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P/N 98991230 01…09

MAIAC 400NT

PM No. 6991 5219 01 Translation of the original handbook


LIST OF CONTENTS

List of contents ......................................................................................................................... 2


Foreword .................................................................................................................................. 3
User-friendly .............................................................................................................................. 3
Operating instructions............................................................................................................. 3
Potential hazards ..................................................................................................................... 3
Warranty and liability .............................................................................................................. 4
Prescribed use of the machine ............................................................................................. 4
Improper use ............................................................................................................................ 4
Personal safety......................................................................................................................... 4
Safety devices ......................................................................................................................... 6
General safety instructions ..................................................................................................... 6
Copyright.................................................................................................................................. 6
General..................................................................................................................................... 7
Training the operating personnel .......................................................................................... 7
Training record ......................................................................................................................... 9
Safety instructions for manual operation ............................................................................. 9
Hazards of electricity ............................................................................................................ 10
General safety regulations ................................................................................................... 11
Type plate .............................................................................................................................. 13
Machine views ....................................................................................................................... 13
Controls................................................................................................................................... 14
Operating panel and indicators ......................................................................................... 14
Plug-in connections .............................................................................................................. 15
Main dimensions .................................................................................................................... 15
Transport weight & dimensions ............................................................................................ 16
Technical data ...................................................................................................................... 17
Technical Descripton ............................................................................................................ 18
Water adjustment 400NT for Portlandcement and MAI® Anchor mortar ...................... 19
Filter parts ............................................................................................................................... 20
Initial settings .......................................................................................................................... 20
Directions before start-up..................................................................................................... 21
Connections before start-up ............................................................................................... 22
Start-up ................................................................................................................................... 22
Start-up for manual operation ............................................................................................. 25
Start-up with remote control ................................................................................................ 25
Interruptions and downtime ................................................................................................ 26
Termination of work and cleaning ...................................................................................... 26
Machine maintenance ........................................................................................................ 27
Procedure in the event of frost ............................................................................................ 28
Transport ................................................................................................................................. 28
Checklist for remedying faults ............................................................................................. 30
Check list for annual technical inspection (Master Copy) .............................................. 31
Main and control system circuit .......................................................................................... 33
MAI® INTERNATIONAL
GmbH

Replacement parts MAI®grout pump MAI®400NT............................................................. 34

FOREWORD OPERATING INSTRUCTIONS


Dear MAI customer! These operating instructions contain the most
important directions for a safe operation of the
We wish to congratulate you on your purchase machine. The manual should therefore always
of the MAI®grout pump MAI®400NT. The be kept in the tool box so that it is at hand
MAI®grout pump MAI®400NT is a fully automatic when required.
mortar mixing pump for continuous processing
of all kinds of machine-processable anchor Please read the operating instructions carefully
mortar and building site cement. before starting the machine to familiarize your-
self with its handling and trouble-free operation
The pump is driven by one motor only. A deliv- of the machine.
ery screw in the mixer transports the dry anchor
mortar to the mixing chamber where it is con- A working knowledge of the basic safety regu-
tinually mixed with water. lations and instructions is the prerequisite for
safe handling and trouble-free operation of the
The water can either be supplied direct if the machine.
pressure is high enough or an optional water
pump can be fitted, if required. Every single person working with the machine
must not only observe the operating instruc-
Once the material is thoroughly mixed, the tions and the safety regulations in particular,
entire amount is then drawn in and pumped but also the applicable rules and regulations
away by the clampless, maintenance-free governing accident prevention at the location.
screw pump.

The most important features of the MAI®grout POTENTIAL HAZARDS


pump MAI®400NT are the high quality of the
components used, the user-friendly layout of The MAI®grout pump MAI®400NT is built to the
the controls and the rugged design which state of the art and in accordance with recog-
proves its worth, day in and day out on de- nized safety regulations.
manding building site applications.
If not used properly, the ma-

User-friendly ! chine can however constitute a


danger to life and limb for the
operator or third parties, or ad-
o Simple to service and dismantle thanks to
the modular design. DANGER versely affect the machine or
other material resources
o Clearly structured operating elements.
o Economical. The machine may only be operated for the
prescribed use and if it is in perfect condition
o The patented MAI mixing and pumping conforming to the safety regulations. Faults that
technology guarantees continuous blend- could affect safety must be remedied immedi-
ing of dry material, uniform mixing ratio, ately.
constant mixing quality and therefore ade-
quate processing.

