P-25 User Manual Hydraulic and Electric
Contents
1. 2 A T 015 U010U 04 pa VIS dhfd IN I3 3 Page 7 Pump Unit D pump series Typical delivery 106 ft hr 400 RPM D Pump 1 D Rotor 2 D Stator 3 Mount flange 4 tie rod 5 Nut 6 Output flange 7 Washer 8 Pump seal Outputs are theoretical and typically 25 higher than seen in practice Outputs are also subject to material type moisture levels application method and as such testing should be performed to establish suitability Page 8 Drive unit The machine is supplied with either an electric motor drive or a Hydraulic motor drive Both methods of drive are compatible with both pump units Electric Drive unit A A N PA R 1 Drive Haul bracket 2 Grease seal 3 Motor flange 4 Compression ring 5 Location dowel 6 Electric motor 7 Set Screw 8 Key 9 Bolt 10 Lock washer 11 Grease sert Note GREASE ON A DAILY BASIS Page 9 Electronic Drive module The electronic Drive module comprises of a variable speed frequency inverter allowing the use of 220V AC two phase to run the high torque 3 Phase gear motor The unit is rated at 7 5 HP providing plenty of power to run the P 25 unit The module is supplied with an input plug allowing immediate wiring into your own 220V AC 2 phase supply Must be carried out by an approved installer The motor is supplied with a pre wired plug that f2. ANY WARRANTY OF MERCHANTABILITY OF FITNESS FOR A PARTICULAR PURPOSE In no event shall Machine Technologies be made liable for incidental general or consequential damage loss or any expense directly or indirectly related and resulting from use or lack of use caused by delay in delivery parts failure or any other causes associated with the product use No person firm or corporation is authorized to assume for Machine Technologies any other liability in connection with the sale of Machine Technologies products Page 24 RL VETETTE LS RR IS SER TI NTETE
3. operation speed setting The following are to be completed by trained and experienced persons familiar with the pumping system provided 1 Connect a hose to the output coupler on the end of the pump unit 2 Fill the P 25 hopper with water and a suitable lubricant 3 Place the discharge end of the hose into the hopper making sure that the end cannot come into contact with the moving parts inside the hopper Turn on the machine in the FWD direction and observe fluid to be displaced from the hopper through the tube and then back to the hopper in a recirculatory manner Using a suitable collection vessel and a stop watch time the volume discharged in a given period Convert this amount displaced into gallons minute Compare this figure with the required figure and adjust the speed accordingly Do not run the machine with water and lubricant for more than five minutes at a time or damage will result to the pump unit General notes for operation Grease hauling bracket seal daily with water resistant corrosion inhibited grease For starting the pump Ensure that the speed control is at minimum and direction control are set to forward Turn main power switch on Push start button Adjust speed to desired output Do not let hopper run dry while pump is running To stop machine push the stop button If a hose plugs while pumping reverse direction on pump to relieve line pressure Never point hose towards personne
4. TECHNOLOGIES P 25 User Manual Hydraulic and Electric Revision 5 10 11 07 1130 Blue Mound Road West Ste 400 Haslet TX 76052 Ph 817 439 1108 Fax 817 439 0633 www machine technologies com Dear Customer Before starting this machine please complete the following Machine Date of purchase Machine serial number ori tament see Please read the following information contained within this manual and fully familiarize yourself vvith the equipment Page 1 Contents Page Section 1 General Safety information ssoessosssscsssccssocesooesoocsoocsesocessecssocesocssoosesossssee Danone Section 2 Machine Description 000000000000 000000000000000000000000000 CLLELLELILIS 000000000 0 00 00 CC 000000000000000000000000000 eoccccccccce I Function sesscscescccsecsesseccesscscucesassuscesseacesssseeescestecseseseceuedeesecsesvascosdcessedsosessessocvesesseveaseswoceess Machine illustrations ccccccsssssssssssssscscscscscscscssscscscssssscscscscssscssscscscccscscscscscscscssscses Hopper UHI Rial ca tenia mei met lent des socassa obps iaaea Siesoo daisse el can da Front and rear seal location vi sccisess sacecssscccsvess coscdecsccsscdsscedeseseccedessocessdessecasctscsessosseess ecccccccccce Machine nine coscescedececcactcssaasdcecaseascoecestesecsoccctcssdeeasssasecscosceseecescecscbcssaee D ecccccccccce Electronic Drive module cicte
