Safety and Operation Instr 6991 5280 01a Unigrout Flex S
Safety and Operation Instr 6991 5280 01a Unigrout Flex S
Safety and Operation Instr 6991 5280 01a Unigrout Flex S
Flex S
Safety and Operating Instructions
Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Personal precautions and qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Hoisting and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Storage, repair, maintenance and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Personal protective equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Drugs, alcohol or medication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Hoisting and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Operation, precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Maintenance, precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Unintended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Flex S E15-110/80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Mixer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Power unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety on and around the rig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Dangers on the rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Danger zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safe zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Emergency stop button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fire extinguisher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Setting up the rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Pre-start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Safety check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pre-start procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Start procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Mixing and emptying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Water dosing kit (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Programming water dosing kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Injecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Presetting of maximum low grout pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Presetting of maximum high grout pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cleaning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Mixer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Agitator and pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Lubricant recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Flex S E15-110/80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Sound power level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Introduction
These instructions are intended for operators of the Atlas Copco equipment. The aim of the
instructions is to provide you with knowledge of how to use the equipment in an efficient
and safe way. These instructions also give you advice and tell you how to perform regular
maintenance on the equipment. It does not replace thorough training of operator, it is a
complement. For further information concerning service measures, please contact your
nearest Atlas Copco representative.
Always read these instructions carefully and make sure that you understand all of them
before starting for the first time.
The owner of the equipment is granted the permission to take copies of this publication
solely for internal use. It is recommended, however, to order additional copies from Atlas
Copco representative in order to benefit from the latest revision. Atlas Copco Craelius AB
reserves the right to make changes in its products in order to improve design or performance
characteristics without notice. The information in this publication is assumed to be accurate at
the time of publication, but is subject to changes in order to remedy detected deficiencies or
to follow changes in the product.
Any user of this publication is requested to inform Atlas Copco Craelius AB about deficiencies
found, particularly in matters concerning product safety.
Safety area
WARNING Dust hazard
WARNING Falling objects can cause serious
injury or death When drilling with compressed air, the rock cuttings
are carried out of the bore in the form of small cuttings,
During operation, falling objects from great heights can and dust, which can cause serious injury.
cause bodily injury and extensive damage.
Some dusts, fumes or other airborne material created
►Close off the working area. during use of the machine may contain chemicals
►Before starting always make sure no unauthorized known to the State of California to cause cancer
persons are within the working area of the drill rig in and birth defects or other reproductive harm. Some
use. examples of such chemicals are:
►Immediately stop operation when persons are Crystalline silica, cement and other masonry
present in the danger area. products.
Arsenic and chromium from chemically-treated
rubber.
Hoisting and transport Lead from lead-based paints.
WARNING Heavy equipment can cause serious ►To reduce your exposure to these chemicals, work in
injury a well-ventilated area and work with approved safety
equipment, such as dust masks that are specially
►Use a sling dimensioned for the load it will carry.
designed to filter out microscopic particles.
►Use only straps that are intact and intended for the
►Use a dust collector, or spray water with a water/
load in question.
foam pump.
►Never use a damaged rope/sling.
WARNING Unexpected movement can cause
►Fasten straps in lifting eyes when present. serious injury
►Always lift at the center of gravity. If control levers and switches are not set to neutral
position, starting the machine can lead to unexpected
►Always make sure that nobody is under or anywhere
movements and can therefore cause injury.
near a suspended load or within the swing radius of
the rope/sling. ►Set control levers and switches to the neutral
positions prior to starting up.
►Observe great care when strapping and lifting heavy
objects. WARNING Noise hazard
NOTICE Sling can damage components High sound levels may cause permanent hearing loss.
►When lifting, make sure that the sling will not ►Use hearing protection in accordance with
damage the hydraulic hoses, mechanical occupational health and safety regulations.
components etc.
WARNING Emergency situation
An emergency situation can occur due to material
Operation, precautions failure or incorrect handling.
►Stop the operation by pushing the emergency stop
WARNING Hydraulic oil at high pressure button or if available pull the trip wire.
