390153-00 CIFAMOOVE 30 (EN)

ASSEMBLY, USE AND
MAINTENANCE MANUAL
CIFA
AMOOVE 30
TRANSLATION OF THE ORIGINAL INSTRUCTIONS
390 153
Via Stati Uniti d'america, 26 - 20030 - SENAGO (MI)
Tel.: (+39) 2 99013.1 - Fax: (+39) 2 9980786 - cifa@cifa.com - www.cifa.com
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CIIFA
AMO
OOVE 30
US
SE AND MAINTENANCE
MA
AN U AL
WARNING: READ AND MAKE SURE YOU UNDERSTAND THIS MANUAL BEFORE USING THE
MACHINE.
WARNING: KEEP THIS MANUAL INSIDE THE MACHINE.
TRANSLATION OF THE ORIGINAL INSTRUCTIONS
Review
Date of latest review
Edition
0
05/2013
ENGLISH
Creation date
05/2013
User and Maintenance Manual
CIFAMOOVE 30
PA
4
PREFACE
Dear Customer,
Thank you for choosing us.
We are delighted to have you as a customer and we are sure you will be
fully satisfied with this machine. All parts of this machine, which is the result of research and decades of
experience, have been built using extremely reliable commercial materials and components that make it
a high performance machine with low maintenance and operating costs. Finally, remember that we are
happy to provide our technical services and proven experience now and in the future.
IMPORTANT
To avoid damaging the machine or its smooth operation, and to ensure proper life of the components is
recommended to use ORIGINAL PARTS.
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5
IN
N D EX
1 INTRODUCTION ............................................................................................................................... SECT.1:2
1.1 GENERAL LETTER AT DELIVERY............................................................................................... SECT.1:2
1.2 USE OF THIS MANUAL ................................................................................................................ SECT.1:3
1.2.1 GENERAL INFORMATION ......................................................................................................... SECT.1:3
1.2.2 PURPOSE OF THIS MANUAL ................................................................................................... SECT.1:3
1.2.3 PRESERVATION OF THE MANUAL .......................................................................................... SECT.1:4
1.2.4 HOW TO UPDATE THE MANUAL.............................................................................................. SECT.1:4
1.2.5 CONSULTING THE MANUAL ................................................................................................... SECT.1:4
1.3 SYMBOLS ..................................................................................................................................... SECT.1:5
1.4 WARRANTY................................................................................................................................... SECT.1:6
1.5 PLANT IDENTIFICATION .............................................................................................................. SECT.1:7
2 DESCRIPTION .................................................................................................................................. SECT.2:2
2.1 DESCRIPTION OF THE CIFAMOOVE 30 PLANT ........................................................................ SECT.2:2
2.1.1 ACCESSORIES AND COMPLETION......................................................................................... SECT.2:3
2.2 INTENDED USE OF THE MACHINE............................................................................................. SECT.2:5
2.3 REASONABLY FORESEEABLE MISUSES.................................................................................. SECT.2:7
2.4 TECHNICAL DATA ........................................................................................................................ SECT.2:8
2.5 OVERALL DIMENSIONS .............................................................................................................. SECT.2:9
2.6 FLOW DIAGRAM........................................................................................................................... SECT.2:10
2.7 DESCRIPTION OF MAIN UNITS ................................................................................................... SECT.2:11
2.7.1 DESCRIPTION OF AGGREGATES BATCHING UNIT............................................................... SECT.2:11
2.7.2 DESCRIPTION OF MIXING UNIT............................................................................................... SECT.2:13
2.7.3 DISCHARGE HOPPER............................................................................................................... SECT.2:16
2.7.4 PNEUMATIC SYSTEM................................................................................................................ SECT.2:17
2.8 DESCRIPTION OF CONTROL PANEL ......................................................................................... SECT.2:18
2.8.1 CONTROL PANEL...................................................................................................................... SECT.2:18
2.8.2 AUTOMATIC OPERATION ......................................................................................................... SECT.2:19
2.9 LOCATION OF CONTROL EQUIPMENT ...................................................................................... SECT.2:20
2.10 LOCATION OF SAFETY EQUIPMENT ....................................................................................... SECT.2:21
2.10.1 SAFETY DEVICES AND LIMIT SWITCH ................................................................................ SECT.2:21
2.10.2 FIXED AND MOVEABLE GUARDS. ........................................................................................ SECT.2:21
2.11 LOCATION OF SAFETY SIGNS .................................................................................................. SECT.2:22
2.12 SCHEME FOR NOISE EMISSIONS ........................................................................................... SECT.2:24
2.12.1 MAIN COMPONENT NOISE EMISSIONS TABLE ................................................................... SECT.2:24
2.13 AIR EMISSIONS DIAGRAM ........................................................................................................ SECT.2:24
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3 SAFETY REGULATIONS ................................................................................................................. SECT.3:2
3.1 TERMINOLOGY AND DEFINITIONS ........................................................................................... SECT.3:2
3.2 DPI - INDIVIDUAL PROTECTIVE DEVICES ................................................................................. SECT.3:4
3.3 GENERAL WARNINGS ................................................................................................................. SECT.3:5
3.3.1 PREREQUISITES FOR EMPLOYEES RESPONSIBLE FOR PLANT
ASSEMBLY, USE AND MAINTENANCE............................................................................................. SECT.3:5
3.3.2 PROTECTION AGAINST NOISE................................................................................................ SECT.3:6
3.3.3 RULES OF CONDUCT ............................................................................................................... SECT.3:7
3.3.4 WARNING - EXTINGUISHER .................................................................................................... SECT.3:8
3.3.5 LIGHTING - RECOMMENDATIONS.......................................................................................... SECT.3:8
3.4 INFORMATION FOR GENERAL USE .......................................................................................... SECT.3:9
3.5 MAINTENANCE INFORMATION.................................................................................................. SECT.3:10
3.6 INFORMATIONS FOR WELDING OPERATIONS (EXTRAORDINARY MAINTENANCE)........ SECT.3:12
3.7 INFORMATION ON USE OF LUBRICANTS ................................................................................ SECT.3:12
3.7.1 WARNING: RISKS RELATED TO USE OF LUBRICANT, TOXIC OR IRRITANT
EFFECTS, SLIPPING, FIRE. ............................................................................................................... SECT.3:12
3.8 INFORMATION OF THE USE OF ADDITIVES.............................................................................. SECT.3:13
3.9 FALL PROTECTION WARNINGS ................................................................................................ SECT.3:13
3.10 INFORMATION ON TRANSPORT AND ASSEMBLY ................................................................ SECT.3:14
3.10.1 LIFTING EQUIPMENT ............................................................................................................. SECT.3:14
3.10.2 DISTRIBUTION OF LOADS ................................................................................................... SECT.3:14
3.10.3 MANUAL MOVEMENT OF LOADS.......................................................................................... SECT.3:15
4 TRANSPORT .................................................................................................................................. SECT.4:2
4.1 INFORMATION .............................................................................................................................. SECT.4:2
4.2 OVERALL DIMENSIONS DURING TRANSPORT ........................................................................ SECT.4:3
4.3 LIFTING.......................................................................................................................................... SECT.4:4
4.4 TRANSPORT ................................................................................................................................. SECT.4:4
ASSEMBLY 5 ASSEMBLY ................................................................................................................. SECT.5:2
5.1 ASSEMBLY PERSONNEL............................................................................................................. SECT.5:2
5.2OPTIMAL ASSEMBLY CONDITIONS ............................................................................................ SECT.5:3
5.2.1 ARRIVAL OF MATERIAL AT WORKSITE .................................................................................. SECT.5:3
5.2.2 WHAT TO PREPARE BEFORE INSTALLATION ....................................................................... SECT.5:3
5.3 LIST OF EQUIPMENT NECESSARY FOR ASSEMBLY ............................................................... SECT.5:4
5.4 BOLT TIGHTENING TABLE .......................................................................................................... SECT.5:6
5.5 LIFTING AND POSITIONING THE CIFAMOOVE 30 .................................................................... SECT.5:7
5.5.1 AGGREGATES UNIT POSITIONING ......................................................................................... SECT.5:7
5.5.2 MIXER UNIT POSITIONING ....................................................................................................... SECT.5:8
5.5.3 SUPPORT BRACKET POSITIONING ........................................................................................ SECT.5:9
5.5.4 FASTENING THE AGGREGATES AND MIXER UNITS ON THE FOUNDATION ..................... SECT.5:10
6
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5.5.5 LANDING ASSEMBLY................................................................................................................ SECT.5:11
5.5.6 MIXER PORTAL POSITIONING ................................................................................................. SECT.5:12
5.5.7 LADDER AND LANDING COMPLETION .................................................................................. SECT.5:13
5.5.8 EXTRACTOR BELT POSITIONING ........................................................................................... SECT.5:14
5.5.9 AGGREGATE GATE POSITIONING .......................................................................................... SECT.5:19
5.5.10 MIXER DEDUSTING FILTER ASSEMBLY ............................................................................... SECT.5:23
5.5.11 DIRT RECOVERY CHUTE ASSEMBLY ................................................................................... SECT.5:24
5.6 ELECTRICAL CONNECTIONS ..................................................................................................... SECT.5:25
5.7 RAMP CONTAINMENT BULKHEAD ASSEMBLY (OPTIONAL) .................................................. SECT.5:26
6 START-UP........................................................................................................................................ SECT.6:2
6.1 START-UP .................................................................................................................................... SECT.6:2
6.2 CALIBRATIONS AND CONTROLS............................................................................................... SECT.6:3
6.3 CALIBRATING SCALES ............................................................................................................... SECT.6:4
6.4 START-UP...................................................................................................................................... SECT.6:4
7 USE OF THE PLANT ....................................................................................................................... SECT.7:2
7.1 LOADING MATERIALS IN THE PLANT ...................................................................................... SECT.7:2
7.2 AUTOMATIC CYCLE START-UP................................................................................................... SECT.7:3
7.2.1 FLOW CHART SEQUENCE ....................................................................................................... SECT.7:3
8 MAINTENANCE ............................................................................................................................... SECT.8:2
8.1 INTRODUCTION ........................................................................................................................... SECT.8:2
8.2 ORDINARY PLANT MAINTENANCE ............................................................................................ SECT.8:3
8.2.1 MAINTENANCE ON ELECTRIC PLANTS ................................................................................ SECT.8:3
8.2.2 EXTRAORDINARY PLANT MAINTENANCE ........................................................................... SECT.8:3
8.3 MAINTENANCE OF MAIN UNITS ................................................................................................. SECT.8:4
8.4 INSTRUCTIONS FOR ORDINARY AND EXTRAORDINARY MAINTENANCE ........................... SECT.8:8
8.4.1 SAFETY DEVICES...................................................................................................................... SECT.8:8
8.4.2 MIXER ......................................................................................................................................... SECT.8:8
8.4.3 CONCRETE DISCHARGING HOPPER...................................................................................... SECT.8:11
8.4.4BUTTERFLY VALVES VFS - CEMENT BATCH FEEDER AND VFF - CEMENT SILOS............ SECT.8:11
8.4.5 PNEUMATIC PLANT .................................................................................................................. SECT.8:12
8.4.6ELECTRICAL SYSTEM ............................................................................................................... SECT.8:13
8.5 LUBRICATION ............................................................................................................................... SECT.8:14
8.6 TROUBLESHOOTING .................................................................................................................. SECT.8:14
8.6.1 BELT ........................................................................................................................................... SECT.8:15
8.6.2 OLEODINAMIC PLANT .............................................................................................................. SECT.8:15
8.6.3 CEMENT BUTTERFLY VALVES ................................................................................................ SECT.8:16
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9 DISASSEMBLING THE PLANT ..................................................................................................... SECT.9:2
9.1 GENERAL INSTRUCTIONS .......................................................................................................... SECT.9:2
9.2 OPERATIONS PRIOR TO DISASSEMBLY ................................................................................... SECT.9:2
9.3 DISASSEMBLY SEQUENCE......................................................................................................... SECT.9:2
9.4 TRASPORT.................................................................................................................................... SECT.9:3
9.5 DISPOSAL ..................................................................................................................................... SECT.9:3
10 SPARE PARTS AND AFTER SALES ............................................................................................ SECT.10:2
10.1 PROCEDURES FOR MAKING REQUESTS .............................................................................. SECT.10:2
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Sect.1:1
Use and Maintenance Manual
CIFAMOOVE 30
Chapter 1
INTRODUCTION
Sect.1:1
User and Maintenance Manual
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Sect.1:2
1 INTRODUCTION
1.1 GENERAL LETTER AT DELIVERY
This Use and Maintenance Manual, drafted in accordance with the Machines Directive 89/392 EEC, aims
at collating the instructions for staff operating site machinery for transporting and distributing concrete.
Given that these instructions apply to various types and models of machines, there may be slight
differences in the technical descriptions of the various parts compared to the type of machine you own.
This manual is intended to assist users of site machines so that they are used correctly to avoid personal
injury and damage to property.
Observance of the rules contained here is essential for operating responsibly and safely.
In all cases, the Italian version of the manual is to be regarded as the reference version.
For all the components of the machine system, consult the specific manuals.
Since it is humanly impossible to foresee all the situations which may arise when working on site, the user
retains full responsibility, essential for observing the aim of “Safety and Health” according to the criteria of
the EEC directive and all current laws.
This page is for certifying that on receiving the machine the Use Manual has been delivered by the
manufacturer and that the operator assumes the responsibility of studying it and applying it step by step.
For constant enhancements this manual is updated periodically.
This document contains proprietary information.
All rights reserved.
