BVL V-BIO Combi User instructions

ENGLISH
V-BIO Combi / Combi 2D
Rev. 6 /04.16 Art. no. 108108
Printed in Germany –translation of the original operating
manual
www.bvl-group.de
Assembly and Operating Manual

User information
2
Translation of the Original Operating Manual
V-Mix Combi / V-Mix Combi 2D Solids Dispenser
Identification data
Enter the identification data of the machine here.
The identification data is specified on the type plate.
Machine number: ________________________________
Type: ________________________________
Year of manufacture: ________________________________
Manufacturer's address
Bernard van Lengerich
Maschinenfabrik GmbH & Co. KG
Operations: Grenzstrasse 16
Post address: Postfach 1154
D-48488 Emsbüren
Tel : [phone]
Fax : [phone]
Internet: http://www.bvl-group.de
e-mail: [e-mail]
Spare part orders / Service
For the address, see the manufacturer's address
Tel.: [phone]
Fax.: + 49 (0) 5903 951-37
Mobile: + 49 (0) 172 281 63 22
Internet: http://www.bvl-group.de
e-mail: [e-mail]
When ordering spare parts, always provide the series, type, machine number and the year of manufac-
ture of your machine.
Formal information about this operating manual
Document number: 108108
Date created: 04/20/2016
Copyright Bernard van Lengerich
Maschinenfabrik GmbH & Co. KG, 2014
All rights reserved.
Reprints, even in excerpts, only with the written permission of Bernard van Lengerich Maschinenfabrik
GmbH & Co. KG.

User information
V-BIO Combi / V-BIO Combi 2D Biogas Equipment
Translation of the Original Operating Manual
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Preface
Dear Customer,
You selected a quality product from the extensive product range of Bernard van Lengerich
Maschinenfabrik GmbH & Co. KG. We would like to thank you for putting your trust in us.
After receiving your solids dispenser, verify that no transport damage has occurred and that all parts are
present. Use the delivery note to check if the shipment of your solids dispenser is complete and also in-
cludes the special equipment you ordered. Claims for damages cannot be accepted unless submitted
without delay.
Read and observe this assembly and operating manual and, in particular, the safety instructions before
putting your equipment into operation. After reading this information carefully, you can immediately start
enjoying all the benefits of your recently purchased solids dispenser.
Make sure that all personnel operating the solids dispenser have read this assembly and operating man-
ual before putting the accessory equipment into operation.
Solids dispensers are available with special equipment. When customizing your solids dispenser, you
may find that not all descriptions contained in this assembly and operating manual apply to your specific
solids dispenser. Special equipment is identified in this assembly and operating manual.
If you have any questions on how to handle your solids dispenser or regarding this assembly and operat-
ing manual, please contact us.
Regular maintenance and the timely exchange of worn or damaged parts will increase the service life of
your solids dispenser.
User evaluation
Dear reader,
Our assembly and operating manuals are revised on a regular basis. You help us increase the user
friendliness of our assembly and operating manuals by sending us your tips and recommendations on
how we can improve them. Please submit your suggestions by fax.
Bernard van Lengerich
Maschinenfabrik GmbH & Co. KG
Operations: Grenzstrasse 16
Post address: Postfach 1154
D-48488 Emsbüren
Tel : [phone]
Fax : [phone]
e-mail: [e-mail]

