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Operating Instructions

Continuous-Flow Mixer
calypso D30
220 V 60Hz 3ph

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2 calypso D30 43

2003 m-tec mathis technik gmbh

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.

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
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instructions, please contact m-tec.


42 calypso D30 3

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 _______________________

Application _________________________________
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4 calypso D30 Circuit diagram 41

Table of contents

1 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
2 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
3 Transport and Set-up .............................................................................................................. 22
3.1 Transport ........................................................................................................................... 22
3.2 Machine set-up ................................................................................................................. 23
4 Start-up ...................................................................................................................................... 24
4.1 Electrical connections ..................................................................................................... 24
4.2 Water connection ............................................................................................................. 25
4.3 Rotary direction ................................................................................................................ 26
4.4 Adjusting water flow ....................................................................................................... 27
5 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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Fig. 21: Circuit diagram D30 with water pump


(Art.-no.392246/001-09/01)
40 calypso D30 Table of contents 5

6 Cleaning .................................................................................................................................... 32
10 Circuit diagram 6.1 Cleaning after work termination ..................................................................................... 32
6.2 Cleaning prior to material change .................................................................................. 34
7 Maintenance ............................................................................................................................. 35
Keys for fig. 21 7.1 Lubrication schedule ....................................................................................................... 35
7.2 Oil change ......................................................................................................................... 36
7.3 Maintenance of water filters .......................................................................................... 37

Disc1 Main switch 8 Troubleshooting ...................................................................................................................... 38

Disc2 Reversing switch 9 Accessories/spare parts ........................................................................................................... 39


9.1 Accessories ...................................................................................................................... 39
CB1 Motor protecting switch mixer 9.2 Spare parts ....................................................................................................................... 39
CB2 Motor protecting switch waterpump 10 Circuit diagram ......................................................................................................................... 40
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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6 calypso D30 Accessories/spare parts 39

1 Safety 9 Accessories/spare parts

DANGER
1.1 Warning Symbols and Hazard Categories
According to the standards defined in ANSI Z535.1-5,
Modifications of the machine are prohibited. Use
only spare parts and accessories supplied by m-tec !
the following hazard categories are used in these mathis technik gmbh. m-tec mathis technik gmbh
Operating Instructions, to draw attention to dangers can not be held liable for accidents and/or dam-
possibly occurring when operating the Continuous- ages resulting from the use of non-approved spare
Flow Mixer D30. parts and accessories.

The hazard messages are divided into five categories, 9.1 Accessories
depending on the seriousness of the specified hazard. Application range and handling of the Continuous-Flow
The signal words (e.g. Danger) communicate the level Mixer D30 can be considerably improved by using
of hazard seriousness. accessories supplied by m-tec mathis technik gmbh.
The following accessories are available for this
DANGER machine:

! 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)
WARNING Water pump 400 V incl. attachment
Filter hood incl. accessories
! indicates a potentially hazardous situation which, if
not avoided, could result in death or serious injury.
Conveyor screw D30 pitch 30
Conveyor screw D30 pitch 50
Conveyor screw D30 pitch 70
CAUTION
Additional water pump AD33, 230 V 1ph
indicates a potentially hazardous situation which, if
! not avoided, may result in minor or moderate
injuries.
Suction hose 3/4", 4 m complete
Water hose 3/4", 20 m with GEKA
flow meter, complete
Tarpaulin for material trough
CAUTION
is used without safety alert symbol to indicate a
potentially hazardous situation which, if not 9.2 Spare parts
avoided, may result in equipment damage.
For spare parts please refer to our spare-parts catalog.
NOTICE Send orders to:
is used without safety alert symbol to indicate a m-tec mathis technik gmbh, Sales Dept.:
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potential situation which, if not avoided, may Tel. no.: ++49 / 7631 / 709-112 or -216
result in an undesirable event or state. Fax no.: ++49 / 7631 / 709-116
38 calypso D30 Safety 7

The signal word is accompanied by a pictogram


8 Troubleshooting 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
DANGER hazard, and how the hazard can be avoided.

