D-25 Continuous mixer User Manual Electric
Contents
1. Page 20 Assemble the breaker bar into the hauling bracket and secure with the bolt provided This bolt is only intended to prevent the breaker bar from becoming decoupled when the nozzle is removed Page 21 If required Assemble the feed screw assembly over the end of the breaker bar from the front of the hopper Rotate the feed screw round until the hole in the breaker bar and the holes in the feed screw align Once aligned then the roll pin must be driven into the holes until it sticks out either end by approx 4 Use a punch of less than 3 8 diameter with a location peg to drive the pin into position see illustrations Assemble the front section of the mixing shaft to the fitted two rear sections of the full breaker mixer assembly Ensure that the cross pin is aligned with the slot in the front of the metering shaft fitted within the hopper wear liner assembly Remove the two wedges from the front of the hopper using a hammer if required Page 23 Grease the edge of the seal and assemble the nozzle APPLY PETROLIUM er GREASE VASELINE TO SEAL LIP TO AID ASSEMBLY AND REMOVAL USE THREAD LOCK TO SEC DO NOT OVER TIGHTEN BOL PLATE WILL DISTORT Assemble the nozzle over the end of the mixer shaft along its length then over the wear liner assembly ensure that the end of the mixing shaft locates into the bearing in the end of the nozzle tube REMOVE WE2. The module has a main power isolator a combine stop start switch a spring return reverse switch a speed control potentiometer internal breakers for each input phase a large capacity cooling fan in addition to the fan fitted to the inverter and a remote socket providing the optional capability for remote operation Upon delivery the inverter drive inside the control box is pre configured to suit your machine the configuration can however be altered to specifically suit many special needs regarding torques min speeds and max speeds For information on these topics please contact Machine Technologies directly Page 13 To access the control box remove the two pins from either side of the frame assembly and withdraw the handle with the control box mounted to it from the main frame Do not fully withdraw the handle and box as damage could result from dropping to the ground REMOVE LUCK PIN WITHDRAW HANDLE Page 14 Drive motor unit The machine is supplied with an electric motor drive ITEM NO QTY JESCRIP TION 1 JRIVE AUGER PUMP X SEAL GREASE MOTOR G BOX 3 FLANGE MOTOR MACHINED 4 ADAPTER MOTOR F LANGE 2 7 JOWEL SEAL RETAINER 6 MOTOR GEARBOX ABM 4K W 7 SCREW SET 1 4 20x1 4 8 KEY SPECIAL DRIVE DUG 35 DIA SHAFT 9 4 BOLT HEX 53 16 18 UNC 1 1 4 LONG 10 WASHER SPLIT 5 16 11 NIPPL
3. ccccccsooes sseseveres OO Page 3 Section 1 General Safety information Danger Follow these instructions very carefully in order to avoid injury to yourself or others Electrically powered machine Always ensure that all power to the machine has been turned off and isolated before ANY maintenance repair work is carried out on the machine Ensure that all guards are correctly fitted before starting or attempting to operate the machine Ensure that all fasteners are present and correctly fitted before attempting to start or operate the machine Ensure that the nozzle unit is correctly fastened to the front of the mixer unit of the machine and free of damage before attempting to start or operate the machine Ensure that the breaker assembly is free to rotate within the nozzle assembly prior to starting the machine The D 25 continuous mixer unit can produce high torques and can use high voltages Care must be taken by authorized persons when using and working with this machine Page 4 Section 2 Machine Description Function The continuous mixer uses pre bagged pre blended material that is broken via the bag breaker on the hopper and poured into the hopper that then discharges into the nozzle and mixes it with water to provide a usable mixture at its outlet The machine has a drive motor that turns a drive shaft within a material hopper that in turn rotates a helical feed screw in turn rotating a mixing s