No part of this document may be photocopied, reproduced or translated into another language without
prior written consent from CIFA S.p.A.
Sect.1:2
Introduction
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Sect.1:3
1.2 USE OF THIS MANUAL
1.2.1 GENERAL INFORMATION
This user and maintenance manual must be read carefully and stored in a safe location as it contains
essential information for the machine’s proper use.
The machine has been built in compliance with the EU directives regarding the free circulation of industrial
products throughout the European Community. It therefore comes complete with all the documentation
required by these directives.
ATTENTION
This manual is to be considered an integral part of the machine and must be treated like any other
component of the machine itself.
This instruction manual is intended to be used by the following figures:
-
The personnel involved in the transportation, loading and unloading operations
-
The machine’s operators and installers
-
The personnel responsible for the machine’s maintenance
The illustrations shown in this manual are not binding. All the technical information contained herein is the
exclusive property of CIFA Spa and is to be considered confidential. It is therefore forbidden to reproduce
and/or distribute this manual, whether in whole or in part, without the manufacturer’s written authorization.
1.2.2 PURPOSE OF THIS MANUAL
The purpose of this manual is to provide the user with a general knowledge of the machine and the
maintenance instructions deemed necessary for its proper functionality.
This manual must be considered an integral part of the machine and must be preserved for the entire
duration of the machine’s service life. The manual must even accompany the machine in the event that it
is to be sold to a third party.
ATTENTION
THE INSTRUCTIONS CONTAINED IN THIS MANUAL MUST ALWAYS BE SCRUPULOUSLY
RESPECTED!
THIS MANUAL MUST BE READ AND FULLY UNDERSTOOD BEFORE ATTEMPTING TO USE THE
MACHINE AND/OR PERFORM ANY OPERATIONS UPON IT.
Chapter 2, entitled “SAFETY”, contains important and detailed information and warnings regarding safety
issues, and must therefore be read with particular care. The same information will be referenced, in
concise form, for the operational situations in which the described risks are present.
Introduction
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1.2.3 PRESERVATION OF THE MANUAL
This manual is to be considered an integral part of the machine and must always accompany the machine
in the event that it is to be transferred or resold. The manual must be stored in a dry and easily accessible
location for quick reference throughout the machine’s service life.
If the manual is damaged or lost, immediately request a copy from the manufacturer.
1.2.4 HOW TO UPDATE THE MANUAL
It is recommended to keep this manual constantly up to date by integrating it with any eventual
amendments, additions or modifications which may be issued by the manufacturer.
In the case of minor changes, the new pages will be sent out and the user will be required to integrate
them within the manual by replacing the relative pages in the chapters and/or sections concerned.
In the case of significant changes to the machine, a new revision of the manual will be sent out to replace
the existing version, which in turn must be rendered unusable.
1.2.5 CONSULTING THE MANUAL
The manual is divided into consecutively numbered chapters and sections.
The fastest way to retrieve the desired information is to consult the table of contents. The required
information may also be sought by examining the titles of the individual chapters and sections, as these
constitute key references for easy consultation.
ATTENTION
It is strongly recommended to contact the CIFA S.p.A. Support Service or your local agent/dealer
in the event that any problems should arise regarding the comprehension/interpretation of any
portion of this manual: the relative addresses, telephone numbers and fax numbers are listed on
the cover and title page of this manual.
IMPORTANT
Be sure to have the machine’s model and serial number on hand when contacting the technical
support service.
Annexed manuals: In order to integrate and complete this manual, the Machine’s SPARE PARTS
manual has been provided as an annex.
Sect.1:4
Introduction
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Sect.1:5
1.3 SYMBOLS
Specific instructions are provided whenever the situations described in this manual involve issues
regarding personal safety or the machine’s proper functionality and use. These instructions are indicated
and highlighted using SPECIAL SYMBOLS.
The three special symbols (or safety symbols) used in this manual are always accompanied by keywords,
which classify them based on the danger level of the situation in question.
The symbols are associated with appropriate messages, which describe the potential risks, as well as
the considerations and conduct to be adopted. Wherever appropriate, these messages also highlight
any prohibitions to be observed and/or provide appropriate instructions in order to eliminate the risks in
question.
In certain cases the messages may also be accompanied by illustrations.
The special symbols (or safety symbols) are listed below in order of importance:
Indicates that it is necessary to consult specific manuals
Indicates the instructions to be followed in order to avoid the risk of
ATTENTION
personal injury; provides information regarding potential hazards and
how to avoid them, and suggests proper conduct.
Indicates situations that could pose potential risks for the machine
WARNING
and/or the product being processed and/or the environment.
Indicates useful information for consulting the manual and for the
IMPORTANT
machine’s proper functionality.
Pay close attention to the special symbols while reading the manual
and take note of the explanations for the situations indicated by the
PROHIBITED
symbols themselves.
Introduction
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Sect.1:6
1.4 WARRANTY
Warranty falls if by using the plant the instructions given by this handbook are not properly followed and if
original spare parts are not used. (Warranty does not include wear and consumable parts: e.g. Skip lifting
cables, wearing plates inside the mixing unit, internal coating of discharging hopper, wheels of loading
bucket, etc…)
Anyway sales conditions have always main validity.
Any claim under guarantee must be sent to Cifa Spa, by writing, immediately after the verification of
defect, giving the plant serial number (which is stamped on the CE plate – see § 1.5).
Cifa Spa only can decide if a defect should be solved by Cifa Service or by third parties.
Sect.1:6
Introduction
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Sect.1:7
1.5 PLANT IDENTIFICATION
Manufacturer:
CIFA S.p.A.
Address:
Via Stati Uniti d’America, 26 - 20030 Senago – MI - Italy
For a proper identification of the batching plant, refer to Plant identification CE plate with following data:
Type/model of plant
Production no.
Year of construction
Moreover, reference to component (mixing unit, electric engine) plates can be given which indicate serial
number of each machine.
Introduction
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Sect.2:1
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Chapter 2
DESCRIPTION OF PLANT
Sect.2:1
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Sect.2:2
2 DESCRIPTION
2.1 DESCRIPTION OF THE CIFAMOOVE 30 PLANT
The CIFA CIFAMOOVE plant is a compact, pre-assembled, easily road transported and easy installation,
quick activation plant for the production of ready-mix concrete.
This plant has been designed for road transport in a single module.
Further transport vehicles are required for optional accessories only.
CIFAMOOVE is essentially composed of two main units:
•
Aggregates batching unit which involves the storage dosing and weighing system of batched
aggregates and the conveyor belt for transferring aggregates into the mixer.
Aggregate storage
Conveyor belt
Weighint system
Sect.2:2
Plant description
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Sect.2:3
Mixing unit, composed of a mixer, or concrete, water and additive dispensing components, a filter,
a support structure complete with a ladder and working surfaces. The support frame also houses the
control cabin.
Cement
Batcher
Mixer dedusting
Water
batcher
Mixer
Aggregates
Batcher
Access ladders
Inspection
platform
Support
structure
Control cabin
2.1.1 Accessories and completion
The CIFAMOOVE plant is integrated with the following units (supplied upon request), which together form
a concrete mixing plant:
•
Storage and concrete batching unit, composed of one or more concrete silos, dosing augers and any
necessary extensions.
•
Accessories: vibrators, filters, butterfly valves, level indicators, probes, etc.
Plant description
Sect.2:3
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•
Sect.2:4
Ramp containment bulkheads for creating aggregate unit loading ramps with filler material.
containment bulkheads
filler material
Sect.2:4
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Sect.2:5
2.2 INTENDED USE OF THE MACHINE
The plant has been built according to recognized technical safety standards. Despite this, dangers to the
physical integrity and life of operators or others, or damage to the machinery/equipment or other assets
may occur during its use.
Use the machine/plant only in perfect technical conditions, in accordance with the provisions described
in the manual, in full awareness of safety and dangers and in compliance with its instructions for use. In
particular, be sure to eliminate any malfunctions that may affect safety.
This plant has been designed for batching the components necessary for packaging concrete and cannot
be used for any other purpose.
ATTENTION
Any use differing from the one described in this manual is not to be considered up to standard. The
manufacturer is therefore not liable for any damage that any misuse may cause. Risk is borne exclusively
by the user.
For correct use of the plant, in addition to careful reading of this manual, users must have knowledge and
experience in the field of concrete production.
The plant is intended exclusively for industrial use.
The workstation is provided in the cab. Access to other areas is limited to operations involving loading
materials, checks and maintenance.
The materials that can be added in the plant are:
•
Aggregates: natural or crushed with a granulometry of no more than 40 mm and a specific
weight of no more than 1800kg/m³
•
Cement: with specific weight of no more than 1400 kg/m³
•
Water
•
Additives
Maximum quantities that can be added for each component:
•
Aggregates:
1000 kg
•
Cement:
200 kg
•
Water:
100 kg
The plant is prepared for outdoor installation and needs no special protection
Plant description
Sect.2:5
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Sect.2:6
Maximum climate conditions to which the plant may be subjected are as follows:
Earthquake
•
Wind
•
Nsnow
S=9 ( DM96 ) Zone 4 ( Italian Law 'Testo Unico' / Eurocode 8)
Zone 5 cat II (New Italian law ‘Testo Unico’ / Eurocode 1) - Wind speed 29 m/sec
Zone 1 and elevation 500 m (Italian law ‘Testo Unico’ / Eurocode 1 ) Snow pressure 204
kg/m²
IMPORTANT
•
The operating ambient temperature must be between +50 and -15. Machine/plant use in environments
with temperatures higher or lower than this temperature interval can jeopardise proper operation of the
machine/plant and limit performance, and therefore CIFA must be notified in advance of this type of
use.
•
The positioning of the machine/plant should not exceed a height of 700 m above sea level, above
2000 m could compromise correct operation of the machine and most certainly affects performance
and therefore CIFA must be notified in advance of this type of use.
•
In its standard version, the plant is not suitable for use in potentially explosive environments.
Precise and accurate communication of the “Serial Number” and “Model” allows our service personnel to
reply with fast, accurate answers.
All operators must possess the necessary permits for operating the machine and must read and
understand all safety instructions in this Manual. The allocation of duties and tasks must be carried out
by the site safety manager in compliance with the requirements of European directives on safety in the
workplace.
Sect.2:6
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Sect.2:7
2.3 REASONABLY FORESEEABLE MISUSES
Any use other than the one mentioned in paragraph 2.2 INTENDED USE is to be considered an
IMPROPER USE.
CIFA spa is not liable for damages to persons and/or property resulting from incorrect, and therefore
improper, use of the machine. The relative risks shall be borne entirely by the user.
In particular, it is strictly forbidden to use the machine, even partially:
•
Without its protective guards and/or with its safety devices deactivated, malfunctioning or missing;
•
If it has not been correctly installed
•
In explosive atmospheres or in places where fire hazards may be present
•
For the mixing of aggregates of sizes other than those which have been defined in the technical
specifications
•
Under hazardous conditions or in the case of machine malfunctions
•
For improper uses or on behalf of untrained personnel
•
In the case of defects with the machine’s intake plant
•
In the case of serious lack of maintenance
•
After any unauthorized modifications or interventions
•
In the case of partial or total negligence of the instructions
Please refer also to all notes, cautions and prohibitions contained in the various chapters of this manual.
Plant description
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Sect.2:8
2.4 TECHNICAL DATA
Technical data for the plant
CIFAMOOVE 30
Total weight
18000 kg
Total weight in transport
16000 kg
Power voltage
400 V
Frequency
50 Hz
No. of phases
3
Signals voltage
24 V
Commands voltage
24 V
Mixing motor power
18,5
kW
Power of control unit to open cover
2,2
kW
Belt engine power.
18,5
kW
Pneumatic compressor motor power
3
kW
Deduster Filter motor power
1,1
kW
Power capacity
78
kW
Power consumption
45
kW
Maximum speed of belt.
1,2
m / min
Minimum concrete mixing time
30
secondi
Volume of concrete yield from mixer
0,5
m³
Theoretical production of vibrated concrete yield
30
m³ / h
Height of aggregate feed ramp on 2 sides
3,6
m
Quantity of aggregate compartments
4
Total capacity of aggregates hopper
32
m³
Maximum particle size of aggregates
40
mm
Aggregates capacity
4000
kg
Cement capacity
1000
kg
Water capacity
500
kg
Water hookup (customer’s responsibility)
2” male attachment
with free discharge with Slump S3 - S4 - S5
(see flow diagram) (cap. 2.5)
Capacity 300 l/minute
Pressure 0.3 MPa
Sect.2:8
Plant description
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Sect.2:9
2.5 OVERALL DIMENSIONS
Plant description
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Sect.2:10
2.6 FLOW DIAGRAM
Following is the theoretical production cycle of 50 m3/h, with batching and discharge times (indicated in
seconds) for the various components provided by concrete with the following formula:
AGGREGATES = 1000 kg/m3
CEMENT = 200 kg/m3
WATER = 100 l/m3
3600: 60=60 cycles/h
Mixer = 0.5 m3
60 * 1.5 = 30 m3/h
Production is considered in free discharge, considered in continuous cycles (except the start-up cycle) and
does not include truck mixer handling times.
Sect.2:10
Plant description
User and Maintenance Manual
CIFAMOOVE 30
PA
Sect.2:11
2.7 DESCRIPTION OF MAIN UNITS
2.7.1 DESCRIPTION OF AGGREGATES BATCHING UNIT
The aggregates batching unit is composed of the following:
1) Storage hopper for aggregates to be batched, divided into 4 compartments through internal bulkheads,
for total storage capacity of approx. 32 m .
3
The aggregates unit can be equipped with an optional heating system.
