SIVAJET MONO

BRIEF USER MANUAL for machine operator and maintenance staff

do not operate the machine before fully understanding the user manual

Do not hesitate to contact us if you have any queries: ASE MAK. İNŞ. ELEKTRİK. SAN VE TİC A.Ş. ADRESS: GERSAN SAN. SİT. 2307 SK. NO:54 ANKARA - TURKEY HOTLINE: +90 312 256 56 33 FAX : +90 312 256 61 50 WEB: www.ase-co .com

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A. FOREWORD Founded in 1996, ASE is the first company in Turkey to manufacture plaster/mortar mixing, pumping and spraying

machines.

With its professional production and management staff, ASE has closely followed the latest technological developments

and today it is the greatest company of the industry in Turkey.

With the largest manufacturing substructure of Turkey in the plastering and screed machines, ASE is one of the leading

machinery manufacturers of the industry in the world.

As ASE puts a great emphas is on quality in manufacture, it makes machines as compliant to international standards and

suitable for harsh site conditions. It has ISO 9001:2008, CE, GOST-R quality certificates.

ASE manufactures all its machinery in Turkey with engineers and technicians - all experts in their fields, under high quality

standards. The company exports its economic, efficient and high quality products to more than 40 countries, including

especially the European countries.

As well as ASE's being the market leader and pioneer in Turkey, ASE machinery is also operated in a great number of

regions all around the world in an efficient and satisfactory manner. ASE properly represents the Turkish Products image

and quality in the international arena.

Adopting the principle "real work begins aſter sales", ASE puts so much importance on aſter sales support and service. It

responds to customer demands swiſtly and creates fast solutions.

Anyone from any part of the world contacting us any time would find the well-known Turkish friendliness and cordiality.

We will be happy to share all our knowledge and experience with you.

Partially or totally copying, reprint and translation of this document is only with clear and explicit permission by our

company.This manual may not republished partially or completely or used unauthorized for the purpose of

competition.We reserve the right to make technical changes for improvement.

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EC DECLARATION OF CONFORMITY

MANUFACTURER

NAME : ASE MAK. İNŞ. ELEKTRİK. SAN VE TİC A.Ş

ADDRESS : GERSAN SAN. SİT. 2307 SK. NO:54 A NKARA - TÜRKİYE

TEL : +90 312 256 56 33 FAX: +90 312 256 61 50 WEB: www.ase-co .com

Name and Address of the

Person authorised to compile the

technical file : ALİ TUNA

GERSAN SAN. SİT. 2307 SK. NO:54

ANKARA - TÜRKİYE

The undersigned declares that the described products meet the essential requirements of the below mentioned standards

as based on Machinery Directive 2006/42/EC, Low Voltage Directive 2006/95/EC.

The item of equipments which identified below has been subject to internal manufacturing checks with monitoring of the

final assesment by ASE MAK. İNŞ. ELEKTRİK. SAN VE TİC A.Ş

MACHINE DESCRIPTION : MIXING, PUMPING AND SPRAYING MACHINES

MODELs : SIVAJET MONO

APPLICABLE DIRECTIVES :

2006/42/EC MACHINE SAFETY DIRECTIVE

2006/95/EC LOW VOLTAGE DIRECTIVE

APPLICABLE REGULATIONS :

EN ISO 12100:2010, EN 60204-1: 2006+A1:2009

SIGNED ON BE HALF OF THE MANUFACTURER

NAME : ALİ TUNA

POSITION : General Manager

PLACE/ DATE : GERSAN SAN. SİT. 2307 SK. NO:54

ANKARA - TÜRKİYE

SIGNATURE :

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This machine is only used to make plaster application by mixing all sorts of dry mixture

materials, all the time, automatically until its homogeneous and pumping or spraying

it. Any other usage beyond the materials and the purpose is considered contrary to the

procedure and means misuse of the machine.

The safety equipment of the machine is used to prevent any industrial accident.

Removal, replacement or disabling functions of these may cause an industrial accident.

In these cases the responsibility belongs to the user.

This machine’s automation, electrical and mechanical systems are guaranteed for 2

years. User errors or any errors caused by improper usage of the machine according

to the user manual will be excluded from the warranty.

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B. APPLIED DIRECTIVES AND STANDARDS

This machine is manufactured according to the directives and standards listed below.