4. 60010054 60010085 60010093 60010084 60010108 60010098 60010106 60010099 60010107 i pez od lt kd machine d TECHNOLOGIES N _ f D 25 Continuous mixer User Manual Electric ASSY MIXER CONTINUOUS D25 132LB ASSY MIXER CONTINUOUS D25 78LB ASSY MIXER CONTINUOUS D25 2 ASSY MIXER CONTINUOUS D25 132LB 3 PHASE ASSY MIXER CONTINUOUS D25 78LB 3 PHASE ASSY MIXER CONTINUOUS D25 2 3 PHASE ASSY MIXER CONTINUOUS D25 132LB 480V 3 PHASE ASSY MIXER CONTINUOUS D25 78LB 480V 3 PHASE ASSY MIXER CONTINUOUS D25 2 480V 3 PHASE REV 6 08 30 08 620 County Road 4841 Haslet TX 76052 Ph 817 439 1108 Fax 817 439 0633 www machine technologies com Dear Customer Before starting this machine please complete the following Machine Date of purchase snar Machine serial number sa ra Please read the following information contained within this manual and fully familiarize yourself with the equipment Page 2 Contents Page Section 1 General Safety information 0 ee 0 0 0 0 sss sss sss ess 00 IDETTE stats Section 2 Machine Description sss sss ss sss sss sees sees esse sees sss ees sess sara sese 6666666666666666 666666666 4 4 5 1 TTG STT en pa Machine tu Y 1 S T TT O 6 7 8 9 E IM PTO TTT Base Frame assembly cc0 0 0 0 00 0 0000 Soo o 00000000000000000000000 H pper ansa cos
5. individually replaceable The wear liner assembly is also available as a replaceable part Maintenance Apply a petroleum based grease such as Vaseline to the lip of the mixer seal after each cleaning to help allow easier nozzle assembly Each week the motor flange must be greased using a good quality general purpose water proof grease Pump the grease until it can be seen slightly oozing from around the hauling bracket seal Wipe off any excess to prevent immediate material build up After each clean down grease the external square bore mixing nozzle bearing until grease can be seen oozing from the bearing seals Do not grease any of the mixing shaft connections as the lubricant will attract material and cause premature wear Check the condition of the mixing shaft parts on a regular basis and ensure that they fully engage with each other Check for the level of play between parts and replace when they become loose or increased levels of wear will occur on other mating parts Check that all fasteners are fully assembled and tight at all times Ensure that the water control is free of leaks and that the system is drained if being stored or not used in freezing conditions Replace any bent damaged or torn parts immediately to prevent further damage to the machine and or personnel Ensure that the safety grid is always replaced after any hopper or shaft maintenance Check the condition of all electrical
6. BAIS ES 2 ael eal 2 L E x m dl x gt eg eel aj GST TI G E N EL o gt gt gt T Dl lt Alal al al al l el sa LW Al Al al Dl A Do Eal l lt t Bla Z a Page 10 The primary difference between ALL the various combinations of low standard and high output shaft tube etc assemblies is the dosing feed screw Dosing Feed screw 60010069 ASSY HELIX CONT MIXER 132LB fp V A G S A es J A Jj Va aw N MJ Page 11 Wear liner assembly Seal Seal clamp Bolts and Washers ITEM NO QTY PART NO DESCRIPTION 1 1 160010064 ASSY LINER WEAR CONT MIXER a 4 1 44010186 SEAL MIXING NOZZLE 5 1 44010196 CLAMP BOBBIN SEAL 6 8 10000084 WASHER 3 16 FLAT 5 7 8 10000083 BOLTHEX_10 24x1 2 S lt Page 12 Electronic Drive module The electronic Drive module comprises of a variable speed frequency inverter allowing the use of 220VAC two phase to run the high torque 3 Phase gear motor The unit is rated at 4K W providing plenty of power to run the D 25 unit The module is supplied with an input plug allowing immediate wiring into your own 220VAC 2 phase supply Must be carried out by an approved installer The motor is supplied with a pre wired plug that fits into the 3 Phase outlet of the module
7. DGES WEAR LINER ASSEMBLY T NOZZLE TUB ENSURE MIXER SHAFT PASSES THROUGH BEARING Page 24 Assemble wedges using a hammer ENSURE that the nozzle flange is parallel with the hopper flange Re assemble the safety grid to the top of the hopper using the grid keepers and bolts originally fitted Ensure that the bag breaker is fitted to the grid and is facing upwards CAUTION as the sharp edge can cause injury if not already fitted Operation of this machinery without the grid in place is prohibited Page 25 Electrical connections a Ensure that there are no power connections to the Electronic drive module Connect the motor power plug into the socket on the control box under the hopper Ensure that the water solenoid connector from the control box is plugged onto the water solenoid Obtain a suitable connection lead for single phase 220VAC feed to the drive module The length must be such that the delivered voltage to the drive must be 220VAC and capable of supplying 30A on each leg phase Turn the breakers OFF in the box and remove it from the bus bar to ensure that no voltage exists on the cables Make the connection between the drive module and the main distribution box using the supplied electric plug and your supplied cable Ensure that the Earth is connected as well as the two 110 VAC phases Connect the plug to the drive module and ensure that the drive module rotary isolator switch i