The loading outlet for each compartment is 3,1 meters.
The hopper is loaded with a wheel loader from two access ramps, which can be made on concrete or on
the ground. For the latter, containment bulkheads can be provided upon request in order to secure the
support frame (refer to foundation drawings).
2) Aggregates batching system
An aggregates batching system is located under the hopper for weighing different aggregates depending
on the desired formula. It is composed of batching vents and a weighing system.
The vents are activated by pneumatic cylinders. Vibrators and moisture probes can be applied on the rear
vents (sand batching).
The weighing system is composed of 4 load cells which support the mixer feeding conveyor.
3) Mixer feeding conveyor belt
The task of the conveyor belt is to transport the correct quantity of aggregates to the mixer.
Safety nets are located on the conveyor belt. Maintenance can be carried out without removal of nets.
ATTENTION
Refer to the manufacturer's manual included in the literature accompanying the product for information
regarding proper assembly, use and maintenance.
Plant description
Sect.2:11
User and Maintenance Manual
CIFAMOOVE 30
PA
Sect.2:12
rear load cell
Loading vents
Motovibrator
pneumatic cylinder
discharge hopper
Loading vents
conveyor belt
front load cell
Support structure
Sect.2:12
Plant description
User and Maintenance Manual
CIFAMOOVE 30
2.7.2
PA
Sect.2:13
DESCRIPTION OF MIXING UNIT
The mixing unit connected to the aggregates batching unit essentially consists of the following parts:
•
Supporting frame in structural steel, complete with ladders and walkways for access to the batching
module and mixer. A cab from where the entire plant is supervised is present in the support structure.
•
Batching system, where the cement, water and additifs are batched.
•
Mixer, where the concrete is mixed.
•
Mixer unloading hopper to permit concrete to be unloaded into the concrete mixer.
Batching module
Mixer
Access ladder
discharge hopper
Support
structure
Control
cabin
Compressor
Plant description
Sect.2:13
User and Maintenance Manual
CIFAMOOVE 30
PA
Sect.2:14
2.7.2.2 Batching group
The batching group includes:
•
cement batcher with weighing system by load cells
•
water batcher with weighing system by load cells
•
pneumatic and electric service plant
•
Filter for dedusting the mixer
•
aggregates batching
dedusting filter
cement
batcher
additive
batcher
water
batcher
Mixer
The position of the batching module is over the mixer and is accessible directly from the mixer level.
Concrete is unloaded from the screw conveyors and weighed in the batcher, which is supported on three
compression load cells.
The batched concrete is unloaded into the mixer by means of two supplied electro-pneumatic Ø200 mm
butterfly valves. To facilitate the descent of the material, the concrete batcher is equipped with an electric
vibrator.
The batcher is connected to the mixer with a small Ø110 mm spiral tube which allows venting during
concrete batching.
Sect.2:14
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User and Maintenance Manual
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Sect.2:15
IMPORTANT
In order to avoid distorting weighing, connections between the concrete batcher and the batching screw
conveyors and between the batcher and the mixer are carried out with rubber sleeves, fastened with metal
collars.
The batching and water feeding unit is composed of a tank hanging on a load cell, of a batching valve
(1”1/2 ball valve), of an exhaust valve (DN125 butterfly valve) and of a mixing distribution system. A rubber
sleeve is set between the butterfly valve and the mixing distribution system.
During material unloading (aggregates, concrete and water), air is sucked through the spiral tube in the
mixer, connected to the removing air filter.
The exhaust air is purified in the filter by the dust parts and with the aid of the fan is blown outward.
Refer to the supplier instructions, which are an integral part of the documentation
supplied with the machine, for information regarding correct use of the filter. Data and
technical specifications are also contained in the relative instructions.
The dust collection hopper located under the filter is connected to the mixer with a Ø200 mm spiral tube.
Through this tube, during the suction phase, the air rises from the mixer to the filter, and during the sleeve
cleaning phase, the dust descends and is recovered in the mixer.
An electrical panel for filter, screw conveyor and concrete silo derivation box connection is also set on the
batching level (fluidification and filters).
2.7.2.3 Filter for mixing
Operation description
A 12 m2 dedusting filter can be installed on the mixer to suction and dedust air loaded with concrete from
the mixer and prevent dust emissions into the environment.
Only air can pass through the filter pockets to reach the outside, while concrete dust is held back by the
pockets and left to fall inside the mixer itself.
Refer to the supplier instructions, which are an integral part of the documentation
supplied with the machine, for information regarding correct use of the filter. Data and
technical specifications are also contained in the relative instructions.
2.7.2.4 Fume exhaust tube
Dedusted air comes out from the filter through the fan output, to which a chimney with a mouth for fume
exhaust can be applied by the competent authorities.
Plant description
Sect.2:15
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User and Maintenance Manual
CIFAMOOVE 30
Sect.2:16
2.7.2.5 Filter for concrete silos – Silotop type
Operation description
One or more 25m3 dedusting filters can be installed on the silos to suction and dedust air loaded with
concrete during silo loading and prevent dust emissions into the environment.
Only air can pass through the filter pockets to reach the outside, while concrete dust is held back by the
pockets and left to fall inside the silo itself..
Refer to the supplier instructions, which are an integral part of the documentation
supplied with the machine, for information regarding correct use of the filter. Data and
technical specifications are also contained in the relative instructions.
2.7.2.6 Dual shaft mixer
This is a planetary type mixer, in which mixing is carried out by rotation around the central vertical axis
of the mixer, distributing the intense action of mixing and transferring all mixing energy directly into the
concrete. This mixing technology ensures complete and even mixing in the shortest time possible.
A power motor with a robust gearbox is assembled over the mixing tank and moves the rotor with the side
scraper blades. The mixing stars are assembled off-centre with respect to the rotor. The star axis rotates
and turns around the planetary gearbox. 1, 2 or 3 mixing stars are provided depending on the size of the
mix.
The planetary transmission is fully sealed against dust contamination. It is easily accessed and is also
continuously self-lubricated.
The motor assembled at the top and the transmission technology do not limit the mixing tank, allowing fast
mixing and easy cleaning.
Refer to the supplier instructions, which are an integral part of the documentation
supplied with the machine, for information regarding correct use of the mixer.
2.7.3
Discharge hopper
The mixer discharge hopper is generally covered in rubber or other material to ensure that the concrete
slides easily and to protect the hopper walls.
The rubber stocking is located in the lower part of the hopper, fastened by a collar.
Sect.2:16
Plant description
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User and Maintenance Manual
Sect.2:17
CIFAMOOVE 30
2.7.4
Pneumatic system
The pneumatic system is composed of:
compressor
solenoid valves
pneumatic panel with filter, pressure reducer, lubricator and pressure switch
piping and fittings for sending compressed air to the various components
The various devices connected to the compressor include:
•
solenoid valves for activating aggregate vent cylinders
•
cement silo fluidification and filters (1 filter at a time)
•
pneumatic panel on the mixing unit (see §2.7)
Note: The compressor assembled on the plant is able to provide cleaning of 1 filter per cement silo. This
means that one silo should be loaded at a time, selecting the filter to be cleaned.
A second compressor must be installed (optional) in order to load multiple silos at the same time.
Plant description
Sect.2:17
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CIFAMOOVE 30
2.8
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Sect.2:18
DESCRIPTION OF CONTROL PANEL
Inside the control cabin is the electric control panel, for automatic, or manual operation by computer.
2.8.1 Control panel
Electromechanical CONTROL PANEL is able to manage all the loading and discharging operations of the
existing scales, with PC and PLC.
It is composed of an aggregate, water and additive weighing indicator set inside the panel, of a main
switch and of an emergency push button.
This panel includes the PLC appropriately connected to the manual system in order that the entire system
can also operate in automatic mode.
Control panel accessories
Programmable Logic Controller (PLC) inside the control panel, with the function of executing commands
sent from the PC to activate motors, valves, etc. and to receive system signals from limit switches,
sensors, load cells and humidity probes, etc.
Personal Computer (PC) : the machine is used only for data management, and it serves as an operating
terminal and memory for formulas, customers, delivery notes, etc. It’s equipped with an HD (hard disk)
where the control programs and data are stored. By means of the PC it is possible to communicate with
other systems such as PLC, HOST COMPUTER, MODEM, etc.
Printer for delivery notes (optional) and printer for reports.
The power, supplied by the main power source (e. g. diesel generator) goes from the CONTROL PANEL to
the Uninterruptible Power Supply unit (UPS) . Inside the UPS the power is converted to achieve the ideal
characteristics, appropriate for power supply of CONTROL PANEL components, PLC, PC and PRINTERS
(if connected). Refer to the “UPS Connections” page of the electric diagram.
Basic system composition
n°1 PLC;
n°1 Powerware UPS
n°1 PC industrial colour monitor;
n°1 Printer for notes; (optional)
n°1 Printer for various documents;
n°1 Hardware key with serial number;
n°1 User manual.
The hardware key is identified by a serial number that must be identical to the number on the licence form;
if the numbers are different please contact the assistance immediately to regularize the supply.
Sect.2:18
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User and Maintenance Manual
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Sect.2:19
2.8.2 Automatic operation
Automation has the following principal functions::
•
Intuitive graphic interface for ease of operation
•
Control of plant in manual with computer or completely automatic operation
•
Management and control of complete production cycle, with batching of solid and liquid components
and set-up of discharge sequences
•
Storage of concrete recipes based on 1m³ of dry components
•
Optimizing the m³ for each cycle, based on the quantity required
•
Wattmeter to indicate absorption of the mixer during the mixing phase
•
Management of alarms and events, with printing possible, if a printer is installed
•
Storage of production data, with production print possible, if a printer is installed (only with PC)
•
Print of production reports for each cement truck load
•
2 monitors 19”.
Automation is designed to control the following components:
•
Batching up to 4 aggregates on the cumulative scale through individual nozzles
•
Set-up of quantity of material “on the way “ for batching precision
•
Automatic control of vibrators in 2 batching nozzles (sand compartments)
•
Ability to manually set humidity for all aggregates
•
Automatic acquisition of humidity value for 2 sands, through capacity sensors
•
Offset of aggregate and water batching based on humidity detected or set
•
Batching up to 4 types of cement on a single cumulative scale
•
Automatic control of 4 systems: fluidification, cement, silos and vibrator, for cement balance
•
Water batching from network by weight.
•
Batching up to 2 types of additives with separate scales.
For use and maintenance of the control panel, consult the specific manual attached
included in the delivery.
Plant description
Sect.2:19
User and Maintenance Manual
CIFAMOOVE 30
2.9
LOCATION OF CONTROL EQUIPMENT
(1)
Main electrical control panel (inside the control cabin)
(2)
Electrical panel for remote control of mixer (Manual operation)
(3)
Lever for manual opening of mixer discharge door (to be used only if there is no
electrical power)
Sect.2:20
Plant description
PA
Sect.2:20
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User and Maintenance Manual
Sect.2:21
CIFAMOOVE 30
2.10
LOCATION OF SAFETY EQUIPMENT
The plant is equipped with safety equipment, operation and emergency limit switch and protection for
moving parts, either fixed or mobile.
Fixed guards (nets or casing) have been set to prevent accidental contact with moving parts that do not
require frequent maintenance.
In the even that periodic access to a hazardous area is necessary, interlocked moveable guards (doors)
have been provided. Opening of these doors requires the use of a key that interrupts power.
Thus, for plant safety it is indispensable to keep these protections maintained, by remounting the fixed
protection after intervention and periodically checking the functioning of the safety limit switches.
2.10.1 SAFETY DEVICES AND LIMIT SWITCH
1
EMERGENCY MUSHROOM push button
1a-on main panel in booth
1b-on remote mixer panel
2
SIREN (warns for about three seconds that the conveyor loading the mixer is about to move)
3
2 CONVEYOR/LOCK DEVICES. (Show where limit switches are)
2.10.2 Fixed and moveable guards.
4
Belt transmission COVER, front conveyor part.
5
SAFETY NETS ON CONVEYOR BELT
6
SAFETY SYSTEM on Mixer DOOR composed of lock.
Plant description
Sect.2:21
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2.11 LOCATION OF SAFETY SIGNS
Sect.2:22
Plant description
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Sect.2:22
User and Maintenance Manual
CIFAMOOVE 30
Pos.
1
2
3
4
Signal
PA
Sect.2:23
Description
ATTENTION: Cut off electricity before performing any works
on machines or electrical parts.
CAUTION ELECTRICAL HAZARD:
Do not activate the machine if guards are not completely in
place.
DO NOT APPROACH - Automatic start-up machines
PNEUMATIC SYSTEM WARNINGS
5
1) Discharge compressed air before performing maintenance
2) Check pressure daily
3) Check oil weekly
6
Skip ropes must be replaced every 50000 m3
7
ATTENTION: Disconnect power every night before exiting
Plant description
Sect.2:23
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Sect.2:24
2.12 SCHEME FOR NOISE EMISSIONS
2.12.1 Main component noise emissions table
The noise produced by each individual component is reported below.
Pos.
Quantity
description
theoretical noise level
a
1
Electric vibrator on cement batcher
=
80 dB (A)
b
2
Electric vibrator on aggregates batch feeders
=
80 dB (A)
c
1
Filter fan 1.1 kW
=
max 82 dB (A)
d
1
Skip belt
=
<80 dB (A)
e
1
Mixer
=
<80 dB (A)
f
1
Truck mixer during loading
=
<80 dB (A)
g
1
Electrocompressor 3 kW
=
max 85 dB (A)
h
1
Mixer cleaning unit (optional)
=
max 85 dB (A)
2.13 AIR EMISSIONS DIAGRAM
DEDUSTED POINTS
FILTER CHARACTERISTICS
EMISSION CHARACTERISTICS
No°
filters
Filter
Filter
speed
m/min
m2
filter
Flow rate
Mixer
1
DUST211
1,5
12
1200 m3/ h
Cement silos
1-4
SILOTOP
1
24.5
1600 m3/ h
Pos.