5. a an electronic variable speed inverter supplied by two phase 220V AC 50 60 Hz OR a remotely supplied hydraulic high pressure hydraulic supply into a hydraulic motor Both style of drives transmit their rotary action through a drive shaft equipped with bridge breakers which help to mix and convey the material from the hopper towards the pump unit The pump unit is a progressive cavity pump unit comprising of a helical rotating rotor with the rubber lined stator As material is drawn fed into the pump unit it is forced through a series of cavities that deform causing the material to be moved from the hopper towards the outlet Once the material has reached the outlet it is guided through an output flange assembly into the dispense hose through to the hose outlet where typically a spray nozzle is attached allowing with the assistance of an auxiliary air supply the material to be sprayed on to the substrate A number of different devices can be fitted to the outlet of the tube for different means of application For details of these different devices please contact your supplier of Machine Technologies equipment or Machine Technologies directly Page 4 Machine illustrations Machine 1 Hopper unit 2 Pump unit 3 Drive unit elec shown 4 Drive shaft with bridge breakers Page 5 Hopper unit Page 6 Front and rear seal location AO
6. aces are flush PUMP FLANGE Note the drive shaft will become tight between the two drive slots during static assembly Once the unit has been running the compressive force will be reduced or eliminated to within working limits During pumping the compression will be present during reverse the compression will be relieved Important Replace the safety grid back onto the top of the hopper and secure using the 4 clips bolts and washers Operation of this machinery without the grid in place is prohibited Page 18 Electrical connections electric version only 1 Ensure that there are no power connections to the Electronic drive module 2 Site the drive module with 6 of the P 25 unit as this is the fitted power lead length from the electric drive motor to the connecting plug 3 Obtain a suitable connection lead for single phase 220V AC feed to the drive module The length must be such that the delivered voltage to the drive must be 220V AC and capable of supplying 30A on each leg phase Turn the breakers OFF in the box and remove it from the bus bar to ensure that no voltage exists on the cables 4 Make the connection between the drive module and the main distribution box using the supplied electric plug and your supplied cable Ensure that the Earth is connected as well as the two 110 VAC phases 5 Connect the plug to the drive module and ensure that the drive mod
7. chine Ensure that the seal between the hauling bracket and the motor is greased each day with a water resistant corrosion inhibiting grease Grease until a small amount of grease can be seen oozing from around the hauling bracket GREASE SEEN TO OOZE OUT HERE Page 22 Section 7 Notes on wear of rotor stator pump unit Wear issues Dry running of a rotor stator pump A screw pump can only work reliably if there is adequate and appropriate lubrication The lubricant produces sliding friction between the rotor and the stator If this lubricating film is damaged high temperatures are reached and the elastomer wears within a very short time Even if dry running lasts only a few seconds with new parts the effect resembles that of a wheel spin on a car tire dramatically affecting length of service Dry running of rotor stator pump due to dry pockets in mixed material It is possible for pockets of material to pass through the pump which are dry inside if mixing is inadequate or in the case of some problematic materials Since these pockets are partially squashed between rotor und inside of stator some degree of dry running ensues which interrupts the lubrication film between rotor and stator with severe detrimental effect on service life Page 23 L E TECHNOLOGIES Concret and Mixtng Prong LIMITED WARRANTY POLICY Machine Technologies warrants each of its new machines to be free of defects in material and workman
8. er to the machine has been turned off and isolated ie The hydraulic power pack must be turned off and prevented from being started before ANY maintenance repair work 1s carried out on the machine Electrically powered machine Always ensure that all power to the machine has been turned off and isolated before ANY maintenance repair work is carried out on the machine Ensure that all guards are correctly fitted before starting or attempting to operate the machine Ensure that all fasteners are present and correctly fitted before attempting to start or operate the machine Ensure that the pump unit is correctly fastened to the front of the hopper unit of the machine and free of damage before attempting to start or operate the machine Ensure that the hydraulic motor the flange and the hydraulic hoses are correctly fitted and free from damage before attempting to start or operate the machine The P 25 pump unit can produce high pressures high torques and can use high voltages Care must be taken by authorized persons when using and working with this machine Page 3 Section 2 Machine Description Function The machine has a drive motor that turns a drive shaft within a material hopper that in turn feeds a progressive cavity rotor stator pump unit that delivers the material from the hopper to the dispense head via a material hose hoses The machine is driven by either an electric motor powered by 220VAC 3 phase 50 60Hz vi
