MAI M400NT Bedienungsanleitung

AI PUMP

OPERATING INSTRUCTION

CERTIFIED

MAI International

GmbH

MAI International

GmbH

LIST OF CONTENTS

List of contents......................................................................................................................................................3

Foreword ................................................................................................................................................................4

User-friendly ..........................................................................................................................................................4

Operating instructions ..........................................................................................................................................4

Potential hazards...................................................................................................................................................4

Warranty and liability ............................................................................................................................................5

Prescribed use of the machine ............................................................................................................................5

Improper use..........................................................................................................................................................5

Personal safety ......................................................................................................................................................5

Safety devices........................................................................................................................................................6

General safety instructions ..................................................................................................................................6

Copyright................................................................................................................................................................6

General ...................................................................................................................................................................7

Training the operating personnel ........................................................................................................................7

Training record ......................................................................................................................................................8

Safety instructions for manual operation ...........................................................................................................8

Hazards of electricity ............................................................................................................................................8

General safety regulations ...................................................................................................................................9

Machine views .....................................................................................................................................................10

Operating panel and indicators .........................................................................................................................11

Plug-in connections ............................................................................................................................................11

Main dimensions .................................................................................................................................................12

Technical data......................................................................................................................................................12

Technical Descripton ..........................................................................................................................................13

Filter parts ............................................................................................................................................................14

Initial settings ......................................................................................................................................................14

Transport weight & dimensions.........................................................................................................................15

Controls................................................................................................................................................................16

Directions before start-up...................................................................................................................................16

Connections before start-up ..............................................................................................................................17

Start-up.................................................................................................................................................................17

Start-up for manual operation............................................................................................................................20

Start-up with remote control ..............................................................................................................................20

Interruptions and downtime ...............................................................................................................................21

Termination of work and cleaning .....................................................................................................................21

Machine maintenance .........................................................................................................................................22

Procedure in the event of frost ..........................................................................................................................22

Transport..............................................................................................................................................................23

Checklist for remedying faults...........................................................................................................................24

Main and control system circuit ........................................................................................................................25

Spare parts...........................................................................................................................................................26

MAI International

GmbH

FOREWORD

Dear MAI customer!

We wish to congratulate you on your purchase of

the MAI m400NT mortar mixing pump. The MAI

pump m400NT is a fully automatic mortar mixing

pump for continuous processing of all kinds of ma-

chine-processable anchor mortar and building site

cement.

The pump is driven by one motor only. A rubber

screw in the mixer transports the dry anchor mortar

to the mixing chamber where it is continually mixed

with water.

The water can either be supplied direct if the pres-

sure is high enough or an optional water pump can

be fitted, if required.

Once the material is thoroughly mixed, the entire

amount is then drawn in and pumped away by the

clampless, maintenance-free screw pump.

The most important features of the MAI pump

m400NT are the high quality of the components

used, the user-friendly layout of the controls and the

rugged design which proves its worth, day in and

day out on demanding building site applications.

User-friendly

oSimple to service and dismantle thanks to the

modular design.

oClearly structured operating elements.

oEconomical.

oThe patented MAI mixing and pumping tech-

nology guarantees continuous blending of dry

material, uniform mixing ratio, constant mixing

quality and therefore adequate processing.

OPERATING INSTRUCTIONS

These operating instructions contain the most im-

portant directions for a safe operation of the ma-

chine. The manual should therefore always be kept

in the tool box so that it is at hand when required.

Please read the operating instructions carefully

before starting the machine to familiarize yourself

with its handling and trouble-free operation of the

machine.

A working knowledge of the basic safety regulations

and instructions is the prerequisite for safe handling

and trouble-free operation of the machine.

Every single person working with the machine must

not only observe the operating instructions and the

safety regulations in particular, but also the applica-

ble rules and regulations governing accident pre-

vention at the location.

