................................... 32
6.2 Cleaning prior to material change .................................................................................. 34
Maintenance ............................................................................................................................. 35
7.1 Lubrication schedule ....................................................................................................... 35
7.2 Oil change ......................................................................................................................... 36
7.3 Maintenance of water filters .......................................................................................... 37
Main switch
Troubleshooting ...................................................................................................................... 38
Disc2
Reversing switch
CB1
CB2
CON1
CON2
PB1
PB2
Push button on
LT1
Lamp work
TGS1
TR1
SOL1
Solenoid volve
TRAN1
Transformator
FU1
Fusible
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Accessories/spare parts
calypso D30
Safety
9.1 Accessories
Application range and handling of the Continuous-Flow
Mixer D30 can be considerably improved by using
accessories supplied by m-tec mathis technik gmbh.
The following accessories are available for this
machine:
DANGER
indicates an imminently hazardous situation which,
if not avoided, will result in death or serious injury.
WARNING
CAUTION
indicates a potentially hazardous situation which, if
not avoided, may result in minor or moderate
injuries.
CAUTION
is used without safety alert symbol to indicate a
potentially hazardous situation which, if not
avoided, may result in equipment damage.
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NOTICE
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Accessories/spare parts
DANGER
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38
Safety
calypso D30
Troubleshooting
DANGER
No water
fails to open
Mortar too dry
Consistency of
material fluctuates
Cause
No power
Mortar hardened in
mixing pipe
Motor overload switch
triggered
Overload switch could
be triggered
Solenoid valve
Insufficient water
Overload switch of
water pump (option)
was triggered
Water flow valve
insufficiently opened
Too much
water
Filter in pressure reducer,
inlet filter, or filter hood
fabric clogged
Remedy
Check power
connection and fuses
Clean mixing pipe
(see section 6.1)
Open control panel, reset
overload switch (fig. 20)
Check motor overload switch
mixer motor (fig. 20, 1)
Coil could be defective,
replace solenoid valve
Check water supply. The
pressure must be at least
2 bar. If necessary, install
a water pump (available as
accessory for the D30,
see section 9)
Check motor overload switch
water pump (fig. 20, 2)
ENVIRONMENTAL HAZARD
This symbol indicates that laws, rules, and regulations for environmental protection must be observed.
NOTE
This symbol draws your attention to important or
additional information relevant to the machine or
documentation thereof.
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Problem
Mixer motor
fails to run
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Maintenance
calypso D30
1.2 General Safety Instructions
7.3
DANGER
Follow these safety instructions carefully. Failure
to do so may increase the risk of accident or injury.
These safety instructions apply to all directions
throughout this manual, and must be applied to all
aspects of the machines use, including, but not
limited to, transport, assembly, operation, maintenance or disassembly.
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1
2
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36
Safety
calypso D30
ENVIRONMENTAL HAZARD
Always comply with environmental regulations
when disposing of waste oil, grease and cleaning
agents,.
The gear motors are furnished pre-lubricated, they are
maintenance-free up to
8000 hours of operation. They should then be cleaned
thoroughly with a suitable rinsing oil, and refilled with
fresh oil.
Recommended type of oil for the gear motor: Shell
Tivela Oil 82; quantity 400 cc.
One of the following substitute oil types can be used if
the type specified above is not available:
Degol BG 220
Energol GR-x P220
Bisol Oil MSR 114
Sparton EP-220
Molygear 115
Mobilgear 630
Omala 220
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ARAL
BP
CALYPSOL
ESSO
HOUGHTON
MOBIL
SHELL
10
Maintenance
calypso D30
1.3 Intended Use
Maintenance
DANGER
Always switch the machine OFF, and disconnect it
from the electrical supply network before working
on the machine. Certain parts of the machine
remain live when the machine is switched OFF.
The safe working condition of the machine must
be verified in accordance with legal requirements
(or at least once per year) by a specialist engineer.
Use only spare parts and accessories supplied by
m-tec mathis technik gmbh. m-tec mathis technik
gmbh can not be held liable for injuries or
damages resulting from the use of non-approved
spare parts and accessories.
Masonry mortar
Various rendering plasters
Adhesive mortar
Floor cement
Fine concrete
DANGER
Use of the machine for any other purpose than
those described above may result in bodily or even
fatal injury, and/or in damage of the equipment or
other property.
7.1
Lubrication schedule
Lubricate the grease points on mixer motor and
mixing pipe every 4 - 6 weeks, using a highpressure grease gun (1 - 2 shots) containing
bearing grease (fig. 18).
Regularly relubricate the rubber packing on the
mixer motor, using a grease gun.
35
Socket pin
34
Safety
calypso D30
DANGER
Startup, operation and maintenance of the machine carried out by unqualified personnel may
result in bodily or even fatal injury, damage of the
equipment or other property.
