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ACS APS Paper Shredder User Manual

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1. a da y bi m Se iM 2 E d GRN4 610 Chapter 2 Functional Description 19 of 73 Id a MU unc z J The ground material will be discharged by a conveyor belt Hydraulic pusher The ram consists of a double acting telescopic cylinder and the pusher itself which is a heavy durable welding construction The pusher is moving on 3 sets of high performance guide roller skids Those adjustable skids are running on 3 independent guide rails The position of the pusher is controlled by an optical distance sensor Illustration 1 Hydraulic stage cylinder 2 Guide roller 3 Guide rail 4 Pusher Illustration 1 Pusher front plate 2 Guide rail GRN4 610 Chapter 2 Functional Description 20 of 73 Illustration 1 Distance sensor 2 Reflecting area Control Panel Illustration Control panel 1 Emergency STOP 2 Ampere meters 3 Elapsed hour counter 4 Part 1 5 Part 2 GRN4 610 Chapter 2 Functional Description 21 of 73 Hlustration Part 1 1 Error lights 2 Control lights 3 Start buttons 4 Stop buttons 5 Control light hydraulic 6 Start Stop switch hydraulic Illustration Part 2 1 Error lights 2 Control lights 3 Star buttons 4 Stop buttons 5 Overload light shredder 6 Oil filter jam 7 Overload light Ram 8 Reset GRN4 610 Chapter 2 Functional Description
2. GRANULATOR LOCATION Adequate area for routine maintenance should be provided in order to open the machine for knife screen or cleanout service Proper service area clearances also should allow people who are working on the machine to be clearly visible to others thereby reducing the potential safety hazards SAFE HOUSEKEEPING The work area must be kept clean and uncluttered during periods of operation or maintenance No hand tools or other metal objects should be left on or around the machine Any tools or other metal objects that mistakenly fall into the hopper feed opening can cause severe damage to internal cutting chamber rotor and screen components I SAFETY GLASSES OR A FACE SHIELD MUST ALWAYS BE WORN when servicing or operating the machine Although our machines are designed for the maximum in flyback control caution must be used when operating near the hopper feed opening in order to guard against unexpected material flyback I EAR PROTECTION may be required when operating the machine during granulation of very hard or noisy materials The Occupational Safety and Health Act of 1970 has established guidelines for Permissible Noise Exposures OSHA 1910 95 that should be followed M NEVER attempt to operate the granulator unless it is fully assembled with all guards and interlocks in place and functional M OBSERVE all danger warning caution and safety labels on the equipment Upon completion of any machine
3. Chapter 5 Maintenance 5 1 Preventative Maintenance Schedule Only trained personnel may perform maintenance on the machine The maintenance must be performed within the specified time and also documented for records Regular maintenance is important to the continued effectiveness and efficiency of the machine Electrical voltage causes danger while starting the machine for maintenance the main switch MUST be turned to 0 the machine must be safeguarded with a padlock and a warning sign must be attached Maintenance Plan GRN4 610 The following maintenance must be completed after every 8 operation hours e Check protective devices for proper function e Check mountings of cutters and bed knives e Check the condition of the cutters and bed knives The following maintenance must be completed after every 40 operation hours e Check that all screws are tightened e Check all wearing parts e Check hydraulic oil level and consistence The following maintenance must be completed after every 2000 operation hours e Check the oil level in the gearbox motor The following maintenance must be completed when necessary e Clean the machine e Check the main bearings bearing clearance lubricant renewal Yearly Maintenance e purpose of yearly maintenance 15 to check the general condition of the machine and to arrange for the arrival of any necessary replacement parts in good time A service engineer can assist in performin
4. Controlpiel 0 Comolabme 000808 Proximity switch 110297 5 3 Cable for Proximity switch E10200 1 0 907 1 Laser distance sensor01DI000 o 9 3 LightbarrerYM T0 18 OS 705 706 707 708 709 710 711 112 800 801 802 803 804 901 902 903 04 9 IN E ua uz MES N Chapter 7 Appendix 71 of 73 7 5 Technical Assistance Parts and Service Department The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications which will maximize your equipment s performance and efficiency To assist in expediting your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service For immediate assistance please contact North Central and South America 8am 5pm CST 1 800 483 3919 for drying conveying heating and cooling and automation For size reduction 1 800 229 2919 North America emergencies after 5pm CST 847 439 5855 North America email acsuscanadacustserv corpemail com Mexico Central amp South America Email acslatinamericacustserv corpemail com Europe Middle East amp Africa 48 22 390 9720 Email acseuropecustserv corpemail com ndia 91 21 353
5. Grinding Material In feed The grinding material can be fed into the shredder using the following methods Manual in feed of the grinding material directly into the feeding trough e Manual in feed of the grinding material with the help of an additional in feed device 1 e hydraulic feeding unit In feed Hopper The grinding material in feed ensues via a feeding trough The pipe can be placed easily in the feeding trough by a forklift Illustration Feeding trough The feeding trough has a hydraulically operated cover which is closed after it is filled with material A hydraulic ram system is than pushing the material towards the rotor GRN4 610 Chapter 2 Functional Description 16 of 73 Illustration 1 Stage cylinder 2 Cover 3 Lock 4 Pusher Illustration 1 Base frame 2 Lower housing flap 3 Upper housing flap 4 Gear box 5 Drive motor 6 V belt protection 7 Discharge conveyor GRN4 610 Optional not included in standard machine the feeding trough can be equipped with a hydraulic feeding device The machine housing is mounted on the base frame and the drive motor and the gear box are mounted on the machine housing This design makes the machine compact Chapter 2 Functional Description 17 of 73 Drive The drive of the rotor ensues by means of an electric motor via V belts The motor which is mounted on sliding rails or a motor plate can be adjusted for regulati
6. Tu T PUT mm End heldine Ts 00 S 2000 12 31 10 59 59 You can read the ram position when the machine running End holding time When the ram reach end position it will has 20 seconds delay this time could be modified GRN4 610 Chapter 2 Functional Description 26 of 73 Time setting menu selection 7 Message SIEMENS SIMATIC PANEL End Holding Standard Push Standard Pull Pulse Push Pulse Stop Illustration Operation panel time setting menu T B EM M amp n End holding the ram reaches end position and delay time Standard push VVhen the ram pushes this action lasts 30 seconds and then will has a 1 second pull action So the 30 seconds is standard push time and the 1 second ss standard pull Standard pull See above Pulse push When the ram moves to 700mm point before end position it will act as this rule pushes 3 seconds and stop 1 second so the 3 seconds is pulse push and 1 second is pulse stop Pulse stop See above GRN4 610 Chapter 2 Functional Description 27 of 73 Position setting menu Illustration selection C Message SIEMENS Operation panel position setting menu Half Position 0000 ma 25 Half position the whole length of ram stroke is 7200mm our setting is 3600mm but it could be modified Pulse position to avoid current peak and motor overload this setting is 6700mm it could be modified GRN4 610 Chapter 2 Functional Descrip
7. direction of the directional arrow If running in the wrong direction re connect the motor connection immediately Damage to the machine will result from operating in the wrong direction Chapter 3 Installation 36 of 73 GRN4 610 Start up Checklist 1 E RS II K K N 4 When the housing panel is opened check the cutter mounting screws using a torque wrench Search the grinding chamber for foreign matter Check oil level of the gearbox motor Examine in feed device for foreign matter Check that they Emergency Stop buttons are unlocked Check all safety devices for proper function Switch ON the machine for a short time to check the rotational direction can be seen at the discharge air fan of the drive motor observe the running direction arrow Allow machine to run approximately 10 minutes without grinding material Connect material discharge and in feed device check rotational direction drives Feed grinding material uniformly too much material can cause the machine to overload Check the temperature of ground material if necessary Monitor the ammeter This displays the present current consumption and provides information on the load of the machine Chapter 3 Installation 37 of 73 Chapter 4 Operation 4 1 Start up Machine Checks Prior to Start up M The cutters are properly set and the screws are tightened with the specified torque M The grinding chamber is free of foreign matter M