Plant
component
A
B
Note: filter B have no fan.
Sect.2:24
Plant description
Theoretical
emission
<10
mgNm3
<10 mg/
Nm3
Emission height
12 m
16 m
User and Maintenance Manual
CIFAMOOVE 30
PA
Sect.3:1
Use and Maintenance Manual
CIFAMOOVE 30
Chapter 3
SAFETY REGULATIONS
Sect.3:1
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User and Maintenance Manual
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Sect.3:2
3 SAFETY REGULATIONS
3.1 TERMINOLOGY AND DEFINITIONS
Apply:
WORK AREA: means those areas of the machine where the operator runs the commands required to
operate in accordance with the machine intended use the same as described in this manual.
INTENDED USE: Use of the machine according to the information provided in the instructions for use.
Reasonably foreseeable misuse: Use of the machine in a manner not foreseen at design and different
from the one indicated in the user’s manual, but that may result from readily predictable human behaviour.
DANGER: a potential source of injury or damage to health
DANGEROUS ZONE: any zone within and / or around machinery in which the presence of a person
constitutes a risk to the safety and health of such person
RISK: A combination of the likelihood and severity of an injury or harm to health that can arise in a
dangerous situation
EXPOSED PERSON: any person wholly or partially in a danger zone
OPERATOR: The person or persons installing, operating, adjusting, cleaning, repairing and moving
machinery, or performing routine maintenance. Before using the machine the operator must have read and
understood the instruction manual and learn about all operations for the first start. If it was appropriate to
CIFA engineers are available to provide all information necessary for the proper use of the machine.
SHELTER, HOUSING: part of a machine used specifically to provide protection by means of a physical
barrier
PROTECTION DEVICE: Device, other than a guard, which reduces the risk, either alone or in conjunction
with a guard
PERSONAL PROTECTIVE EQUIPMENT : It is intended for personal protective equipment all equipment
designed to be worn and held by the worker to protect him against one or more sources of risk to health or
safety at work, and any addition or accessory designed for this purpose.
PERSONAL PROTECTIVE EQUIPMENT must be used when the risks cannot be avoided or sufficiently
reduced by technical measures of prevention, by means of collective protection, measures, methods or
procedures for organizing the work.
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Sect.3:3
PERSONAL PROTECTIVE EQUIPMENT must:
• be appropriate for the risks involved, without itself a major risk;
• be adapted to existing conditions at the workplace;
• take account of ergonomic requirements or health of the worker;
• be adaptable to the user according to his needs.
In case of multiple sources of risk, requiring the simultaneous use of multiple PPE, they must be
compatible and able to maintain, even when used simultaneously, their effectiveness against the
corresponding risks
Safety requirements
Sect.3:3
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Sect.3:4
3.2 DPI - INDIVIDUAL PROTECTIVE DEVICES
The DPI are divided according to the parts of the body or the human functions they protect. Therefore
there are protective devices:
•
of the head
•
of the hearing
•
of the eyes
•
of the respiratory tract
•
of the hands and arms
•
Of the feet and legs
in the particular case of use of truck mixer must be protected:
The hearing, during the phases in which the engine of the machine turns at maximum
and that is, at the loading moment in the head-firm and at the unloading moment in
the building yard. In the building yard the safety device is necessary if there are strong
.
noises made from other people by operating machines, motocompressors, demolishers
and when the concrete is unloaded in the pump.
The respiratory tract if the head-firm does not have suitable equipment for the picking up
of concrete dusts, in particular way in the dry load of the mix and during the pneumatic
unload of the concrete.
The head: in the building yard is compulsory the use of the protective helmet. The habit
of wearing it always, also during the drive, has often protected and saved from hard
injuries.
The hands: wearing protective gloves is always good because the mix of concrete that is
often touched can irritate and provoke dermatitis. Moreover is better to protect our hands
defending them from scratches and small cuts or abrasions because of the contact with
metallic parts.
The feet: in the building yard maybe there are nails or other material that can perforate
the sole. The safety shoes must have a no-slip sole.
Eyes: must be protected from dust and above all from squirts of concrete mix during the
washings.
Sect.3:4
Safety requirements
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User and Maintenance Manual
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Sect.3:5
3.3 GENERAL WARNINGS
•
The employer must ensure that employees understand the instruction manual.
•
Personnel using the machine (authorised operators) must be previously trained and must have read
the manual.
•
Keep a copy of the manual in the control cab of the system.
•
For proper use, the working environment must comply with the legal provisions in force in the country
of use.
•
In particular, workers must be provided with suitable changing areas and a place of shelter during work
breaks within the site area. These premises shall be equipped with artificial lighting, seating, furniture
for personal belongings and a first aid cabinet.
•
A toilet must be set adjacent to the changing room.
ATTENTION
Compliance with all instructions and precautions below is essential as failure to do so may create problems
with serious consequences for persons and property.
3.3.1 PREREQUISITES FOR EMPLOYEES RESPONSIBLE FOR PLANT ASSEMBLY, USE AND
MAINTENANCE
•
Plant employees must meet the psychological and physical requirements set forth by law.
•
Works on/with the machine/plant can be performed by reliable personnel only.
•
Comply with the minimum age prescribed by law.
•
Employ only trained or instructed personnel, clearly define the personnel tasks for control, installation,
maintenance and repair.
•
Make sure that the machine is only operated by duly authorised staff.
•
Personnel in training, who are in the learning and education phase or are employed as part of general
training can operate the machine/plant only under the constant supervision of an experienced person.
•
Loose clothing is prohibited.
•
All employees must be provided with individual protection devices with the EC label (protective
helmets, accident-prevention footwear, noise reducing earphones, earplugs, gloves, protective
goggles, safety harness) and the Worksite Head must instruct them in their proper use.
Safety requirements
Sect.3:5
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CIFAMOOVE 30
•
PA
Sect.3:6
The Worksite Head shall require workers to comply with company regulations, rules, and the
appropriate use of individual and collective protective devices.
3.3.2 Protection against noise
Avoid spending long periods in very noisy areas: if this is not possible, use personal protective devices
such as earphones, earplugs, etc.
ATTENTION
If the operator is exposed to more than 85 dB(A) per day in noise, periodic medical examinations are
required.
Sect.3:6
Safety requirements
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User and Maintenance Manual
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Sect.3:7
3.3.3 RULES OF CONDUCT
•
Concentrate properly and take all precautions before any action. Do not become distracted, but rather
act prudently when performing hazardous work.
•
During work, carefully check equipment movements in order to avoid striking anything or being struck.
•
Always keep a clear view of the entire work area. Do not work under poor lighting conditions: use all
lights available and ensure that they are efficient.
•
Fully comply with all warnings to be attentive, watch for hazards and take precautions as indicated in
the manual, and obey the safety lights on the plant.
•
Immediately disinfect all wounds, cuts or abrasions, even minor ones: often small scratches cause
local infections that could be serious, as well as tetanus infections that may be deadly.
•
When perspiring, avoid sudden shifts in temperature.
•
Do not leave the plant unattended when it is in operation.
•
Keep the control station orderly and clean, avoiding any dust collection on control devices.
•
Always keep steps, walkways, the booth and shoes free of oil and grease, to avoid slipping.
•
Before the start of the work shift, check all safety devices, and note any deficiencies found.
•
Immediately advise the employer, manager or person in charge of any deficiencies in equipment and
safety and protection equipment, as well as any hazardous conditions of which you become aware.
•
In case of emergency, insofar as you are competent and capable of such, eliminate or reduce said
•
deficiencies or risks.
•
Advise your service head and the co-worker who will take over the shift of the status of work and
measures to be taken to safely continue it.
•
Do not touch any moving parts or live parts of the plant (or the electrical cabinet), sources of heat,
pressurized pipes, areas where you may be cut (for example, sharp edges), and do not lean or sit on
any part of the plant when it is in operation.
•
Do not walk on any uncovered pipes or cables, and do not walk on weak edges, pipes or surfaces.
•
Do not leave tools, nuts or bolts on conveyor belts or walkways, as they could be hazardous if they fall
off. Do not abandon waste materials, especially if they have sharp edges or protrusions.
•
Do not use cracked wrenches or other equipment, because if subjected to force they may break.
•
Do not jump from the plant, but instead use the ladders to climb up or down, and hold on to the
handrail.
•
Do not remove the labels or signs on the machine.
•
If they are damaged, immediately replace them with new signs.
Safety requirements
Sect.3:7
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Sect.3:8
PROHIBITIONS
•
It is prohibited to come near the aggregate feed openings and the skip for cleaning or maintenance,
while they are in motion.
•
It is prohibited to enter in the aggregate group during plant operation.
•
It is absolutely prohibited to enter in the mixer for cleaning or maintenance during plant operation.
•
Do not remove or modify the mesh or safety and protection devices unless you are authorized to do
so.
•
Do not remove barriers that prevent people from entering dangerous areas.
•
Do not change the program settings to obtain higher performance than what was anticipated during
planning and inspection.
•
All operations that may alter the stability of the structure are prohibited. In particular:
•
It is prohibited to construct containment sides that increase the capacity of the store of aggregates .
•
It is also prohibited to place any structure supporting the cover of the aggregates storage unit on top of
the sides if this has not been supplied by CIFA.
3.3.4 WARNING - EXTINGUISHER
•
We recommend installing a carbon dioxide or dry chemical product fire extinguisher (not included in
CIFA supply) in the control booth or its immediate vicinity.
•
All personnel responsible for maintenance and operation must be instructed in the use of the fire
extinguisher.
•
The fire extinguisher must be inspected regularly to ensure that it is completely functional at all times.
3.3.5 LIGHTING - RECOMMENDATIONS
•
The plant is located outdoors, and thus it is subject to environmental conditions.
•
The covered portions (booth, aggregates batching unit, etc.), must have lighting equivalent to 300 lux
(normal environmental conditions).
•
The control booth is equipped with a lighting system.
•
Installation of a lighting system in the other areas (which CIFA usually does not provide) must be done
using an appropriate electrical circuit dedicated to it, by a specialized electrician who issues the legal
documents required (declaration of the system’s conformity).
•
To perform maintenance operations, a mobile source of light may be useful.
Sect.3:8
Safety requirements
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User and Maintenance Manual
CIFAMOOVE 30
Sect.3:9
3.4 INFORMATION FOR GENERAL USE
In the event of an anomaly or emergency, press the mushroom “STOP” button located on the machine.
(For location, see paragraph 2.10)
During plant operation, no other person except the operator should be anywhere on the worksite or at the
control station.
Danger: aggregate falling from side walls - Safety helmet compulsory near cabin and aggregate group.
Before positioning the truck mixer, the driver should ensure that there is no one near the loading point.
The truck mixer can be loaded only if the vehicle is positioned correctly below the hopper, and after the
operator has ensured that no other persons are near the loading point.
Always operate under good lighting conditions.
During use of the plant, the operator is responsible for the entire area that constitutes the work
environment, and this must be delimited in a very visible way.
ATTENTION:
before leaving your control station, lock the stopping device in the off position and remove the key.
Safety requirements
Sect.3:9
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Sect.3:10
3.5 MAINTENANCE INFORMATION
•
Before performing any maintenance or leaving the machine unguarded, lock the stopping device in the
off position.
STOPPING DEVICE on control panel
ON
Lock the
stopping device
with a padlock.
OFF
Position of switched on tension
Plant ON
Position of switched off tension
Plant OFF
•
In addition, you must have the key needed to access the appointed place.
•
The keys for reactivating the energy source and the control panel must be kept by the operations
•
•
head.
•
When the machine is out of service for repair or maintenance, no one but the person responsible for
operations underway should be able to put it into motion.
•
Place a “MAINTENANCE UNDERWAY” sign on the control panel.
•
Before starting up the system, ensure that no one is performing maintenance operations.
Off position
OFF
Lock the stopping device with a padlock
Sect.3:10
Safety requirements
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User and Maintenance Manual
Sect.3:11
CIFAMOOVE 30
•
The aggregates batching unit is comprised of moving parts, such as nozzles, cylinders and
especially the bucket. For any cleaning or maintenance work to the aggregates unit, the electric power
must be shut off.
ATTENTION
Inside aggregate group batching openings are low: knock danger – Safety helmet compulsory
•
The plant, in standard supply, is without winter cover.
•
In case of bad weather conditions, don’t go on cement and water batching group: sliding danger.
•
The screw conveyors should also comply with safety regulations; maintenance should be performed
when the motor is off; the inspection doors cannot be opened and for no reason may the feed socks
connecting to the batch feeder be removed if the screw feeder is in movement.
•
Cleaning and maintenance of the mixer are potentially very dangerous operations and must be
performed only after the power is shut off. Follow the procedure described in §8.3.
•
Danger of sliding if the mixer is wet: wait until mixer is dry before enter for sheet or blades adjustment
or replacement.
•
Any work on pneumatic or oil pressure plants should be done only after discharging the pressure
within said plants.
•
Do not work below or near a linkage (for example, tipping hoppers or tilting channels) unless
adequately supported and locked.
•
Repairs of electrical systems should be made with the power shut off and the emergency button
inserted. Wait for at least 5/6 minutes before approaching the electronic equipment, to allow the
condensers to discharge any remaining energy.