! The table Troubleshooting is not intended to


replace the detailed instructions in the individual
Special type sof pictograms and indicated kind of
hazard used in this operation instructions:
chapters of these Operating Instructions. Always
comply with the safety notes noted in each chapter! This symbol indicates that hazard is generated by
electric current.
Problem Cause Remedy
Mixer motor No power Check power
fails to run connection and fuses
Mortar hardened in Clean mixing pipe This symbol indicates that hazard isgenerated by
mixing pipe (see section 6.1) rotating machine components.
Motor overload switch Open control panel, reset
triggered overload switch (fig. 20) This symbol indicates that only RCD (Residual
No water Overload switch could Check motor overload switch Current protective Device)circuit breakers with the
be triggered mixer motor (fig. 20, 1) symbol shown opposite should be used.
Solenoid valve Coil could be defective,
fails to open replace solenoid valve This symbol indicates that safety goggles must be
Mortar too dry Insufficient water Check water supply. The worn. The frame of the goggles must comply with
pressure must be at least the standard of the Occupational Safety & Health
2 bar. If necessary, install Assosiation (OSHA).
a water pump (available as
accessory for the D30, Further symbols and signal words used in these
see section 9) Operating Instructions:
Overload switch of Check motor overload switch
water pump (option) water pump (fig. 20, 2) ENVIRONMENTAL HAZARD
was triggered This symbol indicates that laws, rules, and regula-
Water flow valve Increase opening of valve tions for environmental protection must be ob-
insufficiently opened (see section 4.4) served.
Mortar too thin Too much Close water flow valve
water as required NOTE
(see section 4.4) This symbol draws your attention to important or
Consistency of Filter in pressure reducer, Clean filters (see section 7.3) additional information relevant to the machine or
material fluctuates inlet filter, or filter hood documentation thereof.
fabric clogged Beat dust particles out of filter
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hood fabric (optional)


8 calypso D30 Maintenance 37

1.2 General Safety Instructions 7.3 Maintenance of water filters


The water filters in water fitting and water pump
DANGER
should be cleaned every 4 - 6 weeks. These filters are
! Follow these safety instructions carefully. Failure
to do so may increase the risk of accident or injury.
located in the water inlet (fig. 19, 1) and in the
pressure reducer (fig. 19, 2).
These safety instructions apply to all directions
throughout this manual, and must be applied to all Remove filters using a special tool.
aspects of the machines use, including, but not Clean the filters under running water.
limited to, transport, assembly, operation, mainte- Use compressed air for filter blow-out.
nance or disassembly.
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 regula-
tions as well as other generally recognized rules
Fig. 19: Cleaning filters
and regulations pertaining to industrial safety
1 Filter in pressure reducer
and medical care.
2 Filter in water inlet
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).
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36 calypso D30 Safety 9

7.2 Oil change Modifications of the machine are not permitted. All
replacement parts, accessories and lubricants must
be furnished by m-tec mathis technik gmbh. The
CAUTION
use of unauthorized parts, accessories or lubricants
Do not replenish gear oil between oil changes. may result in death or serious injury, and could
Over-lubrication could cause overheating of the cause damage of the machine, and will nullify all
machine. liability on the part of the manufacturer for result-
Never mix different types of oil. This could cause ing damage.
the oils to decompose, leading to irreparable
This machine must be operated in compliance with
damage of the gear unit.
all applicable federal, state and local laws, rules,
and regulations at all times. This includes, but is
ENVIRONMENTAL HAZARD not limited to, the requirements of TITLE 29 of the
Always comply with environmental regulations CODE OF FEDERAL REGULATIONS, PART 1926 (29
when disposing of waste oil, grease and cleaning CFR 1926). Failure to operate this machinery in
agents,. compliance with all applicable laws, rules, and
regulations may result in death or serious injury.
The gear motors are furnished pre-lubricated, they are When transporting, assembling, dismantling,
maintenance-free up to operating, cleaning, and servicing the machine, all
8000 hours of operation. They should then be cleaned applicable national and international safety laws,
thoroughly with a suitable rinsing oil, and refilled with rules, and regulations must always be observed,
fresh oil. even if such regulations are not explicitly men-
Recommended type of oil for the gear motor: Shell tioned in these instructions.
Tivela Oil 82; quantity 400 cc. The machine must be inspected by a specialized
One of the following substitute oil types can be used if engineer in accordance with applicable safety laws,
the type specified above is not available: rules, and regulations. Such inspection should be
ARAL Degol BG 220 scheduled at least once per year.
BP Energol GR-x P220 The proper use of this machinery requires the
CALYPSOL Bisol Oil MSR 114 operator to be in full control of the machinery at all
ESSO Sparton EP-220 times. None of this equipment must be used by an
HOUGHTON Molygear 115 operator under the influence of alcohol or drugs,
MOBIL Mobilgear 630 including prescription drugs that may impair an
SHELL Omala 220 operators ability to safely operate this equipment.
Failure to adhere to this requirement may result in
death or serious injury.
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10 calypso D30 Maintenance 35