8. 22 of 73 Operator panel Illustration Control panel 1 Part 1 2 Part 2 3 HMI operator panel 4 Emergency STOP Illustration Part 1 1 System ON 2 Automatic Manual switch 3 Error light Ram 4 System OFF 5 Half stroke 6 Manual rotor move 7 Reset 8 Pulse push switch 9 Manual push button for Rotor move GRN4 610 Chapter 2 Functional Description 23 of 73 Hlustration Part 2 1 Control light Overload reverse 2 Control light Ram PUSH 3 Control light Ram PULL 4 Lid open 5 Lock open 6 Ram PUSH 7 Lid close 8 Lock close 9 Ram PULL Illustration HMI operator panel GRN4 610 Chapter 2 Functional Description 24 of 73 Machine HMI operation manual Start menu Message C run status time set LL positionset O 1848 SIEMENS SIMATIC PANEL Fl Status Kl Selection F2 Time Set F3 Po sition Illustration Operation panel start menu Set K4 St op F4 Me ssage You can select the second menu what you want to read F1 ram running status F2 the timer what you want to modify when you operate this machine F3 the ram position where you want to modify F4 alarm information K1 go back to start menu K4 stop HMI GRN4 610 Chapter 2 Functional Description 25 of 73 Machine running status r SIEMENS Illustration Operation panel running status RAM
9. Facility 2900 S 160 Street ACS Warsaw 72 of 73 New Berlin WI 53151 UL Dzialkowa 115 Phone 1 262 641 8600 02 234 Warszawa Fax 1 262 641 8653 Phone 48 22 390 9720 Fax 48 22 390 9724 GRN4 610 Chapter 7 Appendix 73 of 73
10. V Chapter 1 Safety 1 1 Hovv to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your granulator The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light corrective maintenance No other maintenance should be undertaken without first contacting a service engineer The Functional Description section outlines models covered standard features and safety features Additional sections within the manual provide instructions for installation pre operational procedures operation preventive maintenance and corrective maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the granulator We can also provide the assistance of a factory trained technician to help train your operator s for a nominal charge This section includes instructions checks and adjustments that should be followed before commencing with operation of the granulator These instructions are intended to supplement standard shop procedures performed at shift daily and weekly intervals The Operation chapter includes a description of electrical and mechanical controls in addition to information for operating the granulator safely and efficiently The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipme
11. carefully place the rotor into the bearing seats Attach the bearing housing to the bearing seats with screws Return the distance sleeve to the rotor axis Return the gearbox motor to the rotor axis Return the rotor cover plates Carry out a test run The mounting forces must always engage the inner ring or roller body damage will result The hardened bearing rings are sensitive to stressed impact never hit the rings directly with a hammer It is recommended to use a brass arbor or piping piece made from soft material The bearing should be put onto the shaft using light blows When performing this task the force of pressure must be evenly distributed on the circumference of the bearing ring Chapter 5 Maintenance 43 of 73 Lubricating the Main Bearings A correct lubricant supply is an important requirement for operational safety and long service life of bearings Every machine is greased and test runs are performed before delivery NOTE Unsuitable lubricant lubricant deficiency excessive lubricant or impurities in the lubricant lead to overheating and extreme wear of the bearings Lubrication intervals Use the following table to determine when to check and replace the lubricant Shift Operation When to Replace When to Check One shift operation Every 18 months Monthly Two shift operation Every 9 months Monthly Three shift operation Every 6 months Monthly Checking lubricant quality When determining
12. dirt hub If bushing does not loosen immediately tap on hub Table for the tightening torque of the screws Tensioning element Screws Tightening Screw details Type 2 Number Size BSVV GRN4 610 Chapter 5 Maintenance 47 of 73 Mounting the TAP Proceed as follovvs ER LOCK tensioning element Remove the protective coating from the bore and outside of bushing and bore of hub After ensuring that the mating tapered surfaces are completely clean and free from oil or dirt Insert bushing in hub so that holes line up Sparingly oil thread and point of grub screws or thread and under head on cap screws Place screws loosely in holes threaded in hub shown thus O in Clean shaft and fit hub to shaft as one unit and locate in position desired remembering that bushing will hip the shaft first and then will be slighting drawn on the bush Using a hexagon wrench tighten screws gradually and alternately to certain torque Hammer against large end of bushing using a block or sleeve to prevent damage This will ensure that the bushing is seated squarely in the bore Screws will now turn a little more Repeat this alternate hammering and screw tightening once or twice to achieve maximum grip on the shaft If a key 1s to be fitted place it in the shaft keyway before fitting the bushing It is essential that it is a parallel key and side fitting only and has TOP CLEARANCE After drive has been running under load for a shor
13. maintenance be certain ALL SAFETY GUARDS AND COVERS are securely and properly fastened prior to resuming machine operation All fasteners must be in place and properly tightened ANY SHORTCUTS MAY RESULT IN INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT M NEVER wear any loose fitting clothes neckties or dangling items such as earrings belts or shoestrings Jewelry such as wristwatches bracelets or rings should NEVER be worn Long hair must be tied back or placed in a tight fitting hairnet NEVER lean against or rest hands or feet on the granulator when it is in operation or open for maintenance NEVER stand on the granulator when it 1s in operation GRNA 610 Chapter 1 Safety 10 of 73 GRN4 610 ROTATION OF MOTORS The correct rotating direction for the granulator motor is clearly marked on the machine Always check for proper rotation of motors Incorrect rotation direction can cause severe damage ELECTRICAL GROUNDING All electrical equipment on the granulator must be grounded in accordance to all local codes and Article 250 of the National Electric Code ALWAYS DISCONNECT AND LOCKOUT the main electrical power to the granulator before performing any service SAFETY INTERLOCKS MUST NOT BE BYPASSED The mechanical and electrical safety interlocks ensure the safety of personnel They should never be tampered with or removed for ANY reason They should be checked frequently by a qualified mechanic for proper operation NEVER modif
14. whether a lubricant needs to be replaced check for the following e Change in consistency Discoloration Degree of soiling Replacing or refilling lubricant e Fill the bearings uniformly with grease until all operating surfaces are well greased A lubricant quantity of 1 3 to 1 2 of the bearing volume per bearing is required If too much grease is used the lubricant will become unusable due to excessive temperature e Only one type of grease must be used Mixing different types of grease together is prohibited The bearings are filled at the factory with lithium base saponification roller bearing grease F3 Use the List of lubricants to determine which lubricants from which manufacturers to use GRN4 610 Chapter 5 Maintenance 44 of 73 GRN4 610 Refilling lubricant The grease travels through the circulating grooves and bores via lubrication nipples into the interior of the bearing The greasing quantity is 2 oz 60g to 3 5 oz 100g roller bearing grease F3 per bearing Grease nipple Replacing lubricant Renewing the lubricant between the specified intervals is only necessary when unusual bearing noises or overheating occurs Mounting and dismounting the bearings must be performed according to the instruction in the operation manual Follow the steps below to replace the lubricant 1 Open the bearing 2 Remove the bearing housing and the bearing cover 3 Carefully clean the bearing wi
15. 1 Safety device for lower housing flap 2 Safety device for upper housing flap The shredder can only be operated if the housing flap is closed and thus deactivating the safety switch If the housing flap 15 opened the contact is GRN4 610 Chapter 2 Functional Description 30 of 73 broken If the housing flap will be opened during operation the safety switch is activated thus switching off the machine V belts and pusher protector V belt and pusher protection are fixedly connected to the machine They can be dismounted for installation and maintenance work However this may only then be carried out when all rotating parts have come to a complete standstill Illustration V belt cover Pusher cover If machines are delivered on the request of the customer without drive motors the operator is obliged to fit and mount the protective devices delivered together with the machine himself in line with the current legal safety regulations GRN4 610 Chapter 2 Functional Description 31 of 73 Safety Light grid The feeding trough in feed is safeguarded by a light grid During opening and closing of the cover it 1s activated If somebody walks inside this light grid the hydraulic will be stopped After the cover is opened or closed the light grid is deactivated Illustration safety Light Grid Safety markings safety markings are attached to the machine If one of these markings becomes detached or is no lon