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MAI® INTERNATIONAL
GmbH

MAI® International GmbH shall cancel all obli-


WARRANTY AND LIABILITY gations entered into by MAI International
GmbH and/or its dealers, such as guarantees,
Our „General Terms and service agreements etc., without notice if any
Conditions of Sale“ apply to other than original MAI Pump or MAI® Interna-
warranty and liability. The tional spare parts are used for operation,
purchaser will have received maintenance or repairs.
a copy on conclusion of
the contract at the latest.
PRESCRIBED USE OF THE MA-
Warranty and liability claims CHINE
in the event of personal inju-
ry or material damage shall The prescribed use of the MAI®grout pump
be excluded if they are MAI®400NT is for mixing and pumping commer-
caused by one or more of the following rea- cially pre-mixed, machine processable anchor
sons: mortar or dry mortar such as cement accord-
ing CEM II-32,5 to CEM II-42,5 or with a max.
Operation of the machine for any other than grain size of 4 mm. Working with microfine ce-
the prescribed use: ment can not be guarantee.
o Improper assembly, start-up, operation and
Please note that the MAI®grout pump
maintenance of the machine.
MAI®400NT can only function properly if the
o Operation of the machine with defective mortar or cement used is indeed machine-
safety devices or incorrectly fitted or non- processable material (e. g. verified with a
functioning safety and protective devices. manufacturer’s certificate).
o Non-observance of the directions in the
operating instructions regarding transport,
storage assembly, start-up, running,
IMPROPER USE
maintenance and set up of the machine. Any uses for the MAI®grout pump MAI®400NT,
o Unauthorized alterations to the motor (e. g. other than those prescribed above are prohib-
power or speed), mixing shaft, delivery ited. The MAI®grout pump MAI®400NT is not
screw, mixing chamber, controls etc. intended for mixing non-machine processable
dry mortar or other materials, such as inflam-
o Inadequate monitoring of machine parts
mable or potentially explosive substances or
that are subject to wear and tear (e. g. mix-
from asbestos existing materials used in the
ing shaft, delivery screw or worm pump).
chemical industry.
o Unauthorized structural changes to the
machine. In the event of improper use, the operator runs
the risk of jeopardizing life and limb, damaging
o Improperly carried out repairs.
the machine and other property, having an
o Unforeseen disasters as a result of external unforeseeable impact on the environment,
influence or force major. and impairing efficient operation of the ma-
chine.
Please note that the manufacturer’s warranty
shall expire if your machine is not operated and
serviced in accordance with these operating
instructions.
PERSONAL SAFETY
The machine purchaser must provide the nec-
essary personal safety equipment.

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MAI® INTERNATIONAL
GmbH
All the existing safety devices on the machine
must be inspected at regular intervals and
checked to ensure that they are functioning
properly.

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MAI® INTERNATIONAL
GmbH

SAFETY DEVICES COPYRIGHT


Before starting the machine, ensure that all the All parts of this documentation are subject to
safety devices are fitted correctly and func- copyright (©).
tioning properly.
Photocopying or circulating the documenta-
Safety devices may only be removed: tion, in part or in whole, is prohibited.

o after a standstill and No part of this documentation may be repro-


o if the machine is prevented from being duced, stored in a retrieval system, transmitted
restarted (e.g. padlock on master or translated in any form or by any means
switch). without the prior written permission of MAI® In-
ternational GmbH.
When components are replaced, the purchas-
er must ensure that the safety devices are fit- Copies of individual parts may be made and
ted again properly. passed onto third parties if they are required for
locating faults.

GENERAL SAFETY INSTRUC- © Copyright 2012 MAI® International GmbH. All


rights reserved.
TIONS
MAI® International GmbH
The operating instructions must always be kept Werkstrasse 17
on the machine. A-9710 Feistritz/Drau
Company Register No. 191388d
In addition to the operating instructions, the Klagenfurt Provincial Court
general and local regulations on accident pre- We reserve the right to alter any technical de-
vention and environmental protection must be tails of the machine compared with the speci-
made available to the operator and observed. fications and illustrations in the present manual.

All safety regulations and warnings on the ma- No claims against the manufacturer, especially
chine must be legible and replaced as re- regarding design and structure of the machine
quired. may be derived from statements made in the
operating instructions.

MAI® und MAI-PUMP® are registered trade-


marks of MAI® International GmbH.

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MAI® INTERNATIONAL
GmbH

IMPORTANT: this symbol indi-


GENERAL cates important information for
correct handling of the ma-
In the operating instructions we have listed the chine.
most important directions for correct operation
and maintenance of the MAI®grout pump
Non-observance of these directions can cause
MAI®400NT.
faults on the machine or in the work environ-
ment.
The prerequisite for the use of the machine is a
thorough knowledge of the technical docu-
NOTE: indicates directions for
mentation and observation of the instructions
and directions, especially the safety regula-
tions.

The operating, safety and work instructions are


i
NOTE
preventing faults or tips for
economical use of the ma-
chine.

binding. The special symbols illustrated below


indicate important instructions which affect In addition, the manual contains useful infor-
machine and personal safety: mation to help you to make the most of your
machine.
DANGER: This symbol means

! imminent danger to the life and


health of people. TRAINING THE OPERATING
DANGER PERSONNEL
1. The qualification required by the machine
Non-observance of these directions will cause operator are physical and mental aptitude,
serious damage to health and even lethal inju- a sense of responsibility and reliability in
ries. carrying out the tasks assigned, proof of the
necessary skills and a declaration to the
WARNING: this symbol means a
company that training regarding opera-

!
potential risk to the life and
tion, maintenance and repair of the ma-
health of people.
chine has been received. The minimum
WARNING age for machine operators is 18 years.
2. In accordance with use as prescribed, the
Non-observance of these directions can cause machine may only be started if the manu-
serious damage to health and even lethal inju- facturer’s operating instructions are ob-
ries. served.

CAUTION: this symbol means a 3. Only trained and instructed personnel may
work with the machine. The responsibilities
! potentially dangerous situation.
for set-up, operation and maintenance
must be clearly defined.
CAUTION
4. Trainee personnel may only work on the
machine under the supervision of an expe-
Non-observance of these directions can cause rienced person.
slight injury or damage to property.
5. The machine controls may only be operat-
ed by trained personnel.

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MAI® INTERNATIONAL
GmbH
6. Training on the machine must, without ex-
ception, be confirmed in writing.

