Eldan Mpr200t User manual

ELDAN MULTI PURPOSE RASPER

MPR200T

Serial number: 34222

Delivery date:

Customer:

Manual for

ELDAN MULTI PURPOSE RASPER

MPR200T

1.1

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TABLE OF CONTENTS Page

1. INTRODUCTION...........................................................................3

2. SAFETY INSTRUCTIONS .............................................................4

3. MACHINE INFORMATION ............................................................7

3.0 Equipment description of MPR200T..............................................................8

3.1 Input definition:..............................................................................................8

3.2 Technical Specifications for MPR200T..........................................................9

4. SAFETY EQUIPMENT.................................................................11

4.0 Introduction .................................................................................................12

4.1 Main switch .................................................................................................12

4.2 Emergency stops.........................................................................................12

4.3 Safety switch ...............................................................................................12

4.4 Service switch .............................................................................................13

4.5 Fire equipment for MPR200T ......................................................................14

4.6 Fire Hazard. ................................................................................................15

5. INSTALLATION..........................................................................16

5.0 Introduction .................................................................................................17

5.1 Lifting points ................................................................................................17

5.2 Gravity and weight statement......................................................................18

5.3 Recommended floor fixing methods ............................................................18

5.4 Dimensions of clearance needed for service and maintenance ..................19

5.5 Power and service details and requirements...............................................19

5.6 Test before starting .....................................................................................19

5.7 Foundations ................................................................................................19

6. SETTING THE MPR200T............................................................20

6.0 Introduction .................................................................................................21

6.1 Safety information .......................................................................................21

6.2 Opening the upper part with hopper ............................................................23

6.3 Cleaning the Rasper and surrounding areas...............................................24

6.4 Information regarding adjustment/exchange of knives ................................25

6.5 Exchange of the static knives......................................................................27

6.6 Exchange of the flying knives......................................................................30

6.7 Adjustment of the distance between static and flying knives.......................33

6.8 Dismounting and mounting of knife holders for 25mm flying knives............34

6.9 Checking .....................................................................................................36

6.10 Closing the upper part with hopper..............................................................36

6.11 Removing the discharge hopper and the screen.........................................37

6.12 Mounting of the screen and discharge hopper ............................................40

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6.13 Torque.........................................................................................................42

6.14 Motor ...........................................................................................................43

7. OPERATION ...............................................................................44

7.0 Introduction .................................................................................................45

7.1 Safety statements........................................................................................45

7.2 Operational procedure.................................................................................48

7.3 Useful information regarding the process....................................................49

7.4 Steel and dust outlet....................................................................................51

7.5 Safety statement regarding emergency stops .............................................52

8. MAINTENANCE..........................................................................53

8.0 Introduction .................................................................................................54

8.1 Maintenance directions ...............................................................................56

8.2 Lubrication scheme summary .....................................................................58

8.3 Adjustment of clutch....................................................................................60

8.4 Adjustment of belt drive...............................................................................62

8.5 Grinding of knives........................................................................................63

9. SPARE PARTS............................................................................66

9.0 Introduction .................................................................................................67

9.1 Spare parts philosophy................................................................................67

9.2 Spare parts stock level recommendations...................................................67

10. DISPOSAL OF THE MPR200T ....................................................69

1. INTRODUCTION

1.1 Congratulations on your purchase of an ELDAN machine. Like many cus-

tomers who have gone before you, you hav e just entered into what we hope

will be a long and beneficial partnership with us.

1.2 To ensure that you get the very best from your machine, we give you this

manual, which forms an indispensable part of your operation.

Please read it carefully as you will find it contains the necessary information to in-

stall, set, operate and maintain the machine in a safe and efficient manner.

1.3 You will notice that we suggest safe operation before efficient operation, not

because we don't think the machine is effi cient but because we feel it is im-

portant for everybody that the machine is operated safely.

To reinforce this you will see in the text the symbol The section on

safety explains what this means, but for the purpose of this introduction,

wherever you see as part of an instruction, it is essential that you

carry out the instruction exactly as s pecified and that you do not attempt to

overlook the safety element in any way.

1.4 Should you require clar ification regarding any of the information or should

you wish to purchase further copies of this manual, please contact your

ELDAN agent or contact us direct.

ELDAN RECYCLING A/S

Vaerkmestervej 4

DK-5600, Faaborg,

Denmark

Tel: +45 63 61 25 45

Fax: +45 63 61 25 40

E-mail: [email protected]

Homepage: www.eldan-recycling.com

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2. SAFETY INSTRUCTIONS

It is a condition that the person, who is going to operate the machine, has

been educated or is familiar with machines of the same type.