16. 1000 Series Pipe Shredder Models Covered APS CPS MPS EPS SPS Part Number MAN EPS 0001 Bulletin Number GRN4 610 Effective August 1 2012 an ACS company Write Down Your Serial Numbers Here For Future Reference We are committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice DCN No O Copyright 2013 All rights reserved GRN4 610 11 Shipping info Unpacking and Inspection You should inspect your granulator for possible shipping damage Thoroughly check the equipment for any damage that might have occurred in transit such as broken or loose wiring and components loose hardware and mounting screws etc In the Event of Shipping Damage According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment Notify the transportation company s local agent if you discover damage Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods before the transportation company s inspection and authorization File a claim with the transportation company Substantiate the claim by referring to the agent s report A certified copy of our invoice is available upon request The original Bill of Lading 1s attached to our original invoice If the shipment was prepaid write us for a receipted transportatio
17. 29112 Email acsindiacustserv corpemail com e Asia Australia 86 512 8717 1919 Email acsasiacustserv corpemail com Sales and Contracting Department Our products are sold by a worldwide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Let us install your system The Contract Department offers any or all of these services project planning system packages including drawings equipment labor and construction materials and union or non union installations For assistance with your sales or system contracting needs please Call North Central and South America 1 262 641 8600 or 1 847 273 7700 Monday Friday 8am 5pm CST Europe Middle East Africa 48 22 390 9720 e India 91 21 35329112 Asia Australia 86 512 8717 1919 Facilities ACS offers facilities around the world to service you no matter where you are located For more information please visit us at www acscorporate com United States Asia Australia India ACS Schaumburg Corporate Facility ACS Suzhou ACS India 1100 E Woodfield Road 109 Xingpu Road SIP Gat No 191 1 Sandbhor Complex Suite 588 Suzhou China 215126 Mhalunge Chakan Tal Khed Schaumburg IL 60173 Phone 86 8717 1919 Dist Pune 410501 India Phone 1 847 273 7700 Fax 86 512 8717 1916 Phone 91 21 35329112 Fax 1 847 273 7804 Fax 91 20 40147576 Europe Middle East Africa ACS New Berlin Manufacturing
18. AE Eo TL 30 CHAPTER 3 INSTAELATION ER ayama day s na 34 S51 Uncra ng TNE EQUIPMENT isis eoo ea a De nae uda eh Men aycu NU DDR Mtas tea d o 34 39 1 jiElecirical CoDIecllollS coii beet et noH bu Don Idee ALAY ons 30 6 2 WANA StartUp aa adit O M 36 CHAPTER 4 38 Al Sta a ene n 38 4 2 vi E st te Coa t er e d y dib 38 45 alice 39 CHAPTER 5 MAINTENANCE 40 5 1 Preventative Maintenance Schedule 40 5 2 Preventative amp Corrective Maintenance 41 CHAPTER 6 TROUBLESHOOTING 59 G21 lilfOQUC SR ae lao eee oes 59 CHAPTER 7 APPENDIX Ra 61 7 1 Technical SpecificauOlS sse pH oc api ula a a i PR YR las anda 61 7 3 Drawings arid Diagrams eorr Uode ttt xia x Evae eden e i DE va veas 62 54 parePars List lanan aaa aldad 69 yo Technical ASSISIan6B ua Ra A b a a 72 Parts and Service Department 72 Sales and Contracting Department 72 GRN4 610
19. The housing panel is closed M All safety devices including devices for the grinding material in feed and discharge devices are checked for proper function Switching Machine ON 1 Switch on the grinding material discharge device Switch on the hydraulics Switch on the machine main switch to 1 Set to automatic on the control board After cover 1s opened put in the pipe Press cycle start button Machine will operate automatically v t a a 4 2 Operation Procedures Manual In feed of Material e Throw the grinding material into the feeding trough than start the cycle e The material should be fed into the front of the machine During opening and closing of the cover the safety light grid is activated The hydraulic will stop when somebody reaches in this light grid Rotating knives can cause serious injuries and death Do NOT reach into the in feed hopper or lean in while the rotor is operating Use only approved grinding material DO NOT climb into the in feed hopper while operating the machine Death will result GRN4 610 Chapter 4 Operation 38 of 73 4 3 Shut down Switching Machine OFF 1 Wait until the cycle is finished and the cover has opened 2 Then switch off the shredder main switch to 0 3 Ifyou want to close the cover of the feeding trough close it manually by pressing the button cover close 4 Switch off the grinding material discharge device GRNA 610 Chapter 4 Operation 39 of 73
20. according to DIN 40040 15 to 70 indoor In humidity levels of higher than 70 apply an anti corrosive agent to the metallic finished machine parts Insulation for the tropics is also necessary The machine may not be operated within range of static discharges or strong magnetic fields this could lead to faults in the machine s control system Unloading and Installing the Machine The machine and or components are packed so they will arrive safely Use a suitable crane or forklift for unloading the packaged machine and or components After unloading the equipment remove the packaging material and all transportation safety devices In the case that the shredder and its accessory components have been delivered as individual items mount these at the site of application in accordance with the assembly drawing Align the machine horizontally using a suitable spirit level Do not use blocks to place underneath the machine use metal strips in order to prevent buckling of the base frame Make sure that an even distribution of weight is achieved on all the points of support Chapter 3 Installation 34 of 73 Suspended load Falling loads can cause serious injury or death Only use a crane or forklift appropriate for the weight and dimensions of the load Use suitable means to stop and pay attention to the center of gravity Do NOT step under the suspended load Wear a safety helmet in addition to the basic protective gear Ove
21. arge chute or any guards or covers are in place and secure Do not circumvent the safety interlocks Prior to clearing a jam or performing any maintenance the motor should be turned off and electrically locked out Be sure that the rotor has come to a stop Hands must not be inserted into the machine to clear the jam Do not extend any part of the body into feed roll openings or discharge area unless the motors are electrically locked out and the rotor and feed rolls are motionless Never extend fingers through holes in screen Be sure that the v belts are properly aligned and that tension is at its maximum Extreme care should be taken to see that all bolts are properly tightened at all times During the operation of the machine rotor knife bolts may come loose Although fine threads are used on the rotor knife bolts because vibration does not easily loosen them you should inspect the tightness of the bolts frequently This machine is designed for the granulation of plastic materials Do not feed any other materials into the machine Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine All personnel engaged in the use of the machine should become familiar with its operation as described in this manual Proper operation of the machine promotes safety for the operator and al
22. cause of the trouble Such hasty substitutions will only destroy the new component Refer to wiring diagrams and schematics Locating mechanical problems should they occur is relatively straightforward When necessary refer to the parts catalog section Chapter 6 Troubleshooting 59 of 73 Possible Cause Possible Remedy Motor doesn t vvork Oil pump doesn t work Oil pump noise Working pressure abnormal Pressure maintain abnormal Work abnormal GRN4 610 Electric source Motor damage Motor not vvorking Pump damage Filter jam Hydraulic oil to thick Poor hydraulic oil quality Pipe leaking Pump damage Motor and pump misalignment Spillover valve and sequence valve jam Pump damage Sealing broken Pipe leak single direction valve jam Pressure abnormal Magnetic valve abnormal Electrical problem Chapter 6 Troubleshooting Correct wire connection Replace motor Correct wire connection Replace pump Clean the filter Change hydraulic oil Change hydraulic oil Tighten pipe connectors Change pump Clean spill over valve and sequence valve Change pump Change sealing Check and solve the leak Clean the valve Clean spill over valve and sequence valve If the valve jams clean it If it 1s broken change it Check and change the broken electrical parts 60 of 73 Chapter 7 Appendix 7 1 Technical Specifications Feeding chamber opening 6720x840 Rotor dimension Diameter