User information
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Translation of the Original Operating Manual
V-BIO Combi / V-BIO Combi2D Biogas Equipment
Contents
1User information 6
1.1 Purpose of the assembly and operating manual 6
1.2 Storing the assembly and operating manual 6
1.3 Location specifications in the assembly and operating manual 7
1.4 Illustrations used 8
1.5 Terms used 8
2Safety instructions 9
2.1 Working in a safety-conscious manner 9
2.2 Organizational measures 10
2.2.1 Responsibilities of the owner 10
2.2.2 Responsibilities of the operator 10
2.2.3 Qualification of the personnel 11
2.2.4 Intended use 12
2.2.5 Misuse 12
2.3 Product safety 13
2.3.1 Safe operation of the machine 13
2.3.2 Safety devices and guards 13
2.3.3 Structural modifications 13
2.3.4 Replacement and wear parts as well as auxiliary supplies 13
2.3.5 Warranty and liability 14
2.4 General safety instructions 15
2.4.1 General information on safety and accident prevention 15
2.4.2 Use of the machine 15
2.4.3 Cleaning, maintenance and repairs 16
2.5 Action-related safety instructions and important information 17
2.5.1 Action-related safety instructions 17
2.5.2 Important information 18
2.6 Warnings and instructions 19
2.6.1 Warnings 19
2.6.2 Instructions 21
2.6.3 Positioning of warnings and instructions 22
2.7 Risks resulting from failure to observe the safety instructions and warnings 23
3Technical data 24
3.1 V-BIO Combi options 24
3.2 V-BIO Combi 2D options 25
3.3 Machine number 26
3.4 Capacity limits 26
3.5 Operating fluids 26
3.6 Information on noise generation 26
4Design and function 27
4.1 Overview of machine types 28
4.2 Solids dispenser –Overview of assemblies 29
4.3 Dispenser container 30
4.4 Dispenser unit 31
4.4.1 Dosing auger with cutting blades 32
4.5 Discharge area (discharge opening) 33
4.6 Weighing system 33
4.7 Safety devices and guards 34
4.7.1 Protective cover 35
4.7.2 Stabilizer struts 35

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5Transport, setup, and initial commissioning 36
5.1 Scope of delivery as supplied 37
5.2 Loading and unloading the machine 38
5.3 Machine setup 39
5.4 Establishing electrical connection 41
5.5 Checking the machine for proper operation 41
6Use of the machine 42
7Cleaning, maintenance and repairs 43
7.1 Cleaning 44
7.2 Lubricating 45
7.2.1 The lubrication chart at a glance 45
7.2.2 Lubrication points - overview 46
7.3 Oil change on planetary gear and gearbox 47
7.3.1 Gearbox BvL 0090273 ECS 1512 48
7.3.2 Gearbox BvL 0094102 PGA 1202 49
7.4 Maintenance schedule –overview 50
7.5 Replace shear bolt of the shear bolt coupling 51
7.6 Entering the dispenser container 52
7.7 Cutting blades of the dosing auger 54
7.7.1 Sharpening cutting blades 54
7.7.2 Swiveling/replacing cutting blades 55
7.8 Tightening torques for bolt joints 56
8Faults 57
9Appendix 58
9.1 EC Declaration of Incorporation 58
9.2 Supplied third-party manufacturer documentation 59

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V-BIO Combi / V-BIO Combi2D Biogas Equipment
1User information
The chapter on user information provides you with information to assist you when using the assembly
and operating manual of the Solids dispenser V-Mix Combi / Combi 2D incomplete machine. The incom-
plete Solids dispenser V-Mix Combi / Combi 2D machine is also referred to as "machine" later in this as-
sembly and operating manual.
1.1 Purpose of the assembly and operating manual
This operating manual:
describes how to operate, clean, service and repair the machine,
provides important information on how to handle the machine in a safe and efficient way.
If you have any questions, please do not hesitate to contact us.
1.2 Storing the assembly and operating manual
The assembly and operating manual is considered part of the machine. Therefore, store this assembly
and operating manual
with the solids dispenser or the overall plant at all times
for future reference.
If selling the machine, pass this assembly and operating manual on to the purchaser.

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1.3 Location specifications in the assembly and operating manual
All location specifications in this assembly and operating manual are given as viewed in the direction of
the drive side of the machine.
Fig. 1-1
(1) Front side (drive side)
(3) Right side
(2) Left side
(4) Rear side
2
3
1
4

