Set of equipment for production of concrete items includes: Machine, Mixer, Sifter
- GENERAL INFORMATION
- DELIVERY SET
- LABELS ON EQUIPMENT
- APPEARANCE AND SPECIFICATIONS
- PERSONAL PROTECTION EQUIPMENT
- REQUIREMENTS TO INSTALLATION PLACE
- REQUIRED SPACE
- GENERAL RULES
- EQUIPMENT CONNECTION AND ADJUSTMENT
- MAINTENANCE CATEGORIES
- DAILY MAINTENANCE (should be carried out at the end of workday)
- MAINTENANCE NO. 1 (should be carried out after 60 hours of operation)
- MAINTENANCE NO. 2 (should be carried out after 120 hours of operation)
1. GENERAL INFORMATION
1.1. DELIVERY SET
Set of equipment for production of concrete items includes:
Button interlocking device (3 pcs)
1.2. LABELS ON EQUIPMENT
(page 4 of flier) All labels on equipment must be presented in flier; not all labels presented now!
1.3. APPEARANCE AND SPECIFICATIONS
|Electric motor AIR||3.0 kW, 1500 rpm, 380 V|
|Volume of oil in tank||12 liters|
|Hopper capacity||95 liters|
|Pressure in high-pressure hose||160 Bar|
|Dimensions||0.94 x 0.65 x 1.45 m|
|Molding unit||125 x 250 mm|
|Volume of finished hard mixture||250 kg|
|Working section length||100 mm|
|Sieve opening||4-5 mm|
|Rotational speed||30-45 rpm|
|Drive||1.1 kW, 220-380 V|
2. SAFETY INSTRUCTIONS
This Manual contains the basic installation instructions, operating guide and maintenance rules. Therefore, personnel must read the Manual before first start-up of equipment. The Manual always should be within convenient reach. Unclear directions should be explained before first start-up of equipment. In such cases please feel free to contact us or your distributor with any questions. It is necessary to keep up to not only basic safety guidelines from this section but specific ones from other sections of this document. Also, compliance with the common safety rules not only safety guidelines contained in this Manual is necessary for accident prevention. Ignoring the safety instructions can lead to personnel and environmental risks. Also, ignoring the safety instructions can lead to loss of reparation of damages.
2.1.1 Power connection
The equipment should be connected to supply main according to electrical circuit and in light of the provisions of both your power provider and DIN/EN 60204-1 and VDE 0100. There are dangerous non-insulated parts within energized electrical units; these parts are alive after switching-on of the main supply switch. Also there are parts which move and rotate during equipment operation!
|REMOVAL OF SAFETY COVERS IS FORBIDDEN!|
Improper maintenance and incorrect service can lead to serious injury and great material damage! Only trained people should operate equipment. Safety persons are responsible for training of operators. Also safety persons should place the User manual delivered with equipment and other necessary documents at places convenient for operators. Safety persons are responsible for close adherence to these documents. Unskilled workers may not use the equipment and should keep away it.
Spraying of any aerosols in distribution boxes and switching devices is forbidden (explosion hazard!)
2.1.2 Responsibility of operating company's chief executive
This equipment is intended for use in industry. Therefore, the operating company should keep the workplace safety rules prescribed by the law.
Safety standards and ecology regulations applied in the area of usage of this equipment should be held in addition to operational safety directions contained in this Manual.
The following points have a prime importance:
Operational company's chief executive should inquire about current labor protection regulations. Operational company's chief executive should perform the risk analysis and detect the extra risks which can arise as a result of specific work conditions in the working area. These extra risks should be documented in respective job instructions.
Above mentioned job instructions should be reviewed by operational company's chief executive during equipment/aggregate life cycle to check the match between the provisions of current regulatory documents and these instructions ones. Job instructions should be reviewed if necessary.
Operational company should well define the job scope of every worker concerned with installation, operation, maintenance and cleaning of the equipment.
Operational company's chief executive is responsible for suitable familiarization of all workers with this Manual. In addition, the training of the personnel and hazard informing of the personnel should be performed periodically.
Also, operational company's chief executive is responsible for technical serviceability of equipment and performance of regular equipment examinations and maintenance works.
Operational company's chief executive instructions for personnel should contain the following points:
Only trained and responsible people should operate equipment. The current legislation provisions about minimal age of worker must be enforced!
Permit-to-work should be given only trained or briefed personnel. Job scope of every worker concerned with operation, fitting out, maintenance and repair of the equipment should be well defined!
Only authorized employers should operate equipment!
Area of responsibility of operator (including observance of traffic laws) should be well defined. Operator should be exempt from liability for nonfulfillment of instructions of third persons if these instructions contradict safety rules!