Ordinary safety rules :The ordinary safety rules of the country in

question must always be obeyed.

Before starting, check that:

All protection devices are placed correctly.

Check conveyors for left tools, screws, bolts, etc.

The operator must be absolutely certain that no service, repair or any

other kind of work on the machine is being undertaken before start-

ing the machine.

The machine is to be adjusted according to the directions in the

manual.

Check the starting procedure in the manual.

During operation:

Do not feed objects into the machine, which may cause damage to

the machine.

Safety during operation:

Never try to remove jammed material or foreign bodies in the rotor

house, etc. until it has been checked that the machine is fully iso-

lated electrically. This means turn off and lock all main switches be-

fore working on the machine.

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When the machine is not delivered with special silencing equipment,

operators must carry earplugs or hearing protectors.

Before the operator begins greasing/maintenance work on the

machine the following precautions should be followed:

In case of stops for maintenance, damage etc. turn off and lock all

main switches before working on the machine. Repair and mainte-

nance work must not be carried out before the machine has been

brought to a complete stop.

After the machine has been stopped there is a caster time of approx.

1 minute. Do not touch rotor and other rotating parts before the ma-

chine has been brought to a complete stop.

Working on the machine, opening of inspection doors or removing

protection screens and safety devices while the machine is operat-

ing, is absolutely prohibited and highly dangerous.

When opening or closing the machine nobody but the operator must

be on or near the machine.

Personal security when carrying out service:

Electrical installations and repairs must only be carried out by

authorised personnel.

The processing area must be satisfactory illuminated so that there are

no dark corners. Illumination must however not be dazzling. The sup-

ply must not be taken from the machine as this must be disconnected

during service work.

It is dangerous to climb the machine. Always use a platform or a step-

ladder where service from the ground is not possible.

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Dust masks are necessary when cleaning the machine.

Use gloves for hand protection by maintenance work etc. The ma-

chine can be very hot after continuous operation.

When replacing the knives the use of safety glasses is necessary be-

cause of the danger of splinters when the knives are exposed to

strokes and bumps.

Oil leaks from hydraulic tubes or pipes may come with such force

that the oil may penetrate the skin. In such cases a doctor's help

should be sought immediately in order to prevent severe infections.

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3. MACHINE INFORMATION

3.0 Equipment description of MPR200T..............................................................8

3.1 Input definition:..............................................................................................8

3.2 Technical Specifications for MPR200T..........................................................9

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3.0 Equipment description of MPR200T

This machine is a heavy duty Rasper ideally suited to the harsh environ-

ment of tyre shredding.

To ensure its durability t he main housing is fitted with replaceable wear

plates and the rotor is manufactur ed from wear resistant and hardened

steel.

Other features include a quick-change kn ife system and a rotor, which is

easily removed.

To enable the screen to be easily cleaned or changed, the screen fits into

a hydraulically operated swinging cradle t hat allows it to be lowered from

the cutting chamber in a matter of seconds.

The transmission system is a combination of 2 motors placed on each side

of the machine, and a belt drive bet ween the motors and the rotor shaft.

The number of belts in each side is 10 pieces.

Mechanical overload protection is provided by friction clutches.

The main housing is construct ed with double skinned walls. The wear

plates are mounted on the inside of the inner skin and the main bearings

are mounted on the outside of the outer skin.

In the case that material such as dust, rubber granulates etc. does get

forced between the wear plates, the ma terial falls into the void between

the skins rather than into the rotor bearings. For further protection of the

bearings a wiper has been mounted between the skins.

Should the rotor and flywheel be stalled by extreme overload, a differential

speed detector protects the transmission.

The Rasper is equipped with a Serv ice Platform to enable service and

maintenance work to be carried out with ease.

3.1 Input definition:

The MPR200T has been designed to process whole steel radial car tyres

up to a size of max tyre height of 250 and max. tyre diameter of 800 mm

or pre-shredded car, light truck and truck tyres with a max. chunk size of

300 mm.

Should other kinds of input materi al than the above mentioned be used as

input material this will be at the customer's own risk.

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3.2 Technical Specifications for MPR200

Rotor length:- 2000 mm

Rotor diameter:- 400 mm

Cutting diameter:- 506 mm

R.P.M. of rotor:- 144

Cutting speed:- 3,82 m/sec

Knives:- 25 flying

26static

Motor:- 2x110 kW 734 rpm, 50 Hz.