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MAI® INTERNATIONAL
GmbH
the safety screen – the machine must stop
when the safety screen is removed.
TRAINING RECORD
PERSON

Person Person Elec- Superi-


trained with tri- or with
tech- cian tech-
ACTIVITY nical nical
qualifi- compe
cations pe-
tence

Start-up

Operation

Trouble-
shooting

Remedying
mechanical
faults

Remedying
electrical
faults

Mainte-
nance

Repair

SAFETY INSTRUCTIONS FOR


MANUAL OPERATION
The machine may only be operated if all the
safety devices are functioning properly.

Before switching on the machine, ensure that


nobody is at risk when it starts.

Inspect the machine for visible damage and


check that the safety devices are in proper
service condition at least once a day.

Especially check the function of the main


switch (with emergency stop switch function)
and the effectiveness of the proximity switch at

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MAI® INTERNATIONAL
GmbH

HAZARDS OF ELECTRICITY
1. Work on the electrical supply may only be
carried out by authorized electricians. In-
spect the machine’s electrical system regu-
larly. Obvious defects, such as loose con-
nections, singed cables etc. must be recti-
fied immediately.

Repairs to the electrical system,

! especially installation, connec-


tion and opening of control
cabinets which are fed by the
DANGER power supply system, may only
be carried out by authorized
personnel.

2. In accordance with use as prescribed, the


machine may only be started if the manu-
facturer’s operating instructions are ob-
served.

3. All safety instruction labels and warnings,


and all devices attached to the machine
for safety and accident prevention must
always be legible, and may not be altered
or removed.

4. Check that the machine is safe for opera-


tion before every start-up. If any faults oc-
cur, proceed as follows:

Minor faults that do not affect safety:

Shut down the machine at once, remedy the


fault and notify the supervisor if necessary.

Faults that affect safety:

Stop operation of the machine immediately,


notify the supervisor and have the faults recti-
fied by authorized personnel.

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MAI® INTERNATIONAL
GmbH

6. Before cleaning the machine with water,


GENERAL SAFETY REGULA- close all openings where water penetrating
could have a detrimental effect on func-
TIONS tion or safety (electric motors, control cabi-
1. Any alterations, additions and conversions net and plug-in connectors). After clean-
to the machine require prior written permis- ing, remove the caps and covers again.
sion from the manufacturer. Failing this, any
warranty and liability claims shall expire. We The MAI®grout pump
also wish to point out that only original MAI
spare parts may be used in the machine. ! MAI®400NT conforms to Protec-
tion Class IP44 in accordance
with DIN 40050 and may not be
All spare parts must meet the manufactur-
er's technical requirements. Original MAI
DANGER cleaned with water jets.
spare parts always meet manufacturer
7. If work has to be carried out on live parts, a
specifications.
second person must be at hand to break
2. The machine may the circuit in case of an emergency.
only be operated
8. Disconnect the power supply before
by qualified, reli-
changing the location of the machine.
able personnel se-
Check that it is connected to the mains
lected by the
again correctly before starting operation
company, trained
again.
in and familiar
with the opera-
9. The machine must be connected to a
tion, mainte-
proper power source, e.g. construction site
nance and work-
distribution board with RCD. (rated fault
ing of the ma-
current I=30mA)
chine.
10. Set up the machine horizontally with safety
3. Trainee personnel
lights in place and safeguarded against
may only be in-
accidental movement.
structed in the
handling of the 11. Ensure that the mortar hoses are laid with-
machine by an al- out kinks and not rubbing on any sharp
ready qualified, edges to prevent them from being dam-
experienced op- aged. Where there is a change of direc-
erator. tion, the bending radius must not be less
than six times the outside hose diameter.
4. Follow the operat-
ing instructions Screw pumps are high pressure
with regard to in-
!
pumps – only use steel-
dicators and procedures for switching on reinforced hoses.
and off the machine.
WARNING
5. The machine must be prevented from ac-
cidental restarting during any maintenance
and repair work. To do this, immobilize the
master switch with a padlock. You can also
apply a warning sign to the master switch.

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MAI® INTERNATIONAL
GmbH
19. The mixer motor must not be switched on
12. Before starting the machine, ensure that
when it is tilted.
machine-processable, easily workable mor-
tar is being used, the hose is not leaking
20. When you fill the dry mortar in the hopper it
anywhere, especially at the unions, and the
can come to strong dust formation. It can
inside of the hose has been sufficiently lu-
be necessary to wear a protective mask.
bricated.
21. The machine may not do in the environ-
ment with danger of explosion which by
types of dust, steams or gases can develop
are used.

22. Before opening the pump flange the ma-


13. Before undoing the unions and the pump
chine should be switch off. The machine
outlet flange, ensure that they are depres-
must be prevented from accidental restart-
surized by start the main motor in „REVERSE“
ing.
direction. To prevent eye injuries protective
goggles is to be used. 23. Is the worm pump not mounted the ma-
chine must not started!
14. Wear protective goggles when removing
obstructions. The person carrying out the 24. Do not operate the machine without a
task must be in a position where he cannot pressure gauge.
be hit by any material that may be dis-
charged. Other people must be kept out of 25. The use of adequate noise control equip-
the immediate vicinity. ment is compulsory if the con-
tinuous sound pressure level ex-
15. The machine must be inspected by a quali- ceeds 85 dB(A).
fied person at least once a year.
26. The anti-twist-device of the stator has to be
mounted on the bottom side of the pump
flange. Tighten the wormpump so that it
can not be twisted. If the wormpump is not
tighten enough the stator will twist and in
16. The control cabinet may only be opened if this case it is possible to squeeze the hand
the machine is disconnected from the or finger
power supply.
Anti twist de-
17. The safety screen must not be removed
while the machine is in operation.