Thin jets of hydraulic oil under high pressure can ►Check proper function of the rig safety equipment at
penetrate the skin and cause permanent damage. least once beginning of each shift.
►Immediately consult a doctor if hydraulic oil has WARNING Gas line pressurized, Explosion
penetrated the skin. hazard
►Never use your fingers to check for hydraulic fluid If the equipment comes in contact with gas lines and
leaks. explosives, an explosion could occur. Explosions will
►Keep your face away from any possible leaks. lead to severe injuries or death.
►Never operate the machine in any explosive
environment.
►Never use the machine near flammable materials, ►Always contact your Atlas Copco Customer Center
fumes or dust. before you modify the machine.
►Make sure that there are no undetected sources of ►Always use original parts and accessories approved
gas or explosives. by Atlas Copco.
►When working in areas where gas lines are buried, WARNING Heavy machine can cause serious
make sure that your equipment is placed on the injury
windward side.
►During service and maintenance work, all
►Shut down all combustion engines, like hydraulic components that may be brought into motion or fall
power pack, generators etc. must be supported or tied secure.
►Leave the machine immediately. WARNING Thermal cracks may arise when
welding
►Warn people to evacuate the area.
►Do not do any welding on the equipment without
►Contact emergency personnel.
consulting Atlas Copco.
►Contact the gas company to shut the gas off.
WARNING Hot engine parts can cause burn
►Stay out of the area until the gas company declares
►Make sure the engine is turned off before all
the area to be safe.
maintenance work and before refueling
►Be careful when draining hot oil and fluids
Maintenance, precautions ►Do not handle flammable fluids in the vicinity of hot
surfaces, sparks or naked flames
WARNING Hydraulic oil
WARNING Electric shock
Spilled hydraulic oil can cause burns, accidents by
slippery conditions and will also harm the environment. ►Do not touch live electrical lines
►Take care of all spilled oil and handle it according to ►Only authorized electricians may carry out work on
your safety and environment regulations. the electrical system.
►Never dismantle the hydraulic components when the ►Only qualified electricians should perform any
hydraulic oil is hot. electrical troubleshooting or maintenance. Remove
all watches and rings that could contact live electric
WARNING Hydraulic system under high circuits.
pressure
►Make sure all power to the system has been cut
Maintenance and repair on the machine and the before carrying out any maintenance work.
hydraulic equipment under pressure can lead to
severe injuries. Connections can loosen suddenly, ►All electric cabinets should remain locked when not
parts can suddenly move and hydraulic oil can be under direct control of qualified electrician.
ejected. ►Do not use the cabinets as a toolbox or spare
►Depressurize the hydraulic system before parts storage container. The inherent vibration and
performing maintenance on the hydraulic magnetism associated with transformer and motor
equipment. starters can cause inadvertent contact of foreign
objects with live circuits.
►Never replace high pressure hoses with hoses of
lower quality than the original or with hoses that ►Some electrical components may have power when
have removable couplings the main circuit breaker is open, verify that power is
disconnected before servicing.
Pressure settings are always performed on a
pressurized system. ►Do not tamper with safety interlock circuits, safety
guards or other safety devices, except as required
►Always exercise the greatest caution. during normal maintenance and troubleshooting.
►Pressure settings must only be performed by trained ►Confirm that all safety devices and circuits are
personnel. replaced and functioning before operation is
WARNING Rotating parts can cause serious resumed.
injury and damage
►Always turn off the engine before performing any
maintenance or service on the equipment.
WARNING Machine modification
Any machine modification may result in bodily injuries
to yourself or others.
Prohibition signs
8915 0020 84
Information signs
Other signs
Fire extinguisher
A
Name
Hoisting/lifting point Type
Serial No.
Diesel power kW
B Rated voltage V Hz C
Electric power kW
I.P.
Gross weight kg D
3716 5522 00 Made in Sweden 201
AIB 100000282_00
A. Machine type
B. Serial number
C. The warning symbol together with the book symbol
means that the user must read the safety and operating
Hydraulic oil pressure instructions before the machine is used for the first time.
D. The CE symbol means that the machine is CE-approved.
See the CE Declaration of Conformity which is delivered
with the machine for more information.
