SIKA Aliva 257 Top User manual

257.001
User manual
Aliva 257 Top
Concrete spraying machine
312831 / TTD / 000 / 01 / AB / EN

Imprint
Declaration of conformity 1
Operating instructions 2
Maintenance instructions 3
Spare parts 4
Schematics 5
Spray equipments Aliva Converto 6
Imprint / TID / 000 / 00 / AA / EN
312831 / TBA / 000 / 00 / AA / EN
312831 / TWA / 000 / 00 / AA / EN
312831 / TEK / 000 / 01 / AB / EN
312696 / TES / 000 / 02 / AC / EN
315558 / TES / 00 / 02 / AB / EN

Imprint
The content of this operating handbook is not part of any earlier or existing
agreement, promise or legal relationship. All obligations of Sika Schweiz AG,
Aliva Equipment arise from the respective purchase contract, which also contains
the complete and exclusively valid guarantee regulations. These contractual
guarantee provisions are neither expanded nor limited by the statements made in
this operational handbook.
The information in this handbook can be changed at any time without special
notice. It does not represent any obligation with regardto functionality from theside
of Sika Schweiz AG, Aliva Equipment, who can carry out extensions and/or
modifications to this handbook or to the machine at any time.
All parts of this documentation are subject to copyright. Any reproduction or
distribution, in whole or in part, is forbidden. No part of the documentation may be
copied, be transferred by photograph, be reproduced, translated or be stored on
any electronic medium or be brought into a machine-readable form. In all such
cases, the express agreement of Sika Schweiz AG, Aliva Equipment,
Tüffenwies 16, CH-8048 Zurich, Switzerland must first be obtained.
Trademarks: Aliva is a protected brand name of Sika Schweiz AG,
Aliva Equipment. Other brand names and product names are protected by their
respective owners.
Printed in Switzerland, 2016Sika Schweiz AG, Aliva Equipment / Switzerland.
© Copyright 2016Sika Schweiz AG, Aliva Equipment
All rights are protected.
Date of issue: 29.02.2016Name: Thomas Grab
Head System Engineering
Sika Schweiz AG, Aliva Equipment
Tüffenwies 16
CH-8048 Zürich
Phone [phone]
Fax [phone]
www.aliva-equipment.com
[email protected]
Service-Line Phone
Fax
e-mail
[phone]
[phone]
[email protected]

257.001
Operating instructions
Aliva 257 Top
Concrete spraying machine
312381 / TBA / 000 / 00 / AA / EN

Translating of the original operating instructions 312830_TBA_AA

Operating instructions Aliva-257 Top
Version 1.0 I
Table of contents
1 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.1 Notice of hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.2 Work instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1.3 Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2.1 Personal safety gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2.2 Who may operate this machine? . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.3 Correct use in accordance to the instructions . . . . . . . . . . . . . . . . . 7
1.2.4 Incorrect use not in accordance to the instructions . . . . . . . . . . . . . 7
2 Description of unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Scope of delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3.1 Control displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Operating parts and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4.2 Control cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4.3 Drive motor / frequency converter . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4.4 Remote control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5 Operating modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.5.1 Dry spraying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.5.2 Wet spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.6 Mode of operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.1 Transport / placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2 Check the ball valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3 Connect hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3.1 Connect compressed air hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3.2 Connect conveyor hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3.3 Clamp Rotor discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.4 Connect the power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.1 Preparing to convey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.1.1 Function check of rotor machine . . . . . . . . . . . . . . . . . . . . . . . . . . 32