23. ced with new ones Bed knives can be turned two times and can be re sharpened for as long as they can be mounted with the long hole NOTE Specialist sharpening of the cutters and bed knives is available through customer service NOTE The cutters and bed knives especially the cutters should only be sharpened or replaced in sets There is danger of balance error if a combination of cutters from different sets 1s used Follow the steps below to sharpen the cutters and bed knives 1 Dismount the cutters 2 Sharpen the cutters A specialist should use the sharpening plan to uniformly sharpen the cutting knives mechanically It is important to make sure that sharpening takes places with small grinding allowance and sufficient coolant supply The sharpening process is finished when the cutting edge is sharply cut Not all indentations must be worked out or the number of possibilities for sharpening is reduced For the sharpening process use soft grinding wheels 40H or 46K Knives with grinding cracks should not be re used due to danger or breakage during operation 3 Whet the cutting edges of the cutters and bed knives with a whetstone 4 Setthe cutters and bed knives 5 Mount the cutters and bed knives Sharp knives are dangerous even while the rotor is at standstill Serious injury can result especially to the hands and fingers wear protective gloves GRN4 610 Chapter 5 Maintenance 57 of 73 Setting the cutters and bed
24. ct you as a user to abide by the foregoing recommendations in order to make operator safety a reality Chapter 1 Safety 14 of 73 Chapter 2 Functional Description 2 1 GRN4 610 Models Covered in This Manual This manual covers the1000 Sertes pipe shredder vvhich includes models APS CPS MPS EPS and SPS The 1000 Series pipe shredder is designed for size reduction of plastic pipes made of PE PP and PVC etc The user is responsible for consequences resulting from incorrect operation This will lead to the loss of the warranty as well as any compensation claims General Description amp Typical Features Mechanical section After the machine has been switched on a hydraulically controlled feeding unit pushes the pipe onto the slow running rotor The in feed is controlled according to the load of the motor The pipes can be fed horizontally and without precutting into the feeding trough of the pipe shredder by a forklift or optionally with a loading device The feeding trough has a hydraulically operated cover which is closed after it is filled with material A hydraulic ram system 1s than pushing the material towards the rotor The ram consists of a double acting telescopic cylinder and the pusher itself which is a heavy durable welding construction The pusher is moving on 3 sets of high performance guide roller skids Those adjustable skids are running on 3 independent guide rails The trough 1s built with tough steel profil
25. e The required torque for the cutter mounting bolts is 120 Nm e Use the table below to determine torque values The tightening capacity decreases on screws that have been loosened and tightened several times New screws of the same material must replace the cutter mounting screws after they have been loosened and tightened several times GRNA 610 Chapter 5 Maintenance 50 of 73 Torque Value Table Grade 8 8 Grade 10 9 Grade 12 9 m m Pux mom Tus Bolt Type x Checking the condition of the cutters The cutters become blunt after a certain number of operation hours They need to be checked regularly Using blunt knives has several consequences including decreased grinding capacity increased current consumption of the drive motor inexact cuts and overheating of the material Sharp knives are dangerous even while the rotor is at standstill Serious injury can result especially to the hands and fingers wear protective gloves Dismounting the cutters Follow the steps below to dismount the cutters See image below 1 Switch OFF the shredder at the main switch Safeguard the main switch with a padlock Open the lower housing panel Safeguard the housing panel Clean the hexagon head socket of the cutter mounting bolt 2 p io ue m ud Loosen the bolt using a high quality Allen key 4 1n 10 mm Lightly knock the Allen key with a hammer to loosen if necessary 7 Take out the cutter mounting bolt the wash
26. e rotor is at standstill Serious injury can result especially to the hands and fingers wear protective gloves Dismounting the bed knives Follow the steps below to dismount the bed knives See image below l GRN4 610 Switch OFF the shredder at the main switch 2 Safeguard main switch with padlock 3 Open the upper housing panel 4 5 Safeguard the housing panel Clean the hexagon head socket of the knife mounting bolts 2 and the cover plates mounting bolts Loosen the cover plate mounting bolts with Allen key lightly knock with a hammer if necessary Take out the bolts and cover plates Loosen the knife adjusting screws for pulling and take them out Loosen the knife mounting bolts using an Allen key knock lightly with a hammer if necessary Take out the knife mounting bolt and the knife Chapter 5 Maintenance 53 of 73 Bed knife Bed knife mounting Screws Bed knife holder Cover plates Bed knife adjusting screw Cover plate holder Cover plate mounting screws Mounting the cutter holders Follow the steps below to mount the cutter holders l 2 Clean the knife pocket and the cutter holder Insert the cutter holder into the pocket NOTE Cutter holder must slide in easily Do NOT damage the cutter holder surfaces with a hammer GRN4 610 3 Attach the cutter holder mounting bolts DIN912 M8x25 12 9 and add some Loctite Make sure that the cutter holder
27. earbox necessary only in exceptional cases Dismounting and mounting the gearbox requires specialized knowledge Please observe the installation requirements of the gearbox manufacturer GRNA 610 Chapter 5 Maintenance 4 of 73 Replacing the Rotor The rotor has a heavy duty design which makes replacement necessary only after a crash i e a hammer falls inside the machine Dismounting and mounting the rotor requires specialized knowledge Dismounting the rotor Follow the steps below to dismount the rotor 1 Dismount the gearbox motor Remove the rotor mounting slot cover plates from the housing Screw in hooks on both shaft ends 2 3 4 Remove the bearing housing mounting bolt 5 Carefully lift the rotor out of the housing using suitable lifting equipment 6 Place the rotor in a safe location appropriately sized timber beams are suitable for this Mounting the rotor Clean the bearing seat surfaces and check the key before proceeding as follows to mount the rotor 1 Lift the rotor using suitable lifting stopping equipment and place the rotor carefully into the bearing seats Attach the bearing housing Pos to the bearing seats with screws Place the gearbox motor onto the rotor axis Return the rotor mounting slot cover plates 27 55 00 Carry out a fest run Replacing the Main Bearings The dimensions of the main bearings make a replacement necessary only in exceptional cases Dismounting and mounting the b
28. earings requires specialized knowledge therefore please observe all instructions provided by the manufacturer or call customer service for assistance The bearings mounting in this machine are indicated in the spare parts list A requirement for dismounting and mounting the bearings is a suitable pulling off device GRN4 610 Chapter 5 Maintenance 42 of 73 Dismounting the main bearings Follovv the steps belovv to dismount the main bear ngs p 2 3 4 5 6 7 8 9 10 LT Dismount the gearbox motor Pull the distance sleeve from the rotor axis Remove the rotor cover plates from the housing Screw in hooks eye bolts on both shaft ends Hang the rotor from hooks eye bolts on both shaft ends Remove the bearing housing mounting bolt Carefully lift out the complete rotor using suitable lifting equipment Place the rotor in a safe location timber beams are recommended Loosen the bearings cover mounting screws and take off the bearing cover Pull the bearing housing off using a pulling off device Pull the bearing off the rotor axis using a pulling off device Mounting the main bearings Thoroughly clean the bearing surfaces and the shaft surfaces and grease them lightly before following the steps below to mount the main bearings l 25 10 0 T ums NOTE GRN4 610 Mount the bearing in bearing housing Attach the bearing with the bearing housing to the rotor axis Lift the rotor using suitable equipment
29. eding trough _ Bolt 1 for cylinder for cover ZRS1000 04 02 00 Bolt II for cylinder for cover ZRS1000 04 03 00 Bolt III for cylinder for cover ZRS1000 04 04 00 Anti vibrating foot 80050273 Pneumatic cylinder SI 63x160 S CB 80040369 Lock GH72425 Bolt 1 ZRS1500 11 07 Bolt IT ZRS1500 11 08 209 8 Circlip DINA7I 16 ee Safety grid ZRS1500 16 00 Safety bar for cover ZRS 1500 18 00 30072 Bains Bearing housing SN236 Bearing 22236 W33 Bearing Cover A GSH80120 021 03 Bearing Cover B GSH80120 021 03 305 0 Bearing Cover C 757777 Sealing DIN3760 D200 x 230 x 15 30712 0177 2RS 1000 06 02 Fixing bolt DIN912 M12 x 30 8 8 777 Washer DINI2S 25 Fixing bolt DIN912 M24 x 70 amp amp 312 2 Spring washer DINI27 24 313 8 Washer DIN125 A24 314 8 Fixing bolt DIN912 M24 x 11 8 8 EE 315 8 Spring washer DINI27 B24 400 2 45 kW 401 2 Motor 45 kW NENNEN Chapter 7 Appendix 69 of 73 GRN4 610 402 2 Gear pulley 5 75 4 8000234700 80002370 404 2 Key 00 17 o 405 8 V BeltSPC3350 0022X2X0217282X2 406 2 Motorpuley 5 3 75 4 408 2 411 Gear box SEW MC3PLHFO6SD 14 i 41 777 Gear box SEW MC3PLHFOS5SD 23 1 41 50000 413 8 Bolt DIN933 M24x140 12 9 O 414 16 Washer DIN433 25 300HV 0088071717 415 8 NuDINO4 M24 O 417 40 Disc sp