•
Before doing any work on electric motors, wait for them to cool: danger of burns!
•
Whenever units must be disassembled or installed, be certain that they are supported by a lifting
device that is appropriate for the load to be sustained. Immediately transfer the load to adequate
means of support or trusses.
•
Never use gasoline, solvents or flammable fluids to clean parts, instead use approved commercial
detergents that are non-toxic and non-flammable.
•
Use tools (mechanical and electric) that comply with current safety regulations.
Safety requirements
Sect.3:11
User and Maintenance Manual
CIFAMOOVE 30
PA
Sect.3:12
3.6 INFORMATIONS FOR WELDING OPERATIONS (extraordinary maintenance)
Before welding, physically DISCONNECT the LOAD CELLS. Danger of cells damaging.
ATTENTION
Do not weld pipes or parts containing hydraulic oil or flammable substances: “DANGER OF EXPLOSION.”
ATTENTION
In case of welding on zinc plated parts, toxic smoke could be emitted. If possible, remove zinc
from the part to be welded. Use proper smell preventing masks.
3.7 INFORMATION ON USE OF LUBRICANTS
ATTENTION
3.7.1 WARNING: Risks related to use of lubricant, toxic or irritant effects, slipping, fire.
•
When handling lubricants, do not smoke, eat or drink. Follow the instructions on handling mineral oils
and greases.
•
Before handling lubricants, in order to prevent irritation or allergies, always wear goggles or an antispray mask, oil-proof gloves and an oil-proof suit.
•
Keep the lubricants in a place with natural ventilation, far from sources of heat (electrical panels, open
flame, etc.).
•
We advise avoiding direct contact of lubricants with pure oxygen and acids.
•
All lubricants may be disposed of by turning them over to bodies which are authorized to collect used
oils.
•
If there is a lubricant spill, to clean it up, scatter sawdust on the surfaces to absorb the product, then
collect it with a spatula and send it to the incinerator at bodies authorized to collect special wastes. To
wash surfaces, use solvents (chlorinated and aliphatic compounds) and be sure that their vapours do
not remain in the work area.
•
For persons who are especially sensitive to lubricants, there is a possibility that they may have an
allergic reaction or acne caused by oil, especially if the skin has been previously injured by a sticky or
abrasive substance (pastes for washing hands or wounds) or a chemical substance (solvents, strongly
alkaline detergents, etc.). Contact with the eyes may cause irritation.
•
If lubricants are improperly handled, effects due to overexposure may occur, such as, for example, a
slight irritation of the eyes or skin; if this occurs, avoid further exposure and see a doctor.
•
If the skin comes in contact with lubricants, wash it with soap and water.
•
If the eyes come into contact with lubricants, rinse them with pure water.
•
If a lubricant classified as an “oil” is swallowed, do not cause vomiting and immediately see a doctor.
Sect.3:12
Safety requirements
PA
User and Maintenance Manual
CIFAMOOVE 30
•
Sect.3:13
If a lubricant classified as a “grease” is swallowed, call a doctor if the quantity is small. If more than a
half litre is ingested, drink 1 or 2 glasses of water and immediately call a doctor. If the person has lost
consciousness, do not induce vomiting or give him anything by mouth.
3.8 INFORMATION OF THE USE OF ADDITIVES
ATTENTION
Be especially careful when handling additives used for concrete, as they are corrosive and
hazardous to the health.
Carefully follow the instructions on the additive safety charts provided by the manufacturer.
In particular, use appropriate IPD (Individual Protection Devices) and ensure that there is no open flame in
the case of flammable products.
3.9 FALL PROTECTION WARNINGS
•
For ordinary maintenance, use provided gangways with parapets. In case of maintenance on skip
motorization group, use safety harness.
•
For extraordinary or ordinary maintenance in points without gangways, use aerial lift and safety
harness.
•
The operator must always use all INDIVIDUAL PROTECTION DEVICES (such as safety shoes, safety
harness, gloves, helmet, etc.).
•
In any case should be forbidden to climb onto the structures or use inappropriate equipment (for
example, ladders simply placed against the structure).
Safety requirements
Sect.3:13
PA
User and Maintenance Manual
CIFAMOOVE 30
Sect.3:14
3.10 INFORMATION ON TRANSPORT AND ASSEMBLY
3.10.1 LIFTING EQUIPMENT
Lifting equipment must be appropriate for the nature, form and volume of the loads for which it is to be
used. The maximum load capacity must be indicated on the lifting equipment.
Hooks must be equipped with locking devices at the entrance, to prevent the load from becoming
unhooked. The maximum load capacity must be indicated on the hooks, and this must always be
observed. Before lifting the load, be sure that the hook locking device is locked.
Three U-bolt clamps must be mounted for a good connection of the metal cable: the first as close as
possible to the thimble, and the others at a distance of six times the diameter of the cable.
All accessories (chains, cables, hooks, rings, clamps, wire terminals, etc.) must be controlled before use.
Be on the lookout for any cuts, elongation, crushing, deformation or loose pins. Replace any equipment
that appears damaged.
3.10.2 DISTRIBUTION OF LOADS
Uniformly distribute loads to avoid imbalance. Basket slings are preferable, with cables passing below the
load. In case of especially long loads, a balancer should be used, especially if the centre of gravity is not
immediately identifiable.
Use corner protections for lifting cables.
Also ensure that the load is fully balanced, by lifting it just a few centimetres.
During transfer, it is important to avoid dangerous fluctuations in the load.
EDGE
PROTECTOR
Sect.3:14
Safety requirements
User and Maintenance Manual
CIFAMOOVE 30
PA
Sect.3:15
3.10.3 MANUAL MOVEMENT OF LOADS
Loads must have a maximum weight of 30 kg. The lifting and depositing of loads should be carried out
with your back straight, in a squatting position.
Safety requirements
Sect.3:15
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Sect.3:16
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Sect.3:16
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Sect.4:1
Use and Maintenance Manual
CIFAMOOVE 30
Chapter 4
TRANSPORT
Sect.4:1
User and Maintenance Manual
CIFAMOOVE 30
PA
Sect.4:2
4 TRANSPORT
4.1 INFORMATION
The CIFAMOOVE plant is designed to be transported by road in a single module, with parts that can
easily be lifted for operation.
Additional accessories will, of course, require additional means of transport.
Before moving the plant, the worker should check the weight and dimensions of the individual parts and
verify the availability of the following:
LIFTING MACHINERY (crane, overhead travelling crane, etc.) WITH AN ADEQUATE CAPACITY (50 -60 t)
CHAINS, CABLES AND HOOKS in sizes based on the weight of the equipment
ONE OR MORE MEANS OF TRANSPORT WITH ADEQUATE CAPACITY AND DIMENSIONS
ATTENTION
Important: before lifting, read the information in chapter 3, in particular § 3.4.
Sect.4:2
Transport
User and Maintenance Manual
CIFAMOOVE 30
PA
Sect.4:3
4.2 OVERALL DIMENSIONS DURING TRANSPORT
N°2 Container High cube 40”
Weight
MEASUREMENTS
Calibration
3800-4150 Kg
Maximum load
weight
26580-26600 Kg
External
Internal
Door Opening
Length
12192 mm
12020 mm
-
Width
2438 mm
2340 mm
2290 mm
Height
2896 mm
2680 mm
2570 mm
Volume
75.70 / 76.00 m3
Transport
Sect.4:3
User and Maintenance Manual
CIFAMOOVE 30
PA
Sect.4:4
4.3 LIFTING
To lift the equipment, use the hook-up points provided on the equipment, indicated in red or by indicator
signals.
The unit must be moved in a horizontal position: establish the exact length of the chains based on
balancing the unit. Adjust before the four external chains, and then middle chains.
If the modules must be lifted separately, carefully sling the individual items as necessary, complying with
general safety rules for suspended loads.
ATTENTION: no one should be standing within the load range of action.
4.4 TRANSPORT
1) During transport, the plant must be appropriately positioned on the means of transport on wooden
blocks of an adequate height, and fastened to the means of transport by appropriate chains (wooden
blocks and attachment chains are not included in the CIFA supply)
2) Check to see that loose parts have been solidly positioned and fastened.
3) Ensure that all connecting points and blocks for transport are properly fastened.
Sect.4:4
Transport
User and Maintenance Manual
CIFAMOOVE 30
PA
Sect.5:1
Use and Maintenance Manual
CIFAMOOVE 30
Chapter 5
ASSEMBLY
Sect.5:1
User and Maintenance Manual
CIFAMOOVE 30
PA
Sect.5:2
5 ASSEMBLY
5.1
ASSEMBLY PERSONNEL
Assembly must be performed solely by specialized, adequately trained personnel following the instructions
in this manual.
•
CIFA S.p.A. usually provides the following assembly solutions:
•
Turnkey assembly: assembly and inspection are performed entirely by CIFA personnel.
•
Assembly assistance: CIFA provides a specialized technician to coordinate assembly and inspection
operations, which are performed by the customer’s personnel.
•
Customer assembly: assembly is performed entirely by the customer, to whom CIFA provides the
necessary designs and instructions.
If assembly is performed by the Customer or through assembly assistance, the following must be available
at the worksite:
•
A plant operation and maintenance worker
•
At least 3 assemblers who can perform assembly and structural work
•
At least one specialized electrician for assembly and inspection of the electrical system.
•
At least 1 mobile crane with a 60 t capacity and the relative operator, with features appropriate for
lifting and assembly of the various pieces that comprise the plant.
The following telephone numbers must be readily available at the worksite:
-
Work Management Director
-
Worksite Director
-
First Aid
-
Fire Department
-
Emergency Services
Sect.5:2
Assembly
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User and Maintenance Manual
CIFAMOOVE 30
5.2
Sect.5:3
OPTIMAL ASSEMBLY CONDITIONS
5.2.1 Arrival of material at worksite
Before the materials arrive at the worksite, the customer must have prepared an appropriate area that
is not subject to collapse or flooding, where the pre-assembled units, crates and various structural
components can be unloaded.
This area must be fenced using a special chain and must prohibit access to unauthorized persons.
The worksite director must indicate authorized personnel.
5.2.2 What to prepare before installation
To assembly the plant properly in compliance with safety norms, the following conditions must be met
before work begins:
•
Set-up of support surface of the CIAFAMOOVE plant before arrival of the assembly manager,
depending on the type of anchorage to the ground. (See fixing).
•
The resting surface must be perfectly flat and level, and strong enough to support the loads indicated
in the foundation design.
•
The ground must be prepared so that elements such as rain, ice etc. do not sink the structure; thus an
appropriate sub-base must be laid (not supplied by CIFA ).
•
Any masonry work must be completed as per the project before the assemblers arrive, and the work
area must be free from materials used for masonry work.
•
The assembly area must be level and delimited, with the necessary visual accident prevention
signals. The area must prohibit access to unauthorized personnel.
•
All plant components must be available within the range of action of the lifting machinery.
•
There must be a deposit area for the assembly team’s container and its equipment.
•
The work area must be illuminated adequately to permit equipment assembly without risk to the
operators.
•
The worksite must also provide electrical energy, water and compressed air for the equipment
required for assembly (welders, drills, etc.) and to inspect the plant (according to the data listed on the
foundation design).
Assembly
Sect.5:3
User and Maintenance Manual
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5.3
PA
Sect.5:4
LIST OF EQUIPMENT NECESSARY FOR ASSEMBLY
n° 1
Safety belt for each operator
n° 1
Protective helmet for each operator
n° 1
Set of gloves and safety shoes for each operator
n° 1
Ladder that can be extended to 8 m
n° 1
Level to check surfaces
n° 4
Dowel pins with minimum diameter of 5 mm, maximum diameter of 30 mm , and
length of 250 mm
n° 1
Series of star wrenches (key 7-8-10-13-17-19-24-30)
n° 1
Series of box spanners (key 7-8-10-13-17-19-24-30)
n° 1
1/2” jack with bushings key 19-24-30
n° 1
3/4” jack with bushings key 19-24-30
n° 1
Electric or pneumatic starter for bolts with 19-24-30 key
n° 1
Monkey spanner, maximum aperture 32 mm
n° 2
Small Claw hammers
n° 1
Chisel
n° 1
Hacksaw with 5 blades for steel
n° 1
Electric drill with points up to 13 mm
n° 1
Complete electrician’s trusse
n° 2
1500 kg chain lever hoist with chain width 3 - 4 m
n° 1
5 kg sledgehammer
n° 2
2 kg hammers
n° 2
0.8 kg hammers
n° 1
2” pipe wrench
n° 1
Hemp cable piece diameter 16 mm length 30 m
n° 1
Electric welder complete with accessories (power cable - cable with callipers length 30 mwelding mask - electrodes - etc.)
n° 1
Clamp
n° 1
Tester
n° 1
Complete set of tools for electricians
n° 1
Big levers series
n° 1
Set of socket wrenches from 8 to 36
n° 1
Spanner to open up to 32 mm
n° 1
Air Compressor
n° 1
Crane 50 t*. handling and installation inert unit
n° 2
Hydraulic jacks, with a capacity greater than 10-15 t
Sect.5:4
Assembly
User and Maintenance Manual
CIFAMOOVE 30
n° 1
PA
Sect.5:5
Oxyacetylene device for cutting with accessories (30 m long pipe, cutting torch,
glasses, 1 oxygen bomb ,1 acetylene bomb, etc.)
n° 1
Big grinder
n° 1
Small grinder
n° 2
Set of drill bits for concrete
n° 2
Set of drill for steel hole
n° 1
Series of saws for metal dia.16 up to 60 mm
n° 2
Set of screwdrivers
n° 2
Crimping Pliers
n° 2
Pliers for end sleeves
n° 2
Scissors
ATTENTION: USE OF A SCREW MACHINE WILL GREATLY DECREASE ASSEMBLY TIME.