POTENTIAL HAZARDS

The MAI pump m400NT is built to the state of the

art and in accordance with recognized safety regu-

lations.

If not used properly, the machine

can however constitute a danger

to life and limb for the operator or

third parties, or adversely affect

the machine or other material re-

sources

DANGER

The machine may only be operated for the pre-

scribed use and if it is in perfect condition conform-

ing to the safety regulations. Faults that could affect

safety must be remedied immediately.

MAI International

GmbH

MAI International GmbH shall cancel all obligations

entered into by MAI International GmbH and/or its

dealers, such as guarantees, service agreements

etc., without notice if any other than original MAI

Pump or MAI International spare parts are used for

operation, maintenance or repairs.

WARRANTY AND LIABILITY

one or more of the follo

Operation of the machine for any other than the

osembly, start-up, operation and

odefective safety

ons in the operat-

otions to the motor (e. g.

ochine parts that

oges to the ma-

oerly carried out repairs.

sult of external

Ple cturer’s warranty shall

r „General Terms and

nditions of Sale“ apply to

rranty and liability. The

rchaser will have received a

opy on conclusion of the

ontract at the latest. PRESCRIBED USE OF THE

MACHINE

rranty and liability claims in

e event of personal injury or

aterial damage shall be

luded if they are caused by

wing reasons:

The prescribed use of the MAI pump m400NT is for

mixing and pumping commercially pre-mixed, ma-

chine processable dry mortar such as cement or

anchor mortar with a max. grain size of 4 mm.

Please note that the MAI pump m400NT can only

function properly if the mortar or cement used is

indeed machine-processable material (e. g. verified

with a manufacturer’s certificate).

prescribed use:

Improper as

maintenance of the machine.

Operation of the machine with IMPROPER USE

devices or incorrectly fitted or non-functioning

safety and protective devices.

Non-observance of the directio

Any uses for the MAI pump m400NT, other than

those prescribed above are prohibited. The MAI

pump m400NT is not intended for mixing non-

machine processable dry mortar or other materials,

such as inflammable or potentially explosive sub-

stances or from asbestos existing materials used in

the chemical industry.

ing instructions regarding transport, storage as-

sembly, start-up, running, maintenance and set

up of the machine.

Unauthorized altera

power or speed), mixing shaft, rubber screw,

mixing chamber, controls etc.

Inadequate monitoring of ma

In the event of improper use, the operator runs the

risk of jeopardizing life and limb, damaging the ma-

chine and other property, having an unforeseeable

impact on the environment, and impairing efficient

operation of the machine.

are subject to wear and tear (e. g. mixing shaft,

rubber screw or worm pump).

Unauthorized structural chan

chine.

Improp PERSONAL SAFETY

oUnforeseen disasters as a re The machine purchaser must provide the necessary

personal safety equipment.

influence or force major.

ase note that the manufa

All the existing safety devices on the machine must

be inspected at regular intervals and checked to

ensure that they are functioning properly.

expire if your machine is not operated and serviced

in accordance with these operating instructions.

MAI International

GmbH

SAFETY DEVICES COPYRIGHT

Before starting the machine, ensure that all the

safety devices are fitted correctly and functioning

properly.

All parts of this documentation are subject to copy-

right (©).

Photocopying or circulating the documentation, in

part or in whole, is prohibited.Safety devices may only be removed:

oafter a standstill and No part of this documentation may be reproduced,

stored in a retrieval system, transmitted or trans-

lated in any form or by any means without the prior

written permission of MAI International GmbH.

oif the machine is prevented from being re-

started (e.g. padlock on master switch).

When components are replaced, the purchaser

must ensure that the safety devices are fitted again

properly.

Copies of individual parts may be made and passed

onto third parties if they are required for locating

faults.

GENERAL SAFETY IN-

STRUCTIONS

rights reserved.

MAI International GmbH

The operating instructions must always be kept on

the machine.

