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Operating Instructions

Continuous-Flow Mixer
calypso D30

387595 11/03

220 V 60Hz 3ph

calypso D30

43

2003 m-tec mathis technik gmbh

387595 11/03

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.

387595 11/03

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 _______________________

387595 11/03

Application _________________________________

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42

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

Machine Description ................................................................................................................ 15


2.1 Function ............................................................................................................................. 15
2.2 Machine illustration ......................................................................................................... 16
2.3 Operating elements ......................................................................................................... 18
2.4 Water supply ..................................................................................................................... 19
2.5 Technical data ................................................................................................................... 20
2.6 Symbols on the machine ................................................................................................. 21
2.7 Components supplied ...................................................................................................... 21

Transport and Set-up .............................................................................................................. 22


3.1 Transport ........................................................................................................................... 22
3.2 Machine set-up ................................................................................................................. 23

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

Fig. 21: Circuit diagram D30 with water pump


(Art.-no.392246/001-09/01)

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

Keys for fig. 21


Disc1

Main switch

Troubleshooting ...................................................................................................................... 38

Disc2

Reversing switch

CB1

Motor protecting switch mixer

Accessories/spare parts ........................................................................................................... 39


9.1 Accessories ...................................................................................................................... 39
9.2 Spare parts ....................................................................................................................... 39

CB2

Motor protecting switch waterpump

CON1

Main contro! re ois mixer

CON2

Main control relais woterpump

PB1

Push button off

PB2

Push button on

LT1

Lamp work

TGS1

Switch sensor on/off

TR1

Time relais sensor

SOL1

Solenoid volve

TRAN1

Transformator

FU1

Fusible

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10 Circuit diagram ......................................................................................................................... 40

Accessories/spare parts

calypso D30

Safety

Modifications of the machine are prohibited. Use


only spare parts and accessories supplied by m-tec
mathis technik gmbh. m-tec mathis technik gmbh
can not be held liable for accidents and/or damages resulting from the use of non-approved spare
parts and accessories.

According to the standards defined in ANSI Z535.1-5,


the following hazard categories are used in these
Operating Instructions, to draw attention to dangers
possibly occurring when operating the ContinuousFlow Mixer D30.
The hazard messages are divided into five categories,
depending on the seriousness of the specified hazard.

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:

The signal words (e.g. Danger) communicate the level


of hazard seriousness.

DANGER
indicates an imminently hazardous situation which,
if not avoided, will result in death or serious injury.

Connection cable 5 x 1,5 mm2,


50 m, 400 V (16A 5pol 6h)
Water pump 400 V incl. attachment
Filter hood incl. accessories
Conveyor screw D30 pitch 30
Conveyor screw D30 pitch 50
Conveyor screw D30 pitch 70
Additional water pump AD33, 230 V 1ph
Suction hose 3/4", 4 m complete
Water hose 3/4", 20 m with GEKA
flow meter, complete
Tarpaulin for material trough

WARNING

indicates a potentially hazardous situation which, if


not avoided, could result in death or serious injury.

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.

9.2 Spare parts

is used without safety alert symbol to indicate a


potential situation which, if not avoided, may
result in an undesirable event or state.

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NOTICE
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Accessories/spare parts
DANGER

1.1 Warning Symbols and Hazard Categories

39

For spare parts please refer to our spare-parts catalog.


Send orders to:
m-tec mathis technik gmbh, Sales Dept.:
Tel. no.:
++49 / 7631 / 709-112 or -216
Fax no.:
++49 / 7631 / 709-116

38

Safety

calypso D30

The signal word is accompanied by a pictogram


which can be of different shape to emphasize the kind
of hazard. It is followed by a description of the hazard,
the probable consequence of involvement with the
hazard, and how the hazard can be avoided.

Troubleshooting
DANGER

No water

fails to open
Mortar too dry

Mortar too thin

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

Special type sof pictograms and indicated kind of


hazard used in this operation instructions:
This symbol indicates that hazard is generated by
electric current.

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)

This symbol indicates that hazard isgenerated by


rotating machine components.
This symbol indicates that only RCD (Residual
Current protective Device)circuit breakers with the
symbol shown opposite should be used.
This symbol indicates that safety goggles must be
worn. The frame of the goggles must comply with
the standard of the Occupational Safety & Health
Assosiation (OSHA).
Further symbols and signal words used in these
Operating Instructions:

ENVIRONMENTAL HAZARD
This symbol indicates that laws, rules, and regulations for environmental protection must be observed.