ATTENTION:
This list contains only the main equipment for the assembly it is possible that some equipment may be
excluded.
Assembly
Sect.5:5
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5.4
PA
Sect.5:6
BOLT TIGHTENING TABLE
During assembly operations, tighten bolts based on the tightening pairs indicated in the following table:
Before tightening, ensure that the classes of resistance between screw and nut comply with the Screw and
Nut association table
Precarichi "P" e momenti di serraggio (coppia) "M" per bulloni con filettatura metrica ISO a profilo triangolare.
Pre-loads "P" and driving torque "M" for bolts with metric thread ISO having triangular profile
Vorbelastungen "P" und Anzugsmoment "M" für bolzenmit metrischen Gewinde ISO mit dreieckingem
Precargas "P" y per de torsiòn "M" para pernos con roscado mètrico ISO con perfil triangular
Pre-charges "P" et couple de serrage "M" pour boulons avec filetage métrique ISO avec profile triangulaire.
Diametro e passo vite
Area resistente
Screw diameter and pitch
Resisting area
Classe vite
Screw class
Durchmesser und Abstand der Schraube
Widerstandsbereich
Schraubenklasse
Diàmetro y paso del tornillo
Diamètre et pas vis
Area resistente
Zone résistente
Clase tornillo
Classe vis
dxp
Sr
mm
mm2
M12 x 1.75
4.6
6.6
8.8
10.9
P
M
P
M
P
M
P
M
84.3
16
39
24
58
38
91
47
113
M16 x 2
156.7
30
96
45
144
70
225
88
281
M20 x 2.5
244.8
47
188
71
282 110 439
137 548
M24 x 3
352.5
68
325
102 487 158 758
197 948
M30 x 3.5
560.6
108 646
M36 x 4
816.7
157 1129 235 1694 366 2634 457 3293
M42 x 4.5
1120.9
215 1808 323 2712 502 4218 628 5273
M52 x 5
1757.8
338 3510 506 5265 788 8190 984
TABELLA ASSOCIATIVA VITE E DADO
161 969 251 1507 314 1884
Normali
ALTA RESISTENZA
Standard
Standard
Estàndar
Normale
High resistance
Hochwertige
Alta resistencia
Haute résistance
Associative table of screw and nut
Tabla asociativa tornillo y tuerca
Tableau associatif vis et ècrou
Vite
Screw Schraube
Tornillo
Vis
4.6
6.6
8.8
10.9
4A
5D
6S
8G
Dado
Nut
Tuerca
Sect.5:6
Mutter
Ecrou
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Sect.5:7
5.5 LIFTING AND POSITIONING THE CIFAMOOVE 30
5.5.1 Aggregates Unit Positioning
1- Lift the Aggregates Unit and position it on the floor of the foundation.
Total Weight
9000 Kg.
WARNING:
THE AGGREGATES UNIT MUST BE HANDLED HORIZONTALLY:
•
CHOOSE THE EXACT LENGTH OF THE CHAINS BASED ON UNIT BALANCE.
•
WITH THE AID OF A LEVEL, CHECK THAT THE FRAME IS COMPLETELY FLAT, INSERTING
SHIMS UNDER THE SURFACE IF NECESSARY
Assembly
Sect.5:7
User and Maintenance Manual
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PA
Sect.5:8
5.5.2 Mixer Unit Positioning
2- Lift the Mixer Unit and position it on the floor of the foundation with the Aggregates Unit
WARNING:
The Mixer Unit must be handled horizontally. Choose the exact length of the chains based on unit
balance.
ATTENTION:
With the aid of a level, check that the frame is completely flat, inserting shims under the surface if
necessary.
Total Weight
7000 Kg.
Sect.5:8
Assembly
User and Maintenance Manual
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Sect.5:9
5.5.3 Support bracket positioning
3 - Join the Aggregates Unit with the Mixer Unit and lock using bolts (See bolt tightening torque table).
4 - Using the lifting means, support the Mixer Unit and dismantle the brackets connecting the base of the
control cabin to the mixing portal.
Brackets
Assembly
Sect.5:9
User and Maintenance Manual
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Sect.5:10
5.5.4 Fastening the Aggregates and Mixer Units on the foundation
5 - Re-position the brackets between the Mixer Unit and the Aggregates Unit.
Brackets
6 - Before starting start-up operations, make sure to secure the Mixer Units and the Aggregates Units on
the foundation using chemical anchors.
Sect.5:10
Assembly
User and Maintenance Manual
CIFAMOOVE 30
PA
Sect.5:11
5.5.5 Landing Assembly
7 - With the aid of lifting means, lift the mixer portal to free up the space underneath to be able to overturn
the landings.
8 - Overturn the landings on the portal and fasten with bolts.
9 - Overturn the discharge hopper and fasten it to the front landing.
Landing
Discharge
hopper
Assembly
Sect.5:11
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Sect.5:12
10 - Complete assembly with the side landings and safety guard-rails.
5.5.6 Mixer portal positioning
11 – Lift the mixer portal with the aid of lifting means, position the support tie rods to the cabin frame and
fasten with relative pins (fig.A).
Lock pins with safety pins
FIG.A
Sect.5:12
Assembly
User and Maintenance Manual
CIFAMOOVE 30
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Sect.5:13
5.5.7 Ladder and landing completion
12 – Position the middle landing on the cabin frame (fig.A), assemble the ladder ramps, fastening them
with pins at the top (fig.B) and with bolts at the bottom (fig.C).
ATTENTION:
Assemble using an aerial platform
ATTENTION:
Before going up to the mixer level, verify correct ladder fastening.
Finish the ladder with guard-rails.
B
C
A
Assembly
Sect.5:13
User and Maintenance Manual
CIFAMOOVE 30
5.5.8 Extractor belt positioning
13 – Before lifting the belt, check for the presence of rotation pins at the rear of the belt. (fig.A)
14 – Fasten lifting ropes to corresponding belt connections. (fig.B)
15 – Remove the tie rod pins on the frame (fig.C)
A
B
Sect.5:14
C
Assembly
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Sect.5:14
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Sect.5:15
16 – Lift the belt until it goes over the holes on the tie rod pins (fig.A).
17 – Re-position tie rod pins (fig.B).
19 – Unhook lifting ropes from belt connections.
A
B
Assembly
Sect.5:15
User and Maintenance Manual
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20 – Hook the belt at the front with ropes (fig. A).
A
21 – Rotate the belt until it rests on the connecting flanges and fasten with bolts (fig. B).
ATTENTION:
See Tightening torque
B
Sect.5:16
Assembly
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Sect.5:16
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Sect.5:17
22 – Position the rear load cells between the batcher belt and the aggregates frame.
Assembly
Sect.5:17
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Sect.5:18
23 – With the aid of a connection means, lift the belt until it is detached 5 mm by the tie rod pin (fig.A), the
position the front load cells. (fig. B)
ATTENTION: Assembling safety bars on load cells is mandatory.
B
Safety bar
Sect.5:18
Assembly
User and Maintenance Manual
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Sect.5:19
5.5.9 Aggregate gate positioning
24 – With the aid of lifting means, lift and position the gates in the sequence indicated (from A to D). Use
the type of eyebolts indicated in figure 1 for lifting.
Fasten gates with bolts, referring to the tightening torque table.
A- Central gate
B- Rear central gate
C- Front central gate
D- Left side gate
E- Right side gate
F- Front front gate
Assembly
Sect.5:19
User and Maintenance Manual
CIFAMOOVE 30
Figure 1
G- Rear front gate
Sect.5:20
Assembly
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Sect.5:20
User and Maintenance Manual
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Sect.5:21
25 – With the aid of lifting means, lift and position the hutch in the sequence indicated.
Fasten the hutches with bolts. Use the type of eyebolts indicated in figure 1 for lifting.
A- Front side hutch
B- Central side hutch
C- Rear side hutch
D- Front central hutch
Figure 1
E- Rear central hutch
Sect.5:21
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Sect.5:22
26 – Verify correct assembly and fastening of front (Figure A) and rear (figure B) load cells and of tie rods
under the belt (Figure C).
Once verification has been completed, remove the rotation pins (figure D).
B
A
D
ATTENTION: Make sure safety bars are present.
Sect.5:22
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Sect.5:23
5.5.10 Mixer dedusting filter assembly
27 - Lift and position the dedusting filter over the mixer. Connect the spiral tube and relative electrical
connections.
Sect.5:23
User and Maintenance Manual
CIFAMOOVE 30
5.5.11 Dirt recovery chute assembly
28- With the aid of an aerial platform, position the dirt recovery chute under the extractor belt.
Chute
29- Complete electrical, pneumatic and water system connections.
Sect.5:24
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Sect.5:24
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Sect.5:25
5.6 ELECTRICAL CONNECTIONS
•
Connect the electrical system according to the wiring diagram attached to the manual.
•
The electric lines to be carried out on site and the cable sections must be those permitted by current
regulations.
•
Connect the electric line to the control panel positioned inside the control cab. The local mains voltage
and the control panel voltage must coincide.
ATTENTION
No changes can be made to the panel without prior authorisation from CIFA S.p.A., with the penalty of
annulment any liability on the part of the same.
•
All work on electrical equipment must be carried out by qualified electricians only.
•
Electrical system protection from weather elements (electric shock, lightning, etc.) is the responsibility
of the customer. Plant grounding.
ATTENTION
PERFORMING OPERATIONS ON THE ELECTRICAL SYSTEM WITHOUT CUTTING OFF POWER IS
PROHIBITED.
Sect.5:25
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Sect.5:26
5.7 RAMP CONTAINMENT BULKHEAD ASSEMBLY (OPTIONAL)
1. Assemble ramp containment bulkheads on the ground, connecting them to one another using bolts (A).
2. Peg bulkheads against the sliding with chemical anchors (not included in CIFA supply) (B).
3. Connect safety ropes to bulkheads (C).
A
B
C
4. Create two ramps with suitably compacted filler material in compliance with permitted loads on the
ground of 3.5 Kg/cm2.
filler material
Sect.5:26
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Sect.5:27
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Sect.6:1
Use and Maintenance Manual
CIFAMOOVE 30
Chapter 6
START-UP
Sect.6:1
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User and Maintenance Manual
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Sect.6:2
6 START--UP
For the cement silos and cement screw conveyors, perform the operation start-up
indicated in the specific manuals.
6.1
START-UP
1) Aggregates scale
•
Loosen the locking plates of the aggregates scale and the lateral contrasts. These devices must keep
the bucket in position without interfering with weighing. ATTENTION: PLANT SWITCHED OFF
2) Cement batch feeder
•
Loosen the nuts on the threaded safety rods below the flange of the cement batch feeder to leave a
maximum play of 5 mm between the nut and the plate. ATTENTION: PLANT SWITCHED OFF
3) Water batcher feeder
•
Loosen the lower nuts of the threaded safety rod to leave a maximum play of 5 mm between the nut
and the plate of the water batch feeder. ATTENTION: PLANT SWITCHED OFF
4) Connect the hydraulic system on-board the machine with the tubes (responsibility of customer) to the
water mains or the water cistern.
5) Connect the additive tanks (responsibility of customer) with the batcher by means of the tubes supplied
by CIFA.
Provide installation and verification of the following where required:
1) Ice batcher in the appropriate supports, verifying that, after weighing system assembly, they are free
from obstructions. batcher feeding systems (such as an screw conveyor or belt) are not included in Cifa
supply.
2) Verify connection to the pneumatic system and the opening and closing of the discharge vents.
Sect.6:2
Commissioning - Start-up
PA
User and Maintenance Manual
CIFAMOOVE 30
6.2
Sect.6:3
CALIBRATIONS AND CONTROLS
1)
Aggregate feed openings.
•
The aperture of the aggregates feed opening valve may be regulated (based on the type of
aggregate) by moving the limit switch located on the pneumatic cylinders along its housing.
•
Adjust the electric vibrator on the aggregates nozzles to minimum, with the two masses
counterpoised(if supplied).
•
(Consult the specific manual attached).
•
If vibration is not enough, increase it rotating the masses.
•
Factory setting
•
Aggregate batcher 100%
2) Calibrate the pressure reducers on the pneumatic plant of the aggregates unit and on the pneumatic
panels:
•
maximum pressure for movement of cylinders, valves and filters = 5 to 7 bars.
•
maximum pressure for fluidification of cement silos = 2 bars.
3) Verify the proper functioning of the pneumatic butterfly valvesfor cement batching and water
discharge.
4) Verify the proper functioning of the ball valves for water batching.
5) Verify the proper functioning of the fluidification nozzles applied to the cement silos. Verify that
non-lubricated air arrives for fluidification.
6) Adjust to minimum the vibrator on the cement batch feeder, with the two masses counterpoised.
(Consult the specific manual attached).
Factory setting 10%
7) Verify the proper functioning of the manual butterfly valves below the cement silos If foreseen.
8) Start up the mixer and the washing plant, if applicable. Verify wear plates bolts. Verify the distance
between blades and mixer. (Consult the specific manual attached).
9) Start up the filter (consult the specific manual attached).
10) Calibrate the magneto-thermal protection devices. (see wiring diagram).
Commissioning - Start-up
Sect.6:3
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User and Maintenance Manual
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Sect.6:4
11) Verify the safety and protection devices (for location see § 2.10):
•
Verify that all protective casings are mounted and securely attached.
•
Verify that the mushroom emergency stop button is functioning (figure).
•
Verify that the acoustic warning (siren) is functioning.
