User Guide

User Guide

Multiflow Mixer CN070

Impact Test Equipment Ltd www.impact-test.co.uk & www.impact-test.com

Impact Test Equipment Ltd. Building 21 Stevenston Ind. Est.

Stevenston Ayrshire

KA20 3LR

T: 01294 602626 F: 01294 461168

E: sales@impact-test.co.uk

Test Equipment Web Site www.impact-test.co.uk

Test Sieves & Accessories Web Site

www.impact-test.com

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CONTENTS SAFETY INFORMATION ............................................................................................ III INTENDED USERS ................................................................................................. III WARNINGS AND RECOMMENDATIONS TO REDUCE RISKS AGAINST INJURY (1 OF 2) .................................. IV WARNINGS AND RECOMMENDATIONS TO REDUCE RISKS AGAINST INJURY (2 OF 2) ...................................V

GENERAL NOTES …………………………………..………………………………………………………………………………….….6 INSTALLATION INSTRUCTIONS..................................................................................... 7 WIRING INSTRUCTIONS ........................................................................................... 7 INITIAL START UP OF MIXER...................................................................................... 7 WIRING DIAGRAMS 1PH 240V & 1PH 110V ...................................................................... 9 WIRING DIAGRAM 3PH 415V ………………..………………………………………………………………………………..…………..9

OPERATING INSTRUCTIONS (PAGE 1 OF 2)....................................................................... 10 BEFORE USING THE MIXER ...................................................................................... 10 OPERATING INSTRUCTIONS ...................................................................................... 10 OPERATING INSTRUCTIONS (PAGE 2 OF 2)....................................................................... 11 AUDIO TEST SE (ELECTRIC) MIXER ............................................................................ 11 AUDIO TEST SP (PETROL) MIXER.............................................................................. 11

MAINTENANCE INSTRUCTIONS.................................................................................... 12 GENERAL ADVICE ............................................................................................... 12 MIXER ADJUSTMENTS............................................................................................ 13 ADJUSTMENT OF BLADES ........................................................................................ 13 ELECTRICAL/MECHANICAL SAFETY .............................................................................. 14 ELECTRICAL COMPONENTS FITTED: .............................................................................. 14

SCHEMATICS OF MIXER BLADES .................................................................................. 14 POSITION OF MIXER BLADES ……………………………………………………………………………………………………...16 POSITION OF MIXER GUARDS ……………………………………………………………………………………………………..17 PARTS IDENTIFICATION LIST (PAGE 1 OF 2) ……………………………………………………………………..……..18 PARTS IDENTIFICATION LIST (PAGE 2 OF 2) ……………………………………………………………………….…...19

RECOMMENDED LUBRICANTS ……………………………………………………………………………………………….... 20

HONDA PETROL ENGINES DECLARATION …………………………………………………………………………….…… 21

HONDA NOISE INFORMATION …………………………………………………………………..………………………………..22

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Safety Information Intended users This manual has been written to instruct the operator(s) in the safe use of the mixer, to give guidance in getting the best results from the machine and to maintain the machine in a serviceable condition fit for its intended use. In order to achieve this condition, reliance is placed upon you the customer to ensure it is regularly serviced and that faulty/worn-out parts are replaced as necessary. We strongly recommend that this manual be read in its entirety before attempting to operate the mixer. Take particular notice of all caution and danger information signs; they are fitted to warn you of potential risks which could result in injury or fatality to the user or other personnel. The guards listed below have been fitted to your mixer to reduce the chance of injury to anyone operating the mixer. It is important that the mixer is not used without these guards and that damaged guards be replaced.

Part No. Guard Location S8 Glassfibre Headguard Top of Pan S11 Metal Shield Between Gear Unit & Electric Motor S12 Metal Shield Between Gear Unit & Petrol Engine S39 Coupling Guard Over Spider Coupling

Important: Only genuine spares must be fitted to the mixer. Parts not manufactured or supplied as genuine spares will immediately invalidate the warranty and could affect the safe operation of the mixer (EC MACHINERY DIRECTIVE 89/336/EEC). We cannot accept responsibility for injury to personnel or damage to equipment that has been altered from the original manufacturers design/specification. If you should experience any problems or if you have any questions regarding your mixer, please contact our technical department. Keep this manual to refer to at all times, particularly to inform all those who intend to use the machine. Pass this manual to the new owner should you sell the mixer.