1.3 Intended Use 7 Maintenance


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 DANGER
used for materials of the following types:
Masonry mortar
Always switch the machine OFF, and disconnect it
from the electrical supply network before working
!
Various rendering plasters on the machine. Certain parts of the machine
remain live when the machine is switched OFF.
Adhesive mortar The safe working condition of the machine must
Floor cement be verified in accordance with legal requirements
Fine concrete (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
DANGER damages resulting from the use of non-approved
! Use of the machine for any other purpose than
those described above may result in bodily or even
spare parts and accessories.
Regularly remove mortar residues from the mixing
fatal injury, and/or in damage of the equipment or
other property. pipe, and dispose of them according to
environmental regulations.
It may also impair efficient functioning of the
machine. Regularly inspect hoses and cable connections to
ensure that they are in working condition.
Use of the machine for any other purpose than that
described above is prohibited!
Modifications to the machine are prohibited. Use 7.1 Lubrication schedule
only spare parts and accessories supplied by m-tec
mathis technik gmbh. If spare parts and accesso- Lubricate the grease points on mixer motor and
ries of other types are used, m-tec mathis technik mixing pipe every 4 - 6 weeks, using a high-
gmbh can not be held liable for occurring pressure grease gun (1 - 2 shots) containing
damages. bearing grease (fig. 18).
Regularly relubricate the rubber packing on the
1.4 Target Group mixer motor, using a grease gun.

This document is intended for personnel in charge of


startup, operation and maintenance of the machine.
Such personnel must be qualified according to speci- Fig. 18: Lubrication points
fications stated in chapter 1.5. 1 Socket pin
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34 calypso D30 Safety 11

6.2 Cleaning prior to material change 1.5 Qualified Personnel


Proceed as described in section Cleaning after DANGER
work termination.
Release eccentric catch Mixer motor and tilt the
Startup, operation and maintenance of the ma-
chine carried out by unqualified personnel may
!
mixer motor back. result in bodily or even fatal injury, damage of the
Clean the material trough without using water. equipment or other property.
Tilt the mixer motor back and lock it in position. Startup, operation and maintenance of the ma-
chine may only be carried out by qualified person-
nel.
It is the duty of the operator to have the operating
staff thoroughly study and understand the operat-
ing 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
Fig. 17: Cleaning before material change The Operation and Service Manual must always be
1 Eccentric catch Mixer motor
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.
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12 calypso D30 Cleaning 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 manufac-
turers address on the back of the cover).
Fig. 15: Mixing pipe
They should also use the directions to familiarize
1 Mixing shaft
themselves with the operation and controls of the
pump. This prevents damage and injury and ensures
efficient machine operation.
Tilt mixing pipe back (fig. 16)

1.7 Safety at Work

DANGER Fig. 16: Mixing pipe tilted back


1 Shaft coupling
! Secure operating conditions can not be guaranteed
if the safety regulations are disregarded.
2
3
Dosage pipe
Material trough
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 equip-
ment.
NOTICE
Prior to every shift, carefully inspect the machine for
Keep the shaft coupling (fig. 16, 1) clean, dry and
obvious signs of damage, in particular electric
free of grease.
cables, plugs, feed and air hoses. Any damage must
be repaired before shift start. 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 Clean bearing cover, mixing pipe, and mixing shaft
(plugged-in); this could result in serious injuries. with brush and water.
Clean the dosage pipe (fig. 16, 2) while it is dry.
WARNING
Re-assemble the machine in reversed sequence.
! 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.
in such a way that all operating elements are easily
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accessible at all times.