Disconnect the machine from

!
the power supply before re-
moving the screen or carrying
out any cleaning and repair
WARNING work

18. The cover on the flange of the mixer motor


and the flange of the pump outlet must not 110 Nm
be opened while the machine is in opera-
tion.

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MAI® INTERNATIONAL
GmbH

TYPE PLATE MACHINE VIEWS


The type plate is stick on the charge hopper
and in the controll cabinet.

In case of spare part order please announce


the “Maschinen Nr.

1. Drive unit with main motor


2. Delivery and mixing unit
3. Safety screen with bag opener
4. Charge hopper
5. Mixing chamber
6. Water injection unit
7. PU lining tube
8. Worm pump
9. Pump outlet
10. Vibrator
11. Water system
12. Water pump (optional)
13. Control cabinet

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MAI® INTERNATIONAL
GmbH
Green button

CONTROLS „STARTS“ the main motor in forward direc-


tion or for establishing readiness for opera-
tion.

Yellow button
Starts the main motor in „REVERSE“ direc-
tion for depressurizing the hoses before
opening the quick-change-coupling
(when needed).

Red indicator or fault display


When illuminated, indicates a “FAULT”
caused by motor overload.
1... Plug for remote control
2... Vibrator switch
3... Switch for Remote Control – Hand – In-
jection
4... Hour meter White button Water injection
5... Plug for power supply Water can be injected into the mixing
6... Plug for main motor chamber by pressing the white button.
7... Fault indicator When illuminated, indicates that enough
8... Switch for water pump ON – OFF – AU- water pressure is available.
TO (Optional)
9... Main switch
10... Button and indicator for water injection Main switch „EMERGENY OFF“
11... START button System power ON-OFF, lockable with
12... STOP button safety disconnection and short circuit
13... REVERSE button function.

OPERATING PANEL AND INDI- Mode switch:

CATORS „REMOTE C– HAND – INJECTION“


Manual operation (setting „HAND“) is the
Red button
normal operation mode of the machine.
“STOPS” or shuts-off the machine when
When on “REMOTE C” the machine can
running or ready for operation
be operated with the remote control.
When on “INJECTION” the machine can
be operated with the Mai Injection pres-
sure switch

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MAI® INTERNATIONAL
GmbH
Mode switch vibrator: „0FF – ON“
The vibrator, located on the mixing
MAIN DIMENSIONS
chamber of the mortar mixing pump,
prevents the dry mortar from bridging.

Mode switch water pump (optional)


“ON – OFF-AUTO”
Setting “ON” the Water pump is continu-
ous running
Setting “AUTO” water pump running with
main motor

A... ca. 173 cm B... ca. 96 cm


C... ca. 57 cm D... ca. 12 cm
Hour meter
Indicates how long the main motor has
been running.

PLUG-IN CONNECTIONS

A... ca. 173 cm B... ca. 96 cm


C... ca. 57 cm D... ca. 12 cm

1... Socket for remote control or injection pressure switch


2... Socket for main motor 400V 5x16A 200V 4x32A
3... Main power plug ~3x400V/50Hz/32A/5-poles
Main power plug ~3x200-220V/50-60Hz/32A/5-poles

A... ca. 173 cm B... ca. 92 cm


C... ca. 57 cm D... ca. 9 cm

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MAI® INTERNATIONAL
GmbH

TRANSPORT WEIGHT & DIMEN-


SIONS
Pump unit

A... approx. 1040 mm D... approx. 500 mm


B... approx. 570 mm E... approx. 320 mm
C... approx. 955 mm Weight of components approx. 27 kg
Weight of components approx. 120 kg

Drive unit

F... approx. 600 mm


G... approx. 200 mm
A... approx. 1040 mm
B... approx. 570 mm Weight of components approx. 55 kg

C... approx. 955 mm


Weight of components approx. 130 kg

Safety screen with bag opener

H... approx. 660 mm


I... approx. 575 mm
Weight of components approx. 5 kg
A... approx. 1040 mm
B... approx. 570 mm Weight of 400NT approx. 213 kg
C... approx. 920 mm
Weight of components approx. 125 kg

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MAI® INTERNATIONAL
GmbH
Noise emission A-weighted 73.5 dB(A)
noise emission
TECHNICAL DATA assessment
Model Mortar mixing 400NT
and injection
1. In addition to other factors, the operating pressure and pumping
pump
distance depends on the mortar speed, material quality, con-
Drive Mixer motor ~3x400V/50Hz/6kW sistency, maximum grain and the nominal width of the pump

~3x400V/60Hz/6kW outlet.

~3x440-480V/60Hz/6kW
2. Prerequisite for reaching the listed figures is the use of machine
~3x200-220V/50-60Hz processable dry materials.
6kW

Connection Electricity ~3x400V/50Hz 3. These figures can only be reached in exceptional cases with

special materials.
~3x400V/60Hz

~3x440-460V/60Hz 4. Only use steel-reinforced hoses.

~3x480V/60Hz
5. The water pump is not included in the standard scope of delivery
~3x200-220V/50-60Hz
(i. e. available as an optional extra).