9. he pump unit pump wedges and the breaker bar from the hopper Consult the final inspection record supplied in the packing for details of your machine and the items checked prior to shipment Keep this document for your records SAFETY CATCHES WASHERS AND BOLIS FOR GRID SAFETY GRID ROTOR AND PUMP UNIT BREAKER BAR DRIVE SHAFT PUMP UNIT ELEC SHOWN Page 15 Machine assembly Ensure that the motor wedges are secured and in place MOTOR WEDGE D ECTRIC M HYDRAULICMUI aN Assemble the breaker bar into the hopper and engage one of the flat ends into the slot in the drive hauling bracket DRIVE HAULING BRACKE DRIVE SHAFT BREAKER BAR Page 16 Rotate the drive shaft by hand until the other flat end of the shaft aligns with the approximate position of the slot in the end of the rotor in the pump unit Lubricate the O ring seal and slid the pump unit towards the hopper over the location shafts locating the drive shaft into the end of the slot in the pump unit PUMP ATTON SSN Page 17 Ease the pump assembly into position then assemble the two wedges into the slots Manipulate the pump unit and the wedges until the pump flange is within 1 8 of the hopper flange then drive the wedges into position until both flange f
10. idges being formed through the material in the hopper and at the same time move material towards the inlet of the pump unit Ds 4 TI NI dE N Lo 4 7 7 D U cures 1 Drive shaft 2 Drive paddle 3 Bridge breaker Page 13 Section 3 Transportation and positioning The machine is typically manually transported around the job site using the two carrying handles and the wheels in a similar manner to a wheelbarrow The handles swing vertically down and out of the way when not in use If the machine is to be permanently positioned then they can be removed and stored for later replacement MACHINE CARRYING ANDLES SWING DUT R TRANSPORTATION I Ay If the machine is being transported between sites normally the pump unit will have been removed from the front of the machine due to cleaning between jobs providing access for lifting hooks around axle on each side of the machine and from the front of the unit The illustration of the machine above refers to the electrical version if hydraulics are being used then attention will have to be taken towards the two hydraulic hoses from the power unit to the machine itself Page 14 Section 4 Machine set up Unpacking Remove the safety grid from the top of the machine by removing the 4 bolts clips and washers Remove t
11. its into the 3 Phase outlet of the module The module has a main power isolator a combine stop start switch a reverse switch a speed control potentiometer internal breakers for each input phase a large capacity cooling fan in addition to the fan fitted to the inverter and a remote socket providing the optional capability for remote operation A carrying handle is provided on the top of the module for convenient re location around the job site 1 Mains isolator 2 Start Stop buttons 3 FWD REV switch 4 Speed control 5 Remote plug connector 6 3 ph power out connector Page 10 Inverter drive 9 Single phase mains power inlet 8 7 fan filter covers Page 11 Hydraulic Drive unit 1 Motor flange 2 Grease seal 3 Compression ring 4 Location dowel 5 Drive bracket 6 Motor plate 7 Set screw 8 Grease sert 9 Hydraulic motor 10 Motor fixing bolt 11 Plate fixing bolt 12 split washer Note GREASE ON A DAILY BASIS Page 12 Drive Shaft with bridge breakers The drive shaft couples the motor drive to the pump unit and allows one to turn the other The drive is equipped with bridge breakers which prevent br
12. l when pump is working When cleaning the pump do not remove grate while pump is running Wash out hopper with water and let it run out of the hose When the hopper is clean run foam balls through hose with clean water Do not spray water on or in control box Control box should be wiped down with a damp rag If access is required in to the hopper disconnect power source before removing grate Pump can be disassembled by removing wedges this facilitates easier transport and final clean up Pump is supplied with an adjustable stator The sleeve can be tightened to bring working pressure back to normal range as the stator wears down This should be done in small increments Over tightening the stator will cause premature wear and heat up material Always check hoses and cords for wear The unit runs on high voltage and is capable of high pressures in the hoses Page 21 Section 6 Simple maintenance The P 25 pump unit is very simple to maintain By far the biggest part of maintenance of the P 25 machine is cleaning after a job Failure to clean properly after use will damage seals paint and moving parts due to material build up causing wear Pay particular attention when cleaning to the seals between the Rotor stator flange and the flange on the front of the hopper to the seal between the motor mounting flange and the rear of the hopper to the seal around the drive hauling bracket fixed to the drive flange at the rear of the ma