8. E GREASE 1 4 28 le SCREW SET 1 4 28 1 2LNG Page 15 ow oy Water Control Module The water control module allows the hook up of a typical water feed to the inlet port When the solenoid is turned on via the connector from the control box water flows through the inline pressure regulator through the solenoid valve into the adjustable visual flow meter and out though the outlet connector The flow rate can be adjusted at the base of the flow meter using the control knob ol WATER When the unit is left standing for any length of time or to be stored for freezing temperatures the water within the system must be drained to prevent damage due to freezing loosen the two drain cocks 7 and allow the water to drain out leave loose unit the unit is to be re used DO NOT OVER TIGHTEN when putting back into service 4 GPM unit shown l Water flow meter 2 Pressure regulator 3 Solenoid valve 4 Mounting 5 water INLET 6 Water OUTLET 7 Drain cocks Page 16 Section 3 Transportation and positioning The machine is typically manually transported around the job site by dropping and locking the wheels in the down position then using the nozzle like the handles on a wheel barrow Lift the machine at the wheel end and lift UP the axle lock bar and the wheels will drop to the ground At the same time the
9. LANGE GEKA STYLE FITTING 1 NPT FEMALE GEKA STYLE HOSE END CAP 2 COLLAR LOCKING 5 8 BORE Mixing Nozzle Assembly 132LB shown 60010056 The complete mixing nozzle assembly is available in three different versions low output 78LB standard output 132LB and High output 2 ay No Dk ITEM NO JQTY PART NO DESCRIPTION 1 1 160010065 ASSY CONT MIXER MIX TUBE 2 1 160010066 JASSY BREAKER DUSING MIX D29 132lb 3 1 4010128 _ SEAL CUNT MIXER i 2 _ 10000065 BOLT HEX 1 4 20x1 2 B 1 44010129 _IGUARD FINGER D25 6 1 140000017 SQ BEARINGFLANGE GREASE FLANGE 7 4 10000075 BULT CARRIAGE_1 2 13Xe 8 4 4 0 SPACER 1 2 BORE 1 OD 9 4 10000090 NUT NYLUC 1 2 13 THIN THK 10 1 0000009 GEKA STYLE FITTING 3 4 MALE PIPE Page 9 Assy Breaker Dosing Mix D25 132LB shown 60010066 Alternatively the complete Assy Breaker dosing mix is available in three different versions Low output 78LB 6001007 Standard output 132LB 60010066 shown and High output 2 60010091 A I iaa SF N CU 5 L ALL ay a x KE T OM EN IRI l a Ka wul gt of S gt lt ap gt zZ A Ei S 5 SH z a 1 4 CU GG A we F elal a al ay cy 0 l zZ Z l L ES l au OB 5 D gt st s ol a Li co S Xx ARRE
10. connections a shift by shift basis Clean the whole machine on a shift by shift basis Page 29 ee machin TECHNOLOGIES Cun and Mixing Pangu LIMITED WARRANTY POLICY Machine Technologies warrants each of its new machines to be free of defects in material and workmanship under normal use and services for a period of one 1 year from the date of delivery The warranty is issued ONLY to the INITIAL USER The warranty period begins when the product is delivered to the initial user or when first put into service whichever occurs first Said warranty is void if the machine is subject to misuse neglect accident or abuse Machine Technologies obligation under this warranty is limited to correcting without charge at its warehouse any parts or parts thereof which shall be returned to its warehouse transportation shipping prepaid and upon Machine Technologies examination proves to have been originally defective Correction of such defects by repair or replacement shall constitute fulfillment of all obligations to the initial user This warranty does not include labor or transportation charges unless specifically identified and authorized in writing by Machine Technologies Nor does the warranty apply to any unit upon which repairs or unauthorized alterations have been made The warranty does not apply to normal maintenance service or to normal replacement of certain machine parts which are subject to normal wear including but not lim
11. erate then press STOP and turn off the machine The machine is now ready for use by trained and qualified operators Page 27 Section 5 Machine operation speed setting The continuous mixer will discharge approx 132 LBS 78 LBS of course grain sand 280 RPM Max RPM with the knob at half scale the RPM will be 140 and the delivery approx 66 LBS 39 LBS The following are to be completed by trained and experienced persons familiar with the mixing system provided 1 Fill the D 25 hopper with material By dropping bags over the bag breaker twisting left and right by approx 15 degrees then lifting both ends of the bag to tear it in the middle Allow the material to drop into the hopper then remove the bag from the grid area into a disposal container 2 Turn the water supply OFF and establish the speed the mixer should run by either measuring the output within a certain time or by weighing the output within a certain time 3 Turn ON the water supply and disconnect the hose to the mixing nozzle Place the hose end on the ground where water will not damage anything 4 Hang a bucket on the end of the mixing nozzle to catch material 5 Turn the machine ON in the FWD direction and observe water to flow through the meter Quickly set the water flow to suit the amount of material being delivered base mix ration on manufacturers information STOP the machine 6 Remove the bucket and return the contents to the hopper Reconnect t