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1.4 Illustrations used
Instructions for actions and responses
Actions that need to be carried out following a specific sequence are identified as numbered instructions
for action.
Strictly adhere to this order. In certain cases, the result of the instruction for action will be marked with an
arrow.
Example:
1. Instruction for action 1
→Result of instruction for action 1
2. Instruction for action 2
Lists
Unordered lists are displayed as lists with bullet points.
Example:
Item 1
Item 2
Item numbers in illustrations
Figures included in round brackets refer to the item numbers included in the adjoining illustration.
Example (1)
Item 1 in the adjoining illustration
1.5 Terms used
The term ...
signifies ...
Work tools
... the gear motor, the gear unit, the dosing auger, and the cutting blades.
third parties
… all persons other than the operator.
Hazard
... the source of a potential injury or damage to a person's health.
Manufacturer
... Bernard van Lengerich Maschinenfabrik GmbH & Co. KG.
Machine
… the solids dispenser V-BIO COMBI and V-Mix Combi 2D.

Safety instructions
V-BIO Combi / V-BIO Combi 2D Biogas Equipment
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2Safety instructions
This chapter contains important information for the owner and the operator on how to operate the ma-
chine in a safe and trouble-free manner.
Observe all safety instructions provided in this assembly and operating manual!
Most accidents are caused due to a failure to observe the simplest of safety rules.
You help prevent accidents by observing all safety instructions provided in this assembly
and operating manual.
2.1 Working in a safety-conscious manner
This machine has been constructed according to the latest technological standards and the recognized
safety and accident prevention regulations. Regardless, using the machine carries certain risks and may
impair:
the life and limb of the operator or third parties,
for the machine itself,
other material assets.
Observe the following to ensure the operational safety of the machine:
this assembly and operating manual, particularly:
othe general safety instructions, the action-related safety instructions, and the instructions for
actions,
othe information on proper use.
the warnings attached to the machine,
all national, generally applicable regulations regarding safety and accident prevention as well as
environmental protection,
Do not operate the machine unless all of its safety features are in proper working order.

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2.2 Organizational measures
The assembly and operating manual:
must always be stored at the location of the machine,
must be freely accessible to operator and maintenance personnel at all times.
2.2.1 Responsibilities of the owner
The owner is required to:
observe all national, generally applicable regulations regarding safety and accident prevention as
well as environmental protection,
limit work with/on the machine to personnel who:
oare familiar with all general safety and accident-prevention regulations,
ohave been instructed in how to work with/on the machine,
ohave read and understood this operating manual.
keep all warnings attached to the machine legible at all times,
replace damaged warnings,
provide the necessary personnel protective equipment such as:
oSafety goggles,
oWork gloves,
oSafety shoes,
oProtective suit,
oSkin protection, etc.
2.2.2 Responsibilities of the operator
Before commencing work, all personnel designated to work with/on the machine are required to:
observe all national, generally applicable regulations regarding safety and accident prevention as
well as environmental protection,
read and observe chapter "Qualification of the personnel", starting on page 11 of this operating
manual,
read the chapter "Warnings and instructions", starting on page 19 of this operating manual and ob-
serve it while operating the machine,
become familiar with the machine,
read the chapters in this assembly and operating manual that are essential for the execution of the
work tasks they have been assigned.
If detecting that a fixture is no longer fully compliant with the safety regulations, the operator is required
to remedy this defect immediately. If the correction of a fault is not part of the operator's responsibilities
or the operator lacks the necessary expertise, the operator must report the defect to his supervisor or the
owner.