Increase opening of valve


(see section 4.4)
Close water flow valve
as required
(see section 4.4)
Clean filters (see section 7.3)
Beat dust particles out of filter
hood fabric (optional)

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

The table Troubleshooting is not intended to


replace the detailed instructions in the individual
chapters of these Operating Instructions. Always
comply with the safety notes noted in each chapter!

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Maintenance

calypso D30
1.2 General Safety Instructions

7.3

The water filters in water fitting and water pump


should be cleaned every 4 - 6 weeks. These filters are
located in the water inlet (fig. 19, 1) and in the
pressure reducer (fig. 19, 2).

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.

Remove filters using a special tool.


Clean the filters under running water.
Use compressed air for filter blow-out.
Install cleaned filters and tighten their fastenings.

The Continuous-Flow Mixer D30 is designed


according to the state-of-the-art, it is reliable in
operation and it has left the factory in perfect
condition. Nevertheless, it can pose a danger if it
has been installed improperly or contrary to
directions (see Chapter 3 and 4), or if it is operated
by untrained/unauthorized personnel.
In order to protect the machine against damage,
and to enable personnel to operate it properly and
safely, every operator must observe the following
instructions prior to machine start-up:
Read and understand the Operation and Service
Manual and familiarize yourselves with proper
machine operation. Chapter Safety
Safety is of major
importance.
Observe applicable accident prevention regulations as well as other generally recognized rules
and regulations pertaining to industrial safety
and medical care.
Prior to start-up of the machine be sure that any
difficulties are resolved (see the manufacturer
s
manufacturers
address on the back of the cover).

Fig. 19: Cleaning filters

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1
2

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Maintenance of water filters

Filter in pressure reducer


Filter in water inlet

37

36

Safety

calypso D30

Modifications of the machine are not permitted. All


replacement parts, accessories and lubricants must
be furnished by m-tec mathis technik gmbh. The
use of unauthorized parts, accessories or lubricants
may result in death or serious injury, and could
cause damage of the machine, and will nullify all
liability on the part of the manufacturer for resulting damage.

7.2 Oil change


CAUTION
Do not replenish gear oil between oil changes.
Over-lubrication could cause overheating of the
machine.
Never mix different types of oil. This could cause
the oils to decompose, leading to irreparable
damage of the gear unit.

This machine must be operated in compliance with


all applicable federal, state and local laws, rules,
and regulations at all times. This includes, but is
not limited to, the requirements of TITLE 29 of the
CODE OF FEDERAL REGULATIONS, PART 1926 (29
CFR 1926). Failure to operate this machinery in
compliance with all applicable laws, rules, and
regulations may result in death or serious injury.

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:

The machine must be inspected by a specialized


engineer in accordance with applicable safety laws,
rules, and regulations. Such inspection should be
scheduled at least once per year.

Degol BG 220
Energol GR-x P220
Bisol Oil MSR 114
Sparton EP-220
Molygear 115
Mobilgear 630
Omala 220

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The proper use of this machinery requires the


operator to be in full control of the machinery at all
times. None of this equipment must be used by an
operator under the influence of alcohol or drugs,
including prescription drugs that may impair an
operators ability to safely operate this equipment.
Failure to adhere to this requirement may result in
death or serious injury.

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ARAL
BP
CALYPSOL
ESSO
HOUGHTON
MOBIL
SHELL

When transporting, assembling, dismantling,


operating, cleaning, and servicing the machine, all
applicable national and international safety laws,
rules, and regulations must always be observed,
even if such regulations are not explicitly mentioned in these instructions.

10

Maintenance

calypso D30
1.3 Intended Use

The Continuous-Flow Mixer D30 is suitable for universal


mixing of dry mortars already mixed by the
manufacturer. The Continuous-Flow Mixer D30 can be
used for materials of the following types:

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.

Regularly remove mortar residues from the mixing


pipe, and dispose of them according to
environmental regulations.
Regularly inspect hoses and cable connections to
ensure that they are in working condition.

It may also impair efficient functioning of the


machine.
Use of the machine for any other purpose than that
described above is prohibited!
Modifications to the machine are prohibited. Use
only spare parts and accessories supplied by m-tec
mathis technik gmbh. If spare parts and accessories of other types are used, m-tec mathis technik
gmbh can not be held liable for occurring
damages.

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.

1.4 Target Group


This document is intended for personnel in charge of
startup, operation and maintenance of the machine.
Such personnel must be qualified according to specifications stated in chapter 1.5.
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Fig. 18: Lubrication points


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35

Socket pin

34

Safety

calypso D30

1.5 Qualified Personnel

6.2 Cleaning prior to material change


Proceed as described in section Cleaning after
work termination.
Release eccentric catch Mixer motor and tilt the
mixer motor back.
Clean the material trough without using water.
Tilt the mixer motor back and lock it in position.