Directives

2006/42/AT Machine Directives (MD)

2006/95/AT Low Voltage Directives (LVD)

Standards

EN ISO 12100:2010 Safety of machinery - General principles for design - Risk assessment and risk reduction

EN ISO 13857:2008 Safety of machinery - Safety distances to prevent hazard zones being reached by upper and lower limbs

EN 60204-1:2006 Safety of machinery - Electrical equipment of machines Part 1: General requirements

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C. SAFETY

1. Used Safety Signs and Meanings

Symbol Meaning Description

General Danger

Shows that fatal/serious accident can happen and/or

the product can be seriously damaged if manual is not

followed.

High Voltage This mark indicates electrical hazards that could result

in personnel injury or death.

Entanglement Hazard

(hand in gears)

Moving parts can crush and cut. Follow lock-out

procedures before servicing..

Important Note Warning sign about the important points and issues.

Manual Indicates that you need to read the manual before

operation.

Glove Related work in the area where the mark is found,

appropriate protective gloves is essential.

Protection Headset Where this sign is located, appropriate headset or ear

plugs must be used.

Security Cover

In case of opening part where the mark is expressed to

be at risk. This cover can only be opened by experts

and trained persons, if the main switch is off and it is

forbidden to operate the machine while the cover is

open.

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2. Status And Control Of Security Systems The security functions below are used in this machine:

- Emergency Stop Button - Protective Covers

After receiving the machine, security equipment dysfunction or defect is under your responsibility. You must check and document about the security equipment repeatedly in time. You might need extra control in the cases below: • After setting up the machine and making its connections • After changing the location of the machine • If the machine wasn’t used in a while • After maintenance and repair If you spot any defects or failures in the security equipment stop the machine immediately. And fix the flaws before operating again.

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CAUSES OF DANGER

Even though the machine isn’t working at that moment do not touch the rotating parts of the machine before turning the

main switch off.

Before operating the machine make sure that there is no one dangerously close to the machine.

Do not insert your hand inside the screw pumps and the mixer shaft while the machine is working at any

circumstances.

SAFETY EQUIPMENTS

Emergency stop button is used to stop the machine in a dangerous situation.

When the emergency stop button is pressed:

Pump stops.

Motor gets deactivated. Emergency stop

All of the control panel buttons and switches get deactivated.

To cancel the EMERGENCY STOP situation, remove the EMERGENCY STOP button from its locked position by turning it.

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BASIC SAFETY SIGNS

The terms below are used for especially important phrases inside the user manual.

NOTICE:

Economical usage of the machine is supervised at special statements.

CAUTION!

Special statements, orders or restrictions are only made to prevent damages.

CAUTION!

Only operate this machine; when the technical aspects are free of deficiencies, with an appropriate purpose, when you are

aware of the safety information, according to the user manual.

Any error that might affect the job safety should be handled immediately by using the maintenance and repair sections in

the user manual.

We would like to mention the primary safety rules first to make it as clear as we can for you.

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BASIC SAFETY SIGNS 1. On the machine should be paying attention to all safety and hazard and will be kept in legible form.

2. At least once every work shift and the lack of externally visible damage must be controlled! Significant changes to the

machine immediately stop and notify the person concerned.

3. The changes, which will not provide the security of machine, additions and adjustments, do not do this without talking

to producers. This also applies to be installed to the safety equipment.

4. Spare part is required to comply with the technical requirements of the manufacturer's replacement.

5. Only should use personnel have been trained or taught. For handling, preparation, maintenance and protection must

be clearly identified of personnel qualifications.

6. Apprentice, trainee or general personnel training within the framework should be operated in the machine only under

the supervision of a person experienced.

7. The study of electrical machinery only may be made by an intern electricians or a trainee electrician in accordance

with the technical supervision.

8. Run - stop process and control signals, should be considered according to the user manual.

9. Is the machinery not closed entirely during maintenance and repair should be taken prevent to unexpected starting.

(E.g. closure of main switch and key removal or fact sheets on the main switch).

10. Before cleaning the machine with pressurized water due to security and interoperability, should cover all the open

parts prohibited from entering the water and be sure there is no energy in the system.

11. Only must be used original fuses on the written current intensity.

By working with electricity transmission parts in an emergency situation must be kept a second person to cut off electrical

current

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12. When the machine is moved in a short distance, all of the electricity connections should be discontinued. After moving

the machine, reconnect the machine with electricity grid.

13. The machine should be placed in a way it won’t fall over. Hazardous actions should be avoided.

14. While carrying the material transfer hose, be sure that the area is safe and pull without bending it around sharp

corners.

