ICARO CALANDRA 34 Instruction manual

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CALANDRA 34
Manual of use and maintenance
COMPILED FROM:ICARO SCAFFOLDING
LAST REVISION: April 2009

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The builder declares that the machinery is conforming to the laws and Technical
Norms of good construction to the state of the art,existing during the present
declaration
DECLARATION OF THE MANUFACTURER
The Icaro Scaffolding it declares under the personal responsibility of Mr.Carmine
Re, General director and administrator of the society,born in Milan 1969 resident in
Milan via degli Alerami n.5 that the CAL 34,register N° ..........................CE
It has been realized near the establishment in Trezzo S/Adda and it is conforming to
the essential safety of the MACHINES FORESEEN by the followings Laws and
Normative:
-DPR 547/55 Norms for the prevention of the accidents on the job
-EUROPEAN NORM CENELEC EN 60204-1(NORM CEI 44-5)ELECTRIC
EQUIPEMENTS OF INDUSTRIAL MACHINES.
-DL 15/08/91 N.277 –Workers’ protection against consequential riscks from
expo sure to lead ASBESTOS,noise and to chemical,physical and biological
agents
-Directive EEC 89/392 amended
-DL 626/94
In respect to the prescriptions of which to the enclosure V to the Directive
Community 89/392 ECC and 91/368 EEC,it declares that the machinery in object of
the present declaration of conformity respect the safety and sanitary essential
requisite.
The Icaro in the person of his legal representative identified in precedence,
IT DECLARES BESIDES
That to the technical office of the brand,the followings are avaible documents:
-Sketches of together of the machinery
-Schemes encircled voters
-Sketches of the particular ones
-Documentation related to the installed components
-Analysis of the conformity of the car to the essencial requisite of the quoted
directive
-Norms and use technical specifications
Date Stamp and signature

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IDENTIFICATION OF THE MACHINERY
MANUFACTURER
Icaro Scaffolding srl
ADDRESS
Via S. Agnese
DENOMINATION PLOTS
CALANDRA –SPIRALATRICE
MODEL
CAL 34
REGISTER NUMBER
...........................CE
YEAR OF
CONSTRUCTION
20............
TENSION
Three phase ...............Volts
FREQUENCY
........... Hz.
TECHNICAL ASSISTENCE
SOCIAL REASON
ADDRESS
TELEPHONE NUMBER
On the car it is rivetted a plate on whitch the followings data are recapitulated:
-Builder
-Model
-Register number
-Year of construction
-Marked CE
To the arrival of the machinery to make sure some presence of the complete
nameplate of the data of identification above listed.
In case of lack or incompleteness of the data,to immediately tell the builder or the
retailer.
The present documenti s of reserved ownership.And it is forbidden the reproduction without specific authorization.

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INDEX
Pag.
1.0 INTRODUCTION…………………………………………………………..…6
1.1 INTRODUCTION…………………….…………………………..…....6
1.2 FORESEEN AND NOT FORESEEN USE………...….…….……...7
1.3 WAY OF CONSULTATION OF THE MANUAL…………………….8
2.0 DESCRIPTION OF THE MACHINERY……………………..……………10
2.1 CHARACTERISTIC
TECHNIQUES………………………………………………………..11
3.0 SAFETY PRESCRIPTIONS………………..……………………………..13
4.0 SAFETY SYMBOLS…...……………….………………………………….16
5.0 SAFETY DEVICES…………………………………………………………18
5.1 PROTECTIONS OF THE ORGANS OF FOLDING..….……..…18
5.2 EMERCENCY STOP………………….…….…………..…………18
5.3 OPENING ELECTRIC PANEL……..……….…………………….18
5.4 COMMAND PEDAL…….……………….…… ……...……………18
6.0 PREPARATION OF THE INSTALLATION AREA……………..………20
7.0 MOVEMENT AND STOCKPILING RECEPTION……………………….20
7.1 SAFETY PRESCRIPTIONS FOR THE MOVEMENTS………....20
7.2 CONTROLS IMPLEMENTATION AT THE RECEPTION…........21
7.3 DISPOSAL OF PACKAGING MATERIAL...……..……………….21
7.4 STOCKPILING AND MAINTENANCE…...…………..…………...21
8.0 INSTALLATION……………………………………………..……………...22
8.1 ELECTRIC CONNECTION.….…………………………………….22
8.2 SENSE OF ROTATION CHECKING…….………………….…….24
8.3 SAFETY DEVICES CHECKING………………………..……..…..24
9.0 USE…...……………………………………………………………………...26
9.1 COMMANDS…....……………………………………………………26
9.2 REGULATIONS..……………………………………………..……..28
9.2.1 REGULATION SCREW..………….……………………..….28
9.2.2 REGULATION ROLLS….….………………………………..28
9.3 OPERATOR POSITION…………..………………………………..28
9.4 MACHINERY STARTING…………….………………………..…...29
9.4.1 PRELIMINARY CONTROLS…...…………………….……..29
9.4.2 STARTING…..……………………..……………….………...29
9.5 MACHINERY STOP………………………………………….……..29
9.6 REACTIVATION AFTER A FORCED INTERRUPTION………...29