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Warnings and Recommendations to reduce risks against injury (1 of 2)

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Warnings and Recommendations to reduce risks against injury (2 of 2)

General Notes Introduction

The mixer is driven by an electric motor, either single or three phase. The gear unit is of the worm reduction type with fitted flange for direct motor attachment, obviating the need for couplings, etc. All mixers incorporate a no-volt release system and should the power cease for whatever reason, this will happen automatically. To re-start the operative will have to re-energise the unit by pressing the green start button. This is a safety feature to stop the machine restarting upon restoration of power supply.

Note: All 3 phase mixers should incorporate a triple pole isolator fitted with an over current protection device i.e. motor rated fuse, or M.C.B. (miniature circuit breaker) to protect each phase. This is particularly important in preventing damage to the motor in the event of the phase being lost, i.e. as a result of phasing. This causes the motor to make a whirring noise and may cause difficulty in starting. In this event stop the motor immediately, isolate the electrical supply and check the fuses (replace or re-set as necessary).

Electrical supply It is important that all electric motors have sufficient current available to ensure correct ‘running’. This particularly applies to single phase motors and even more so to 110 volt motors. Failure to supply motors with the correct voltage can lead to the motor burning out and starter contactor faults. Please ensure that the correct size cable is used at all times to ensure the minimum voltage drop. Up rate the cable size according to the distance from the electrical source to maintain voltage.

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A suitable cable of the correct rating complete with gland and plug must be used for all electrical connections.

For 1 phase, 240 volt/110 volt, you require 1 phase, Live and Neutral. Earth must be connected to the main contactor as shown in the relevant wiring diagram.

For 3 phase 415 volt, you require 3 phase L1, L2 and L3 plus Earth. REFER TO WIRING DIAGRAM FOR INSTALLATION DETAILS This machine must be earthed and the wiring comply with current IEE Regulations as appropriate and the work carried out by a qualified industrial electrician.

Initial Start Up of Mixer

After wiring the mixer according to the above instructions the mixer will be ready for use. To start the mixer the mixing head must be placed in the up position. Press the green start button on the starter box. A slight click will be heard from the panel which is quite normal. Pull the head completely down to its natural position and lock the head into the mixing pan with the head locking handle (S6). To stop the mixing pan revolving, press the red stop button. To start another mixing cycle return ensure the mixing head is locked into the mixing pan, press the green start button. The pan will then revolve once again and will continue until the red stop button is pressed.

Important: To stop the machine at any time press the red stop button. The mixing cycle will also stop automatically in the event of a power cut. To restart the mixer the mixing head must once again be placed in the up position and the green start button pressed. If the mixer is wired correctly but will not start, i.e. no click heard from the starter box press the red stop button which activates the internal re-set and try again, making sure the mixing head is in the up position.

SAFETY NOTICE Electrical/Mechanical Hazards Before undertaking any electrical/mechanical repair or maintenance work on the mixer: ISOLATE THE POWER SUPPLY FROM THE MAINS SUPPLY. Do not remove the starter box covers without isolating the power supply first. At all times refer to the Product Manual supplied which contains information for the safe use of the mixer. Inform all personnel who use these machines of the safe and correct operational procedures.

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Note: Only suitably qualified persons should carry out the wiring installation. SE Mixer: 240 Volt 1 Phase 50Hz

Note:Only suitably qualified persons should carry out the wiring installation. SE Mixer: 110 Volt 1 Phase 50Hz

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Wiring Diagrams Note:Only suitably qualified persons should carry out the wiring installation. SE Mixer: 415 Volt 3 Phase 50Hz

SAFETY NOTICE Electrical/Mechanical Hazards Before undertaking any electrical/mechanical repair or maintenance work on the mixer: ISOLATE THE POWER SUPPLY FROM THE MAINS SUPPLY. Do not remove the starter box covers without isolating the power supply first. At all times refer to the Product Manual supplied which contains information for the safe use of the mixer.

Most Important: Inform all personnel who use these machines of the safe and correct operational procedures. 9

Operating Instructions (Page 1 of 2) Before Using The Mixer

READ THE OWNERS INSTRUCTION MANUAL THOROUGHLY before operating this machine. Study the mixer illustrations and parts list to familiarise yourself with the mixer and refer to them whilst reading these operating instructions. The Model S Mixer can be supplied with a Pan Carrying Handle (Part No. S36) which allows one man to remove the pan from the turntable and carry it to another area where the material can be processed and used. Be aware that the pan and its contents will be heavy. Alternatively, the Model S Mixer can be supplied with a Pan Tipper (S35) which can be tipped allowing the mixed material to be discharged from the pan. Petrol Engine Instructions. The Model S Mixer can be supplied with a petrol engine (Model SP). Refer to the starting sequence for Petrol as per the supplied “instruction booklets”. Note: Starting/stopping/running/procedures are also shown in the form of adhesive labels attached to the petrol engines in addition to the booklet. Electric drive starting/stopping instructions are text based and included in this manual.