Startup, operation and maintenance of the machine may only be carried out by qualified personnel.
It is the duty of the operator to have the operating
staff thoroughly study and understand the operating manual, especially chapter Safety, and that
their qualification is adequate for safe operation of
the machine.
Qualified persons are those who, through training and/
or experience, have sufficient knowledge in the field of
mortar-feeding and mortar-spraying machines, and
who are sufficiently familiar with legislation regarding
safety, accident prevention, guidelines and general
technical procedures to allow them to assess the safe
condition of such machines.
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12
Cleaning
calypso D30
33
Mixing shaft
DANGER
1
2
3
NOTICE
WARNING
The machine must be positioned:
firmly on a level surface. It must be secured to
prevent it from tilting or moving.
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Shaft coupling
Dosage pipe
Material trough
32
Safety
calypso D30
DANGER
Cleaning
DANGER
Always switch the Continuous-Flow Mixer OFF, and
pull the power supply plug before cleaning the
machine!
ENVIRONMENTAL HAZARD
CAUTION
Bearing cover
Eccentric catch Mixing pipe
Eccentric catch Dosage pipe
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2
3
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14
Operation
calypso D30
ENVIRONMENTAL HAZARD
Always dispose residual mortar in accordance with
the regulations concerning building waste.
Always observe environmental regulations when
disposing of used oil, grease, or cleaning agents.
Wear proper personal protective equipment, including, but not limited to, eye and hearing
protection at all times while operating the
machinery. In order to prevent the risk of serious
injury, keep hands, feet, hair and clothing away
from all moving parts of the equipment. Avoid
wearing loose-fitting clothing or jewelry when
near the machine, and secure long hair in order to
keep it away from moving parts.
ENVIRONMENTAL HAZARD
Do not use liquid or runny material. Collect it in a
bucket and correctly dispose of it.
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Draining valve
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30
Machine description
calypso D30
5.3 Work interruptions
Machine Description
CAUTION
The length of work interruptions must be limited.
Always keep the setting time of the mortar in mind.
Hardened mortar in the mixing pipe causes
difficulty in starting the motor and may cause
permanent damage of the mixer.
2.1 Function
In its standard form, the Continuous-Flow Mixer D30 is
designed for processing bagged mortar material.
The material is poured into the material trough. The
dosage screw carries the material from the trough into
the mixing pipe where it is mixed with water and
conveyed to the discharge outlet.
CAUTION
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16
Operation
calypso D30
2.2 Machine illustration
29
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1
2
3
4
5
6
7
28
Machine description
calypso D30
Operation
DANGER
When operating the machine, all applicable national and international safety laws, rules, and
regulations must always be observed, even if such
laws, riles, and regulations are not explicitly
mentioned in these instructions.
Prior to every shift, carefully inspect the machine
for obvious signs of damage, in particular electric
cables, plugs, feed and air hoses. Any damage must
be repaired before shift start.
Do not reach into the machine, or into the mixing
pipe, while the machine is connected to the power
supply network, as this may cause serious injury.
Water fitting
Water pump
Machine internal water connection
NOTICE
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18
Start-up
calypso D30
2.3 Operating elements
27
WARNING
Do not reach into the machine!
If necessary, adjust the water flow as required at
the fine-control valve (fig. 11, 1) of the water fitting.
To increase the flow of water turn the fine-control
valve counter-clockwise.
To decrease the flow of water turn the fine-control
valve clockwise.
The machine should be started with the fine-control
valve fully opened for products of unknown water
requirement.
At operation start turn the fine-control valve back
until the correct material consistency is achieved.
Fine-control valve
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ENVIRONMENTAL HAZARD
Always dispose of mortar residues as building
waste!
26
Machine description
calypso D30
19
CAUTION
WARNING
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1
2
3
4
5
6
7
8
9
20
Start-up
calypso D30
CAUTION
NOTE
The machine requires a constant water pressure of
2 bar in order to furnish mortar of a constant
consistency.
Be sure the water intake filter is in place and clean.
Connect the internal water hose (fig. 8, 3) to the
mixing pipe (fig. 8, 2).
Connect the exterior water hose with GEKA coupling
- directly to the fitting (fig. 8, 4); or
- to the water pump (optional, fig. 8, 1), if installed.
Turn water supply ON
Use a water butt if water supply is insufficient. The
water supply hose (3/4") must be thoroughly vented
before turning the water ON.
Water
connection
Dimensions
Weight
Noise level
Drive motor
Electrical
connection
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Mixing capacity
1
2
3
4
5
6
25
24
Machine description
calypso D30
21
Start-up
DANGER
Operating instructions
Phase inverter
WARNING
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calypso D30
23
DANGER
WARNING
3.1 Transport
WARNING
Always observe the following instructions if the
machine is transported by crane or truck:
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