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.

1.6 Instructions Book


NOTICE
The Operation and Service Manual must always be
kept in the pocket on the machine provided for this
purpose, having it permanently accessible to all
machine operators. All personnel operating or
servicing the machine must know where to find
this Manual.

Fig. 17: Cleaning before material change

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Eccentric catch Mixer motor

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11

12

Cleaning

calypso D30

33

All persons involved in operating the machine must


read the operating instructions, and ensure that any
difficulties are resolved prior to start-up (see manufacturers address on the back of the cover).
Fig. 15: Mixing pipe

They should also use the directions to familiarize


themselves with the operation and controls of the
pump. This prevents damage and injury and ensures
efficient machine operation.

Mixing shaft

Tilt mixing pipe back (fig. 16)

1.7 Safety at Work


Fig. 16: Mixing pipe tilted back

DANGER

1
2
3

Secure operating conditions can not be guaranteed


if the safety regulations are disregarded.
Failure to observe the following safety instructions
and notes can result in death or serious injury, and/
or in damage of the machine or adjoining equipment.

NOTICE

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.

Keep the shaft coupling (fig. 16, 1) clean, dry and


free of grease.
Do not allow water to flow into material trough or
dosage pipe.

Do not reach into the machine, or into the mixing


pipe, as long as the power supply plug is connected
(plugged-in); this could result in serious injuries.

Clean bearing cover, mixing pipe, and mixing shaft


with brush and water.
Clean the dosage pipe (fig. 16, 2) while it is dry.
Re-assemble the machine in reversed sequence.

WARNING
The machine must be positioned:
firmly on a level surface. It must be secured to
prevent it from tilting or moving.

in such a way that all operating elements are easily


accessible at all times.

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in an area where no objects can fall onto it from


above. If this is not possible, it must be protected by
a safety guard.
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Shaft coupling
Dosage pipe
Material trough

32

Safety

calypso D30

DANGER

Cleaning

Before working on electrical components, always


pull the power plug, as certain components remain
live when the machine is switched OFF.
The Continuous-Flow Mixer must be connected to
a regulation site distributor box with RCD
automatic circuit breaker. Use a 20A 4-pole 9h
plug. The connecting cable must be of a cross
section of SJO 14/4 and a 16A fuse.

DANGER
Always switch the Continuous-Flow Mixer OFF, and
pull the power supply plug before cleaning the
machine!

ENVIRONMENTAL HAZARD
CAUTION

Dispose of mortar residues according to


environmental regulations!

In case of incorrect rotary direction immediately


switch the machine OFF at the red main switch,
and pull the power supply plug.

6.1 Cleaning after work termination

The maximum operating pressure of the water


pump (optional) must not exceed 10 bar.

Uncouple the hose from the mixing pipe.


Release the eccentric catch on the mixing pipe (fig.
14, 2), and remove the bearing cover (fig. 14, 1).

Work interruptions are to be kept to limited length


in time. Keep the setting time of the material being
processed in mind when interrupting the work.
Hardened mortar in the mixing pipe causes
difficulty in starting the motor and can cause
permanent damage of the mixer. For extended
work interruptions be sure the water fittings are
completely drained.
The machine could be seriously damaged if the
water in the fittings freezes. At sub-zero
temperatures all water fittings of the machine must
be emptied and dried. For extended work
interruptions be sure the water fittings are
completely drained.

Fig. 14: Complete mixing pipe

Do not replenish gear oil between oil changes.


Overfilling the machine with lubricants can cause
overheating. Never mix different types of oil, as this
can cause the oils to decompose and lead to
irreparable damage of the gear unit.

Bearing cover
Eccentric catch Mixing pipe
Eccentric catch Dosage pipe

Remove the mixing shaft (fig. 15, 1).


Release the eccentric catch of the dosage pipe (fig.
14, 3).

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1
2
3

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13

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.

1.8 Personal Safety Equipment


DANGER
Failure to observe the following safety instructions
could result in serious injury.

Fig. 13: Drainage of water fitting and flow meter

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.

Have the material trough run empty.

ENVIRONMENTAL HAZARD
Do not use liquid or runny material. Collect it in a
bucket and correctly dispose of it.

Always observe the following safety instructions:


The proprietor/operator of the machine must provide
personal noise protection equipment for personnel
using the machine if the noise level at the place of
work exceeds 85 dB (A).