Trainees and coaches should work only under constant scrutiny of experienced specialist! Working with electrical equipment should be carried out by only professional electrician or briefed worker under the direction and supervision of professional electrician. Such work should be carried out in accordance with electrical regulations.
Working with running gears, brake system and steering system should be carried out by only specially trained personnel!
Working with hydraulic unit should be carried out by only personnel with special skills and
respective professional experience in the sphere of hydraulic systems.
Skills shortage can lead to injury! Mishandling can lead to severe injuries and great property loss.
Special works should be carried out only by the persons specified in respective sections of this Manual.
Specialists should be involved in the performance of work if problem is aroused.
Minimal personnel qualification requirements:
Worker’s physical conditions should provide him to control of equipment.
Workers should be able to operate equipment according to this Manual and safety rules.
Workers should understand of operating principles of this equipment. Workers should be able to detect and avert danger.
Workers should understand of this Manual and use the information contained in the Manual.
Operational company's chief executive is responsible for implementation of these rules. Current performance requirements according to local legislation should be satisfied. Verification, debugging and repair should be carried out only by the authorized persons.
This Manual specifies the following personnel skill levels for carrying out of different types of works:
Such worker should be briefed by Operational company and should obtain the information concerning his tasks and possible dangers which can arise as a result of inadequate fulfillment of work tasks.
Specialist should be able to perform his tasks on the ground of his special education, experience and knowledge of respective regulations. Specialist should be able to detect the possible danger without assistance.
3. GENERAL SAFETY REQUAREMENS FOR ACCIDENT PREVENTION
3.1 PERSONAL PROTECTION EQUIPMENT
Usage of protection equipment is of importance to organization of safety. Absence and improper state of protection equipment raises the risks of personal injury.
Worker can use such elements of protection equipment as:
respiratory protection equipment
hearing protection equipment
protective face/eyes equipment
Wearing of loose clothes leads to higher risk of capture of clothes by rotating parts of machine, reeling of such clothes on rotating parts; also loose clothes can caught on projecting part of machine. As a result, the severe or fatal injuries are possible.
Wear tight clothes at work
Remove rings, chains and other “pretty pretties” at work
Use hairnet if your hair is long
Wear firm or protective shoes
All safety instruction from this Manual, other in-plant operating directions and Operational company safety rules and requirements should be fulfilled.
Warning plates and direction signs contain important safety directions. Execution of these directions is needed for ensuring of your security.
You must familiarize yourself with all facilities and control elements before starting of the work. Familiarization with functions of facilities and control elements during the work is not allowed!
Personnel should wear tight clothes. Wearing of loose clothes is not allowed!
The equipment should be kept clean. Nonfulfillment of this requirement can lead to fire breaking-out!
Working area and near-by territory should be inspected before first start-up and before every starting of equipment (children!)
Visibility at working area should be sufficient. Ask for help to the specialist if it is necessary!
First start-up of equipment should be done only after mounting and set-up of all protective devices!
Workers should being outside the turn/moving zone of equipment!
3.1.1 Risks aroused as a result of ignoring of safety precautions
Nonfulfillment of safety requirements can lead to following risks:
Hazard to operator and neighbor persons can arise if protective devices haven’t been mounted and set-up!
Key function of the equipment can be disrupted!
Maintenance and repair can be performed incorrect!
Hazard to operator and neighbor persons can arise as a result of physical and chemical impacts!
Environmental hazard can arise as a result of fluid leak from hydraulic system, fuel tank, pipelines, motors and reducers!
3.1.2 Electrical safety rules
Only original safety fuses for indicated current strength should be used! Equipment should be off immediately if mains interruption is taken place!
Working with electrical equipment should be carried out by only professional electrician or briefed worker under the direction and supervision of professional electrician. Such work should be carried out in accordance with electrical regulations.
Checking and verifying of machine electrical equipment should be carried out on a regular basis. Such defects as loose connections and fire-damaged cables should be removed immediately.
Machine has electronic components, and electromagnetic radiation of outside devices can effect on the functions of these components. Such interference can lead to the undesirable effects in the case of nonfulfillment of the following safety directives.
If machine was equipped by additional electrical/electronic devices, the user is personally responsible for investigation of severity of these devices effect on the workability of machine electronic components (this is particularly so with mobile phones and wireless intercoms).
Installed additional electrical/electronic devices should meet the requirements of EMC Directive 2004/108/EC (current version) and have "CE" mark.
3.1.3 Hydraulic system safety rules
Repair, maintenance and cleaning of hydraulic system should be carried out only if motor is turned off and pressure in system is absent.