Protection Board distribu- min. 3x32A


tion with RCD
only

Cable diame- Power supply min. 4x4 mm²


ter

Nominal power Overall system 6,2 kW

Ext. power unit Minimum size 16 kVA

Water connec- Hose min.3/4” at least 2,5 bar (dy-


tion namic)

Operating If the hose is max. 40 bar*1


pressure*1 chocked, the
pressure can rise
to 100 bar).*1

Operating with hose NW 25 approx. 40-60 m*2


distance *1
with hose NW 35 max. 200*3

Mortar hose All the figures Steel reinforced hose


quoted here NW 25 and NW 35. Burst
refer to MAI pressure = 160 bar *4
products and
MAI hoses only.

Water pump*5 No self priming ~3x400V/50Hz/


pump 0,53kW

~3x400V/60Hz/
0,53kW

~3x220V/60Hz/
0,53kW

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MAI® INTERNATIONAL
GmbH

Thanks to careful component selection and


TECHNICAL DESCRIPTON combination, the MAI system provides opti-
mum problem solutions:
The compact MAI®grout pump MAI®400NT uses
patented, proven MAI mixing and conveying MAI Pump, MAI anchor mortar and MAI injec-
technology to process various types of ma- tion hollow core anchors guarantee unique
chine-processable anchor mortar and cement. product and application advantages.

Function
All MAI International GmbH products feature
Only one main motor is required to mix the ma-
diverse application options and MAI’s re-
terial in one pass and to pump the quantity
nowned quality, making the MAI®grout pump
which is required without any problems.
MAI®400NT cost-effective to purchase and
The volume to be mixed and pumped can be economical to use.
varied by using different types of worm pumps.
Long service life, minimal susceptibility to faults,
For particularly large volumes the MAI®grout low maintenance and running costs keep your
pump MAI®400NT can also be fitted with the expenses down and ensure that you benefit
MP 12 conversion kit. from these efficient, economical solutions.
The MAI®grout pump MAI®400NT is successfully
in use all over the world – in tunneling, engi-
neering and mining applications, and for secur-
ing pits and slopes. The proven mixing and
pumping technology is especially suitable for:
o injection work
o grouting
Pumping volume, distance,
o

o
filling in bore holes

backfillings
i
NOTE
pressure and wear depend on
the material (type, consistency,
grain and grading curve) and
worm pump used.

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MAI®INTERNATIONAL
GmbH

WATER ADJUSTMENT 400NT


FOR PORTLANDCEMENT AND
MAI® ANCHOR MORTAR

Wassereinstellung MAI® 400NT


WATER SETTING MAI® 400NT
für Portlandzem ent CEM II 42,5N / FOR PORTLAND CEMENT CEM II 42,5N
and
MAI® Ankerm örtel / MAI® ANCHOR MORTAR
(nicht gültig für M400 / NOT VALID FOR M400)
1050
1025
1000
975
950
925
900
875
850
825
Wassereistellung/ WATER SETTING

800
775
750
725
700
675
650
[ l/h ]

625
600
575
550
525
500
475
450
425
400
375
350
325
300
275
250
225
200
0,40

0,45

0,50

0,55

0,60

0,65

0,70

WATER / CEMENT FAKTOR

MP8L PORTLAND CEMENT 42,5N MP8L MAI® ANCHOR MORTAR


MP4L PORTLAND CEMENT 42,5N MP4L MAI® ANCHOR MORTAR
MP3L PORTLAND CEMENT 42,5N MP3L MAI® ANCHOR MORTAR

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MAI® INTERNATIONAL
GmbH

FILTER PARTS

Pressure reducing valve „water system“


Setting range: 1 – 2 bar
Filter for mud
Max. water flow at 1 bar approx. 800 l/h
Max. water flow at 2 bar approx.1300 l/h
INITIAL SETTINGS

Thermal relay main motor


Pressure sensor „water system“ Relay setting 400V 6kW: 12,1 A
Automatic adaptation to the setting of pressure reducing Relay setting 440-480V 6kW: 11 A
valve

Relay setting 200-220V 6kW: 23 A

Thermal relay water pump


Relay setting 400V 0,5kW 50Hz: 1,7 A
Relay setting 400V 0,5kW 60Hz: 1,85 A

Relay setting 220V 0,5kW 50Hz: 3 A


Relay setting 220V 0,5kW 60Hz: 3,2 A

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MAI® INTERNATIONAL
GmbH

DIRECTIONS BEFORE START-UP

To guarantee trouble-free start-up, ensure that


all the components have been cleaned
properly and are in perfect condition. Check
that the machine is horizontal and stable so
that it cannot slip if moved accidentally.

Check that all the cables and safety devices


are functioning correctly.

Ensure that the machine is horizontal and


standing safely.

Check that all the components have been


mounted properly.

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MAI® INTERNATIONAL
GmbH

CONNECTIONS BEFORE START-


UP
Connect the main power plug on the control
cabinet with the cable to the construction site
distribution board.

Plug the drive motor into the socket on the


control cabinet.

Connect the water supply hose (use a mini-


mum diameter of ¾”) to the coupling in the
water system.
Switch on the machine by turning the master
switch to position “I”.
START-UP
The machine may only be con-
Close all the water supply and drain valves.

Connect the water supply hose (minimum di-


! nected to a construction site
distribution board fitted with a
residual current-operated cir-
ameter ¾” for 4 bar min. dynamic water pres-
DANGER cuit breaker. Electrical protec-
sure). Slowly open the water supply cock.
tion: 3x25 A distribution board,
rated fault current I=30mA

Connect the ~3X400V/50Hz ~3X220V/60Hz


power supply with the electricity cable (use
only 5x4 mm² H07RN cable).

Press the white “WATER INJECTION” button and


set the required water volume by turning the
knob on the needle valve.