32 calypso D30 Safety 13

6 Cleaning DANGER
Before working on electrical components, always
pull the power plug, as certain components remain
live when the machine is switched OFF.
DANGER The Continuous-Flow Mixer must be connected to
! Always switch the Continuous-Flow Mixer OFF, and
pull the power supply plug before cleaning the
a regulation site distributor box with RCD
automatic circuit breaker. Use a 20A 4-pole 9h
machine! plug. The connecting cable must be of a cross
section of SJO 14/4 and a 16A fuse.
ENVIRONMENTAL HAZARD
Dispose of mortar residues according to CAUTION
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.
Work interruptions are to be kept to limited length
Release the eccentric catch on the mixing pipe (fig.
in time. Keep the setting time of the material being
14, 2), and remove the bearing cover (fig. 14, 1).
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.
1 Bearing cover
2 Eccentric catch Mixing pipe Overfilling the machine with lubricants can cause
3 Eccentric catch Dosage pipe overheating. Never mix different types of oil, as this
can cause the oils to decompose and lead to
Remove the mixing shaft (fig. 15, 1). irreparable damage of the gear unit.
Release the eccentric catch of the dosage pipe (fig.
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14, 3).
14 calypso D30 Operation 31

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, in- 1 Draining valve
cluding, 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 5.5 Work termination
from all moving parts of the equipment. Avoid
wearing loose-fitting clothing or jewelry when Have the material trough run empty.
near the machine, and secure long hair in order to
ENVIRONMENTAL HAZARD
keep it away from moving parts.
Do not use liquid or runny material. Collect it in a
Always observe the following safety instructions: bucket and correctly dispose of it.
The proprietor/operator of the machine must provide Dispose of mortar residues according to
personal noise protection equipment for personnel environmental regulations.
using the machine if the noise level at the place of
work exceeds 85 dB (A). Have dosage pipe and mixing pipe run empty.
If the noise level at the place of work exceeds 90 Switch the main switch to position 0.
dB (A), the use of noise protection equipment by Turn water supply OFF.
personnel is mandatory.
Always wear safety goggles when removing
blockages and during spraying work.
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
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and safety shoes or boots.


30 calypso D30 Machine description 15

5.3 Work interruptions 2 Machine Description


CAUTION
The length of work interruptions must be limited.
Always keep the setting time of the mortar in mind. 2.1 Function
Hardened mortar in the mixing pipe causes
difficulty in starting the motor and may cause In its standard form, the Continuous-Flow Mixer D30 is
permanent damage of the mixer. designed for processing bagged mortar material.
To prevent the mortar from setting, work interruptions The material is poured into the material trough. The
should always be shorter than the setting time of the dosage screw carries the material from the trough into
material. The Continuous-Flow Mixer D30 must be the mixing pipe where it is mixed with water and
stopped and cleaned if the work interruption exceeds conveyed to the discharge outlet.
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
5.4 Operation in winter water main pressures, this auxiliary pump (which also
incorporates a pressure reducer) retains a constant
CAUTION water pressure of 2 bar.
The machine could be seriously damaged if the The required quantity of water is adjusted manually at
water in the fittings freezes. At sub-zero the fine-control valve, water pressure can be
temperatures all water fittings of the machine must monitored by a flow meter (optional).
be emptied and dried. For extended work
The Continuous-Flow Mixer D30 can also be used for
interruptions be sure the water fittings are
hopper material, through installation of a filter hood
completely drained.
(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
Close all draining valves before re-starting the
machine.
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16 calypso D30 Operation 29

2.2 Machine illustration 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


1 Bearing cover with outlet
2 Mixing pipe
3 Flow meter (optional)
4 Dosage pipe
5 Control panel (see page 18)
6 Material trough with safety grid
7 Mixer motor

Fig. 12: D30 with filter hood


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28 calypso D30 Machine description 17

5 Operation

DANGER

! When operating the machine, all applicable natio-


nal 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
Fig. 2: Rear view
pipe, while the machine is connected to the power
1 Water fitting
supply network, as this may cause serious injury.
2 Water pump
3 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
Always dispose of empty bags in accordance with
environmental regulations.
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Fig. 3: D30 with filter hood (optional)


18 calypso D30 Start-up 27

2.3 Operating elements 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.
Fig. 4: Control panel The machine should be started with the fine-control
valve fully opened for products of unknown water
1 Socket sensor (wet mortar) 16A 4pol 9h
2 Main switch with under-voltage trigger (USPA) requirement.
3 Selection switch (rotary direction) At operation start turn the fine-control valve back
4 Dual push-button ON/OFF until the correct material consistency is achieved.
5 Switch sensor ON/OFF
6 Mixer socket 20A 4pol 9h
7 Water pump socket 20A 5pol 9h
8 Solenoid valve 24V
9 Input socket 20A 4pol 9h
Fig. 11: Water fitting
1 Fine-control valve
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. ENVIRONMENTAL HAZARD
Always dispose of mortar residues as building
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waste!
26 calypso D30 Machine description 19