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10.0 OPERATIONAL PRACTICES..……………………………..…………….30
10.1 EXECUTION OF CIRCLE ARCS….…………………………….…30
10.2 EXECUTION OF CIRCLES…….…………………………………..30
10.3 EXECUTION OF SPIRALS…...…………………………………….30
11.0 MALFUNCTIONING……………….……………………………………….31
12.0 RESIDUAL RISK…………………………………………………………...32
13.0 MAINTENANCE..………….……………………………………………….33
13.1 SAFETY PRESCRIPTIONS……….………………………………..33
13.2 DISSECTION DEVICES FORESEEN….……………….…………34
13.3 PROGRAMMED MAINTENANCE CARD………….………….…..35
13.4 PROGRAMMED MAINTENANCE OPERATIONS……..………...35
13.5 LONG PERIODS STOP……………………………..……………...36
14.0 DISPOSAL…….…………………………………………………………….36
14.1 PRODUCTION REJECTS.………………………………………….36
14.2 MACHINERY DEMOLITION………...……………………………...36
15.0 ENCLOSURES TECHNICAL………………..……………………………36
TABLE IDEX :
Table 1 Technical data……..………………………………………………….11
Table 2 Calandering capacity…...……………………………………………11
Table 3 Characteristics of the material to be worked………………....…12
Table 4 Safety symbols…………………..……………………………………16
Table 5 Maintenance card……………………………………………………..35

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1.0 INTRODUCTION
1.1 INTRODUCTION
This manual is destinated to the staff employed to the installation,to the use
and to the maintenance of the machinery,and it has been created for allowing
the operators a correct and sure job.
We remember that this document has to be always available at the
employes,which,before effecting any operation on the
machinery,obligatorily have to read and to assimilate all the contained
indications in this manual.
All the operations of installation,use and maintenance must be perform
from the qualified and authorized staff.
If some part of this manual doesn’t sufficiently result clear,our department of
technical support is available to furnish all the information that were held
necessary.
In case of necessity ask to:
Icaro scaffolding srl
Via Sant’Agnese
20148 Milano
Italia
This manual contains reserved sketches,projected and realized by Icaro.
And it’s forbidden any reproduction,also partial,without specific authorization.
All the rights are reserved,also those of translation.

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1.2 FORESEEN AND NOT FORESEEN USE
The machinery is destined to the calandering of steel bars,smooth or
nervate,for armed cement.
It’s forbidden to use the machinery for other non foreseen uses.
Particulary it is forbidden to work material with different characteristics
from those foreseen in table 2 and table 3.
The improper use of the machinery and the missed observance of the
procedure of job,of safety and of maintenance,can cause risks for the
operators and the staff,as well as damages to the structure of the machinery
and its components.
The builder doesn’t answer to the possible consequential damages from
improper use or from changes brought to the machinery.Responsibility
reverts,in this case,on the consumer.