12. es sio saso s ossos dasiro cossos sosse at Mixing Nozzle Assembly e seccscossssessseesscoscocesooseoocssoocssecscocecoosesoesssoosssoscosssosssssesssse Assy Breaker Dosing Mix D25 eesssesssesssecssecesocesoosesocessccesocesocessoesssesesocesoosssosessee LO Dosing Feed screw 60010069 ASSY HELIX CONT MIXER 132LB 11 Dosing Feed screw 60010074 ASSY HELIX CONT MIXER 78LB 11 Dosing Feed screw 60010088 ASSY HELIX CONT MIXER 2 L Wear liner assembly Seal Seal clamp Bolts and Washer sccscccsssscssssreeee 12 Electronic Drive module sasssa na skanna ar Driv motor ks da L Water Control Module 0 0 0 0 0 veil 6 Section 3 Transportation and positioning 00000 00 00000000 00 00 0000 0 L7 Section 4 Machine set up keisaranna ees oessa esse essen 10 Unpacking and assembly sss ssssssssssssssssssssssssssssssss nds skessa nr Electrical Connections i nk sanka kv ar i ak i ka sena oesi DO Section 5 Machine operation speed setting sassa 2O General notes for operation sss sss sss sdececsexscasevecdscacedavsascbandedcoveciuodeatadeceivesjeesepiodsdecdo 20 Section 6 Maintenance sss sss sss sss sees ssssss sss ssss sse skannar sese 6666666666666666 6666666666 6666666 sese 6666666666666666 6666 6666666666666 LN TA Ta LTTE Maintenance 00000000es s s0s000 0000 rs 29 LIMITED WARRANTY POLICY
13. haft The combination of these shafts and mixing components move material from the hopper through to the mixing nozzle that with the addition of an adjustable water control that hydrates the mixture to the desired level The mixing tines in the nozzle tube mix and shear the material so that once it emerges from the discharge aperture the mixture is correctly mixed and sheared ready for use or for pumping to the application The machine is driven by an electric motor powered by 220VAC 3 phase 60 50Hz via an electronic variable speed inverter supplied by two phase 208VAC 60 Hz or 220 240 VAC 50 60Hz or 440 480 VAC 60Hz 3phase Input power The inverter control box allows the user to adjust the speed of rotation and in turn the volumetric displacement per rev of the feed screw to provide the require flow of material The control box also contains control for a water valve that operates when the unit is started in the feed direction If the unit is reversed for any reason the water will turn off and then turn back on once the reverse knob is released The continuous mixer is fitted with a water control assembly that contains a pressure regulator a control valve and a visual water flow meter The flow of water out of the flow meter into the mixing nozzle is adjustable via the control knob at its base Turning clockwise slows the flow rate counter clockwise increases the flow The difference between the machines is primarily the mater
14. he hose to the mixing nozzle 7 The machine is now ready for use General notes for operation Turn main power switch on Push start button Adjust speed to desired output Do not let hopper run below the top of the mixing shaft while mixing or the mix rations will change To stop machine push the stop button When cleaning the mixer do not remove grate while mixer is running Do not spray water on or in control box Control box should be wiped down with a damp rag If access is required in to the hopper disconnect power source before removing grate Mixer can be disassembled by removing wedges this facilitates easier transport and final clean up Always check hoses and cords for wear The unit runs on high voltage and is capable of high torques Ensure that after every 3 hours of operation that the nozzle is removed together with the mixing shaft for cleaning Check that the feed screw section of the shaft in the hopper is cleaned at the end sticking from the hopper as this is prone to water contamination and can suffer a material build up Page 28 Section 6 Maintenance Wear parts It is normal for wear to occur on the mixing shaft and in the mixing nozzle The rate of wear is very dependant upon the materials being mixed and the throughput of the machine The feed metering section of the mixing shaft is also subject to wear as is the wear line assembly The mixing shaft is made of 3 sections each part is