The water pressure must be at least approxi-


mately 2,5 bar when the valve is open (dynam-
ic). If this is not the case, the machine cannot
be started or stops automatically if already in
Set the mode switch “REMOTE C – HAND - IN-
operation.
JECTION” to the “HAND” position. (All controls,
such as switches, indicators, alarms and but-
tons are illustrated on page 11 and 16).

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MAI® INTERNATIONAL
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Turn the mode switch “REMOTE-HAND-
INJECTION” to position “HAND”. The vibrator
switch must be set on “ON” to prevent the dry
material from bridging at the bottom of the
material hopper.

Undo the eccentric clamp on the mixing


chamber. Open the pump outlet by turning it
to the side to drain the water which was just
sprayed into the mixing chamber.
Place machine processable dry material in the
Close the pump outlet again and lock the ec-
hopper.
centric clamp.
The safety screen must not be

!
removed when the machine is
running or ready for operation.

WARNING

Press the white “WATER INJECTION” button for


approx. 3 seconds to let a defined water vol-
ume into the mixing chamber of the mortar
mixing pump. This is to prevent the eccentric
worm pump from running dry when the ma-
chine starts.

Start the machine by pressing the green


“START” button. Let the mortar mixing pump run
until water starts to come out of the front of the
pump outlet.

The mixer motor must not be

! opened or tilted when the ma-


chine is running or ready for
operation (as long as the pow-
DANGER er supply is connected and/or
the master switch is set to
“ON”).

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MAI® INTERNATIONAL
GmbH

Switch of the machine by pressing the red


While the machine is running, open the slide “STOP” button.
gate, located above the motor, slowly and in
stages until it locks into 1.)
the guide rod notch. To prevent chocking, we recommend wetting
2.) the inside walls of the hose with water or pref-
3.) erably lime or cement slurry.

During the wetting process with


water it is absolutely necessary
that any excess water is com-
pletely drained from the hose
otherwise grains could be
washed out when the machine
is started, especially in the case
of coarse grain materials, such
After 10 – 15 seconds the mortar consistency
as anchor mortar with 4 mm
should have adjusted to the value pre-set on
maximum grain. This could
the water flow meter and be coming out of the
cause the hose to choke.
coupling on the pump outlet pulsating slightly
but uniformly. The consistency of the mortar Lay the mortar hose so that it can be easily
can be adjusted to the required application by connected before the machine is started.
changing the water flow rate.

If you are working with un-

i
NOTE
known materials, experience
has proved that it is better to
start with a relatively fluid con-
sistency and then slowly reduce
the water volume with the ma-
chine running until the required
consistency is reached (un-
Connect the quick release coupling on the
known materials: water flow
mortar hose to the male union on the pump
meter setting: approx. 600 li-
outlet.
tre/hour).

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MAI® INTERNATIONAL
GmbH

Start-up for manual operation Start-up with remote control


Proceed as described in the previous section Proceed as described in the previous section
“Start-up”. “Start-up”.

Make sure that the mode switch “REMOTE C – Make sure that the mode switch “REMOTE C –
HAND - INJECTION” is set to “HAND”. HAND - INJECTION” is set to “REMOTE C”.

Start the machine by pressing the green Press the green “START” button. The machine is
“START” button. now ready for operation with the remote con-
trol

To switch off the machine at any time, press Start the machine by turning the switch on the
the “STOP” button. remote control.(Switch shines green)

You can stop the machine at any time by turn-


ing the green switch on the remote control.

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MAI® INTERNATIONAL
GmbH

During the operation of the


TERMINATION OF WORK AND
!
machine with the remote con-
trol not instructed persons in the
direct danger area of the ma-
CLEANING
WARNING chine may not be! After work is completed or in the event of
longer interruptions, run the machine until the
material hopper is empty and then clean it
INTERRUPTIONS AND DOWN- thoroughly.
TIME
Interruptions at work that last longer than 30
minutes should be avoided at all costs be-
cause this material in the mortar hose and in-
jector can start to harden and even set under
certain circumstances.

Starting the machine in this case would cause


a breakdown and a considerable amount of
cleaning.
Depressurize the mortar hose before uncou-
pling them (press the yellow “REVERSE” button).
For material hardening and setting times, see
Check the pressure on the pressure gauge on
the instructions and guidelines issued by the
the pump outlet to ensure that they are no
manufacturer.
longer under pressure.
Every time the injection procedure is interrupt-
ed, there will be slight variations in the con-
sistency after the machine is started again.

These variations are caused by material setting


in the hose, but are no cause for concern. They
usually only last until the hardened material in
the hose passes through the nozzle.

At this stage the pressure in the hose may rise After disconnecting the mortar hoses, leave
considerably. If slight fluctuations in the con- the machine running until water comes out of
sistency occur after work is restarted again, the material discharge opening on the pump
there is no need to alter the water setting right outlet.
away.
Ensure that the machine does
If interruptions or downtimes last longer, clean not run dry during this process.
the machine thoroughly, following the instruc-
tions in the section “Termination of work and
cleaning” described below.
When only water comes out of the worm
pump, the machine can be turned of by press-
ing the red “STOP” button.

Place the hose cleaning ball in the mortar hose


and pump water through at least twice.

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MAI® INTERNATIONAL
GmbH
and replace the machine.

Stop the machine by pressing the red “STOP”


button on the control cabinet, and turn the
main switch to “0” to prevent the system from
being started accidentally.