Operating Instructions

Note: Isolate/stop the machine whenever it is not in use. Maintain safe-working practices at all times. Keep non-operative persons, members of the public, children etc. away from the mixer at all times. Prevent unauthorised use of the machine at all times. 1. Ensure that the mixing pan is located upon the turntable. 2. Load the mixing pan with materials. DO NOT OVERFILL THE PAN - APPROX. 120mm DEPTH OF MATERIAL IS THE FULL LOAD CAPACITY: OVERLOADING ONLY CAUSES EXTRA LOAD PLACED ON THE ENGINE/MOTOR, AND WILL CAUSE THE EXTRA MATERIAL TO BE EJECTED OVER THE SIDE OF THE MIXING PAN. 3. To start: press the green start button on the starter box – a slight click will be heard from the starter box which is quite normal. (To start Model SP Mixer (petrol engine) refer to the starting/stopping procedures in the supplied booklet.) 4. Lower the mixing head into the mixing pan and at about 45º the mixing pan will start to rotate. Pull the head completely into the mixing pan. There is no need for undue force as the tendency of the mixing blades is to lower themselves into the mix until they come to their natural rest position. 5. Lock the head into the mixing pan with the locking head handle (S6). 6. When mixing is complete (depends upon the material being mixed but normally under two minutes (refer to material manufacturers’ instructions), press the red stop button to stop. (Note: On the Model SP, the petrol engine will still be running, i.e. ticking over, but the electric motor will be completely stopped although the mixer will be ENERGISED, ready for the next mixing cycle. 7. To empty the mixing pan using the pan tipper, grasp the tipper handles (part number S35) centrally. Adopt a correct and safe lifting posture and pull the handles down and towards the operator. This will enable the pan to be tipped and the contents discharged into a wheelbarrow. 10

Operating Instructions (Page 2 of 2)

8. When the pan has been emptied, relocate the pan by lifting the tipper handles and allow the pan to relocate back upon the turntable ensuring that the pan locates centrally on the raised centre circle ring. The mixer is now ready to repeat the cycle of operation. 9. At the end of the mixing period, isolate and stop the machine. Clean the blades, paddles and mixing pan thoroughly, paying particular care to clean the inside wall and base of the mixing pan, especially where the base of the pan meets the pan side wall. 10. Clean up spillages of materials straight away; do not allow them to harden which may cause difficulty in cleaning later.

REMEMBER: KEEPING THE MIXER CLEAN ALLOWS SAFE OPERATION OF THE MIXER AND PROLONGS THE LIFE OF THE WORKING PARTS. NEVER OPERATE THE MIXER WITH BENT/DAMAGED MIXING BLADES, BUCKLED/WORN MIXING PAN, OR DEFECTIVE PARTS. Replace parts that are worn or defective immediately. This will maintain mixing efficiency and prolong the working life of the mixer. Make maintenance and repairs a daily action to get the best out of your mixer.

Audio Test SE (Electric) MIXER Distance Free Running Empty Loaded Mixing Dry Sand

1 m 56 dB 77 dB

3 m 50 dB 70 dB

Audio Test SP (Petrol) MIXER Distance Free Running Empty Loaded Mixing Dry Sand

1 m 90 dB 88 dB

3 m 83 dB 82 dB

⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯ Tests were carried out by an authorised person appointed by the manufacturer.

Note: Noise level tests were carried out with normal background noise. Readings will vary according to the material being mixed. 11

Maintenance Instructions General Advice

To achieve the optimum efficiency from your Mixer it is essential that the following maintenance program be adhered to. In addition to these instructions we recommend that the mixer be kept clean at all times, paying particular attention to the blades, paddles and mixer pan. Refer to the supplied petrol engine manufacturers handbook for their recommended maintenance programme.

Weekly

• Oil the top of the vertical shafts of the fixed blades to prevent material build up, grease the two star blade bearings (S5) nipples provided.

• Oil the pivot pins to the mixing head. • Check gear unit oil level (use recommended oil only). • Oil pan tipper pivot points (when fitted) • Grease wheel axles (when fitted). • Check mounting bolts for tightness.