II Version 1.0
Operating instructions Aliva-257 Top
4.2 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.2.1 Hold onto the conveyor hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.2.2 Adjust empty air resistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.2.3 Select rotor speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.2.4 Fill Filling hopper / regulate jouncer . . . . . . . . . . . . . . . . . . . . . . . 39
4.2.5 Spray concrete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.3 Interrupt conveying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.4 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.4.1 Dry spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.4.2 Wet spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1 Data sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1.1 Theoretical flow rate of rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1.2 Max. conveying power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1.3 Air consumption while conveying . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.2 Dimensional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.3 Air consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.3.1 Dry spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.3.2 Wet spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.4 Lube pump grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.5 Pneumatic grease gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Operating instructions Aliva-257 Top 1 Notes
Version 1.0 1
1Notes
Purpose This manual provides you with all the information you need for safe, efficient work
with the machine/unit.
Read this chapter carefully; it is important for your safety and that of your
coworkers.
1.1 About this manual
Purpose This chapter provides information about the symbols used in this manual. You will
learn which safety notices you need to consider when working with the machine/
unit, who may operate the machine/unit, and for what purposes.
1.1.1 Notice of hazards
HAZARD
Means that death or severe bodily injury
WILL occur if the corresponding safety
measures are not taken (according to ANSI Z 535.4-1991).
HAZARD
!
WARNING
Means that death or serious bodily injury
CAN occur if the relevant safety
measures are not taken (in accordance with ANSI Z 535.4-1991).
WARNING
!
CAUTION
Meansthatminor bodilyinjury oronlymaterial damage
CAN occur iftherelevant
safety measures are not taken (in accordance with ANSI Z 535.4-1991).
CAUTION
!

2 Version 1.0
1 Notes Operating instructions Aliva-257 Top
1.1.2 Work instructions
1.1.3 Symbols used
INCLINE
Means that death or severe bodily injury
MAY occur if the incline of the floor
surface is more than 2%.
WARNING
Warns of possible minor material damage.
NOTE
Information which simplifies work.
This arrow denotes action instructions.
9This checkmark after an action instruction shows you the result of your
action.
• Lists are highlighted with points.
These arrows show you that the action continues after a result and that
you must turn the page.


Operating instructions Aliva-257 Top 1 Notes
Version 1.0 3
1.2 Safety instructions
Improper operation
• Danger to life due to incorrect operation.
Work with and on the Machine may only be carried out by trained personnel.
Do not remove required covers, such as safety grids, etc.
Do not make modifications to the machine.
Do not point the spray nozzle in the direction of persons.
Use only original replacement parts from Sika Schweiz AG, and install them
properly.
Risk of explosion
• The machine is not Ex-protected.
The machine must not be used in explosive atmospheres.
Compressed air
• Risk of death from compressed air
Never open a ball valve in an uncontrolled manner.
Hold the conveyor hose and nozzle firmly before opening the air supply.
Correct any problems on the machine only if the machine is turned off, the
supply line is shut off, the air supply is stopped, and the air pressure and
additive pressure have dropped to 0 bar.
Inclines
• The machine is not fitted with brakes; there is therefore a risk to life on
inclines.
The machine must only be placed on a firm, slip-free and straight surface.
The maximum permissible incline is 2%.
If the incline is 2% then the machine must be moved very slowly.
Maintain sufficient safety clearance from ditches, embankments, etc .
HAZARD
!

4 Version 1.0
1 Notes Operating instructions Aliva-257 Top
Vibrations
• The machine moves in an uncontrolled manner if knocked or subject to
vibrations when conveying concrete, and can no longer be controlled due to
the heavy weight.
Secure the machine's wheels by placing wedges underneath them.
• Damage to health may occur due to the severe vibrations when conveying.
Never convey more than 6 m3/h concrete with one hand-operated spraying
device.
Faults
• Faults (blockages to the rotor/blow-off chamber/conveyor hose/additive hose/
upper or lower air hose, a pulsing conveyor hose, unusual noises or
vibrations, escape of air between the Rotor discs and the wear plates and the
Filling hopper) may result in explosive escape of compressed air and cause
serious injuries.
If faults occur then switch the machine off immediately, close the supply of
compressed air and pull the electric supply plug.
Caustic materials
• The construction materials and additives used can cause severe injury.
If construction materials or additives contact the skin or eyes, wash the
affected area for at least 15 minutes under flowing water. In case of contact
with the eyes, see a doctor.
Electrical shock
• If electrical components are exposed to moisture, there is a risk of electrical
shock.
Protect all electrical components from moisture.
WARNING
!