Dispose of mortar residues according to


environmental regulations.
Have dosage pipe and mixing pipe run empty.
Switch the main switch to position 0.
Turn water supply OFF.

If the noise level at the place of work exceeds 90


dB (A), the use of noise protection equipment by
personnel is mandatory.
Always wear safety goggles when removing
blockages and during spraying work.

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The frame of the goggles must comply with the


standard of the Occupational Safety & Health
Assosiation (OSHA).
During spraying work, always wear a safety helmet
and safety shoes or boots.

Draining valve

5.5 Work termination

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31

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.

To prevent the mortar from setting, work interruptions


should always be shorter than the setting time of the
material. The Continuous-Flow Mixer D30 must be
stopped and cleaned if the work interruption exceeds
the materials setting time.

The Continuous-Flow Mixer D30 can be provided with


a water pump in order to protect the production of
material against water pressure fluctuations. At low
water main pressures, this auxiliary pump (which also
incorporates a pressure reducer) retains a constant
water pressure of 2 bar.

5.4 Operation in winter


CAUTION
The machine could be seriously damaged if the
water in the fittings freezes. At sub-zero
temperatures all water fittings of the machine must
be emptied and dried. For extended work
interruptions be sure the water fittings are
completely drained.

The required quantity of water is adjusted manually at


the fine-control valve, water pressure can be
monitored by a flow meter (optional).
The Continuous-Flow Mixer D30 can also be used for
hopper material, through installation of a filter hood
(optional); (see Spare parts and accessories).

Turn water supply OFF.


Drain the supply hose leading to water fitting or
water pump (optional), the connection hose between
pump and fitting, and the water hose to and from
the flow meter (optional).
Open the draining valves of the water fitting (fig. 13,
1), and of the flow meter (optional) (fig. 13, 2).

CAUTION

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Close all draining valves before re-starting the


machine.

15

16

Operation

calypso D30
2.2 Machine illustration

29

5.2 Using material from a hopper


This function requires the combination with a filter
hood (see section 9) and a conveyor unit.
WARNING
Switch the Continuous-Flow Mixer D30 OFF, and
pull the power supply plug.
Remove the safety grid.
Install the filter hood and couple the material hoses.
Connect the power supply plug, and switch the
machine ON at the main switch.
The Continuous-Flow Mixer D30 is now supplied with
dry material through filter hood and conveyor. The
conveyor is controlled by a rotary wing sensor in the
material trough.

Fig. 1: Front view


Bearing cover with outlet
Mixing pipe
Flow meter (optional)
Dosage pipe
Control panel (see page 18)
Material trough with safety grid
Mixer motor

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Fig. 12: D30 with filter hood

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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.

Fig. 2: Rear view


1
2
3

Water fitting
Water pump
Machine internal water connection

5.1 Using bagged material


NOTICE
Do not overfill the material trough. Maximum
content 3 x 40 kg.
Tear the bags open on the grid of the material
trough, and allow the material to drop into the
trough.

NOTICE

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Always dispose of empty bags in accordance with


environmental regulations.

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Fig. 3: D30 with filter hood (optional)

17

18

Start-up

calypso D30
2.3 Operating elements

27

4.4 Adjusting water flow


Place a bucket under the outlet.
Set the main switch to position 1. The motor
starts up and the solenoid valve on the water fitting
opens. The water runs into the mixing pipe where it
is mixed with the dry material.
Inspect the consistency of the mortar emerging
from the outlet.

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.

Fig. 4: Control panel


1
2
3
4
5
6
7
8
9

Socket sensor (wet mortar) 16A 4pol 9h


Main switch with under-voltage trigger (USPA)
Selection switch (rotary direction)
Dual push-button ON/OFF
Switch sensor ON/OFF
Mixer socket 20A 4pol 9h
Water pump socket 20A 5pol 9h
Solenoid valve 24V
Input socket 20A 4pol 9h

Fig. 11: Water fitting


1

Main switch with under-voltage trigger (USPA)


The entire machine is free of voltage with the switch
in position 0. In position 1 the machine is ready for
operation.
The under-voltage trigger (USPA) is integrated in the
main switch. It is a safety feature switching the
machine OFF when the voltage drops.

Fine-control valve

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ENVIRONMENTAL HAZARD
Always dispose of mortar residues as building
waste!

26

Machine description

calypso D30

19

2.4 Water supply

4.3 Rotary direction


NOTICE

CAUTION

Inspect the motors rotary direction!

The machine requires a constant water pressure of


2 bar.