12) Verify the proper functioning of the electrical system.
•
Before starting the compressor and before switching the plant ON, verify there is nobody inside
aggregate group.
6.3
•
CALIBRATING SCALES
Aggregate weighing system calibration must be carried out by a specialised and certified company
who must issue an inspection certificate in accordance with reference norms (where required).
•
Calibrated weights are supplied by the client.
Following are some instructions necessary to avoid damaging the cells.
•
The cells have a breaking load (static) of no less than 3 times normal capacity.
•
Each load cell must be insulated by stranded copper applied to the upper and lower supports. Then
connect to the grounding network.
•
Under no circumstances should you remove the safety bars in weighing systems that use
cells. If a cell breaks, these bars will prevent the batch feeder and extractor belt from breaking. These
bars are also meant to limit side to side wobbling.
•
Avoid making welds to the structure when the load cells are mounted.
•
Use sheaths and waterproof fittings to protect cell cables. This protection is already included in
the CIFA supply. It is nevertheless a good idea to periodically verify that these protections are intact
and properly assembled.
•
If any condensation occurs within the equipment, the equipment should always be kept powered.
•
Do not cut the cell cables, even if they are longer than necessary.
6.4
START-UP
Plant start-up must be performed following the procedure of “START-UP PROCEDURE - CHECK LIST”,
delivered with the plant.
Check-list must be filled in by Start-up Tester and sent to CIFA SpA.
Sect.6:4
Commissioning - Start-up
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Sect.6:5
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Sect.7:1
Use and Maintenance Manual
CIFAMOOVE 30
Chapter 7
USE OF THE PLANT
Sect.7:1
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Sect.7:2
7 USE OF THE PLANT
7.1
•
LOADING MATERIALS IN THE PLANT
1) Fill the aggregates storage hopper with various grades of aggregates (up to 4 different sizes)
suitable for the production of concrete.
•
Load the aggregates with a wheel loader, ascending up along the access ramps.
•
Load the sands into two compartments equipped with electric vibrator (back compartments), while
larger particles (gravel) have to be loaded into the compartments on plant.
ATTENTION
Do not load aggregate hopper over the capacity indicated at §2.3, in order to avoid material outflow from
ramp.
ATTENTION
During aggregate loading, nobody must stay near the hopper. Danger: falling material
2) Cements are loaded by connecting the conduit exiting from the cement tank truck used for transport to
the silo loading pipe.
Once the connection is made, begin loading, using the vehicle’s compressor.
Sect.7:2
Commissioning - Start-up
User and Maintenance Manual
CIFAMOOVE 30
PA
Sect.7:3
7.2 AUTOMATIC CYCLE START-UP
The control panel is installed in the cab with a relative PC. The plant is displayed on the screen, as well as
scale displays and a series of buttons and selectors on the panel for emergency unloading of components.
IMPORTANT
Given the complexity of the cycle, use of the plant in manual is allowed only to individually activate some
components for verification or maintenance, always via computer.
For the meaning and use of selectors, see the specific panel manual or instructions on corresponding
plates. It is possible to run single components via the manual selector.
The cycle is carried out automatically by means of the PC installed inside the cab.
During automatic operation, the plant is completely managed by the PC and, once the desired program
has been set, the operator is only responsible for supervising.
An example of a flow diagram (with batches considered to calculate theoretical production) is shown in
§2.5.
Based on the quantity of concrete desired, the plant software optimizes production, dividing the quantity
set into a certain number of cycles (based on the mixer’s capacity).
E.g. 10m³
- mixer capacity 1.5m³
- 7 batches, 1.43m³ each
ATTENTION
Before beginning batching, be sure that there is no one under the aggregates unit
7.2.1 Flow chart sequence
1) Batching and weighing aggregates unloaded into the bucket from the feeding openings, which open
in sequence.
a) For proper functioning, first the sands are batched, then the gravel.
b) The weight detected by the load cells is displayed on the instrument mounted in the installed panel
(Or see the weight on the monitor)
2) Batching and weighing water, cement and any additives.
3) Aggregate transport phase via conveyor belt.
The operator can follow the lifting of material on the monitor.
Note: a limit switch is present and, in the event that the previous cycle has not yet been completed, the
belt stops.
Commissioning - Start-up
Sect.7:3
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Sect.7:4
4) Unloading materials into the mixer.
While the mixer is running, aggregates are unloaded into the mixer, while concrete, water and additives
are unloaded via valve opening (butterfly or ball).
Normally, unloading is carried out as follows: aggregates, partial water discharge, concrete. And final water
discharge.
5) Mixing phase, at zero on scales, the mixing time starts for about 30 seconds according to standard DIN
1045. Time can vary according to the type of concrete set.
6) Concrete discharge from the mixer.
When the mixing phase is complete, the door under the mixer opens and discharges the concrete into the
concrete mixer, positioned as shown in the figure.
•
Following the absorbency value of the mixer, the door opens to full opening.
•
As the absorption value of the mixer decreases, the door opens totally.
ATTENTION
Before discharging the concrete, be sure that the truck mixer is in position and that no one is in the loading
area.
Sect.7:4
Commissioning - Start-up
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Sect.7:5
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Sect.8:1
Use and Maintenance Manual
CIFAMOOVE 30
Chapter 8
MAINTENANCE
Sect.8:1
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User and Maintenance Manual
CIFAMOOVE 30
Sect.8:2
8 MAINTENANCE
8.1
INTRODUCTION
Prompt, careful maintenance is an indispensable prerequisite for ensuring efficiency, reliability and
longevity of the machine.
Plant maintenance includes just a few operations. Nevertheless, as this is a plant with many moving
parts that operate in often unfavourable environmental conditions, it is important to follow maintenance
instructions.
ATTENTION: Before doing any maintenance work, carefully read the safety instructions in chapter 3, in
particular §3.3.
The following figure is intended to set out the most important precautions.
Electric power
disconnected, plant
OFF
MAINTENANCE
UNDERWAY
OFF
The keys must
be kept by the
operations head.
Lock the stopping device
with a padlock.
Sect.8:2
Maintenance
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User and Maintenance Manual
Sect.8:3
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8.2
ORDINARY PLANT MAINTENANCE
Keep in mind that over the course of time, the plant will gradually show wear as a result of age, use and
the environment.
It is thus the user’s task to periodically examine the equipment to decide which parts, either functional or
structural, must be repaired or replaced.
ATTENTION : Use only original CIFA replacement parts
ATTENTION
Operations of ordinary maintenance must be performed by trained technicians.
8.2.1 MAINTENANCE ON ELECTRIC PLANTS
Technicians assigned to maintenance of electric plants must be professional qualified electricians.
8.2.2 EXTRAORDINARY PLANT MAINTENANCE
Extraordinary maintenance must be performed by a specialized technician.
Skilled technician is to be considered who has technical knowledge of plants for concrete production
acquired through training, attendance to specific professional training courses, or experience. Technicians
assigned to intervention to carpentry, electric motor and pneumatic plants must be acquainted with
technical regulations, safety rules and regulations, accident prevention regulations and “good technique”
rules.
Maintenance
Sect.8:3
User and Maintenance Manual
CIFAMOOVE 30
8.3
PA
Sect.8:4
MAINTENANCE OF MAIN UNITS
Following is a list of maintenance operations to be performed, with the recommended frequency. For more
complex operations, refer to §8.3 or the specific manuals attached.
The specific manuals should always be consulted, because they may contain
information in addition to what is reported in this list.
Verify function of upper limit switches.
Aggregate conveyor belt.
Verify function of cable pull limit switches on the conveyor belt
side.
Check the functioning of the electric safety lock for opening and
closing the covers.
The mixer must be washed during prolonged periods without
use (1-2 hours) and at the end of the day.
Twin shaft mixer
Wash the inside using a high pressure jet washer (excluded to
provide cifa) at the end of the day.
DAILY
Check specific manual requirements.
Concrete discharge hopper
Wash with high pressure jet washer (excluded to provide cifa)
during long pauses (1-2 hours) and at the end of the day.
Discharge condensate and impurities from the air filters (near
the compressor, on the batch feeder unit and on the silos)
through the drain plugs.
Pneumatic plant
Discharge condensate and impurities from the compressor tank
through the relative drain plug.
Check to ensure that there is no air loss.
Sect.8:4
Filter
Check status
Belt
Check belt tensioning (see daily maintenance manual)
Maintenance
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User and Maintenance Manual
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Sect.8:5
Check the safety equipment: mushroom button, safety limit
switch, etc. (see location at §2.10 )
General
Control the efficiency of the electrical system components
(commands, acoustic signals and lights).
Aggregate transport unit
Check belt conditions.
Control the condition of wear plates inside the mixer and the
distance between paddles and plates(see specific manual
attached).
Mixer
Control the functioning and quantity of grease in the automatic
greasing device on the mixer (see specific manual attached).
Consumption load 1 kg per day for 8 hours of work.
WEEKLY
Grease the manual greasing points on the mixer.
Butterfly valves for
cement batch feeder
Verify that the area where material passes through is free from
residues; if not, clean it carefully to avoid any obstruction of the
valve.
Control the oil level in the lubricator pan, and if necessary
replenish it.
If there is excessive oil consumption, regulate it by means of
the special batching screws. An oil refill should last from 15 to
20 days, if the plant is operating normally.
Pneumatic Plant
Control to ensure that the air compressor stops and starts
again automatically when it reaches MAX and MIN pressure
values. If not, set the calibration values.
Control the pressure gauge (5-7 bars for solenoid valves and filters,
2 bars for fluidification), or else adjust the pressure reducers.
Clean the spiral pipe of cement filter, to avoid any accumulation
of dust.
Mixer dedusting filter
and cement batcher
Clean the spiral venting pipe (connecting cement batcher and
venting pipe
mixer), to avoid any accumulation of dust.
Check fluidification nozzles on the concrete silos
Maintenance
Sect.8:5
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User and Maintenance Manual
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Sect.8:6
Check the efficiency of the bolted joints. Tighten loose bolts
and anchorings.
Check the stability of the railings.
General
Verify the integrity of the rubber socks (cement batching and
discharge, water discharge) and the hold of the collar bands.
Control the integrity of wear cover s(mixer, concrete hopper, bucket,
aggregate feed openings) where provided.
Aggregate batching group
Grease aggregate feed openings (greaser on the pins)
Aggregate transport unit
Grease bearings mounted on the belt. (see manual)
Remove any material deposited on the load cells.
Load cells weighing systems
Control the efficiency of the insulating copper conductor and
the grounding.
MONTHLY
Control to ensure that the safety bars are in the correct position
(they should have a play of 4-5 mm, to limit fluctuations without
interfering with weighing).
Clean the water filter.
Hydraulic plant
Verify the integrity of the rubber hoses and the seal of the collar
bands.
Control the filtering elements.
Mixer dedusting filter
Verify the functioning of the filter cleaning system.
Remove the plexiglas recipients of the air filter and lubricator
and wash them with soap and water (washing with fuel oil is
never recommended).
Pneumatic plant
Control the level and quality of the compressor’s lubricating oil.
If there are changes in colour (whitish = presence of water dark = overheated) completely replace. In all cases replace the
oil after the first 100 hours of work, and thereafter every 300
hours (see the specific manual attached).
Clean the compressor suction filter.
Control the tension of the compressor transmission belt (see
specific manual attached).
Verify the integrity of the pipes and the hold of the grips.
Clean aggregate inlet zone between mixer cover and skip
Mixer
raceways.
Verify any leaks from the door and adjust as necessary.
Sect.8:6
Maintenance
User and Maintenance Manual
CIFAMOOVE 30
PA
Sect.8:7
1 YEAR
Replace the water filter cartridge.
Hydraulic plant
Hydraulic oil system.
2 YEARS
Verify oil level/purity.
Load cells weighing systems
Every 2 years, have a weigher check the load cells weighing
systems. (in countries where required)
Maintenance
Sect.8:7
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PA
Sect.8:8
8.4
INSTRUCTIONS FOR ORDINARY AND EXTRAORDINARY MAINTENANCE
8.4.1
SAFETY DEVICES
•
Check the limit switches - daily (recommended immediately, upon first cycle):
•
To verify the functioning of the lower, middle and upper proximity limit switch: Make a visual check to
ensure that the three lights (on mimic panel or screen) are illuminated when the bucket passes.
To verify the functioning of the loose cable limit switch: Make a visual check to ensure that, during loading
of aggregates, the loose cable light is illuminated, and then turns off when the bucket starts.
•
Other devices
•
Checking of safety devices: act the device and check if plant stops.
•
Functioning of push button: push for starting, turn and pull to have it back in position.
•
Efficiency checking of sound and light signals: pay attention if, during functioning, lamp on synoptic
are lighting and if siren is heard.
8.4.2 MIXER
For maintenance of mixer parts, consult the specific use and maintenance
manual attached.
8.4.2.1 Daily cleaning of mixer
•
At the end of working day or before any long stop, load the mixer with aggregate and water and mix
for 1 minute.
•
At the end of the day clean with water under pressure. (hydro-cleaning machine excluded to provide
CIFA)
•
The purchase by the client of a pressure washer is recommended.
•
Do not go inside in the mixer for washing operations: Danger of slipping, knock or injuries.
•
To reduce deposit, proper product could be used at work starting (contact your suppliers of specific
additives)
8.4.2.2 Mixer washing with washing plant (optional)
ATTENTION
All washing operations with nozzles on the mixer have to be performed with the windows (on mixer cover)
closed. The washing sequence may be set either from the panel in the control cabin.