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1.3 Way of consultation of the manual
The manual takes in examination all the operations of installation,use and
maintenance of the machinery.
To underline the parts concerning operations or situations that can jeopardize
the safety of the operators or the functionality of the machinery has been
adopted this symbol:
ATTENTION!
We recomends the maximum attentions in the reading of these parts.
The pages containing images,have progressively been marked with the
letters of the alphabet(A,B,C..etc.)and they are situated to the LEFT.
The initials of the suitable details (A1,A2..etc.)it coincides with the descriptive
part that is found on the RIGHT.
NOTE
This manual is delivered to the buyer with the machinery.
It is important that the manuali s introduced to the whole staff entrusted of the
operations of installation,use and maintenance of the machinery,and that it is
available in a defined place.

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A.3
2.0 DESCRIPTION OF THE MACHINERY
The machinery is destined to the calendering of steel bars,smooth or nervate,for armed
cement.
The machinery is constituted by a strong loom in plate,a bench in plate of suitable
thickness, two drawing rolls and an idle roll.
Inside the loom it is installed an electric engine that through a reducer it transmits the
motion to the rolls of drawing.
The idle roll,that has the function to determine the bending radius,it is adjustable acting on
the regulation screw.
The locking lever it maintains the screw in position.
The organs folders are protected from a coverage(A.3)connected to a micro safety
interrupter,that prevents the operation of the machinery with the lifted coverage.

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The calendering command is given by the operative one through special pedal.
Looking at the machinery of forehead,that is from the part of the selector.the toward of
correct job is from left toward right.
This because the drawing rolls are endowed with grooves tilted for making taking on the
bar.
Through the rotation selector it is possibile to reverse the sense of rotation of the rolls,but
this is allowed only phase of return of the calendered bar,and to effect the real
calendaring,is incurred not otherwise in the risk to ruin the Theeths of the rolls.
The machinery is endowed with a locking lever that,during the calendering,it has to be
shut.
ATTENTION!
It’s important that during the job phase,the locking
lever,it’s always shut!
In the iron exit zone a regulation bench roll has fixed.
Regulating the bench roll in exit,it is possible to get the spiral calendering.

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2.1 Characteristic Techniques
CAL. 34
WIDTH
800 mm
DEPTH’
950 mm
HEIGHT
960 mm
MASS
348 kg
DIAMETERS DRAWING
ROLLS
210 mm
DIAMETERS IDLE ROLL
120 mm
STANDARD TENSION
380 V
STANDARD FREQUENCIES
50 Hz
INFERIOR SONOROUS ISSUE
TO
Inferior to 70 dB (A)
I° SPEED
2°SPEED
ABSORWED POWER
2.5 Kw
1.8 kW
ROLLS’ SPEED
11 giri/min
22 giri/min
TRASCINAMENTO VELOCITA’
7.5 m/min
15 m/min
Table 1 Technical data
CALENDERING CAPACITY
Breakup load
R= 650 N/mm2
CAL 34
Bar diameter
Da 6 a 34 mm
Bending radius
Da 120 mm to boundless

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Table 2 Machinery capacity
NOTE
The machinery can works on two speeds(see table 1)
The choice of the speed is effected by the operator in function of calendaring
planned rays and in function of he workmanship bar.
The strenght of calendering speed is superior in I° speed
ATTETION!
The least calendering diameter doesn’t have to be inferior
to how much prescribed by norms in act.
GENERAL CHARACTERISTICS
Maximum diameter
See Table 2
In case of nervate bars,the measured diameter on
the nervous system doesn’t have to overcome of
10% the nominal diameter
Tipo di materiale
Steel bars for construction,smooth or nervate,for
armed cement