13. psncscessvacaioconcdsadbsscandsoveaaiseavcdasccsvcagasveszesse LO Hydraulic Drive unit eoesssoossssooesesooecesosccesssoossssoosessooecesooecesssocssssocesesosesssssssssssso 2 Drive Shaft with bridge breakers sseessecesooessocsssccssocesocecoosesocsssccesocesocessoeessesssesss 13 Section 3 Transportation and positioning sesssccescocssocsssecssocesocesoosssoesssecesocsssesess LA Section 4 Machine set up ii rennes na nana neue L5 Unpacking ss ss ions LS Machine assembly 2ammomooa nome eseese 16 Electrical connections electric version Only sessssoessoccssccssocesooesoocssoeessesssocesecssso LD Section 5 Machine operation speed setting DL General notes for operation vecsscecescssccrescseneseacsecesessocedsesoserencssvtendcconcesvecdycevocssvcecvsevoess ZL Section 6 Simple Maintenance cescccssscsssssrcssssesssssccssssssssscesssssesssasccssssesssssesses 22 Section 7 Notes on wear of rotor stator PUMP Unit 23 Wear CLIC CPR Re ARE A On ssl DS Dry running of a rotor stator PUMP scccsscccssrcsssscesssscsseeseess ss 23 Dry running of rotor stator pump due to dry pockets in mixed material 23 LIMITED WARRANTY POLICY nn nets esrensenretieensessee 24 Page 2 Section 1 General Safety information Danger Follow these instructions very carefully in order to avoid injury to yourself or others Hydraulic powered machine Always ensure that all pow
14. ship under normal use and services for a period of one 1 year from the date of delivery The warranty is issued ONLY to the INITIAL USER The warranty period begins when the product is delivered to the initial user or when first put into service whichever occurs first Said warranty is void if the machine is subject to misuse neglect accident or abuse Machine Technologies obligation under this warranty is limited to correcting without charge at its warehouse any parts or parts thereof which shall be returned to its warehouse transportation shipping prepaid and upon Machine Technologies examination proves to have been originally defective Correction of such defects by repair or replacement shall constitute fulfillment of all obligations to the initial user This warranty does not include labor or transportation charges unless specifically identified and authorized in writing by Machine Technologies Nor does the warranty apply to any unit upon which repairs or unauthorized alterations have been made The warranty does not apply to normal maintenance service or to normal replacement of certain machine parts which are subject to normal wear including but not limited to pins bushings rotors stators hoses spray caps spray nozzles mixing shafts shaft couplings and connectors dosing shafts pump shafts filter elements and tires THIS IS A LIMITED WARRANTY AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING
15. ule rotary isolator switch is turned OFF 6 Replace the breakers into the distribution box onto the bus bar and turn them ON 7 Turn the drive module isolator to ON and listen for the cooling fan to turn on STOP The following must be conducted by a supervisor or a qualified individual experienced in electro mechanical equipment Ensure that there are no persons close to the machine Ensure that there are no obstructions in or around the machine Turn the speed control knob fully clockwise 8 Press the start button and observe the machine to turn the drive shaft and in turn the pump unit PRESS THE STOP button within 5 seconds or damage will result to the pump unit 9 Turn the direction switch from FWD to REV and hold in position as it is spring returned to prevent excessive reverse running 10 Press the start button and observe the machine to turn the drive shaft and in turn the pump unit in reverse PRESS THE STOP button within 5 seconds or damage will result to the pump unit Note the unit may be equipped with an initial motor reverse timer control in which case when in FWD direction the motor will run in reverse until the timer times out then the unit will function in the normal manner The reverse function it to help break loose the rotor within the pump unit 11 The machine is now ready for use by trained and qualified operators Page 20 Section 5 Machine
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