30. er and the cutter GRNA 610 Chapter 5 Maintenance 51 of 73 Cutter Cutter mounting screvv 3 Cutter holder Cutter mounting Screws NOTE It is possible to reach the cutting shaft by climbing into the feeding chamber however it is strongly recommended that the cutters are accessed through the front size door The shaft can be rotated manually by turning the motor V belt pulley Sharp knives are dangerous even while the rotor is at standstill Serious injury can result especially to the hands and fingers wear protective gloves Dismounting the cutter holders Follow the steps below to dismount the cutter holders See previous image Switch OFF the shredder at main switch Safeguard the main switch with a padlock Open the lower housing panel Safeguard the housing panel Clean the hexagon head socket of the cutter mounting 2 5019 30 qs Loosen the bolt using a high quality Allen key 4 1 10 mm Light knock the Allen key with a hammer to loosen if necessary 7 Take out the cutter holder mounting bolts 8 Remove the cutter holder with the delivered Extractor NOTE It is possible to reach the cutting shaft by climbing into the feeding chamber however it is strongly recommended that the cutters are accessed through the front size door The shaft can be rotated manually by turning the motor V belt pulley GRNA 610 Chapter 5 Maintenance 52 of 73 Sharp knives are dangerous even while th
31. er number and date must be supplied No credit will be issued for material that is not within the manufacturer s warranty period and or in new and unused condition suitable for resale Warranty Returns Prior to the return of any material authorization must be given by the manufacturer A RMA number will be assigned for the equipment to be returned Reason for requesting the return must be given All returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied After inspecting the material a replacement or credit will be given at the manufacturer s discretion If the item is found to be defective in materials or workmanship and it was manufactured by our company purchased components are covered under their specific warranty terms V Table of Contents CHAPTER T SEU UOS 6 151 Howto Use This Manual 53 v ya a tnr v a a y al Aaa P Ede 6 Safety Symbols Used in this Manual 6 General Safety IsegulallOlls alie ad 9 1 2 RE SDORSI D ucm MET 9 t s NXVarnindgs and PrFecautloriS seissduciuadm 10 CHAPTER 2 FUNCTIONAL DESCRIPTION 15 2 1 Models Covered in This 1 15 2 2 General Description amp Typical Features 15 U
32. es and all safety features are according latest CE standards for work safety The pipe should be placed horizontally in the feeding trough mounted next to the cutting chamber Attention must be paid that this material does not contain any metal parts The guarantee does not cover any damage to the machine as a result of metal parts being fed into the machine The pipe in the feeding trough is shredded by the rotating knives on the rotor This shredding process is finished when the hydraulic cylinder has reached its full stroke and the pusher is at the end position The 1000 series shredder is equipped with an E style rotor using a standard square concave cutter blocks These cutters make light work of the heaviest pieces Importantly the design allows efficient cutting of material rather than hammering as well as reduced heat build up and degradation of material The cutter blocks have four corners so they can be easily turned once a corner has worn away The projection of the cutter can be easily adjusted to match the aggressiveness of the shredder with the customer s material by adding or removing thin shims on the cutters holder The housing is a rigid welded and very compact construction Upper and lower part of the housing are bolted together and this makes maintenance work very convenient The housing is sitting on a base frame which allows easy installation of a discharge conveyor Due to the compact design this machine can only be used for scree
33. fits properly Tight the cutter mounting bolts using a torque wrench The required torque for the cutter holder mounting bolts is 39 Nm Refer to torque values table Chapter 5 Maintenance 54 of 73 Mounting the cutters NOTE The cutters and bed knives especially the cutters should only be sharpened or replaced in sets There is a danger of balance error if a combination of cutters from different sets is used Follovv the steps belovv to mount the cutters 1 Clean the knife support surface and the hole on the cutter holder 2 Insert sharp cutter or turn old cutter and push against the cutter holder surface 3 Attach the cutter mounting bolt DIN912 M12x40 12 9 and the washer DIN433 13 300HV 4 Screw in the mounting screws and tighten lightly first Make sure the cutter fits planar in the seat 5 Tighten the cutter mounting bolts using a torque wrench The required torque for all cutter mounting bolts 1s 120 Nm refer to the torque values table 6 Make sure the cutting gap is correct and also that the cutters and bed knives do not collide as the rotor turns 7 Remove tools and other objects from the cutter chamber 8 Switch ON the shredder for a brief time without grinding material listen for noises If unusual noises are present determine the cause and eliminate it NOTE Cutters are reversible and have four symmetrical cutting edges which makes it possible to turn the cutters and only to sha
34. g Maintenance Serious injury or death The maintenance doors must amputation caused by run always be tightly locked during down of the rotor operation DO NOT make the run down safety devices ineffective by using technical aids or other manipulations e NEVER use hands to check if the rotor has stopped GRN4 610 Chapter 1 Safety 12 of 73 Type of Danger Activity Possible Consequences Preventative Measures Direct indirect contact with Maintenance start up Serious injury or death Only trained electricians may live parts in terminal box carry out work on the electrical equipment e f work is necessary on parts that could conduct dangerous voltage a second person should be present to break the power supply in case of an emergency The yellow marked lines conduct voltage even when the machine is switched OFF Only use original safety fuses with stipulated intensity of current Faulty electrical components must be replaced immediately If faults occur in electrical energy supply switch the machine OFF immediately The terminal box must be locked during operation Before opening the terminal box turn main switch to O Failure of the Emergency All activities Serious injury or death There must be a guarantee Stop Function that the machine will be stopped immediately upon failure of an Emergency Stop button Fire explosion caused by Grinding Serious injury or death Only grind material that t
35. g this task Chapter 5 Maintenance 40 of 73 5 2 Preventative amp Corrective Maintenance Checking the Protective Devices Check all safety devices for stipulated condition location and function verify they have safe mountings Danger results from non functioning protective devices Serious ZAVVARNING infury or death can result Eliminate all defects before you put the machine into operation If defects occur during operation stop the machine immediately and eliminate the defect Do NOT change or remove any protective devices Do NOT modify the protective devices Cleaning the Machine To clean the machine follow the steps below 1 Switch OFF the shredder at main switch Safeguard main switch with a padlock Open the housing panel Safeguard the housing panel Pre clean the grinding chamber with a hand brush Evacuate the remaining grinding material residue with a suitable suction device Remove any clinging residue with a wooden scraper Close the housing panel ee dene Machine can be started again ZAVVARNING Danger of cutting caused by sharp knives even vvhile the rotor is stationary Serious infury may result especially to the hands and fingers wear protective gloves Inhalation of dust can be hazardous and can result in respiratory injury never blow out the residue and use breathing protection if necessary Replacing the Gearbox Motor The gearbox motor s dimensions make replacing the g
36. ger recognizable it must be replaced You can order new markings at specialist shops or from us GRN4 610 Chapter 2 Functional Description 32 of 73 Personal Protective Gear The following protective gear must be worn when carrying out the outlined tasks Use breathing equipment before inhaling substances that may be harmful to your health if necessary Helmet Boots Goggles Unloading machine X X 677 5 Operations J X X X X Cleanings X X X Maintenance ofbearings X LLL eem 1517 7 motor eene Dx x D LL LL knives Knifesharpening GRN4 610 Chapter 2 Functional Description 33 of 73 Chapter 3 Installation 3 1 GRN4 610 Uncrating the Equipment Choosing Application Site The location of the machine and site of application must exhibit the characteristics listed below Enclosed space Sufficient load bearing capacity Find the machine weight in Chapter 7 Technical Specifications Machine must be freely accessible from all sides Sufficient available room for operating and service personnel Spatial requirements refer to the assembly drawing All hinged parts must be able to be completely opened Vibration free surroundings Sufficient lighting Machine may not be exposed to direct radiation of any kind Room temperature must range from 40 F 5 C to 104 F 40 C Relative atmospheric humidity