4.3 Rotary direction 2.4 Water supply

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. The maximum operating pressure of the water
pump (optional) of 10 bar must not be exceeded!
Observe the rotary direction of the shaft in the
material trough. 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
Correct rotary direction of the shaft is indicated by
! an arrow on the Continuous-Flow Mixer D30.
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.
Fig. 5: Water fitting
1 Flow meter (optional) 6 Connection water fitting/ water pump
2 Drain valve 7 Fine-control valve
3 Connection water fitting/ flow meter 8 Connection water fitting/ mixing pipe
4 Pressure gauge
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9 External water connection to the water pump


5 Pressure reducer
20 calypso D30 Start-up 25

CAUTION 4.2 Water connection


The machine could be seriously damaged if water
in the fittings freezes. All water fittings in the NOTE
machine must be drained and dried at sub-zero
The machine requires a constant water pressure of
temperatures. For extended work interruptions be
2 bar in order to furnish mortar of a constant
sure the water fittings are completely drained.
consistency.
Be sure the water intake filter is in place and clean.
2.5 Technical data
Connect the internal water hose (fig. 8, 3) to the
Mixing capacity approx. 30 l/min (additional equipment mixing pipe (fig. 8, 2).
see section 9) Connect the exterior water hose with GEKA coupling
Drive motor 220 VAC 60 Hz 3ph 4 kW 260 RPM - directly to the fitting (fig. 8, 4); or
Electrical 220 VAC 60 Hz 3ph - to the water pump (optional, fig. 8, 1), if installed.
connection fuse 16 A Turn water supply ON
via RCD circuit breaker (site distributor box), Use a water butt if water supply is insufficient. The
power cable SJO 14/4 water supply hose (3/4") must be thoroughly vented
before turning the water ON.
connected load 11 A
Water 3/4" water hose with GEKA-
connection coupling (furnished)
Dimensions 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)
Weight 220 kg
(247 kg incl. filter hood and accessories)
Noise level 70 dB-A
(Noise-pressure level at 1 m distance, free--
field measurement during operation)

Fig. 8 : Water connection


1 Outlet water fitting
2 Water pump inlet
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3 Water fitting inlet


4 Flow meter inlet
5 Flow meter outlet toward mixing pipe
6 Mixing pipe inlet
24 calypso D30 Machine description 21

4 Start-up 2.6 Symbols on the machine

DANGER

! When transporting, assembling, dismantling, and/


or operating the machine, all applicable national Operating instructions Phase inverter
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 Danger! Do not put hands Operation via RCD
for obvious signs of damage, in particular electric into running machine! circuit breaker only
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.
Drain water under
cold conditions!
4.1 Electrical connections

WARNING 2.7 Components supplied

! The Continuous-Flow Mixer D30 must be


connected to a regulation site distributor box with
The machine is furnished composed of the following
standard items:
RCD automatic circuit breaker. Use a 20A 4-pole 9h
plug. The connecting cable must have a cross Material trough incl. safety grid with bag opener
section of SJO 14/4 and a 16A fuse. Mixer motor
Transport screw D30, pitch 40
Mixer shaft
Plug power supply 1 water hose 3/4" with GEKA coupling
cable with EEC plug
to the input socket
(fig. 7).
Fig. 7: Input socket
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1 Input socket
22 calypso D30 Transport and Set-up 23

3 Transport and Set-up 3.2 Machine 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 The machine must be positioned: !
safety laws, rules, and regulations must always be firmly on a level surface. It must be secured to
observed, even if such laws. rules, and regulations prevent it from tilting or moving.
are not explicitly mentioned in these instructions. in an area where no objects can fall onto it from
above. If this is not possible, it must be protected
3.1 Transport by a safety guard.
in such a way that all operating elements are easily
WARNING accessible at all times.
Always observe the following instructions if the
! machine is transported by crane or truck:
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.

Fig. 6: Lifting points on the D30


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