Hydraulic fluid is under high pressure! Contact of pressurized fluid (hydraulic oil) with skin can lead to penetration of oil through skin and severe injuries! Infection hazard!
Connection of hoses to hydraulic system should carry out if pressure in system is absent.
Severe burns can be caused by the contact with hot hydraulic oil!
Worker should be careful during handling with hot hydraulic system! It is necessary to use of protective gloves and wait until system get hold.
Failure of hydraulic system can lead to fall of structural units of machine and to severe injuries!
Condition of hoses should be checked regularly. Hoses should be replaced if damage or signs of aging are found. New hoses should correspond to technical requirements of machine manufacturer. Period of storage of the hoses and hose operation life are limited even if storage and operation conditions were appropriate; this is the result of natural aging process. Hose operation life can be determined on the base of factual data in consideration of potential risk level.
3.1.4 Particular risks
Other risk factors detected by risk analysis method are described in this section.
Safety instructions and directions from this section and other ones should be kept for minimizing the health hazard and avoid dangerous situation.
Electric trauma can be hazard to life!
Contact with current-carrying details causes immediate danger to life. Defects of insulation and some details can be a hazard to life.
Power supply should be turned off and repair should be performed immediately after detection of insulation failure.
Working with electrical equipment should be carried out by only professional electrician.
Working with electrical equipment should be carried out only after de-energizing of this equipment; absence of voltage should be confirmed.
Power supply should be turned off before starting of maintenance, cleaning and repair in order to eliminate of possibility of inadvertent actuation of equipment.
Fuses shouldn’t be disconnected or replaced by home-made fuses. Pay attention to the value of permissible current strength of fuse (A) in the case of replacement of the one.
Remove moisture from details which should be alive. Moisture can cause short circuit.
Hearing disorders as a result of noise exposure!
Noise in work area can lead to serious hearing disorders.
Hearing protection equipment should be used during work.
Worker should be in dangerous area only if it is necessary.
3.1.5 Safety labels on equipment
Examples of warning plates on equipment (Fig. XX)
|Electrical shock hazard!|
|Be safe! Arm injury is possible!|
|Hearing impairment due to noise exposure is possible!|
4. CONDITIONS OF INSTALLATION
4.1. REQUIREMENTS TO INSTALLATION PLACE
Floor load-carrying ability should be sufficient (floor sag as a result of equipment stress should be absent). Installation place should be flat so much that moving of service/technical personnel would be trouble-free.
4.2. REQUIRED SPACE
4.2.1 Minimal required space
Free access of service/technical personnel to all element of installed equipment should be ensured (the figure presents minimal distances "equipment elements - room walls” (elements are installed in various rooms); the plan presents minimal distances “equipment element - room walls" and “equipment element - equipment element “(elements are installed in one room).
4.2.2 Operator’s working place
Operator's working place is on the side of loading of machine (see scheme below).
5. EQUIPMENT START-UP
5.1 GENERAL RULES
Before equipment start-up and while in operation the following rules should be kept:
Operating equipment shouldn’t be unattended
Inspect equipment regularly for detection of oil leaks. Defect parts should be replaced immediately.
Inspect equipment regularly for detection of contaminations. Clean the equipment if it is necessary.
5.2 EQUIPMENT CONNECTION AND ADJUSTMENT
5.2.1 Placeing of machine
The following operations should be performed before connection and start-up of machine:
- Place the machine on flat foundation.
- Release the machine hopper, feeder and protection elements from packing.
- Install the dispenser under storage hopper, after which install storage hopper on the machine housing. The hopper should be fastened with four bolts on the sides of the platform on which the dispenser moves.
- Put the storage hopper slots on the bolts and tight them.
- Adjust the roller which supports the dispenser platform and tight the nuts. The dispenser should move freely.
188.8.131.52 Electrical connection of machine
The electric motor of machine should be connected by an electrician via magnetic starter (supplied with the machine) in accordance with recommended connection diagram. The direction of rotation of the motor should be same as direction of arrow on the sleeve.
|MACHINE HOUSING MUST BE GROUNDED! (see diagram).|
Electrical connection of machine should be carried out taking into accoun direction of rotation of the motor! Direction of motor rotation indicated by arrow on the sleeve connecting the electric motor with hydraulic pump.
It is necessary to make a test run of the motor (without oil) for 1 second to check the direction of rotation. Press form should be open before starting of blank test.
Pour 10-12 liters of hydraulic oil through tank inlet.
All threaded joints (hoses, fittings) should be inspected after first start since slacking is possible during transportation. Draw up joints if it is necessary.