37. hrowing dangerous corresponds to the agreed objects i e spray cans customer specific into the shredder specifications Damage to hearing All activities Diminished hearing Reduce noise levels by taking headaches impaired suitable measures and wear balance and ear protection deterioration of concentration Instable machine due to vibration All activities Serious injury nstall the machine according to the instructions in the operational manual Loose cutter bed knife All activities Serious injury Check the cutter bed knife mountings due to vibration mountings regularly Inhalation of grinding dust All activities Respirator disease etc Mount a suitable air suction device DO NOT blow out grinding dust when cleaning the machine Crushing cutting All activities Serous injury or death Never make the protective amputation caused by devices ineffective check the manipulation of protective devices regularly for proper devices function GRN4 610 Chapter 1 Safety 13 of 73 GRN4 610 For further information on granulator safety installation and operation see the American National Standard for Plastics Machinery Granulators Pelletizers and Dicers Used for Size Reduction of Plastics Construction Care and Use ANSI B151 11 1982 We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration We expe
38. hs inspect all enclosure is supplied with 3 phase electrical connections for secure electrical power Use caution when attachment For further using or maintaining this product information see the Maintenance Chapter in this manual Hands could be exposed to a Every month inspect the crushing movement shears blades for any type of wear For further information see the Maintenance Chapter in this manual When equipped with belts and Every month inspect the belt s sheaves hands could become for any type of wear For further entangled information see the Maintenance Chapter in this manual Hands can become entangled Every month inspect the or cut if they enter the danger shears blades for any type of zone of gears or cutting shears wear For further information see the Maintenance Chapter in this manual The unit can produce Always wear eye and ear continuous noise above 85 dBA protection when the machine is in and or produce projectiles operation or performing under normal operating maintenance conditions A person could be exposed to a Always be aware of your crushing movement if walking surroundings and do not walk around or under machine that is underneath a suspended machine open suspended for moving GRNA 610 Chapter 1 Safety 7 of 73 Mandatory Symbol Description Explanation Read Operators Manual This equipment must be operated and maintained by properly trained personnel The information contained within
39. in mm 980 Width of cut in mm 1210 LI 0 Motor hydraulic unit Power in kW Range of stage cylinder 7000 Electrical connection data Markings are attached to the maching Noise level Without noise equipment in Approx 95 Depends on plant location dB A and type of grinding With noise equipment in Depends on type of material dB A soundproof GRN4 610 Chapter 7 Appendix 61 of 73 7 3 Drawings and Diagrams See corresponding spare parts lists Rotor knife fixing GRN4 610 Chapter 7 Appendix 62 of 73 Stator knife fixing GRN4 610 Chapter 7 Appendix 63 of 73 Rotor assembly GRN4 610 Chapter 7 Appendix 64 of 73 Drive 412 417 421 427 428 429 VT 405 E AU T 422 423 424 425 402 403 GRN4 610 Chapter 7 Appendix 65 of 73 Guidance GRN4 610 Chapter 7 Appendix 66 of 73 Hydraulic Diagram 84 Pusher Cylinder adu sel PTA N27 1 5 IN LI q 55 decere 0 8 Lock Cylinder 84 Door Cylinder 80 2 M14X1 5 M33x2 M52x2 PT1 1 4 M52x2 eed U 22 R K A ME TUE TAPS MCT als PIT YA6 A A 65cc rev 10cc rev NZ 120 GRN4 610 Chapter 7 Appendix 67 of 73 Hydraulic Pump GRN4 610 Chapter 7 Appendix 68 of 73 7 4 GRN4 610 Spare Parts List E Psinisisunu Patna 1001 V Madhinecomplee 0080808 o 10 2 Sdecve O ZRS d oe UE 3 Fe
40. knives Rotor knives used in this machine don t have to be adjusted All adjustments have to be done vvith the bed knives To simplify knife setting and shorten the standstill the bed knives have four adjusting screws two for pulling and two for pushing the knife Standstill needs to be avoided reduced if there are multiple cutter sets Setting the gap between the cutters and bed knives carefully and correctly is an important requirement for the productivity of the shredder Factors for the size of the gap include the size and design of the rotor and the material to be ground Follow the steps below to set the cutters and bed knives 1 Remove old knives 2 Insert sharp knife or turn old knife 3 Attach the knife adjusting bolts and adjust them roughly Attach the knife mounting bolts DIN912 M12x55 12 9 and tighten lightly first 4 Adjust the gap between the cutter and bed knife to 0 3 in to 0 4 in 0 8 to 1 mm 5 Tighten the knife mounting bolts using a torque wrench The required torque for all knife mounting bolts is 120 Nm refer to torque values table 6 Turn the rotor by hand 7 Make sure the cutting gap is correct and also that the cutters and bed knives do not collide as the rotor turns 8 Mount the knife cover plates Transporting and storing the cutters and bed knives Sharp knives present danger of cutting Serious injury can result especially to the hands and fingers wear protective gloves Onl
41. l workers in its vicinity Becoming familiar with materials inspection speed limitations screens and guard maintenance and total user responsibility will assist you in learning potential areas in need of observation for danger Each individual must take responsibility for observing the prescribed safety rules as outlined All caution warning and danger signs must be observed and obeyed All actual or potential danger areas must be reported to your immediate supervisor Chapter 1 Safety 9 of 73 VVarnings and Precautions Our granulators are designed to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes To avoid possible personal injury or equipment damage when installing operating or maintaining this granulator use good judgment and follow these safe practices LEARN AND OBEY your company s safety policy regarding granulating equipment MOVING OR LIFTING THE GRANULATOR Although our equipment is built and engineered for great ruggedness in operation care must be taken when moving the machine along the floor or lifting it Damage may occur to sheet metal covers electrical cabinets or small brackets if pressure is applied to them when moving the granulator When lifting the granulator be certain of total machine weight and the capability of the lifting equipment See the Granulator Specification Sheets for machine weights and dimensions
42. n bill Advise customer service regarding your wish for assistance and to obtain an RMA return material authorization number If the Shipment is Not Complete Check the packing list as back ordered items are noted on the packing list You should have Granulator Bill of lading Packing list Operating and Installation packet KE IR K RI Electrical schematic and panel layout drawings M Component instruction manuals Re inspect the container and packing material to see if you missed any smaller items during unpacking If the Shipment is Not Correct If the shipment is not what you ordered contact the shipping department immediately For immediate assistance please contact the correct facility located in the technical assistance section of this manual Have the order number and item number available Hold the items until you receive shipping instructions GRN4 610 ii GRN4 610 Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department Credit Returns Prior to the return of any material authorization must be given by the manufacturer A RMA number will be assigned for the equipment to be returned Reason for requesting the return must be given ALL returned material purchased from the manufacturer returned is subject to 1596 75 00 minimum restocking charge ALL returns are to be shipped prepaid The invoice number and date or purchase ord
43. n less operations The heavy duty outboard bearings mounted on the 1000 series shredders minimize the risk of contamination of the recycled materials and also minimize the risk of dust penetrating the bearings and make a rotor change easier Power is transmitted from the electromotor by V belts to the gearboxes which are mounted directly on the shaft end on either side of the rotor In combination with the elastically supported torque arm this construction will reduce stress to both motor and gear The dual drive will further ensure that all loads are evenly distributed into the rotor Chapter 2 Functional Description 15 of 73 Control The pusher feeds the rotor with as much material as it 1s able to process Upon reaching 70 90 of rated current the feeding of the pusher will be stopped and automatically started again after the power consumption has fallen by 20 in comparison with rated current If the high current is applied for longer than 0 7 1 5 sec the main drive motor switches off and runs back after about 3 sec standstill time The pusher plate also runs back whilst the rotor runs back The drive motor then stops for another 3 sec before starting again The position of the pusher is controlled by an optical distance sensor The in feed is controlled according to load Duration of pauses and return as well as the current settings can be adjusted Any alterations however should only be carried out after consulting the manufacturer