Werkstrasse 17

A-9710 Feistritz/Drau

Company Register No. 93560 p

Klagenfurt Provincial Court

In addition to the operating instructions, the general

and local regulations on accident prevention and

environmental protection must be made available to

the operator and observed.

We reserve the right to alter any technical details of

the machine compared with the specifications and

illustrations in the present manual.

All safety regulations and warnings on the machine

must be legible and replaced as required. No claims against the manufacturer, especially

regarding design and structure of the machine may

be derived from statements made in the operating

instructions.

MAI®und MAI-PUMP®are registered trademarks of

MAI International GmbH.

MAI International

GmbH

Non-observance of these directions can cause

faults on the machine or in the work environment.

GENERAL

NOTE: indicates directions for

preventing faults or tips for eco-

nomical use of the machine.

NOTE

In the operating instructions we have listed the most

important directions for correct operation and main-

tenance of the MAI m400NT mortar mixing pump.

The prerequisite for the use of the machine is a

thorough knowledge of the technical documentation

and observation of the instructions and directions,

especially the safety regulations. In addition, the manual contains useful information

to help you to make the most of your machine.

The operating, safety and work instructions are

binding. The special symbols illustrated below indi-

cate important instructions which affect machine

and personal safety:

TRAINING THE OPERATING

PERSONNEL

1. The qualification required by the machine op-

erator are physical and mental aptitude, a

sense of responsibility and reliability in carrying

out the tasks assigned, proof of the necessary

skills and a declaration to the company that

training regarding operation, maintenance and

repair of the machine has been received. The

minimum age for machine operators is 18

years.

DANGER: This symbol means

imminent danger to the life and

health of people.

DANGER

Non-observance of these directions will cause seri-

ous damage to health and even lethal injuries.

WARNING: this symbol means a

potential risk to the life and health

of people.

2. In accordance with use as prescribed, the ma-

chine may only be started if the manufacturer’s

operating instructions are observed.

WARNING

3. Only trained and instructed personnel may work

with the machine. The responsibilities for set-

up, operation and maintenance must be clearly

defined.

Non-observance of these directions can cause seri-

ous damage to health and even lethal injuries.

4. Trainee personnel may only work on the ma-

chine under the supervision of an experienced

person.

CAUTION: this symbol means a

potentially dangerous situation.

CAUTION

5. The machine controls may only be operated by

trained personnel.

6. Training on the machine must, without excep-

tion, be confirmed in writing.

Non-observance of these directions can cause

slight injury or damage to property.

IMPORTANT: this symbol indi-

cates important information for

correct handling of the machine.

MAI International

GmbH

TRAINING RECORD HAZARDS OF ELECTRICITY

PERSON

ACTIVITY

Person

trained

Person

with

techni-

cal

qualifi-

cations

Elec-

trician

Superior

with

techni-

cal

compe-

tence

Start-up

Operation

Trouble-

shooting

Remedying

mechanical

faults

Remedying

electrical

faults

Maintenance

Repair

1. Work on the electrical supply may only be car-

ried out by authorized electricians. Inspect the

machine’s electrical system regularly. Obvious

defects, such as loose connections, singed ca-

bles etc. must be rectified immediately.

Repairs to the electrical system,

especially installation, connection

and opening of control cabinets

which are fed by the power supply

system, may only be carried out by

authorized personnel.

DANGER

2. In accordance with use as prescribed, the ma-

chine may only be started if the manufacturer’s

operating instructions are observed.

3. All safety instruction labels and warnings, and

all devices attached to the machine for safety

and accident prevention must always be legi-

ble, and may not be altered or removed.

4. Check that the machine is safe for operation

before every start-up. If any faults occur, pro-

ceed as follows:

Minor faults that do not affect safety:

Shut down the machine at once, remedy the fault

and notify the supervisor if necessary.