Monthly

• We recommend that after the first month of use the gear unit is drained, flushed out and the oil replaced. We recommend Synthetic Oil Grade 220 be used for this purpose. • NOTE: Dispose of used oil safely, do not tip into drains, open ditches etc. Do not let used oil come into contact with skin; wear the appropriate protection and wash hands after use when filling or draining oil. • Check blade adjustments/settings.

Every three months

• Check the oil level in the gear unit (use recommended oil). • Grease all nipples, except for electric motor. • Check that all nuts and bolts are fully secured and have not worked loose. • Examine the blades and paddles checking for wear/damage and replace as

necessary.

Every six months

• Send the mixer back to us for a full service. If this is not practical request an on site visit. It is most important that regular servicing is carried out by us in order

to maintain the mixer to a safe operational standard. 12

Mixer Adjustments

SAFETY NOTICE Stop the engine and isolate the mixer completely from the power supply before undertaking any repairs, servicing, adjustments, etc.

Adjustment of blades The side scraper blade (part No. S1) has washers fitted on the top of the 3/4” diameter shaft which are retained by means of a split pin. When wear is apparent to the lower part of the side scraper blade, the blade can be lowered further down into the mixing pan by removing one or more washers. By placing the washers on the 3/4” diameter shaft below the side scraper extension arm (S10) any wear will be taken up. This process can be repeated as wear takes place until the side scraper blade horizontal arm remains just clear of the rim of the mixing pan. Once this occurs the blade will have to be replaced. The revolving star blade (S4) can be adjusted by undoing the allen screws situated in the raised bearing collars (S5). To set the blade, loosen the allen screws in both the top bearing housing and the underside bearing housing. Set the blade so that it will clear the bottom of the mixing pan by slightly less than the maximum aggregate size being used in the mix. We suggest that this can be achieved easily if you place a board of the correct thickness in the bottom of the mixing pan. Lock the mixing head with the head locking handle (S6). Lower the star blade down on to the board and tighten the allen screws. Remember to remove the board before materials are placed in the pan.

Important: ROTATE THE MIXING PAN BY HAND IN A CLOCKWISE DIRECTION BEFORE STARTING

THE MIXER, TO ENSURE THAT THE BLADE IS NOT TOUCHING THE BOTTOM OF THE MIXING PAN AT ANY POINT.

Note: When using fine or variable aggregates, set the blade to the bottom by a clearance

relative to the average size of aggregate. In very cold weather the oil in the gear unit may become more viscous and we recommend that the mixer is run without a load for a few minutes before starting the first mix of the day.

Recommendations

Do not run the mixer with badly worn paddles or blades and particularly blades that are not of our manufacture – this invalidates your guarantee. It is more economical to keep a spare set of blades and to interchange these before a great deal of wear has taken place.

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Electrical/Mechanical Safety

Electrical Components fitted:

• GEC/Brooks Motor BS5000 Part 99 1973 or equivalent to IP54 or IP55PVC. • Kopex flexible plastic conduit (fitted between motor and start) BS5750 Part 2 Cert. No, 106658 or equivalent, to IP66 fitted with liquid-tight seals. • Insulated single core multi-strand cable, 4mm and 2.5mm (run in above PVC Conduit between the

Motor and Starter) BS6321 (4mm) and BS6004 (2.5mm) or equivalent. • Danfoss Starter either CIM 9 or CIM 25 to IP55 • Danfoss Contactor either CI 9 or CI 25 to IEC 947-4-1, EN 60947-4-1 • Telemechanique Limit Switch XCL-J564 H29 IEC 947.5.1 Cenelac EN500041 IP66.

Electrical Tests Completed • Visual Inspection of all components. • Meter continuity of earth cable to mixer frame: pass at 0.01 ohms. • Meter continuity of earth cable to motor: pass at 0.01 ohms. • Insulation Test between phase-earth: pass at infinite resistance. • Insulation Test between neutral-earth: pass at infinite resistance. • Insulation Test between phase-neutral: pass at low resistance reading. • Check the amps drawn on the motor under load are not higher than the full load current stated on

the motor plate.

Mechanical Tests Completed Preliminary Checks: (Power Isolated)

• All welds firm, flat and smooth. • Head is set 90° to the base. • Locking Handle operates smoothly/correctly. • Side Scraper Blade is parallel to the pan wall and is in contact for the normal capacity of the pan, and

also touches the base/corner of the pan. • Revolving Star Blade revolves freely/grease nipples fitted. • Fixed Blades are set to the standard correct heights/direction. • Mixing Pan sits correctly on the levelled turntable. • Headguard is covering mixing pan correctly/evenly. • Gear Unit has been fitted with the appropriate oil to the correct level. • Overall general appearance is good.