44. ng the tension of the V belts by means of tensioning screws The V belt pulley is attached with a special tensioning element to the motor shaft Illustration Drive Please observe the operation manual from the manufacturer GRN4 610 Chapter 2 Functional Description 18 of 73 Rotor and Cutters The material is ground between the knives assembled on the rotor and the stator knives which are mounted in a fixed position in the machine lower section All rotors are equipped with square knives These knives make light work of the heaviest pieces The knives have four corners so that they can be easily turned once a comer has worn off The design of the rotor has a significant influence on the quality of the grinding process and its results The rotor construction the type of knife mounting and the number of knives have all been exactly matched to your task allocation Illustration 1 Rotor knife 2 Stator knife 3 Discharge area Due to the compact design this machine can only be used for screen less operations The rotor is accessible after opening the lower housing flap or the upper housing flap The rotor is arranged on roller bearings which are situated outside the housing The V belt pulley is attached by means of a taper bush to the rotor axis The rotor is dynamically counter balanced and has vibration free concentricity Discharge of grinding material Illustration p Conveyor belt discharge 5
45. nt requiring service Preventive maintenance sections are included to ensure that your granulator provides excellent long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions The Appendix contains technical specifications drawings schematics parts lists and available options A spare parts list with part numbers specific to your machine is provided with your shipping paperwork package Refer to this section for a listing of spare parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this Manual The following safety alert symbols are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury ZAVVARNING not avoided could result in death or serious injury ZACAUT ON CAUTTON indicates a potentially hazardous situation or practice that if GRN4 610 WARNING indicates a potentially hazardous situation or practice that if not avoided may result in minor or moderate injury or in property damage Chapter 1 Safety 6 of 73 Figure 1 Safety Tags and warning features Hazard Alert Symbol Description Explanation High Voltage Hazard The electrical Every six mont
46. ring DIN2093 A71 419 2 NuDIN934 M36 10 421 6 Hardwasher 1 ZRS1000 07 06 00 423 2 BolDIN933 MIOx30 88 01712 O 424 2 WasherDINI25 AlO 80 17 85 425 2 Spring washer DINI27 10 7 428 2 DIN933 M16x45 O 429 2 Spring washer DIN127 17 O 600 1 jStatorknifecomplete y 602 8 Prism fixing Bolt DIN912 M12x65 129 0400 603 8 Bolt for pushing DIN912 M12x65 12 9 71 80011290 604 8 Bolt for pulling DIN912 M16x50 129 1717077272 605 8 Knife holder fixing bolt DIN912 16 45 12 9 80011290 606 4 Knife holder plate ZRS1500 01 01 03 03 Chapter 7 Appendix 70 of 73 GRN4 610 P Description Standard Partnumber SAP Pusher complete 7 Stage eylinder 100x140x180x225 7000 VU vv Support roller NATV40PPA Shaft for bearing ZRS1500 05 01 02 01 1 J 1 J CE mS S l Lock washer DIN5406 MB8 Slotted nut DIN98 KM8 Fixing bolt support roller DIN933 M16 Washer DIN125 16 300HV BEEN UO Support roller KRSOPPA 77 Nut DIN934 M30x1 5 10 55 Washer 1 125 31 300HV Bolt for cylinder ZRS1500 12 03 00 r Hyra 0800 Cylinder for cover63x35x80 Hydraulic unit SCH 412 002F158V Connectors 0000705 Hedialpa 0008 Safety switch azis 8080800 Small controlbox 80 7
47. rpen after every fourth cutter change Sharp knives are dangerous even while the rotor is at standstill ZA WARNING Serious injury can result especially to the hands and fingers wear protective gloves GRN4 610 Chapter 5 Maintenance 55 of 73 GRN4 610 Mounting the bed knives Follovv the steps belovv to mount the bed knives l 2 3 4 10 11 Clean the knife supporting surface and the holes on the knife holder Insert sharp knife or turn old knife Attach the knife adjusting bolts Attach the knife mounting bolts DIN912 M12x55 12 9 and tighten lightly at first Adjust the gap between the cutters and bed knives to 0 03 in to 0 04 in 8 Imm Tighten the knife mounting bolts using a torque wrench The required torque for all knife mounting bolts is 120 Nm refer to the torque values table Turn the rotor by hand Make sure the cutting gap is correct and that the cutters and bed knives do not collide as the rotor turns Return the cover plates and mount them with the bolts Remove tools and other objects from the cutting chamber Switch ON the shredder for a brief time without grinding material listen for noises If unusual noises are present determine the cause and eliminate it Chapter 5 Maintenance 56 of 73 Sharpening cutters and bed knives Shredder cutters have four cutting edges which means they can be turned three times After the third turn they should be repla
48. rturning or falling machine Serious injury or death can result n case that the granulation will be placed erect over a pit on a frame oron a platform the machine MUST be secured by placing mounting screws though the holes on the mounting pads see assembly drawing 3 1 Electrical Connections Electrical connections should only be made by qualified electricians Voltage current frequency and protection are marked on the type plate The voltage tolerance is 10 For machines that are not pre wired the electrical connection is to be carried out in accordance with the enclosed wiring diagram in the terminal box When performing this task it is important to follow the regulations of the local electricity authority The required cable cross section is determined according to the rated capacity of the units The wiring schematics are located in the control panel NOTE Alterations to the wiring diagrams require the approval of the manufacturer Failure to obtain approval will result in the termination of all guaranteed claims All work relating to the electricity of the machine may only be carried out by trained electricians Observe the currently effective EMC regulations Caution must be taken to prevent electrical shock when operating certain equipment Installation service alterations and or modifications must only be done by qualified personnel and with a high regard for safety Failing to conform to the requirements could re
49. shing in hub and match half holes to make complete holes each complete hole will be threaded on one side only 2 Oil thread and point of set screws or thread and under head of cap screws Place screws loosely in holes that E are threaded on hub side shown thus l in diagram 3 Make sure bushing is free in hub Slip assembly onto shaft and locate in position desired 4 Tighten screws see note alternately and evenly until all are pulled up very tightly Use a piece of pipe on wrench to FOR REMOVAL ONLY increase leverage See table for wrench torque on reverse ide 75 To Remove 5 Hammer against large end of bushing using hammer and 1 Remove all screws Oil thread and point of set screws or block or sleeve to avoid damage Screws can now be thread and under head of cap screws turned a little more using the specified wrench torque 2 Insert screws in holds that are threaded on bushing side Repeat this alternate hammering and screw re tightening shown thus e in diagram In sizes where washers are until the specified wrench torque no longer turns the screws found under screw heads be sure to use these washers after hammering Note that one screw in each hub is left over and is not 6 After drive has ben running under load for a short time stop used in this loosening operation and check tightness of screws Fill other holes with grease 3 Tighten screws alternately until bushing is loosened in to exclude
50. sult in bodily injury costly damage or death ZA WARNING Dangerous voltage Touching live parts can lead to serious injury or death GRN4 610 Chapter 3 Installation 35 of 73 Connection of Emergency Stop Button The machine must only be operated with installed Emergency Stop buttons If the Emergency Stop buttons are not installed prior to delivery one Emergency Stop button must be installed at the control cabinet and a second one at the grinding material in feed NOTE The control panel with the switches and Emergency Stop button should be installed near the machine the distance should not exceed 16 ft 5 m The connecting cables between the control panel and machine must be protected against damage If the control panel cannot be installed according to these rules an additional Emergency Stop button must be installed on the machine Initial Start up General Advice All work related to the start up of the machine must be carried out by trained and specialized personnel GRN4 610 Check the oil level of the gearbox before operating the machinel Fill hydraulic tank vvith oil Please observe the instructions in the operational manuall Checking the Rotational Direction Rotational direction of the motors must be checked before initial start up The following steps must be completed NOTE Switch the machine on and immediately off again Observe whether the discharge air fan in the drive motor is rotating in the