15. Before releasing the couplings of the mortar hose decrease the pressure level inside the hose.

16. While dealing with blockage, employees must stand at a distance that mortar won’t affect them. And these employees

must wear safety goggles.

17. If continuous sound – pressure is over 85 dB (A) use sound-proof material.

18. Use safety equipments such as safety goggles, safety shoes, work clothes, work gloves and skin protection cream

(optional) if needed.

19. Depending on the need the machine should be checked up by an expert. (at least once a year)

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OVERVIEW

6

1 7

2

3 8

4

5 9

10

11 12

POS DESCRIPTION OF COMPONENTS POS DESCRIPTION OF COMPONENTS

1 MIXER MOTOR 9 PUMP

2 MIXER MOTOR FLANGE 10 MORTAR OUTPUT FLANGE

3 MIXING VESSEL 11 FLOWMETER

4 CONTROL PANEL 12 AIR-WATER REGULATOR SYSTEM

5 SIVAJET CHASSIS

6 PROTECTIVE GRILL

7 BUNKER

8 HANDY K2 COMPRESSOR

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FUNCTION DESCRIPTION

Using the mortar made of the fabrication dry material;

Gypsum plasters,

Plasters with lime and gypsum,

Cement based plasters,

Plasters with lime,

Interior and outdoor plasters,

Grouting mortar,

Self leveling compounds,

Mortar for fixing door frames,

Insulating plasters,

Reinforcing and anchoring mortars,

Self leveling floor screed,

... and many others can be produced.

The machine is made by small, hand-sized and light-weight pieces for better and faster shipping.

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TECHNICAL INFORMATION

Pump capacity : *13 l/min

With a different pump : 6-30 l/min

Pump pressure : *20 bar

Pump distance : *30 m

Operating voltage : 230 V, 20-70 Hz

Pump motor : 3,0 kW

Power supply : 230 V monofaze

Power cable : 3x4 mm2

Protective fuse : 1x25 A

Water connection : 3/4”

Water pressure : At least 2,5 bar

Compressor capacity : 0,9 kW, 250 l/min

Control panel : pneumatic

Pump hose : Ø 25 mm

Loading height : 1060 mm

Size (L/W/H) : 1100/730/1400 mm

Weight : 165 kg (363.76 lb)

* The parameter may vary according to motor speed, mortar quality, composition of mortar, viscosity of mortar, type of pump,

condition of pump, diameter of mortar hose.

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MORTAR PUMP

1. D 4-1/2 stator can be operated up to 30 bar pressure.

2. The possible handling distance depends on the viscosity of the mortar and the diameter of the mortar hose. Thick

mortar with define particles have worse handling traits than fluid materials, fillers, liquid floor screed etc.

3. If the operating pressure will be over 30 bar pressure, we advise you to use a thicker mortar hose.

4. To prevent failures and corrosion on the spare parts use the original:

• Rotor

• Stator

• Mixer

• Mortar hose

These were manufactured to be constructional matches with each other and the whole of the machine.

Otherwise, the mortar quality will decrease and the machine will be out of guarantee.

WARNING!

The main switch should be at the “off” position when plugging and unplugging the mortar pump.

Never operate the pumper when it’s dry.

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STARTING THE OPERATION Keep the ASE SIVAJET unit as close as possible to the workplace.

Fasten the brake wheels before starting the operation.

Before using, check the connections between units.

1) Construction electricity – Control panel connection

2) Control panel – Mixer motor connection

3) Control panel - Compressor connection

4) Compressor - Air-Water Regulator connection

5) Tank- Water pump connection

6) Air-Water Regulator – Air hose connection

7) Air-water Regulator- Mixing vessel water input connection

8) Mortar output flange coupling – Mortar hose connection

9) Mortar hose - Spray gun connection

Make sure that the pneumatic control valve on the spray gun is at the “off” position.

A B C D

Notice these before providing electricity to the control panel:

� Main switch should be at the “off” position

� The water pump switch should be at the “0” position.

� The cover of the control panel should be closed.

A : Mortar hose

B : Air hose

C : Pneumatic control valve

D : Spray guy

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STARTING THE OPERATION

Water pump must be used under water pressure below 2,5 bar.

Preliminary:

Keep a few 200lt barrels in the workspace.

You will achieve the required water pressure by suctioning from the barrel with the water pump.