Operational Checks: (Power On) • Test starter operates motor correctly. • Visual inspection of all components, ensuring motor runs smoothly/free of excessive vibration. • Check Revolving Star Blade revolves freely with the material in the mixing pan. • Check operation of accessories fitted/supplied with the mixer, to function correctly with/on mixer.

Operation Checks: (Power off)

• Final check of all bolts, nuts, etc. for final tightening. • Spray final paint topcoat, and paint inside of mixing pan and blades & paddles with pre-delivery rust

retarder. • Shrink-wrap, palletise, or crate as required.

Schematics of Mixer Blades 14

Large Fixed Blade (S2)

Small Fixed Blade (S3)

Side Scraper Blade (S1) Revolving Star Blade (S4)

Bearing for Revolving Star Blade: 2 off (S5) Nuts & Bolts for Star Blade Bearings: Set of 4 (S5a) 15

POSITION OF MIXING BLADES

S4: REVOLVING STAR BLADE

S5a: SET NUTS & BOLTS FOR BEARINGS

S5: BEARING FOR STAR BLADE (2 OFF)

S1: SIDE SCRAPER BLADE

S2: LARGE FIXED BLADE

S4: SMALL FIXED BLADE

NOTE: ALL BLADES, BEARINGS AND BOLTS MUST BE SECURED CORRECTLY IN PLACE

BEFORE COMMENCING MIXING OPERATION.

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POSITION OF GUARDS

S8: Glassfibre Headguard / or / S08B: Extended (Deeper) Glassfibre Headguard

S11: Metal Shield between Gear Unit and Electric Motor / or / S12: Metal Shield between Gear Unit and Petrol Motor

S39: Coupling Guard over Spider Coupling

Ensure all guards are securely in place before commencing mixer operation.

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PARTS IDENTIFICATION LIST (Page 1 of 2) Part Number S1 Side Scraper Blade S2 Large Fixed Blade S3 Small Fixed Blade S4 Revolving Star Blade S5 Bearing for Star Blade (2 off) S5a Bolts & Nuts for Revolving Star Blade Bearing (set of 4 off) S6 Locking Head Handle S7 Knob for Locking Head Handle S7a Rubber Grip for Lifting Head Handle S8 Glassfibre Headguard S8a Extended (Deeper) Glassfibre Headguard S9 Mixing Pan: 635mm dia. S10 Scraper Blade Extension Arm S11 Shield between gear unit/electric motor S12 Shield between gear unit/petrol engine S13 Spider Coupling S13a Element for Spider Coupling S14 Gear Unit (electric: standard duty) S14a Gear Unit (petrol) S15 Rubber Turntable Pad S16 C/S Nuts, Bolts & Washers for turntable (set of 4 off) S17 Turntable S18 Drive bolts. nuts & washers (set of 4 off) S19 Flanged Coupling S20 - S21 Starter for 3 phase motor S2134 Starter actuator buttons S21341 Stop mushroom head buttons S2301 Contactor S2302 Overload contd. ………..

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PARTS IDENTIFICATION LIST (Page 2 of 2)

Note: Unless where stated, spare parts do not include fitting. All prices are plus carriage and VAT. When ordering spares please quote the mixer serial number together with part numbers where known.

Part Number S24 Starter for 1 phase 110v 60Hz motor (special) S25 Motor 3 phase 415v 50Hz S26 Motor 1 phase 220v 50Hz S26A Fan for motor S27 Motor 1 phase 110v 50Hz S28 Motor 1 phase 110 60Hz (special) S29 Gear Oil Type E.P. (sold per litre) S30 Gear Oil Type 320 grade (sold per litre) S31 Petrol Engine Oil (sold per litre) S32 ¾” Shafting Collar S33 Shaft Extension S34 Castor Wheel (2 off) S35 Pan Tipper (fitting included on new mixer) S36 Pan Carrying Handle S37 Mild Steel Stand S38 Petrol Engine S39 Coupling Guard S40 Complete Set of 4 Blades & Paddles S41 Volume Guard S42 Blue Enamel Paint (per litre) S43 Front Cover and Buttons for Starter Box S44 Output Shaft S45 Output Shaft Oil Seal S46 Output Shaft Bearing S47 - S498 Automatic Power Take Up

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Honda Petrol Engines – Manufacturers Declaration for Mechanical Parts

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For more information on Honda Petrol engines, visit www.honda-engines-eu.com

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