Test the alignment of electric motor and hydraulic pump since shift is possible during transportation.
Lubrication of all oilers should be carried out routinely (every 10 hours).
Conserving grease should be removed before starting.
Position of the hopper should allow free moving of dispenser.
Hydraulic distributor has adjusting bolt. Slacking of it leads to decrease of maximal bypass pressure. Bolt should be adjusted in a manner which assures deceleration of motor rather than motor stoppage at maximal pressure (at the time of brick-molding).
Residues of feedstock should be blown away after every operating cycle. Clean molds by wire brush after every 30-40 operating cycles.
Monitor the temperature of actuating fluid. Take pauses that fluid can get cool (especially in hot weather conditions).
Clean equipment (blow away all residues) at the end of workday. Treat equipment with anticorrosive liquid (e.g. WD-40).
|NO-LOAD TEST SHOULD BE PERFORMED ONLY IF MACHINE IN OPEN STATE!|
Install the protective element on the hydraulic tank by means of fixing bolts mounted on the tank. Prepare the working mixture in the mixer, fill the hopper with this mixture, fill the press form working mixture with working mixture by means of dispenser and test the machine in operation mode.
The machine kit includes a figured matrix for production of special bricks for building of armor-clad belt, arches or channels for communication lines (pipes, cables).
184.108.40.206 Installation of the figured matrix in working position
Lift up the open lower matrix (machine should be in no-loaded state).
Unscrew its fixture (two flush screws) and unscrew the matrix on the cover.
Interchange the matrices and fix them with screws.
Using M-6-45 screws, fix the figured matrix on the matrix, which is located in the press form (bottom).
Lower it down at the no-load mode.
Now machine is ready for production of special bricks for building of channels. Changeover for serial production of bricks is in reverse order.
|ONLY HYDRAULIC OIL SHOULD BE USED!|
220.127.116.11 Adjustment of parallelism of upper and lower brick sides
The parallelism of upper/lower sides of bricks is adjusted by moving the lower part of the power block within the adjusting slots.
- Lower the matrix in the lowest position.
- Loose the threaded connections (see photo).
- Check the distance from top edge of the mold block to the matrix by means of hole-gauge on either side.
- In case of deviations, align the distance between the upper edge of the mold block and matrix by sliding the lower part of the power unit.
- Tighten the threaded connections.
18.104.22.168 Adjustment of hopper and dispenser
- Loose the threaded connections whereby the hopper is fasten to the frame of mold block.
- Make a gap between the rear wall of the hopper and the dispenser ~ 1 mm.
- Check the possibility of dispenser free movements.
- Tighten the threaded connections.
22.214.171.124 Adjustment of hydraulic distribution valve
Hydraulic fluid is under high pressure! Contact of pressurized fluid (hydraulic oil) with skin can lead to penetration of oil through skin and severe injuries! Contact a doctor immediately if You was injured (severe infection is possible). Works with hydraulic system should be carried out only if drive is disabled and pressure in system is absent.
Use care in work with hot hydraulic system. Severe burns can be caused by the contact with hot hydraulic oil!
It is necessary to use of protective gloves and wait until system get hold before starting the works with hydraulic system!
- Loose the control nut of distributor adjusting bolts (see photo).
- Use the hex wrench to turn the adjusting bolt.
- Check how the hydraulic system operates at critical loads (when being under the critical load, the motor should run slightly slowing down but not stopping).
- The adjustment may be changed depending on how the motor is connected (star, triangle) and the supply voltage.
5.2.2 Installation of mixer
The following procedures should be carried out before mixer connection and using:
- Place the mixer on flat foundation.
- Unpack the mixer, hopper, feeder and protection elements.
126.96.36.199 Electrical connection of mixer
5.2.3 Installation of sifter
The following procedures should be carried out before sifter connection and using:
- Place the sifter on flat foundation.
- Unpack the sifter, hopper, feeder and protection elements.
188.8.131.52 Electrical connection of sifter
6 MAINTENANCE CATEGORIES AND MAINTENANCE PROGRAM
The following program of equipment maintenance should be executed to extend the machine life and ensuring of trouble-free equipment operation:
6.1 MAINTENANCE CATEGORIES
- Daily maintenance at the end of workday.
- Maintenance No.1 after 60 hours of operation
- Maintenance No.2 after 120 hours of operation.
6.2 DAILY MAINTENANCE (should be carried out at the end of workday)
Clean the storage hopper, the dispenser, the entire machine and mixer from residues of working mixture (use wire brush).
Clean the matrix and the press form residues of working mixture with a brush and lubricate with WD-40 lubricant.