When the water is supplied from the barrel, the suctioning hose must be covered with filter strainer and the air inside the

water pumper must be evacuated.

To evacuate the air inside, quickly dip and remove the suctioning hose hanging into the barrel. (3-4 times)

See the pressurized water output by opening the relief valve on the air-water regulator block.

Set the main switch on the control panel to “1” position.

Set the water pump switch to “1” position (manually).

Set the water pump switch to “2” position, after reading the pressure value 6-7 bar on the manometer (water).

Press the water button, taking in some of water inside the mixing vessel and adjust the flow meter setting by inspecting

the level of float by rotating the water flow adjustment valve.

Press the start button.

Evacuate the water by positioning the pneumatic control valve on the spray gun to “open”.

Fill the bunker with the dry mixture using a bag ripper over the protective grill.

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The protective grill must be closed during the operation process all the time.

CLACK LEVER

Mix the water and the dry material by opening the dry material bunker clack.

You can change the density of the mixture with the water flow adjustment valve on the flow meter.

To keep the machine working you should supply the bunker vessel with dry material all the time during the operation.

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TAKING A BREAK

You should take a break after considering the chemical properties of the mixture.

CAUTION!

Due to the possibility of material setting the hose might become unusable.

NOTICE:

Manufacturer’s processing instructions must be followed.

The pump must be cleaned before taking longer breaks.

Even though the machine works fine after short breaks, it effects it may change the consistency of the material a bit.

So whenever this occurs please do not change the water flow, instead wait until the consistency turns back to its old

state.

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END OF THE OPERATION and THE CLEANING PROCESS

Fully evacuate the mortar inside the mortar hose and the mixing vessel.

WARNING! Make sure the pressure inside the mortar hose decreases.

Separate the spray gun and the mortar hose.

Press the stop button.

1

1

2

Unplug the power strip (1)

Using the fastened lock open the mixer motor flange (2)

DO NOT OPEN THE MIXER MOTOR FLANGE COVER AND THE BUNKER GRILL WHILE THE MACHINE IS

WORKING.

Unplug the plug on the mixing vessel flange and open it by using the tensioning lever.

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Take out the mixing unit.

Clean the mixing vessel by using a spatula.

Place the cleaning rod and the cleaning wheel as shown below, the scrapper facing down.

Stop the mixing vessel flange and fasten it with the tensioning lever.

Press start and operate for 5-10 seconds.

Stop by pressing the stop button.

Replace the cleaning rod and the cleaning wheel with the cleaned mixer.

Stop the mixing vessel flange and fasten it with the tensioning lever.

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To clean the mortar hose;

Separate the mortar hose and the mortar output coupling.

Place the wet cleaning ball inside the mortar hose.

Combine the mortar hose with the vessel output coupling.

Press the start button.

Operate until the ball comes out of the other side of the hose. (Repeat this action at least once)

CAUTION!

Use Ø 30 cleaning ball for the Ø 25 mortar hose.

Remember to discontinue the water-vessel contact.

Unplug the power plug on the control panel.

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PRECAUTIONS FOR FREEZING DANGER

Clean ASE SIVAJET.

Stop water inlet.

Unplug the mixer unit.

If you are supplying from the water tank (barrel), evacuate the water inside the machine using the suction line hose.

Evacuate all the water inside the machine using the relief valves.

Separate the mortar hoses from each other and clean their interior.

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MAINTENANCE

According to the frequency of the usage of compressor filter clean the compressor unit at least once a week. In case of

intense dirt change the compressor unit.

Clean the strainer filter inside the pressure reducer daily, if needed change it.

The brass strainer lid of the pressure reducer should be removed with a dedicated tool.

Check the strainer filter of water connection’s GEKA-Coupling every day.

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CONTROL PANEL - POWER DIAGRAM