15. ial dosing rate which is controlled by the dosing screw There are three styles of dosing screw available a 132 Ib a 78 Ib and a 2 the differences in the screws being the pitch Page 5 Machine illustrations Machine io 1 Hopper unit 2 Mixing nozzle assembly 3 Base frame assembly 4 Inverter drive module 5 Drive motor 6 Water control module 7 Bag Breaker 8 Water hose assy 9 Power cord and socket Page 6 Base Frame assembly The base frame can be re configured to have the wheels axle etc located at the opposite end of the unit with the handle thus also being mirrored The control panel assembly on handle assembly can be moved by pulling the pins keeping the handle assembly in place in the frame then sliding the handle out allowing access to the control box itself ae Ls um l cu NX a ay 1 Base frame 2 Handle 3 Axle lock 4 Axle 5 Wheel Tire Page 7 Hopper unit Page 8 PART ND DESCRIP TION 1 60010009 JASSY HOPPER WELDED PUMP 12 10000065 BOLT HEX 1 4 20x1 2 12 10000009 WASHER FLAT 1 4 16 10000008 WASHER SPLIT 1 4 60010019 _ ASSY GRID HOPPER ASSY 44010042 _ KEEPER PLATE GRID HOPPER 10000015 BOLT HEX 1 4 20x0 75 2 60010021 ASSYJFLAT SIDE PANEL 4 60010071 ASSY WEDGE 2 PART 44010052 SEAL RUBBER MOTOR G BOX F
16. ited to pins bushings rotors stators hoses spray caps spray nozzles mixing shafts shaft couplings and connectors dosing shafts pump shafts filter elements and tires THIS IS A LIMITED WARRANTY AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING ANY WARRANTY OF MERCHANTABILITY OF FITNESS FOR A PARTICULAR PURPOSE In no event shall Machine Technologies be made liable for incidental general or consequential damage loss or any expense directly or indirectly related and resulting from use or lack of use caused by delay in delivery parts failure or any other causes associated with the product use No person firm or corporation is authorized to assume for Machine Technologies any other liability in connection with the sale of Machine Technologies products Page 30
17. lock bar can be dropped which will lock the axle in the down position allowing the unit to be wheeled to position ROTATE ME LOCK AXLE LOCK ee AXLE LOCK ROTATE AXLE LOCK Page 17 AX Once in position the lock bar can be raised and the whole unit will drop lifting the axle and the wheels The lock bar on level ground will catch the axle to keep it from lowering AXLE LOCKED INTO HOOKS Page 18 Section 4 Machine set up Unpacking and assembly Consult the final inspection record supplied in the packing for details of your machine and the items checked prior to shipment Keep this document for your records Remove the unit from the packing and the pallet If required Pre assemble the motor assembly onto the rear of the hopper hanging it on the location rods Assemble the motor onto the rear of the hopper and secure with the wedges supplied Remove the safety grid from the top of the hopper to allow you to rotate the breaker bar assembly already fitted inside the unit SAFETY CATCHES WASHERS AND BOLTS FOR GRID SAFETY GRID T LJ om EI I SF NK If required rotate the breaker bar in the hopper to engage the flat end into the slot in the drive hauling bracket of the motor assembly DRIVE 7 HAULING BRACKE
18. s turned OFF Replace the breakers into the distribution box onto the bus bar and turn them ON Turn the drive module isolator to ON and listen for the cooling fan to turn on Page 26 The following must be conducted by a supervisor or a qualified individual experienced in electro mechanical equipment Ensure that there are no persons close to the machine Ensure that there are no obstructions in or around the machine Turn the speed control knob fully clockwise Max speed 280 RPM normal configuration 9 10 11 12 13 14 15 16 17 Press the start button and observe the machine to turn the drive shaft and in turn the mixing shaft inside the nozzle tube A scraping noise is normal if heard being the mixing tines running close to the inside of the tube for maximum shear effect Turn the direction switch from FWD to REV observe the machine to turn the shaft and in turn the mixing shaft in reverse Press the stop button Connect a water supply to the inlet connection of the water control Connect the water pipe from the water control to the connection on the nozzle tube Turn the speed to minimum and press the start button If the water doesn t turn on increase the speed knob on the control box until the water valve clicks and turns on the water The motor should not run but a quiet whistle noise from the motor is normal Once the water is proven to op
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