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2.2.3 Qualification of the personnel
Work with/on the machine is limited to qualified and trained personnel. The operator must
clearly define the responsibilities of the personnel with regard to operation, maintenance and
repairs.
A person in training may only work with/on the machine when supervised by an experienced
member of the personnel.
The operator may only perform the work described in this assembly and operating manual.
Work on the machine that requires professional expertise may only be performed by special-
ty workshops. Specialty workshops have the qualified personnel and suitable means (tools,
lifting and supporting devices) that are necessary to perform the work in a professional and
safe manner.
This applies to work:
not described in this assembly and operating manual,
that is identified as "work to be performed at a workshop" in this assembly and operat-
ing manual.
Personnel
Activity
Person specially
trained
to perform this
activity 1)
Instructed
person 2)
Person with pro-
fessional training
(specialty
workshop) 3)
Loading / transport
X
X
X
Commissioning
--
X
X
Setup, adjustment
--
X
X
Operation
--
X
X
Cleaning, maintenance and repairs
--
X
X
Troubleshooting
--
X
X
Disposal
X
--
--
Legend: X permitted -- not permitted
1) A person capable of assuming a specific task and completing this task for a company with the ap-
propriate expertise.
2) An instructed person is someone who is familiar with or has been trained in the tasks assigned to
him and the potential dangers associated with improper conduct and has received instructions
about the necessary safety equipment and safety measures.
3) Personnel who have undergone professional technical training are considered experts (specialists).
They are capable of assessing the tasks assigned to them and the potential dangers involved in
their execution on account of their professional technical training and their familiarity with all appli-
cable regulations.
Note: A qualification that is equivalent to professional technical training can be acquired by working
in the respective field for several years.

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2.2.4 Intended use
The solids dispenser V-Mix Combi / Combi 2D is intended exclusively for collecting and dispensing silage
and other renewable raw materials and may only be operated in combination with the designated storage
container.
The specific weight of those materials may not exceed 500 kg per m³.
The solids dispenser must be set up outside of potentially explosive areas (EX Zones).
The incomplete Solids dispenser machine must not be put into operation until it has been incorporated
into the overall system and the CE conformity of the overall system has been established.
Any other use above and beyond this will be regarded as misuse and is prohibited. Bernard van
Lengerich Maschinenfabrik GmbH & Co. KG cannot be held liable for any damage resulting therefrom.
Intended use also comprises:
Use within the performance limits specified in the chapter 3 "Technical data".
Use as intended and described in the installation instructions and the operating manual.
Observing all information and regulations specified in the installation instructions and the operating
manual as well as all accompanying documents.
Adhering to the inspection and maintenance intervals that are mandatory or listed in the assembly
and operating manual including all accompanying documents.
Ensuring that all activities are performed by trained specialty personnel only.
Ensuring that all spare parts used comply with specifications.
Ensuring that no retrofitting or use of third-party accessories takes place without our consent.
2.2.5 Misuse
Misuse includes the following types of use in particular:
Use for products other than the ones specified in the order.
The use of products with altered product characteristics.
Conveying hard/solid materials such as rocks, metal objects, etc. that will result in damage to or
failure of the incomplete machine.
Operation, maintenance and repairs of the incomplete machine by individuals other than authorized
and trained personnel.
The operation of the solids dispenser unit without a valid CE mark on the overall system.
Operation inside an EX Zone.
Please observe the following for fault-free operation of the dispenser:
Make the substrate conveyable with a maximum stalk length of 100mm
Structure-free material -decomposed, messy, or wet solid manure. Make turkey manure or simi-
lar types of waste, grain strip waste, etc. without structure conveyable by adding structured ma-
terial, such as corn or grass silage, straw, etc.
Avoid foreign objects (stones, wood, bale twine, and nets).
Check the dosing augers repeatedly for wear and damage.
Check the auger blade continuously and re-sharpen or replace as necessary.
Observe the maximum fill weight and height for the dispenser . Loss of warranty.
Reduce the fill quantity when working with stiff materials (solid manure, long-straw grass silage,
etc.).