SAFETY INSTRUCTIONS FOR

MANUAL OPERATION Faults that affect safety:

The machine may only be operated if all the safety

devices are functioning properly. Stop operation of the machine immediately, notify

the supervisor and have the faults rectified by au-

thorized personnel.

Before switching on the machine, ensure that no-

body is at risk when it starts.

Inspect the machine for visible damage and check

that the safety devices are in proper service condi-

tion at least once a day.

MAI International

GmbH

6. Before cleaning the machine with water, close

all openings where water penetrating could

have a detrimental effect on function or safety

(electric motors, control cabinet and plug-in

connectors). After cleaning, remove the caps

and covers again.

GENERAL SAFETY REGULA-

TIONS

1. Any alterations, additions and conversions to

the machine require prior written permission

from the manufacturer. Failing this, any war-

ranty and liability claims shall expire. We also

wish to point out that only original MAI spare

parts may be used in the machine.

The MAI m400NT mortar mixing

pump conforms to Protection

Class IP44 in accordance with DIN

40050 and may not be cleaned

with water jets.

DANGER

2. The machine may

only be operated by

qualified, reliable

personnel selected

by the company,

trained in and

familiar with the

operation,

maintenance and

working of the

machine.

7. If work has to be carried out on live parts, a

second person must be at hand to break the

circuit in case of an emergency.

8. Disconnect the power supply before changing

the location of the machine. Check that it is

connected to the mains again correctly before

starting operation again.

9. The machine must be connected to a proper

power source, e.g. construction site distribution

board with r.c.c.b. (rated fault current I=30mA)

3. Trainee personnel

may only be

instructed in the

handling of the

machine by an

already qualified,

experienced

operator.

10. Set up the machine horizontally with safety

lights in place and safeguarded against acci-

dental movement.

11. Ensure that the mortar hoses are laid without

kinks and not rubbing on any sharp edges to

prevent them from being damaged. Where

there is a change of direction, the bending ra-

dius must not be less than six times the outside

hose diameter.

4. Follow the

operating

instructions with

regard to indicators

and procedures for

machine.

switching on and off the

Screw pumps are high pressure

pumps – only use steel-reinforced

hoses.

WARNING

5. The machine must be prevented from acciden-

tal restarting during any maintenance and re-

pair work. To do this, immobilize the master

switch with a padlock. You can also apply a

warning sign to the master switch.

MAI International

GmbH

19. The mixer motor must not be switched on when

it is tilted.

12. Before starting the machine, ensure that ma-

chine-processable, easily workable mortar is

being used, the hose is not leaking anywhere,

especially at the unions, and the inside of the

hose has been sufficiently lubricated.

20. When you fill the dry mortar in the hopper it can

come to strong dust formation. It can be

necesaary to wear a protective mask.

21. The machine may not do in the environment

with danger of explosion which by types of dust,

steams or gases can develop are used.

13. Before undoing the unions and the pump outlet

flange, ensure that they are depressurized by

start the main motor in „REVERSE“ direction.

To prevent eye injuries protective goggles is to

be used.

MACHINE VIEWS

1... Safety screen with bag opener

2... Water system

3... Control cabinet

4... Water injection unit

5... Mixing chamber

6... Worm pump

7... Pump outlet

8... PU lining tube

9... Vibrator

10... Water pump

11... Main motor

12... Charge hopper

14. Wear protective goggles when removing ob-

structions. The person carrying out the task

must be in a position where he cannot be hit by

any material that may be discharged. Other

people must be kept out of the immediate vicin-

ity.

15. The machine must be inspected by a qualified

person at least once a year.

16. The control cabinet may only be opened if the

machine is disconnected from the power sup-

ply.

17. The safety screen must not be removed while

the machine is in operation.

Disconnect the machine from the

power supply before removing the

screen or carrying out any clean-

ing and repair work

WARNING

18. The cover on the flange of the mixer motor and

the flange of the pump outlet must not be

opened while the machine is in operation.

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