51. t time stop and check tightness of screws Fill empty holes with grease to exclude dirt Dismounting the TAPER LOCK tensioning element Proceed as follows Slacken all screws by several turns remove one or two according to number of jacking off holes shown thus in the illustration Insert screws in jacking off holes after oiling thread and point of grub screws or thread and under head of cap screws Tighten screws alternately until bushing is loosened in hub and assembly is free on the shaft Remove assembly from shaft Work on the V belts V belts are wearing parts which stretch and must be re tensioned In order to guarantee a long service life of the V belts regular checks on the tension force of the V belts and the condition of the V belts are necessary Checking the tension force of the V belt GRN4 610 Chapter 5 Maintenance 48 of 73 1 Verify that the alignment of the pulley is correct Utilizing a straightedge of sufficient length to span from one pulley to the other place it along the sides of both pulleys The entire face of each pulley should fully contact the straightedge 2 Measure the belt SPAN with a measuring tape Record this dimension in your note book 3 Using the deflection tester apply a perpendicular force at the midpoint of any one of the belts to deflect the belt 1 64th of an inch 4 Calculate the deflection force FORCE Lb SPAN IN X 1 64 Lb IN 5 Identif
52. th petroleum ether Petroleum ether petroleum spirit aqueous neutral or alkaline cleaning agents may be used to clean the bearings The bearing must be immediately preserved with the lubricant after cleaning in order to avoid corrosion 4 Fill the bearing with an approved lubricant see list of lubricants Chapter 5 Maintenance 45 of 73 List of lubricants Name Country of Manufacturer Roller Bearing Grease ARAL ARAL Grease HL 3 BP ENERGREASE LS 3 CASTROL CASTROL SPHEEROL AP 3 ESSO Beacon 3 FUCHS FUCHS Grease 1200 FUCHS Grease FWA 220 SHELL SHELL Alvania Grease 3 MOBIL OIL MOBILUX 3 WISURA WISURA Liba L 3 Zeller amp Gmelin ZET GE Grease M 50 FAG FAG L 71 ANTAR Petroles de l Antantique ROLEXA Holland Beverol Beverol Multi Purpose Grease Italy Agip AGIP Grease 33 FD Sweden NYNAS Nynas Fl 3 42 GRN4 610 Chapter 5 Maintenance 46 of 73 Mounting and dismounting TAPER LOCK tensioning element The motor and the gear V belt pulleys are attached onto the shaft by means of a TAPER LOCK tensioning element The disks must be dismounted for certain maintenance work IMPORTANT Foliow all instructions in this manual carefully This is necessary to insure satisfactory performance 1008 to 3030 3535 to 6050 7060 to 10085 120100 To Install 1 Clean shaft bore and outside of bushing and bore of hub taking bushing from hub if already assembled Remove any oil lacquer or dirt Place bu
53. this manual must be read and understood prior to operating this equipment Lock Out This equipment is operated with 3 phase electrical power Therefore when performing any maintenance operations we recommend following the local standards for performing a lock out tag out procedure Wear Safety Gloves This equipment operates with sharp blades and rotors We recommend that technicians use safety gloves while performing maintenance to protect hands from being exposed to these sharp surfaces Wear ear and eye protection This unit may produce loud and continuous noise and may produce projectiles Pneumatic or hydraulic equipment Pneumatic or hydraulic equipment must be kept at a safe pressure Do not reach into unit Reaching into a unit is prohibited while the unit is in operation and may cause serious injury GRN4 610 Chapter 1 Safety S of 73 General Safety Regulations GRN4 610 This machine uses knives for the performance of its intended use Consequently it can be a dangerous machine to operate and maintain unless these safety regulations are followed These regulations should be read understood and periodically reviewed by all personnel involved in any way with this machine Never operate or remove any machine components that are secured by wrench type fasteners unless the motor is electrically locked out and the rotor is motionless Never operate the machine or jog the rotor unless the cutting chamber covers disch
54. tion 28 of 73 information menu llustration cas Opemionpanel SIEMENS SIMATIC PANEL position setting menu 1999 Dr 1 12 n You can read information when the machine has alarm or stops automatically When machine has 3 times overload in 2 minutes or 3 times hydraulic overload in 2 minutes rotor will stop running automatically and also has a message on the HNI meanwhile the red LED will flash Press down ACK which on the HMI at first use up and down moves the wire frame to reset then press ENTER button the ram will goes back to start position and the cover will open after that could restart the machine again GRN4 610 Chapter 2 Functional Description 29 of 73 Pulse Push function In normal process mode the pusher pushes forward continuously till the pusher arm reaches the proximity switch which reverses the function and the pusher moves backwards By changing the switch 9 to Pulse push function on the main control board the pusher moves forward in steps This means after each step the pusher remains in his position for a small while before it moves forward again This function should be used for very heavy applications and in case of danger to overload the system 2 3 Safety Features Protective Devices The machine may under no circumstances be operated without these protective devices or with faulty or manipulated protective devices Safety device for housing flap Illustration
55. y the belt type and measure the small sheave diameter Look up the proper model belt deflection force table and find out what the force is supposed to be 6 The motor position should be adjusted until the actual deflection force matches the force listed in the table BELT SPAN ZACAUT ON 7 In no case should the belts be over tensioned as this can significantly reduce belt and or bearing life GRN4 610 Chapter 5 Maintenance 49 of 73 SMALL DEFLECTION BELT CROSS SHEAVE FORCE SECTION DIAMETER RANGE Lbs SPA 3 9 5 2 5 9 SPA 5 5 7 9 7 7 SPB 6 2 8 9 11 SPC 8 8 14 0 19 8 SPC 14 7 22 0 26 4 XPB 8 8 9 84 7 7 Checking V belt condition replacing V belt Serious injury can result by running V belt Never dismount the V belt cover and window during operation Hair jewelry etc can be pulled into the machine Working on the Cutters The correct grinding properties the correct setting and the correct mounting of the cutters are all important factures to ensure proper function and economic operation of the shredder Replacing and checking the cutter mountings e Certain machine parts are subject to stress while operating due to vibrations which can lead to the loosening of screw connections It is very important to check the cutter mounting screws according to the intervals in the maintenance plan e Tighten the mounting screws on the cutters using a torque wrench set to the required torque for the screw siz
56. y the machine configuration or any individual component without written notice from the factory Chapter 1 Safety 11 of 73 Remaining Risks The machine 1s constructed so that you are able to operate it safely Non avoidable dangers are prevented as greatly as possible by the protective devices Remaining risks always exist Please be aware of the risks described below as this will help operators staff avoid accidents To further avoid danger please adhere to all advice provided in the operational manual Mechanical Dangers Type of Danger Activity Possible Consequences Preventative Measures Crushing due to heavy Unloading transporting Serious injury Wear personal protective gear parts falling down or over the machine and or and follow the instructions components provided in the operational manual Cutting caused by sharp Knife replacement knife Serious injury Wear personal protective gear knives even when the setting knife particularly to the hands and follow the instructions rotor is stationary sharpening and other and fingers provided in the operational maintenance manual Crushing when Maintenance Serious injury Ensure no persons are in the opening closing the doors danger area while closing the on front side of machine door Tripping over cables and All activities Serious injury Lay cables in accordance with other surrounding objects regulations Keep work station clean and tidy Crushing cuttin
57. y transport and store the packaged cutters and bed knives e Grease the cutters and bed knives to avoid rust Protect the cutting edges with doubled cardboard and use adhesive tape to safeguard the cutters and bed knives from slipping out of the sides After unpacking the cutters and bed knives MUST be de greased in order to promote a safe grip GRNA 610 Chapter 5 Maintenance 58 of 73 Chapter 6 Troubleshooting 6 1 GRN4 610 ntroduction The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components All normal trouble shooting must be accomplished with the power off line fuses removed and with the machine tagged as out of service The use of good quality test equipment cannot be over emphasized when troubleshooting is indicated Use a good ammeter that can measure at least twice the AC and DC current that can be encountered for the machine Be sure that the voltmeter has at least minimum impedance of 5 000 OHMS per volt on AC and 20 000 OHMS per volt on DC scales Popular combination meters VOM and VTVM can be selected to provide the necessary functions Before making haphazard substitutions and repairs when defective electrical components are malfunctioning we recommend that you check the associated circuitry and assemblies for other defective devices It is common to replace the obviously damaged component without actually locating the real

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