Undo the eccentric clamp on the mixing


chamber so you can move the motor and
pump parts away to the side. MACHINE MAINTENANCE
Remove the pump part from the machine and Ensure that the motor housing surface and fan
dismantle it into its main components of pump cowl guards are always kept clean so that dust
flange, pump outlet, rotor, stator and pump and dirt do not impair the motor output.
cleaner.
If the motor has become wet, dry it before
starting and have the insulation checked by a
technician.

Change the lubrication on the main drive mo-


tor gears after six months.

Mixer motor: grease, Shell Tivela GL00 or Aralub


EP0

Regularly check that the wearing parts, such as


Remove the mixer and the safety screen from PU-screw, PU sealing from motor and worm
the machine. Clean all soiled parts carefully pump, mixer and worm pump, are in good
with water. condition and dimensionally true, as the func-
tion of the machine, the actual delivery rate
Danger of jamming fingers
and the attainable maximum pressure all de-
! when tilting (opening) and clos-
ing the motor flange.
pend on the condition of these components.

CAUTION Regularly check the PU-


sealing on the motor
coupling and lubricate
The MAI®grout pump
with grease the lubricat-

! MAI 400NT complies with the


®
ing point weekly.
provisions of Protection Class
IP44 in accordance with DIN It is also advisable to
DANGER 40050 and must therefore not check the grease behind
be cleaned with water jets. the PU sealing on a regu-
lar basis and to replace
If the machine is not required
contaminated grease
for a longer period, dismantle
with dry material, and to
the rotor and stator from the
replace the PU sealing if
eccentric worm pump and
necessary
lubricate them with MAI silicone
grease or MAI silicone spray.
Reassemble the components

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MAI® INTERNATIONAL
GmbH
Carry out the following maintenance work dai-
We recommend purging the
ly:
water system with compressed
air.
o lubricate all threads and keep them
clean

o spray pump lubricant on rotor and sta- Turn the main switch to pos. “0” and unplug the
tor electricity cable.

The mechanical and electrical condition of the Drain any residual water from the mortar hoses
machine must be inspected by qualified per- and all other components.
sonnel at least once a year.
Assemble the machine again.

Drain any residual water from the water supply


hose.
PROCEDURE IN THE EVENT OF
Water freezing in the measuring
FROST pipe could destroy it.

If frost is expected always clean the entire ma-


chine first and then follow the procedures de-
scribed below.
The machine is now completely drained ex-
Disconnect the water supply and remove the cept from a small amount of water in the ec-
mixer from the mixing chamber in the mortar centric pump. When you turn on the machine
mixing pump. Disconnect the water supply the next time, start it carefully as there may be
from the water system. some ice left which will mix with the mortar. This
problem only occurs however if the machine is
Open the water drainage valve and drain subject to very low temperature for a longer
cocks on the machine. period.

Connect the power supply and turn the main


switch to pos. “1”. TRANSPORT
Observe the following whenever you move the
machine.

Danger of toppling while load-

! ing and unloading the com-


plete machine.

CAUTION

Transport checklist:
Press the water injection button until all water
has run out of the valves and fittings. o disconnect all electrical connections

o lock the pump motor eccentric clamp

o Check that all parts and components are


mounted, screwed in or assembled proper-

© Copyright 2012-10-05 Page 28


MAI® INTERNATIONAL
GmbH
ly and that all the safety devices are in
place

There are no lifting pins on the

! MAI®grout pump MAI®400NT for


transporting by crane. If it has
to be lifted by crane, ensure
CAUTION
that it is placed in a suitable
container.

The machine must always be carried horizon-


tally during transport.

© Copyright 2012-10-05 Page 29


MAI® INTERNATIONAL
GmbH

CHECKLIST FOR REMEDYING FAULTS


FAULT: Machine will not start Possible causes Fault remedy
Dirt in control cabinet; power cable too Have contactor replaced by a qualified
Contactor defective or does not pick up
long or cable diameter too small; stand- electrician; only use cable with diameter
properly.
by generator has not enough power. of at least 5x4 mm².
Dismantle pump, clean, lubricate, reas-
Unsuitable material, not enough water,
Rotor is stuck in stator. semble, replace rotor and stator if neces-
eccentric pump not lubricated.
sary.
Water pressure sensor defective
Water dirty. Replace water pressure sensor.

Fit safety screen with bag opener, check


Safety screen with bag opener not
proximity switch for damage and re-
mounted properly or removed or proximi-
Machine will not start although power place, if necessary; check that water
ty switch defective; water pressure sensor
and water supplies are in order. pressure sensor is functioning (white light
defective
is illuminated sensor is ok) and replace, if
necessary.
Water dirty; water drawn from river or Clean or replace water supply filter
Water system filter soiled.
container. and/or reversible flow filter screen.
Components not plugged in or circuit
Switch on circuit breaker in control cabi-
FAULT: mixing motor, vibrator or remote breaker tripped because overloaded. A
net. Check each individual component
control not functioning. connected component is defective (e.g.
for proper function.
short circuit)
Unsuitable material; not enough water;
Use machine-processable material; re-
mixer worn out; pressure reducing valve
place mixer or motor coupling; clean
FAULT: mortar flow too thick or thin not set properly; soiled or defective stator
mixing chamber; find cause and rectify
and/or rotor worn or defective; pump
fault.
outlet blocked.
Use machine-processable material; re-
Unsuitable material; poor mixing; mixer or place mixer or motor coupling; clean
FAULT: mortar only intermittent
motor coupling defective or worn. mixing chamber; find cause and rectify
fault.
Rectify fault, if possible. Machine can be
Hose too long; worm pump blocked;
restarted once the red “FAULT” indicator
FAULT: mixing motor overloaded because material to dry; defect moisture
has gone off. Check or replace mixing
in motor coil.
motor if necessary.