Operating instructions Aliva-257 Top 1 Notes
Version 1.0 5
Insufficient light
• Injuries can occur when working in insufficient light.
Ensure sufficient illumination and safety in the workplace.
Insufficient maintenance
• Insufficient maintenance can cause injuries and defects.
Carry out the specified maintenance tasks regularly.
CAUTION
!
CAUTION
Poisoning of drinking water!
Dry spraying runs the risk of contaminating the fresh water line with liquid
accelerator,
During dry spraying, a back flow valve must always be used if the water is
taken from the drinking water supply!
CAUTION
!
NOTE
• Always keep this operating manual in the vicinity of the machine so that quick
access is possible in case of emergency.
• Retain this operating manual for the entire lifetime of the machine.
NOTE
• The connection voltage required for the machine is listed in the instruction
notice inside the Control cabinet or in the electrical schematic.
• If the humidity is too high during dry spraying and the dry concrete has more
than 4% moisture, it will adhere faster to the Filling hopper, the rotor and the
blow-off chamber, resulting in blockages.
• When applying thicker layers of sprayed concrete, make sure that the
temperature of the base concrete does not drop below 15 °C. Lower
temperatures require higher doses of additive.

6 Version 1.0
1 Notes Operating instructions Aliva-257 Top
1.2.1 Personal safety gear
The following lists apply to all people in the danger zone of the machine.
Always wear usual construction site safety equipment, such as:
Since you will be working with cementitious materials and additives, anddue to the
noise level of the machine, you should also wear:
Safety helmet Safety boots Safety clothing Safety gloves
Safety glasses Breathing
protection Ear protection
Caustic materials
• The construction materials and additives used can cause severe injury.
If construction materials or additives contact the skin, mouth or eyes, wash
the affected area (eye/skin/clothes) for at least 15 minutes under flowing
water. In case of contact with the eyes, see a doctor.
WARNING
!

Operating instructions Aliva-257 Top 1 Notes
Version 1.0 7
1.2.2 Who may operate this machine?
This operating manual is intended for any person working on or with the machine:
Cement gun operators, mechanics, machinists, tunnel construction workers,
installers, service technicians, as well as salespeople and representatives of
Sika Schweiz AG.
You may only work with the machine if you
• are qualified to do so as a result of applicable training, experience, and
instruction by Sika Schweiz AG or an authorised representative.
• have read and understood this operating manual.
• have knowledge of all applicable standards, regulations, accident prevention
guidelines, and first aid measures and local medical facilities.
• have also been authorised by the owner of the machine to work on this machine.
1.2.3 Correct use in accordance to the instructions
The rotor machine is intended solely to convey wet and dry mixtures from
aggregates and corresponding additives.
Observe all required safety, operating, and maintenance instructions as well as all
instructionsforthecorrectionofdefects.Observeallapplicableaccidentprevention
guidelines and other generally recognised safety and workplace technical and
medical rules.
1.2.4 Incorrect use not in accordance to the instructions
Anyuseofthemachinewhichdoesnotcorrespondtotheintended uselistedabove
is considered as an incorrect use not in accordance to the instructions (e.g. spray-
washing a car with water).
We, Sika Schweiz AG, bear no liability for any damages resulting from incorrect
use that is not in accordance to these instructions.

8 Version 1.0
1 Notes Operating instructions Aliva-257 Top

Operating instructions Aliva-257 Top 2 Description of unit
Version 1.0 9
2 Description of unit
Purpose The unit description provides you with a description of performance, informs you of
the limits of the machine, and lists the scope of delivery. The individual operating
parts of the machine are shown and explained using photos. Furthermore, the unit
description provides information about the operating modes for thin-stream
spraying, as well as mode of function of the machine.
2.1 Features
The machine is an extremely robust concrete spraying machine for mixture
processing. It functions using the thin-stream process, i.e. with addition of
compressed air.
The machine is on three wheels and is pulled manually with a drawbar to its place
of usage.
2.2 Scope of delivery
• Operating manual
• Machine
• Tool set
• Grease gun
• Remote control (option)

10 Version 1.0
2 Description of unit Operating instructions Aliva-257 Top
2.3 Components
257.002
8 7 5
3
2
4
6
1
1Control cabinet • Controls
2Filling hopper
3Jouncer
4Rotor
5Blow-off chamber
6Chassis
7Air unit
8Solenoid valve • Compressed air supply