Patent protection
Filling Emptying
Number 1 Number 2
1
3716 5565 78
2
3716 5565 79
Before starting,
oil must be filled
according to lubricant
recommendations in the
Maintenance section
On Off
3716 5565 31
3716 5565 27
3716 5565 35
Rotation 3716 5565 36
Rotation
Clockwise Counter-
clockwise
Mixer Agitator
Overview Mixer
To reduce the risk of serious injury or death to The Cemix is a high-speed and high-shear mixer of
yourself or others, read the Safety instructions a colloidal type, producing a thoroughly uniform mix
section found on the previous pages of this manual free of lumps or aggregates. The cement particles
before operating the machine. disintegrate in three stages through shearing
actions:
First in the vortex in the container, created by the
Design and function high-velocity impeller.
The grout plant consists of a high-speed mixer, Second from the shearing action created by the
a agitator and a grout pump mounted on a steel turbulence in the specially designed mixer housing.
platform provided with slots for forklift and lifting Third, through an eccentric formed vortex to
eyes. Two ball valves are mounted on the pump increase the shear forces; this also keeps the dry
outlet: one for the groutline and one for the unmixed particles from forming a floating clod in the
recirculation line back to the agitator. One electrical center.
cabinet with start/stop buttons for the unit. The grout
Each cement particle thus becomes separated and
plant is delivered without electric supply cables.
effectively wetted. The mixing impeller is directly
driven by the hydraulic motor, through a shaft
Intended use extension.
The Unigrout is intended for grout, drilling fluid, mud,
paint and pulp. Agitator
The Cemag is an agitator fitted with a container that
Unintended use has twice the volume of the mixer. This is in order
to ensure that grout is always kept available for the
Any application other than this shall be considered
pump when grouting and mixing are being carried
”non-intended use”. The manufacturer is then not
out simultaneously. The cylindrical container with
liable for damage incurred as a result; such use
a conic base and agitator shaft with offset blades
shall be at the owner’s risk. Proper use also includes
creates the necessary counter currents, which keep
compliance with instructions in manuals as stipulated
the mixture in suspension and release mixed-in air
by the manufacturer.
bubbles.
Main parts
Flex S E15-110/80
A. Emergency stop
B
B. Hydraulic motor G
C. Flow controller H
D. Electrical cabinet D A
E. Platform C
F. Forklift eye
G. Mixer (Cemix)
H. Agitator (Cemag)
I. Grout pump unit (Pumpac Complete) I
E
AIB 100000384_00
Danger zones
Power unit
The Power unit is mounted on a steel platform A
together with a pump which form the unit Pumpac
Complete.
The hydraulic power unit is designed to supply
hydraulic power to one mixer, one agitator and
one grout pump. A variable hydraulic piston pump A A
feeds hydraulic flow to the grout pump for easy,
independent control and setting of grout flow and
pressure. Two hydraulic gear pumps feed hydraulic
flow to the mixer and agitator. One hydraulic pump
for each unit. Both gear pumps are provided with
pressure relief valves set at 210 bar. On the front A
side of the power unit is the operator’s position, with
the electric cabinet and hydraulic controls for all units
and the water flow control for the grout mixer. AIB 100000386_00
Electric motor 15 m ft
A 1 3
Hydraulic power unit.............................................15
kw During normal operation it is advised to always use
personal protective equipment within the danger zone.
Safe zones
The area outside the danger zones are to be
considered safe zones.
AIB 100000391_00
The emergency stop button (A). is located on the front is placed on the back side of the electrical cabinetv.
panel of the power unit. This fire extinguisher is suitable for putting out
fires in electrical cables, fuel and engines and
lasts for approximately one minute when operated
1 2 continuously.
Note: Make sure the fire extinguisher follows local
rules and regulations.
OK
OK
0
0
AIB 100000357_01
70000005 A
The emergency stop buttons are activated by pressing
them (1). To reset a emergency stop button turn it
clockwise untill it pops out to normal position.
Check before each shift that the needle on the gauge
is within the green zone and make sure that the
fire extinguisher is replaced as soon as the needle
approaches the red zone.