Switch the main switch to position 1. The


machine starts.
Observe the rotary direction of the shaft in the
material trough.

The maximum operating pressure of the water


pump (optional) of 10 bar must not be exceeded!
In order to prevent operation problems caused by
water pressure fluctuations, the Continuous-Flow Mixer
D30 can be provided with a water pump (optional).
The water pump retains the water pressure at a
constant level of 2 bar; an integrated pressure reducer
is also used, if required.
The required quantity of water is adjusted manually at
the fine-control valve; it can be monitored using a flow
meter (optional).

Fig. 9: Direction arrow on mixing tube

WARNING

If the direction is incorrect, immediately switch the


main switch to position 0 and pull the power
supply plug.
With a screwdriver press the polarity inverter,
located in the input plug, and turn it 180. The
polarity inverter must click back into position after
having been turned.
Insert the power supply plug and start the machine
anew.

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Fig. 5: Water fitting

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Correct rotary direction of the shaft is indicated by


an arrow on the Continuous-Flow Mixer D30.

1
2
3
4
5

Flow meter (optional)


Drain valve
Connection water fitting/ flow meter
Pressure gauge
Pressure reducer

6
7
8
9

Connection water fitting/ water pump


Fine-control valve
Connection water fitting/ mixing pipe
External water connection to the water pump

20

Start-up

calypso D30
CAUTION

4.2 Water connection

The machine could be seriously damaged if water


in the fittings freezes. All water fittings in the
machine must be drained and dried at sub-zero
temperatures. For extended work interruptions be
sure the water fittings are completely drained.

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.

2.5 Technical data

Water
connection
Dimensions

Weight
Noise level

Fig. 8 : Water connection


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Drive motor
Electrical
connection

approx. 30 l/min (additional equipment


see section 9)
220 VAC 60 Hz 3ph 4 kW 260 RPM
220 VAC 60 Hz 3ph
fuse 16 A
via RCD circuit breaker (site distributor box),
power cable SJO 14/4
connected load 11 A
3/4" water hose with GEKAcoupling (furnished)
L x W x H: 1970 x 690 x 1077 mm
(with installed filter hood: H = 2,090 mm
or 2,600 mm, depending on type)
220 kg
(247 kg incl. filter hood and accessories)
70 dB-A
(Noise-pressure level at 1 m distance, free-field measurement during operation)

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Mixing capacity

1
2
3
4
5
6

Outlet water fitting


Water pump inlet
Water fitting inlet
Flow meter inlet
Flow meter outlet toward mixing pipe
Mixing pipe inlet

25

24

Machine description

calypso D30

21

2.6 Symbols on the machine

Start-up
DANGER

When transporting, assembling, dismantling, and/


or operating the machine, all applicable national
and international safety laws, rules, and regulations
must always be observed, even if such laws, rules,
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.

Operating instructions

Phase inverter

Danger! Do not put hands

Operation via RCD

into running machine!

circuit breaker only

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.
Drain water under
cold conditions!

4.1 Electrical connections


2.7 Components supplied

WARNING

The Continuous-Flow Mixer D30 must be


connected to a regulation site distributor box with
RCD automatic circuit breaker. Use a 20A 4-pole 9h
plug. The connecting cable must have a cross
section of SJO 14/4 and a 16A fuse.

The machine is furnished composed of the following


standard items:

Plug power supply


cable with EEC plug
to the input socket
(fig. 7).
Input socket

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Fig. 7: Input socket

Material trough incl. safety grid with bag opener


Mixer motor
Transport screw D30, pitch 40
Mixer shaft
1 water hose 3/4" with GEKA coupling

22

Transport and Set-up

calypso D30

23

3.2 Machine set-up

Transport and Set-up

Always observe the following rules when placing the


machine at the building site.

DANGER

WARNING

When transporting, assembling, or dismantling the


machine, all applicable national and international
safety laws, rules, and regulations must always be
observed, even if such laws. rules, and regulations
are not explicitly mentioned in these instructions.

The machine must be positioned:


firmly on a level surface. It must be secured to
prevent it from tilting or moving.
in an area where no objects can fall onto it from
above. If this is not possible, it must be protected
by a safety guard.

3.1 Transport

in such a way that all operating elements are easily


accessible at all times.

WARNING
Always observe the following instructions if the
machine is transported by crane or truck:

Fig. 6: Lifting points on the D30

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Remove any material remaining in the material


trough of the machine before transporting.
Lifting gear (e.g. rope or belt) must be of a
minimum load capacity of 400 kg.
Attach ropes or belts in such a way that they
cannot slip.

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