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2.3 Product safety
2.3.1 Safe operation of the machine
The machine must not be started or operated unless no one is in the work area of the machine.
2.3.2 Safety devices and guards
The machine must not be operated unless all safety devices and guards have been properly fitted
and are fully operational.
Faulty or missing safety devices and guards may lead to dangerous situations.
Check all safety devices and guards for obvious external damage and proper operation before put-
ting the machine into operation.
2.3.3 Structural modifications
Do not subject the machine to any structural modifications nor any attachments or retrofitting unless
you have the written permission of the manufacturer to do so.
Use only original spare parts or modification or accessory parts that have been approved by the
manufacturer in order to ensure that:
othe operating permit in accordance with national and international regulations will remain valid,
othe machine remains fully operational.
The manufacturer does not accept any liability for damages caused by:
ounauthorized modifications of the machine,
ounapproved modification and accessory parts,
owelding and drilling operations on load-bearing sections of the machine.
2.3.4 Replacement and wear parts as well as auxiliary supplies
Replace parts of the machine that are not in proper technical condition without delay.
When doing so, use only original parts made or approved by the manufacturer. When using replacement
and wear parts made by third parties, you are not guaranteed that these parts are designed and con-
structed in a way that would ensure operational reliability and safety.
The manufacturer is not liable for any damage caused by using unapproved replacement and wear parts
or auxiliary supplies.
Wear parts are not covered by warranty!
Parts considered wear parts include:
Knives including their holders and fasteners
Mixing augers, both entire units and parts thereof
Shear bolts
Wear parts must be subjected to regular measurements / visual inspections at 4-week intervals.
If experiencing extensive wear, you can interchange the mixing augers fitted on a multi-spindle
machine. This ensures uniform wear, extending the overall service life of the mixing augers.

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2.3.5 Warranty and liability
Our "Terms of Sales and Delivery" apply as a general rule. The owner has received these terms no later
than by the time the contract was concluded.
Warranty and liability claims are excluded in cases of personal injury and property damage that can be
attributed to one or several of the following causes:
Improper use of the machine,
Improper installation, commissioning, operation and maintenance of the machine,
Operating the machine with defective safety devices or improperly mounted or non-operational
safety devices and guards,
Failure to observe the information provided in the operating manual regarding commissioning, op-
eration and maintenance,
Unauthorized structural modifications on the machine,
Insufficient monitoring of machine parts that are subject to wear,
Improperly performed repairs,
Natural disasters caused by the impact of foreign objects and force majeure.

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2.4 General safety instructions
General safety instructions:
apply in general and are intended to ensure the safe operation of the machine,
are summarized in the subchapters below.
2.4.1 General information on safety and accident prevention
In addition to the safety information provided in this chapter, the general information on safety and
accident prevention applicable in the respective country must be observed.
Wear your personal protective equipment while working on the machine.
Follow the warnings and instructions attached to the machine. These instructions provide you with
important information on how to handle the machine in a safe and trouble-free manner.
In addition to the general safety information provided in the chapter, the action-related safety in-
structions laid out in the other chapters must be observed as well.
Keep everyone away from the immediate area of the machine before putting it into operation.
2.4.2 Use of the machine
Before starting to work, familiarize yourself with all devices and controls of the machine and the way
they operate. It will be too late to do so when work is underway.
Wear close-fitting clothing. Loose-fitting clothing increases the risk of entrapment or entanglement
on shaft drives.
Only commission the machine if all guards are mounted and in safety position.
All personnel are required to stay out of:
othe work / danger area of the machine,
othe turning and slewing range of the moving parts on the machine,
othe area below raised and unsecured moving parts of the machine.

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2.4.3 Cleaning, maintenance and repairs
Adhere to the prescribed intervals for cleaning, servicing and repairs.
Secure the machine from being started inadvertently before cleaning, servicing or repairing the ma-
chine! Turn the main switch to “OFF” and secure it.
Always disconnect the electric current supply before carrying out work on the electrical equipment.
Any residual mechanical, electrical, electronic residual energy stored in the equipment may cause
the machine to start moving inadvertently.
When servicing and repairing the machine, be aware of the existence of residual energy.
Carefully attach and secure larger components using lifting devices before replacing them.
Regularly check nuts and bolt for tightness. Re-tighten loosened nuts and bolts.
Secure the raised machine / raised parts of the machine from being lowered inadvertently before
cleaning, servicing or repairing the machine.
Use suitable tools and wear cut-resistant protective gloves when changing tools with cutting edges.
Regularly check if previously loosened bolt joints are firmly seated. When maintenance is complete,
check if all safety devices and safeguards function properly.
Dispose of oils, greases and filters properly.
Properly handle and dispose of substances and materials used for cleaning the machine, in particu-
lar:
owhen working on lubrication systems and lubrication equipment,
owhen using solvents for cleaning.
Replacement parts must meet the minimum technical requirements specified by the manufacturer!
Compliance is ensured by the use of original spare parts.
Observe the maintenance intervals applicable to wear parts.