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Table 3 Characteristics of the material to be worked
3.0 SAFETY PRESCRIPTIONS
Before using the machinery,the operator has to read and assimilate this manual(page5,7).
This manual constitutes integral part of the machinery and establishes the employement
and the way of use it.(pag 6)
In this manual the operational fuctions,the maintenance and the information are described
for safety that the operator has to follow.
On the machinery are affixed some safety signs.It represents a violation of the safety
prescriptions to remove any of the signs(pag 15).Besides it is obligatory replace in the
briefest possible time the labels and the writings of warning,of danger,that for any motive
are not legible or interpretable.
Use the machinery for the use which is destined.It's forbidden a different or an improper
use(pag6).
The builder doesn't not anwer any consequential damages from an improper employement
of the machinery or from technical changes effected on the machinery.Responsibility
reverts,in this case,only on the consumer(pag 6).
All the operations for installation,use and maintenance must be perform from authorized
and qualified staff,concerning to the prescriptions of this manual,to the norms in force
inside the establishment and to the safety norms for your country.
Before connecting the machinery to the supply line,checking that the line tension is that
projected for the machinery(page2,10).
Before effecting whatever operation on the electric plant or on the components connected
to electricity,it is obligatory remove tension from the machinery disconnecting the supply
cable.
It is forbidden the use of the machinery by not authorized staff;besides it is absolutely
forbidden approach the machinery by external or not authorized person.
It is forbidden to autonomously complete operations or manoeuvres that are not of own
comptence or that can jeopardize the own or others' safety.
The operator can start the machinery only if it is a sure working.
The operator is forced to eliminate or to ìsignal immediately,damages or changes of the
machinery that can jeopardize the safety of it.
It is forbidden to clean,to oil and to fatten up by hands the organs and the elements,or to
complete on them any operation of maintenance and reparation with the machinery at
work.
Every day,before beginning to work at the machinery,check that the safety devices have a
correct working following the law dispositions.Don't get off,modify or put out

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function,machinery components or safety devices.
Take care of the cleaning,and guaratee the good visibility of the work place of
machinery.Dirty traces(for example oil and sawdust on the floor)and obstacles can
jeopardize safety.
The operator has to adopt opportune devices of individual protection(D:P:I:),gloves and
shoes relating to accidents.
It is forbidden to use on the place of job garments or attires,that,in relationship to the
nature of the operations and the machinery characteristics,can constitute a danger for the
staff safety.
The personal garments adopted on the job don't have fluttering parts that can hold on to
machinery gears.
Don't wear bracelets,chains or other objects that can remain entangled in the machinery.
Maintain picked hair during the job.
For all the interventions to be effected on the machinery,use exclusively utensils and fit
equipements and in good conditions.
All the jobs on the electric plant must to be perform only by a qualified electrician.
After every assemblage or reparation of electric parts and before the machinery start,the
protection devices and the correct sense rotation must be checked.
Use with care the foreseen protection devices.
When the workmanship is performed for the first time,use the maximum prudence.
The machinery command must to be submits to an only operator.
In case of flood of the work area,remove the supply power and remove the water.
In case of fire,remove the supply power and extinguish the fire with dust or CO2
existinguishers.Don't use in any case water.
Any anomaly found during the job,it must immediately signal to the "Safety responsible".
Definition of "Dangerous Zones","Exposed Person","Operator".To the senses of the
Directive CEE 89/392:
-DANGEROUS ZONES: any zone in proximity of the machinery in which the presence of
an exposed person constitutes a risck for the safety and the health of this person.
-EXPOSED PERSON: any person that is on the center or near of the dangerous zones.
-OPERATOR: the person entrusted of install,start,regulate,perform
maintenance,clean,mend and transport the machinery.

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In case of accidents or risk situation on the machinery,immediately tell the
builder.
In case of necessity,conctat the service of technical support telling:
-register number
-model
-purchase date
-detailed informations of the problem.
4.0 SAFETY SYMBOLS
THE FOLLOWING SYMBOLS ARE ON THE MACHINERY:
SYMBOL
POSITION
MEANT
ELECTRIC PANEL
DANGER.PRESENCE
OF TENSION
PROTECTION COVER
IT IS FORBIDDEN TO
REMOVE THE SAFETY
DEVICES
IN
CORRESPONDENCE
OF CONNECTION
SCREW PUT ON THE
FLOOR
CONNECTION SCREW
ON THE FLOOR
In represents a violation of the safety prescriptions remove one of any safety
signs.Besides it is obligatory to replace in the briefest possible time the warnings labels
and warning writings,that for any motive are not interpretable.