Belt drive:- 2x10 pcs SPC, length 5600 mm

Total weight:- Approx. 24.000 kg

Machine weight:- 11500 kg

Weight of inlet hopper:- 2300 kg

Weight of flywheel cover:- 500 kg/each

Motor for hopper lift:- P = 0,75 kW

Total width:- 3850 mm

Total height:- 4600 mm

Total length:- 3000 mm

Inlet height:- 4300 mm

Figure 1

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4. SAFETY EQUIPMENT

4.0 Introduction .................................................................................................12

4.1 Main switch .................................................................................................12

4.2 Emergency stops.........................................................................................12

4.3 Safety switch ...............................................................................................12

4.4 Service switch .............................................................................................13

4.5 Fire equipment for MPR200T ......................................................................14

4.6 Fire Hazard. ................................................................................................15

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4.0 Introduction

In this section the safety equipment for the MPR200T will be described.

It is important that the instructions ar e followed very carefully to avoid dam-

age to the operator and the machine.

4.1 Main switch

The machine is equipped with a main swit ch, which can be locked. The main

switch disconnects all voltage to the machine and it is placed on the electrical

cabinet.

4.2 Emergency stops

The machine is equipped with two emer gency stops. One is placed on the

machine and one is placed on the electrical cabinet.

The function of the emergency stops is as follows:

1) When activated all volt age to the machine as well as inlet and outlet con-

veyors is disconnected immediately.

2) An emergency stop can only be reset deliberately. This does not mean

that the machine starts automatically, but only that it is possible to start the

machine again.

4.3 Safety switch

The MPR200T is equipped with a safety system, which protects the operator

from the rotating parts of the machine during maintenance work.

The greatest advantage of the system is that it also protects the operator

from the caster, which appears after the machine has been shut down elec-

trically.

The machine is equipped with a number of switches, which should be liber-

ated before hoppers, upper part etc. can be opened, see Figure 2.

The safety switch can be liberated, when the machine has been brought to a

complete stop and the service key on the electrical cabinet is in zero-position.

Note: After stop a certain period of time must pass, before the switches can

be liberated.

Figure 2

4.4 Service switch

When operating the machine, the switch should be in Position "1".

By repair, maintenance and cleaning the se rvice switch should be set to Po-

sition "0" and removed.

The hydraulic pumping unit for opening of upper part with hopper as well as

screen can only be operated with the service switch in zero-position. Once

the upper part with hopper or screen is opened the hydraulic pump must be

switched off. At the same time the main switch must be disconnected and

locked.

Note: After the machine has been stopped a fixed period of time will have to

pass, before the switches can be released.

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4.5 Fire equipment for MPR200T

The water spraying system

The Rasper is equipped with a water sp raying system with the purpose of re-

ducing the fire risk, but also with the purpose of lubricating/cooling in the rotor

housing.

When processing tyre material in t he MPR200T quite an amount of rubber

and textile dust is liberated and this is quite inflammable.

During operation sparks are produced in the rotor housing. Therefore a water

spraying system is required to moisten t he dusty air in the rotor housing thus

reducing the risk of the sparks from setting fire to the dust.

Water nozzles have been placed in the inlet hopper of the Rasper and be-

tween the sidewalls of the Rasper. The water spraying system operates un-

der normal water pressure and the c onnection is placed on the side of the

Rasper. The water pressure is adjusted by means of a handle, which is also

placed on the side of the Rasper.

The water supply is controlled electrically by means of a magnet valve placed

on the water supply of the machine. This means that the water supply is acti-

vated/stopped when the machine is either started up/shut down.

When processing tyres the water spraying system must always be con-

nected!

The pressure is adjusted in such a way that there is always a fine mist of wa-

ter steam in the rotor housing and between the sidewalls.

It is recommended to clean the water nozzles for dirt once a week.

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4.6 Fire Hazard.

Please observe the risk of fire, which is always present when processing in-

flammable scrap. Please make the necessa ry precautions to prevent a situa-

tion to occur which may cause a fire i.e. secure following:

 that your scrap does not contain explosives or flammable liquids.

 that your equipment is always in an optimal condition.

 that you operate your equi pment according to the written or verbal in-

structions.

 that you use skilled an experienced labour.

 that your facilities are clean and tidy.

 that you have taken all possible measures of fire-extinguishing.

 that you have involved the advisor y support of the Fire-department in

this process.

Eldan Recycling A/S rejects any responsib ility for fires, which occur in con-

nection with the process.

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5. INSTALLATION