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2.5 Action-related safety instructions and important information
The assembly and operating manual contains action-related safety instructions and important infor-
mation. Signal words and symbols are used to allow the reader to view action-related safety instructions
and important information at a glance.
2.5.1 Action-related safety instructions
Action-related safety instructions:
warn of hazards which may arise in a specific situation or in connection with a certain type of action,
are printed immediately in front of the hazardous action described in the corresponding chapter,
are marked by the triangular safety symbol and a preceding signal word. The signal word indicates
the severity of the imminent danger.
DANGER
DANGER
indicates a situation of imminent danger that, unless avoided, carries a high risk of
causing severe injury (loss of body parts or permanent damage) or death.
Failure to observe safety instructions marked with the "DANGER" symbol may im-
mediately result in severe injury or death.
WARNING
WARNING
indicates a situation of potential danger that, unless avoided, carries a moderate risk
of causing severe injury or death.
Failure to observe safety instructions marked with the "WARNING" symbol may po-
tentially result in severe injury or death.
CAUTION
CAUTION
indicates a situation of potential danger that, unless avoided, carries a low risk of
causing minor or moderate injury.
Failure to observe safety instructions marked with the "CAUTION" symbol may po-
tentially result in minor or moderate injury.

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2.5.2 Important information
Important information:
provides instructions on how to handle the machine properly,
provides tips on how to use the machine in the most efficient way possible,
is marked by the adjacent symbols.
IMPORTANT
indicates an obligation to behave or act in a particular way in order to handle the
machine in the proper manner.
Failure to observe this information may lead to faults on the machine or in its vicini-
ty.
NOTICE
indicates tips on proper use and information that is particularly helpful.
This information makes it possible to use all features of the machine in the most
efficient way.

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2.6 Warnings and instructions
The following information has been attached to the machine:
Warnings identify hazard areas on the machine and warn of hazards which may arise
in a specific situation or in connection with a certain type of action.
Instructions contain information regarding the proper handling of the machine.
This information must be kept clean and in legible condition at all times. Replace infor-
mation that has become illegible. Order warnings and instructions from your dealer by
providing their order number.
2.6.1 Warnings
A warning is composed of 2 pictograms:
(1) pictogram used to describe the hazard
The pictogram is composed of an image illustrating
the hazard and enclosed by a triangular safety
symbol.
(2) pictogram intended to help avoid the hazard
The pictogram is composed of an image providing
information on how to avoid the hazard.
Explanations regarding the warnings
The following list contains:
all warnings attached to the machine in the right column,
in the left column, the following specifications regarding the warning shown on the right:
1. The order number.
2. Description of the hazard, e.g. "Crushing hazard for fingers or hands from movements of accessi-
ble, moving parts on the machine!"
3. The consequences of failing to observe the instruction(s) on how to avoid the hazard, e.g. "This
hazard may result in serious injury, including the loss of body parts."
4. The instruction(s) on how to avoid the hazard, e.g. "Never reach into the hazard area as long as
parts are still moving in this area."
11
1
2

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Order number and explanation
72720
Read and follow the assembly and operating manual and the
safety instructions before putting the machine into operation!
Warning
72730
Crushing hazard for fingers or hands caused by accessi-
ble, moving parts of the machine!
This hazard may cause serious injury, including the loss of
body parts.
Never reach into the hazard area as long as parts can be
moving there.
Keep everyone away from the danger area of the ma-
chine before you set the parts of the machine in motion.
Warning
72732
Risk of hands and fingers becoming cut or severed from
the movements of parts that are accessible and moving
while work is in progress!
This hazard may cause serious injury, including the loss of
body parts.
Never reach into the hazard area as long as the engine is
running.
Wait until all moving parts of the machine have come to a
complete stop before reaching into the hazard area.
Warning
94782
Warning that the machine may start up automatically.
Warning
Attention!
Machine starting up automatically.
11
72720
11
72730
11