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B.1
B.3
B.2
B.4

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5.0 SAFETY DEVICES
ATTENTION!
Protection of calendering gears
Without the cover,the gears don't rotate.
It is forbidden neutralize the end stroke of the lock sistem.
Emergency stop
In any danger situation,push the emercency stop button.
Opening electric panel
The acces to the electric panel is exclusively allowed to
authorized staff.That will concern to the norms and that
before intervening on the electric parts it will checking that
the supply cable of the machinery is physically disconnected
from the electric line.In case of reparation,the replaced
exchanges have to have equal charachteristics to the
original ones.
Command pedal
It is forbidden to remove the command pedal protection.
5.1 CALENDERING GEARS PROTECTION
On the calendering gears there is a protection cover(B.1),that prevents the accidental
conctat of body parts with the gears.
If the cover is lifted during the job,a micro interrupter that stops the machinery
intervenes.In this case the machinery reboot is posible only after the protection again been
lowered,and benn repusch the command pedal.
5.2 EMERGENCY STOP
The emercency stop buttons(B.2)are situated on front and retro of the machinery.
5.3 OPENING ELECTRIC PANEL
The opening of the electric panel is possible,with a special key,only with general
interrupter(B.3) on "O".
5.4 COMMAND PEDAL
Command pedal(B.4)it is protected by a carter that prevents its accidental starting.The
pedal is connected to the machinery trough a flexible electric cable, that allows to move
this pedal to the position of the operator.

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C.1

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6.0 PREPARATION OF ISTALLATION AREA
-The structure of the support zone has to be suitable to the machinery
weight(see"Technical data")and preferably in cement opportunely smoothed.
-The installation area must sufficiently light for guaranteeing to the operator a job
in safety conditions.
- The installation area has to be clear from any material.
- The installation area has to be dry and protected from the atmospheric
precipitations.
- The power supply plant has to answer to the norms.
- Foresee a free space in the surrounding perimeter of the machinery,proportional
to the maximum dimensions of the bars that will come calendrate.
7.0 RECEPTION,MOVEMENT AND STORAGE
7.1 SAFETY PRESCRIPTIONS
- For the transport operations make sure that the machinery is stable on the plan of
load of the vehicle and stare at the plan with ropes of suitable section.
- If the plan is not covered ,protect the machinery from bad weather with an
impermeable clothes insured.
- Before effecting the machinery movement operations checking that the area is free
from not authorized staff or animals or other things.
- All the staff have to wear the opportune relating to accidents attire prescribed by
the rules.
- Don't stop or transit under or near suspending unloadings;keep a proper distance.
- For the machinery movement employ means of lifting whose brought is suitable
the load to be lifted.
- Opportunely interdict the zone to not authorized staff to operations of machinery
unloading.
- The unloading and movement zone has to be free from obstacles that can
constitute danger for people or things.
- For the lifting hook the machinery with ropes of suitable course,using the four
holes(C.1)predisposed on the superior part of the machinery.
- Regulate the length of the ropes until get a horizontal lifting.
- Avoid oscillations,tears and abnormal solititations.
- For every move it is necessary lift the machinery,it is absolutely forbidden trai the
machinery.
- The builder declines any responsibilities in case of damages caused by harness or
lifting operations not similar to the prescriptions.

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7.2 CONTROLS IMPLEMENTATION AT THE RECEPTION
The machinery is carefully checked during the posting.In case that,for unexpected
causes,during the movement and transport phases,the components have suffered some
damages,at the moment of the receipt it's necessary to effect a components checking.
Check the integrity of the followings components:
- Electric plan
- Command
- Emergency stop buttons
- Protection cover of calendering gears
Verify besides that the machinery has the identification name-plate of CE rule.
ATTENTION!
If during the controls anomalies are noticed to the various
described components,it is forbidden to connect the
machinery to exernal energy sources.
Immediately tell the technical assistance service.
7.3 DISPOSAL OF PACKAGING MATERIALS
Once unpacked the machinery,the whole resultant materia(wood,platics,etc)cannot be
throw in the normal garbage,but it must be regulary be sell of following the law rules of
your country.
7.4 STORAGE AND MAINTENANCE
In case of not starting,the machinery must have covered with an impermeable tarpauline
avoiding the formation of condenses,storaged in clean and dry place,with in a temperature
among -10 and +50 C° and 80% maximum damp,distant from heat or vibration sources
that could jeopardize the delicate components and the instruments on boards machinery.
The metallic components not painted are covered with a veil of protective oil.