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CONTROL PANEL

1 2 3

11 10 9 8 7 6 5 4

19 18 17 16

14

15

12 13 20 21

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POS DESCRIPTION OF COMPONENTS POS DESCRIBTION OF COMPONENTS

1 CIRCUIT BREAKER 25 A 16 FAILURE LIGHT

2 CIRCUIT BREAKER 16 A 17 WATER BUTTON

3 TRANSFORMER 75VA 26 V 18 STOP BUTTON

4 DILM 25 CONTACTOR 19 START BUTTON

5 DILM12 CONTACTOR 20 MIXER PLUG

6 RELAY MY2 21 COMPRESSOR PLUG

7 TERMINAL

8 FUSE

9 FUSE

10 NEUTRAL TERMINAL

11 GROUNDING TERMINAL

12 MAIN SWITCH

13 WATER SWITCH

14 EMERGENCY STOP

15 CONTROL PANEL LOCK

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MIXING VESSEL

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MIXING VESSEL

POS DESCRIPTION OF COMPONENTS

1 MIXING-PUMPING MOTOR

2 MIXING MOTOR FLANGE

3 TENSIONING LEVER

4 M 8 NUT TORQUE

5 M 8 WASHER

6 M 8 X 35 IMBUS BOLT

7 M 8 X 40 IMBUS BOLT

8 MOTOR COUPLING PROTECTION PIPE

9 SEALING GASKET

10 MIXING VESSEL

11 1” GEKA COUPLING

12 COUPLING GASKET

13 PLUG

14 MIXER

15 CLEANING ROD

16 CLEANING WHEEL

17 M 8x 65 HEXAGONAL BOLT

18 MOTOR COUPLING

19 M 8 NUT TORQUE

20 CANTILEVER LEVER

21 RING PIN

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PUMPING SYSTEMS

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PUMPING SYSTEMS

POS DESCRIPTION OF COMPONENTS

1 M 16 NUT

2 M 16 WASHER

3 MIXING VESSEL

4 SEALING GASKET 120*3

5 TOP FLANGE

6 ROTOR D6-3

7 FIXING STUDS

8 STATOR

9 MORTAR OUTPUT FLANGE

10 NIPEL 1”-1 ¼”

11 MORTAR OUTPUT COUPLING MIG10-X25

12 M 16 RING NUT

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AIR AND WATER SYSTEMS

4 1 13 8 9 11 12 10 2 6 3 6 7 5

AIR AND WATER SYSTEMS

POS DESCRIPTION OF COMPONENTS

1 FLOWMETER PIPE+ FLOWMETER COUPLINGS +FLOAT

2 PRESSURE REGULATOR

3 SOLENOID VALVE

4 FLOWMETER PLUMMET

5 FLOWMETER SWIVEL

6 WATER RELIEF VALVE- FLOWMETER

7 WATER FLOW VALVE

8 PRESSURE SWITCH-AIR

9 PRESSURE GAUGE -AIR

10 WATER-AIR REGULATOR BLOCK

11 PRESSURE GAUGE -WATER

12 PRESSURE SWITCH -WATER

13 WATER PUMP

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SPRAY GUN

SPRAY GUN POS DESCRIPTION OF COMPONENTS

1 Ø 25 LENGHT:750 SPRAY GUN (Ø 14 SPRAY GUN NOZZLE )

2 Ø 25 LENGHT:500 SPRAY GUN (Ø 14 SPRAY GUN NOZZLE )

5 Ø 14 SPRAY GUN NOZZLE

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COMPRESSOR

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POS DESCRIPTION OF THE COMPONENTS

2 ROTOR WITH SHAFT

3 TRUNK (HANDY K2)

4 CYLINDER LID (HANDY K2)

5 PRESSURE PISTON (HANDY K2)

7 TRUNK LID (HANDY K2)

8 FAN (HANDY K2)

9 SILENCER SUPPRESSOR (HANDY K2)

10 ECCENTRIC DISC (HANDY K2)

11 PRESSURE PISTON VALVE SEALING GASKET(HANDY K2)

13 CYLINDER HEAD BASE VALVE SEALING GASKET (HANDY K2)

16 FILTER (HANDY K2)

17 CARRY HANDLE (HANDY K2)

19 SEALING GASKET (HANDY K2)

20 RUBBER FEET (HANKDY K2)

21 DIAPHRAGM / MEMBRANE ORG. (HANDY K2)

21 DIAPHRAGM / MEMBRANE

22 PRESSURE CONTROL VALVE, 5 BARS (HANDY K2)

23 SEALING GASKET 13x20x2 PRESSURE CONTROL VALVE (HANDY K2)

24 O-RING OR 20x3 (HANDY K2)

25 PLUG F11 (HANDY K2)

26 HOSE CAUPLING, SEALED (HANDY K2)

27 SCREW PLUG R 1/4" (HANDY K2)

28 WASHER 8.4x32 (HANDY K2)

29 ROLLING BEARING 6209-2RS (HANDY K2)

30 ROLLING BEARING 6306-2Z (HANDY K2)