© Copyright 2012-10-05 Page 30


MAI® INTERNATIONAL
GmbH

CHECK LIST FOR ANNUAL TECHNICAL INSPECTION (MASTER


COPY)
In accordance with the Trade Association Rules for Occupational Health and Safety (BGR) 183 (5.2),
the machine's operating safety must be inspected annually by a technical expert. This inspection must
be documented, and the record must be kept until the next inspection and produced upon request.

Date of inspection: Inspector: Signature: Machine number:

Component Inspection criterion OK Adjust-


ments/Repla
cements

Material hopper Check all welded seams


Material hopper Corrosion or deformation
Mixing area Check for wear
Mixing section Check mixer/motor coupling/screw conveyor for wear
Protective grating Is the protective grating still level?
Underbody Check all welded seams
Underbody Check tightness of screw connections
Underbody Check for twisting Check machine stability
Rollers / feet / run- Is the underbody still stable?
ners
Motors Connecting cable OK
Motors Are the fan guard and motor clean?
Water flow meter Is the gauge glass still clear, transparent and leak-
proof?
Magnetic valve Functional test
Pressure reducing Check function and setting
valve
Injection nozzle All nozzles functional / not blocked
Control cabinet Inspect visually for obvious defects
Control cabinet Functional test
Control cabinet Are all labels clearly legible?
Control cabinet High voltage test 1000V
Control cabinet Test functioning of all protective switches
Control cabinet Test functioning of all indicator lights
Control cabinet Check tightness of all cable connections
Control cabinet Check protective conductor system integrity
Type plate Available and clearly legible
Operating instruc- Available

© Copyright 2012-10-05 Page 31


MAI® INTERNATIONAL
GmbH
tions
Mortar pressure Functional test
gauge

© Copyright 2012-10-05 Page 32


MAI® INTERNATIONAL
GmbH

MAIN AND CONTROL SYSTEM CIRCUIT


1 2 3 4 5 6 7 8

L1
L2

A
L3
A 1 3 5
FU4
1,6A

2 4 6

Q2 1 3 5 1 3 5 1 3 5 1 3 5

B
B
2 4 6 2 4 6 2 4 6 2 4 6
25A
97 95 97 95

2 4 6 98 96 2 4 6 98 96 400V 42V

T1
c Q1
2 4 6 13 33 23

C
0V 0V
1 3 5 14 34 24

31 32 33

X0

D
Q1 MAIN SWITCH
M1 Q2 SHORT-CIRCUIT PROTECTION
M2 M3 FA1 MOTOR THERMAL RELAY
3 3 3 FA3 WATERPUMP THERMAL RELAY
FU4 CONTROL CIRCUITS PROTECTION SWITCH
K1M MOTOR CONTACTOR "FORWARD"
K2M MOTOR CONTACTOR "REVERSE"
K3M WATERPUMP CONTACTOR "FORWARD"
K4M WATERPUMP CONTACTOR "REVERSE"

E
E
K7 PHASE CONTROL AUXILIARY RELAY
S7 VIBRATOR SWITCH
T1 TRANSFORMER

date 08.02 customer: order number

F
drawn SCZ
F project: manufactured drawing number page
verify SCZ 1
152783.00.00
resp. alteration date name norm DIN first replace for replace through of 1
1

8
7
4

5
3

1 2

1
FA1
A
FA3 P1
FA3 FA1

5
B1 2

K5 S6 X5

S5
K6

S1
X5
Inj FB Inj S8
K6
S2

K0 S6

S3 K5

A1
A2
K0 7
S4
3

K0 H1

H2 H2
8 4

MAI M400NT
M400NT INTERNATIONAL
CONTROL CIRCUIT
1

© Copyright 2012-10-05 Page 33


MAI® INTERNATIONAL
GmbH

REPLACEMENT PARTS MAI®GROUT PUMP MAI®400NT

P/N pcs Description


9899153250 1 Motor coupling complete
9899160386 2 MAI PU Conveying screw for PU mixer
9899160387 2 Mixer PU
9899158549 1 Turbojet mixingbody
9899157984 2 Mixing wing SYM 142 DUO VKT
9899158115 1 Mixing wing SYM 142 MONO VKT
Pressure reducing valve D06FN 1/2" with proximity
9899152787 1 switch
9899153810 1 Solenoid valve 1/2"
9899158240 1 Water flow meter 1/2" w/o MAI logo
9899158237 1 Gauge 6 bar 1/4" w/o MAI logo
9899158236 1 Gauge 100 bar 1/4" w/o MAI logo
9899153516 1 MAI-Quick coupling NW 25 6/4" IT "male"
9899100357 10 Rubber sealing NW25
9899100377 10 Rubber ball NW25 ø30mm
9899102820 2 Diaphragm ø35
9899150961 1 Main switch P1-32/EA/SVB 32A
9899100818 3 MAI-Stator MP 3 large silver
Mortar hose "Injection" NW25L=20 m stole PN60 SYS-
9899101361 1 M
9899152752 2 Mixing tube liner
9899150550 3 MAI-Rotor MP 3 large single
9899152774 2 Gasket
9899153227 2 Gasket pump outlet large
9899152771 2 Nozzles

© Copyright 2012-10-05 Page 34

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