6.3 MAINTENANCE NO. 1 (should be carried out after 60 hours of operation)
Perform all daily maintenance operations.
Grease the lubrication points (see schema) by means of grease syringe through lubricators disposed on the bottom axis levers and lubricators disposed on cover closing axis.
Check all fastening joints, tighten them if it is needed.
Lubricate the lock and gearing parts of upper axis with grease (solid oil, lithium grease)
6.4 MAINTENANCE NO. 2 (should be carried out after 120 hours of operation)
Perform all works prescribed by Maintenance No. 1.
If it is necessary, adjust engagement of latch lever teeth by means of screw disposed under hydraulic cylinder (scheme with location of this screw and what kind of tools should be used)
Block the screw by lock nut after adjustment.
Clean the opening of hydraulic tank plug.
Check tightness of all hydraulic hose fittings, tighten them as needed.
Tighten lock nut disposed on hydraulic distributor valve.
Check machine electrics
|ATTENTION: Turn off the machine before inspection or repair of its electrical system.
In the case of electrical problem detection of failure and repair should be done by only qualified electrician.
PERFORMANCE OF THE ABOVE WORKS WILL EXTEND YOUR MACHINE LIFE!
7. POSSIBLE TROUBLES AND REMEDIALS
|Power supply turned on but equipment is not operating||Defect of power supply circuit||Check contacts and supply cable|
|Instability of the motor in peak-load mode||Bypass valve of distributor is improperly adjusted||Adjust the distributor|
|Working mixture poorly pours out from dispenser||Excessive humidity of working mixture||Decrease the humidity of raw materials by means of drying|
|Bricks collapse when taken off||Deficiency in cementitious agents in mixture||Increase cementing properties of mixture by means of additives and plasticizers|
|Improper humidity of mixture||Reduce of mixture humidity by appr. 10 %|
|Incorrect sequence of mixing||Check the correctness of the execution of prescribed manufacturing operations|
8. WARRANTY STATEMENT
Guarantee period: 1 year from the date of purchase
The following facilities are covered under warranty: electrical equipment, hydraulic equipment subject to adherence to generally accepted regulations concerning operation of hydraulic equipment at 400 V. Expertise of correctness of equipment handling should be carried out if warranty case is appeared.
Buyer pays for expertise and transportation of equipment; this sum will be compensated by manufacturer if it will be proven that the responsibility for equipment failure rests with manufacturer.
Usage of spare parts made by other manufacturers is forbidden. Usage of original spare parts and accessory parts approved by manufacturer ensures safety and failure-free operation of equipment. Manufacturer doesn’t answer for the consequences of the usage of unoriginal spare parts and unapproved accessory parts.
Only original spare parts should be used for replacement of electric or hydraulic parts. Usage of spare parts made by other manufacturers can cause machine damage.
Date of sale________________________________________________
Serial number ______________________________________________
Serial number of electric motor _______________________________
9. STORAGE OF EQUIPMENT
Equipment should be stored indoors according to requirements of GOST15150 in original packing until the start of usage.
Storage of equipment in rooms where vapor of acid, base and other aggressive agents can be present at the concentration injurious to metallic frame and other metallic units is not allowed.
All units of equipment should be cleaned and lubricated by storage oil before long-term storage.
Control panels should be protected against exposure of moisture, frost, solar radiation and dirtying. Control panel should be removed if it is necessary.
10. DECOMMISSIONING AND UTILIZATION
Equipment or components of equipment should be utilized in the established manner after the expiry of their lifetime. At that the directives of local competent authorities should be executed.
Utilization of working fluids requires the usage of special methods. These liquids should not pollute the environment.
Working fluids such as oils, hydraulic fluids, brake fluids and fuel should be considered asspecial waste. Utilize these substances in the prescribed manner.
Follow current local regulations.
Execute the prescriptions of competent local agencies.
This User Manual is designed for operators and persons who carry out maintenance and cleaning of equipment.
Before starting the equipment handling, cleaning, repair, adjusting, installation or supervision over the equipment operation the respective person should read this Manual.
This Manual is a part of delivery set and should be stored and fulfilled during all period of equipment usage.
Equipment should be supplied complete with this Manual in the case of resale!
Manufacturer isn’t responsible for damage resulted from noncompliance with this Manual, activity of untrained personnel, and improper usage of equipment, including usage with the aim other than that prescribed by this Manual. Unapproved change of equipment design (dismantling of equipment parts or mounting of the parts other than those allowed by original design) and other type unapproved re-equipment of machine leads to loss of validity of our Certificate of Conformity (EEC/EC Directives). Only original spare parts should be used.