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Continuous-Flow Mixer
calypso D30
220 V 60Hz 3ph
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2 calypso D30 43
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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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 ________________________________________
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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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
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6 calypso D30 Accessories/spare parts 39
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:
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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
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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
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34 calypso D30 Safety 11
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
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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.
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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CAUTION
Close all draining valves before re-starting the
machine.
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16 calypso D30 Operation 29
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28 calypso D30 Machine description 17
5 Operation
DANGER
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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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
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).
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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DANGER
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1 Input socket
22 calypso D30 Transport and Set-up 23
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