For use
1. Remove the safety pin.
2. Direct the jet towards the base of the fire.
3. Press the handle.
1 2 3
AIB-100000020_04
AIB 100000390_00
Operation Pre-start
WARNING Engine running
If the Unigrout is left unattended with the engine Safety check
running it can cause serious injury.
There are safety devices built into the system of the
►Never leave the Unigrout unattended. Unigrout for your personal safety.
Before each shift commences, a extra and thorough
safety check shall be carried out on the equipment.
Setting up the rig
♦ Check the safety devices at least once every shift
1. Place the platform on level ground, away from to ensure that they are in full working order, so that
falling rocks, in a dry and well illuminated you know that they will be operational the moment
location. you need them.
Note: If platform is not placed on level ground the ♦ If you are unsure of the equipment's reliability, do
vortex might become unstable and mixing efficiency not put it into operation.
will decrease.
2. Connect the water. Pre-start procedure
4. Connect the electricity supply cable.
5. Check the oil level in the hydraulic tank.
6. Connect a water supply hose at the water inlet.
7. Turn on the main switch.
8. Check that the emergency stop button is set to
operation mode.
Start procedure
1. Start the electric motor by pushing the green
start button.
2. Start the agitator with the start and stop valve.
AIB 100000378_00
1. Flow meter
2. EL.magnetic valve
3. Pulse transmitter\Measuring pipe
A
4. Button to scroll-up the menu or increase a value
5. Button to scroll-down the menu or select a digit
to be modified
6. Confirm input and menu points
AIB 100000379_00
►Use flush clothes for protection of the electrical 4. Stop the hydraulic motor and open the mixer
equipment, during cleaning. housing drain plug located at the bottom of the
mixer housing and drain remaining water.
WARNING Rotating parts can cause serious
injury
Agitator and pump
►Stop the engine before doing any inspection and
1. Fill the agitator, close the grout line ball valve
service.
and open the recirculation ball valve.
►Never use sharp objects during cleaning process.
2. Start the grout pump and the agitator, and
WARNING Hydraulic system under high adjust the grout pump to maximum flow using
pressure the groutflow setting valve. The water will now
Maintenance and repair on the machine and the circulate at a high flow rate through the pump,
hydraulic equipment under pressure can lead to the recirculating hose and back into the agitator.
severe injuries. Connections can loosen suddenly, Continue for a few minutes and then open the
parts can suddenly move and hydraulic oil can be grout line ball valve and pump out water.
ejected. 3. Repeat the procedure until the pump, agitator
►Depressurize the hydraulic system before and hoses are clean.
performing maintenance on the hydraulic 4. Switch off the pump and agitator.
equipment.
5. Disconnect the mixer hose to drain the pump
►Never replace high pressure hoses with hoses of inlet and agitator.
lower quality than the original or with hoses that
have removable couplings 6. Wash the equipment to keep it clean.
Spray the platform with anti-sticking oil.
For information on maintenance, see the Safety and
operating instructions for the Cemix, Cemag, Pumpac Important: always cover the CEMIX and CEMAG
and Power unit. openings before spraying with anti-sticking oil.
Anti-sticking oil must never be applied to the
inside of the CEMIX or CEMAG.
Lubricant recommendations
Lubricant Recommendation
Hydraulic oil Use mineral-based hydraulic oil with good anti-wear, rust (oxidation) and foam inhibiting
properties, as well as effective air and water separation abilities. The viscosity grade should
correspond to the ambient temperature and ISO 3448, as follows:
Electrical components
Full link
Some electronic components contain batteries and
other components which could be hazardous to the http://www-1.atlascopco.com/__C125712A0045C780.
environment and personal health. Certain types of nsf/CustViewProd20?OpenView
work lighting contain mercury and could therefore
constitute environmental and health hazards.
Please download the specifications from this link.
♦ Treat according to local regulations in force for
destruction and waste disposal.
Technical specifications
Dimensions
Flex S E15-110/80
mm in
A 1285 50.6
B 1600 63
C 1400 55.1
B
C
AIB 100000389_00
Weight
Weight kg lb
Flex S E15-110/80 912.4 2011.5
Vibration
Position m/s2
Operator's station 0.11
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