Sect.8:8
Maintenance
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User and Maintenance Manual
Sect.8:9
CIFAMOOVE 30
IMPORTANT: See the specific manual attached for the operating sequence.
•
Discharge the wash water into the concrete mixer (or onto a wheel loader) to transport it and
deposit it into a system for the recovery of concrete residues and wash water.
8.4.2.3 Opening of windows on mixer cover:
ATTENTION
To open doors on the mixer, stop the plant, cut off panel power in the cab, put the lock on the selector and
remove the key, cut off power to the main switch and insert the red key in the mixer interlocking system.
IMPORTANT:
For more safety, each window should be LOCKED WITH AN INTERLOCK.
Interlock should be opened with a special key in the control panel. This operation shuts off the power,
and also makes it impossible to turn it back on (until the key is returned to the control panel).
8.4.2.4 Washing with a high pressure jet washer (optional) (excluded to provide cifa)
•
To perform this operation, mixer windows should be opened.
IMPORTANT:
Perform this operation out from the mixer.
•
Disconnect spiral pipes (cement batcher venting and filter connection) to avoid to wash them.
•
Open the window and wash the interior of the mixer, then wash the concrete discharge hopper with
slots in the protective grid located on the sides of the mixer
•
Unload the wash water in the concrete mixer (or onto a wheel loader) to transport it and deposit it
to a system that recovers concrete residues and wash water.
Maintenance
Sect.8:9
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Sect.8:10
8.4.2.5 Cleaning the aggregate entrance area between the cover and aggregate belt.
IMPORTANT:
Switch off the plant before unscrew the nuts and open the window.
•
Clean the inside of the loading hopper with a lance.
8.4.2.6 Examination - replacement of wear plates and mixing paddles
For these operations, it is necessary to enter the mixer.
IMPORTANT:
Before entering the mixer, wash it thoroughly and wait for it to dry, to avoid slipping!
Wear strong clothing, accident prevention shoes, gloves.
To check wear (see specific manual).
IMPORTANT:
When the wash-maintenance operations are completed, CLOSE THE COVERS, remove the keys from the
locks and return them to the remote panel to power it up again.
8.4.2.7 Replacement or maintenance of mixer electric motors - extraordinary maintenance
Execute with PLANT SWITCHED OFF
To replace or repair the electric motors of the mixer, it is necessary to take them off the mixer and place
them on the ground, as follows:
•
Disconnect the electric motors from the electrical part of the mixer (including the transmission) (see
specific attached use and maintenance manual).
•
Bring the lifting equipment near the mixing unit and connect the motor to the lifting eye bolt..
•
Using the lifting equipment, lower the electric motor to the ground so that it can be transported to an
appropriate workshop for repair or replacement..
Sect.8:10
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User and Maintenance Manual
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Sect.8:11
8.4.3 CONCRETE DISCHARGING HOPPER
•
To wash the hopper with jet washer, and to check wearing conditions, use the grids at mixer sides.
•
For extra hopper cleaning, use a special vehicle for working at heights.
•
To change hopper wearing, hook the hopper with a crane and put it on the ground.
8.4.4
BUTTERFLY VALVES VFS - cement batch feeder and VFF - cement silos
IMPORTANT:
Before performing any operation, SHUT OFF THE ELECTRICAL AND PNEUMATIC POWER.
ATTENTION:
The cement batcher valve will last significantly longer if it is cleaned regularly, in particular if the material
tends to harden or compact if it is not used for prolonged periods.
IMPORTANT:
•
No lubrication is necessary for moving parts.
•
No replacement of worn parts is anticipated
EXTRAORDINARY MAINTENANCE (cement silo valve VFF)
•
Before removing the baffle, ASCERTAIN THAT THE BATCH FEEDER BELOW IT IS COMPLETELY
EMPTY.
•
To replace the manual or pneumatic activator, see the specific use and maintenance manual attached.
Maintenance
Sect.8:11
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8.4.5 PNEUMATIC PLANT
The air used to command the pneumatic cylinders
goes through a filter, which eliminates any impurities
(complete with pressure reducer) and then through
Adjustment
screw
a lubricator, whose function is to vaporize the oil
inside it and inject it into the air plant.
Adjustment of lubricator: a batcher screw makes
LUBRICATOR
it possible to regulate the quantity of drops of oil to
be vaporized. A full supply of oil should last from 15
to 20 days, if the plant is operating correctly.
Recommended type of oil: mineral oil or SAE 10.
Adjustment
knob
Calibrating the pressure reducer: using a handle
that must be either turned one way or the other as
needed, checking the pressure on the pressure
gauge.
Pressure
gauge
The air utilized for fluidification (which does not run
through the lubricator) runs through an additional
pressure reducer (calibrated at 2 bars for 0.5 bars
on the plates).
FILTER
PRESSURE
REDUCER
Batcher unit pressure gauge
7
5
bar
6
MAX bar
bar
Pressure gauge
gauge
Sect.8:12
2
Maintenance
Silo gauge
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Sect.8:12
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User and Maintenance Manual
CIFAMOOVE 30
Sect.8:13
Recommended adjustment:
•
Main pressure gauge (nozzle cylinders): 7÷7.5 bars.
•
Pressure gauge of the batching module (batching and water discharge valves and cement
discharge valves): 5÷6 bars.
•
Fluidification pressure gauge (for each silo): 2 bars.
8.4.6
ELECTRICAL SYSTEM
•
Check the efficiency of all electrical control components.
•
At least once a month, ensure that the cables are completely insulated, especially where they meet
the cable locks and cable glands, in order to avoid short circuits that could damage other components.
Screws may loosen due to vibrations or subsequent closing of contactors contained in the cabinet,
causing excessive wire heating with resulting burning of the wire insulation itself and, consequently,
short-circuiting between the wires and between wires and grounding.
•
Also check to ensure that the connection points are perfectly locked and have not oxidized.
•
Always ensure that there is a perfect connection to the electrical plant’s grounding system.
•
At least once every 6 months, verify the ground wires and relative clamps.
Note: to replace any device contained in a control panel, the plant must first be isolated.
If maintenance personnel is not qualified to make any replacements or modifications, the equipment
manufacturer must perform the work
Maintenance
Sect.8:13
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Sect.8:14
8.5 LUBRICATION
ATTENTION:
ALL LUBRICATION OPERATIONS SHOULD BE CARRIED OUT WITH THE PLANT STOPPED
Give exposed mechanical parts a protective surface lubrication.
If equipment is unused for long periods of time, generously lubricate all parts of the machine.
If, while lubricating, it becomes necessary to remove a protection:
•
be especially careful during maintenance operations
•
reassemble the protection before using the machine
8.6
TROUBLESHOOTING
Below is a list of problems (with causes and possible remedies) that can be resolved without consulting a
specialist.
To troubleshoot any problems regarding components not listed in this manual, refer to
the specific manuals.
Intervention in case of blocking of a moving element (opening, skip or screw):
-
Stop the plant.
-
Remove any foreign element and clean out any loose material and then try to re-start the plant.
-
In case of damages, call CIFA service.
Note:
Batching openings have a moving opening system. The falling of material with big dimension during
batching operation can block the opening in open position: this could allow the falling of too much material
and damaging of cylinder.
In case of opening blocking, intervention can be carried out from control panel by trying to open and close
the opening. Otherwise stop the plant, exhaust the air from pneumatic plant to avoid sudden closing of
the door opening (because the cylinder tries to close the door opening). Remove, if possible, the foreign
element and clean off eventual exceeding material.
Screws can be blocked if cement has blocks or rags.
Sect.8:14
Maintenance
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Sect.8:15
8.6.1 BELT
Malfunction
Cause
Possible solutions
Belt
No electrical power.
Check the power and electrical connections.
Emergency Push button ON Check and possible emergencies reset
Upper limit switch blocked
Verify and reset limit switch as necessary
Selector in manual mode
Verify plant operating settings
The mixer has not finished
Check the operation settings of the
plant.
its previous cycle
Upper limit switch triggered
To completely finish the cycle and check if parameters of “delay” are correct for the type of production
( Slump ).
The discharge gate was
left open
Verify that control devices are active for electric lifting hoist on electrical remote control placed
on mixer flat.
8.6.2 OLEODINAMIC PLANT
Malfunction
Cause
Possible solutions
No electric power or
Check the electric power and the electrocompreselecrocompressor switched off. sor.
The pneumatic
cylinder will not open.
Solenoid valves are
noisy.
The feed openings
keep closing
Low air pressure
Check the pressure reducer.
Gaskets are worn
Replace the gaskets
Solenoid valves are fault.
Replace the solenoid valve or only the
coil, if burnt.
Silencers damaged
Replace silencers
Gaskets are worn.
Replace the gaskets.
Pneumatic cylinder scratched
Replace the pneumatic cylinder
Maintenance
Sect.8:15
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Sect.8:16
8.6.3 CEMENT BUTTERFLY VALVES
Malfunction
Cause
Possible solution
The product inside has caused a
The valve does not
block.
open or remains
open all the time.
The air pressure is insufficient.
The valve always remains partially or
The valve opens and completely open.
closes with difficulty
or leaks cement.
The washer is worn.
Sect.8:16
Maintenance
Disassemble, clean and reassemble
Check the pneumatic line and take
necessary action.
See solution proposed above.
Replace the gasket
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Sect.9:1
Use and Maintenance Manual
CIFAMOOVE 30
Chapter 9
DISASSEMBLING THE PLANT
Sect.9:1
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Sect.9:2
9 DISASSEMBLING THE PLANT
9.1
GENERAL INSTRUCTIONS
before disassembling the various components, ensure that you have SHUT OFF THE ELECTRIC
POWER.
Follow the safety instructions previously indicated for assembly operations and wear personal protection
devices.
If the plant is sold to another user, advise CIFA of the change in ownership.
If the installation location is changed, verify that it is appropriate in terms of the seismic, wind and snow
parameters indicated in § 2.2.
9.2
OPERATIONS PRIOR TO DISASSEMBLY
Before disassembling the plant, perform the following operations:
1) Empty the cement silos, the water tanks, and the aggregates storage hoppers.
2) Disconnect the hookup to the electrical and water lines at the worksite.
3) Assemble the aggregate batcher stroke locking plates on the aggregate feeding belt.
4) Tighten the lower nuts of the threaded safety rod against the water batch feeder sheet to lock in the
load cell and thus avoid damaging the cells.
5) Tighten the lower nuts of the threaded safety rod against the sheet of the cement batch feeder to lock
in the load cells.
9.3 DISASSEMBLY SEQUENCE
At this point, proceed with disassembling the plant, performing operations in reverse order from what is
indicated in chapter 5-assembly (to be consulted for details of the individual operations):
1) Disconnect the electrical system power cables.
2) Dismantle optional accessories (ramp containment bulkheads, mixer cleaning, silos and augers, etc.).
3) Disconnect skip ropes and wind them around the winch, releasing the brake and rotating the fan.
4) Dismantle gates.
5) Disconnect the rubber water hosing, batching and cement discharge sleeves, the water discharge
sleeve, and the concrete discharge hopper sleeve.
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6) Dismantle the concrete unloading hopper.
7) Dismantle the mixer dedusting filter.
8) Dismantle walkways, guard-rails and ladders.
9) Hook the crane to the mixing unit, un-bolt it, remove pins and, rotating it on the runway wheels, lower it
to the ground.
10) Remove the pins and disconnect the mixing unit support structure. Dismantle any bases.
11) Remove the runway sliding wheel locking wedges. Slide the mixing unit to the transport position.
Reassemble the wedges in the rear position to lock the runways.
12) Assemble the transport beams and bolt the mixing unit to the lower frame.
13) Dismantle the skip nets.
9.4 TRASPORT
Please see chapter 4 for information on vehicle road transport.
9.5
DISPOSAL
The plant can be dismantled and scrapped without any special precautions.
•
However, be sure to remove the lubricating oil from the reducers, plastic and rubber parts
(venting hoses, rubber stockings, gaskets, wearing sheets, etc.), and dispose of everything through
authorized companies.
•
Deliver control panel and electrics cables to specific authorized companies.
•
Deliver the structural work and metal components to collection centres. The metallic structure
must be disposed of as old metal.
•
In case of maintenance, do not dispose of used oil or rubber parts in the environment, but rather
through authorized companies.
•
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Chapter 10
SPARE PARTS AND AFTER SALES
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10 SPARE PARTS AND AFTER SALES
The supply includes a manual of recommended spare parts; for additional replacement parts, refer
to the specific manuals for the various components, as well as overall designs provided, which,
along with the use and maintenance instructions, you can use to identify the parts.
10.1
PROCEDURES FOR MAKING REQUESTS
Requests for spare parts should be sent to:
CIFA SpA.
- Spare Parts Service
Via Stati Uniti d’America, 26
20030 Senago (MI)
Italia
Telephone
0039-2-990131
e-mail
spareparts@cifa.com
When requesting replacement parts, please include the following information:
•
Type and model (CIFAMOOVE 30);
•
Registration number or purchase order and year of manufacture (reported on the EC plate)
•
Description of replacement part
•
Replacement part code, if indicated
•
Number of parts desired
•
Means of shipment
•
Company name, address, and tax information of requesting party and shipping address.
Requests for after sales Service, should be sent to:
CIFA SpA.
- After Sales Service
Via Stati Uniti d’America, 26
20030 Senago (MI)
Italia
Telephone
0039-2-990131
Fax
0039-2- 99013335
service@cifa.com
e-mail
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Via Stati Uniti d'america, 26 - 20030 - SENAGO (MI)
Tel.: (+39) 2 99013.1
Fax: (+39) 2 9980786
cifa@cifa.com - www.cifa.com