Expleco GLAFS MAXI User manual

BOTTLE CRUSHER
Model : GLAFS MAXI
INSTRUCTION MANUAL
IMPORTANT!
PRIOR TO OPERATION ALL USERS MUST READ THE
ENTIRE INSTRUCTION MANUAL
Expleco Ltd has an ongoing development programme and the product
pictured may differ slightly in appearance.
Specifications are subject to change without notice.

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WARNING
BEFORE USING THIS PRODUCT PLEASE READ THE
FOLLOWING SAFETY PRECAUTIONS, TO AVOID
PERSONAL INJURY. IT IS IMPORTANT TO UNDERSTAND
THE APPLICATIONS, LIMITATIONS AND POTENTIAL
HAZARDS ASSOCIATED WITH THIS PRODUCT.
1. This machine is designed to crush glass bottles or glass cullet ONLY
2. Do not use the GLAFS MAXI for any other use.
3. The machine is not intended for use by young or infirm persons.
4. Children or visitors should be kept well away from the machine and
should not be permitted to handle the machine or power cord.
5. The machine is designed for interior use. Do not use the machine in wet
conditions.
6. Do not use the machine near flammable liquids or gases.
7. The power supply cable should be checked and certified at 6 monthly
intervals by a registered electrician.
8. The power supply must be capable of delivering 3phase 380,415 or 440
volts 50/60hz 63A to suit country of application. Extension cords must not
be used unless they are heavy duty cords that are rated for the current
load.
9. Protective eyewear and ear protection is recommended to be worn.

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10.If handling broken bottles protective gloves must be worn.
11.Before starting the machine check the sand level in 1m3 bag.
12.Do not use the machine if dust is emitting from the filter or inlet. This is an
indication that the filter needs cleaning or bag needs emptying.
13.In the rare occurrence of a bottle jamming protective gloves must be worn
prior to opening the chute and removing the jammed glass.
14.The main crusher housing is a designated LOCK OUT area. It is protected
by an interlock however being a lock out area it must be incorporated in a
Safety Operating Procedure to restrict access until the power supply is
locked and tagged out in accordance with this procedure. Never service
the machine, change components, or open the chute unless the Lock Out
Procedure has been followed and power supply HAS BEEN REMOVED
FROM THE WALL SOCKET.
FOPERATING INSTRUCTIONS
1. Ensure that machine is plugged into a 3phase 380,415 or 460/480 volts
50/60hz 63A to suit country of application
2. Bag must be sitting on Heavy Wooden Pallet to allow removal with forklift.
Check level of sand in 1m3 bag. Bag must never be overfilled. The bag should
be changed when it is ¾ full – it will weigh approx. 1500kg. fig 1.
fig 1

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3. For Heavy industrial Applications we recommend use of a Forklift Tipping Bin
with Expleco Approved Dust cover. Fig 2
fig 2
4. When installing bag or forklift tipping bin ensure that the strap is securely fitted
to the output chute to prevent dust escaping and ensure that the bag is sitting
evenly on a pallet with the 4 hooks secured to ensure that the bag fills evenly.
The bag hooks should firmly hold the loops and can be adjusted by tightening
on bag cleats.
5. Fit appropriate PSE equipment – Safety Glasses, Earmuffs and leather gloves.
6. IMPORTANT! Ensure that a waste bin is located opposite the control station to
enable non bottle debris to be removed from the conveyor feed.
7. Ensure that Main Conveyor, Feed Conveyor and Crusher Speeds are properly
configured as per the table below. Please note the settings are indicative and
dependent on bottle type. The operator must adjust speeds dependent on
machine loading. Configure so that Main Crusher Current does not exceed 35-
38 Amps.
Frequency Settings for Product Output
PROCEEDURE
MAIN MOTOR Hz
FEED
CONVEYOR Hz
MAIN
CONVEYOR Hz
Bottle to SAND
50 Hz
10-15 Hz
25-30 Hz
Bottle to CULLET
25 Hz
10-15Hz
25-30Hz
Cullet to SAND
50 Hz
10 Hz
20Hz

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8. Turn crusher on using the Green Crusher start button. Fig 4. Then turn on the
Main conveyer followed by Feed Conveyor using the relevant Green Conveyor
start buttons. The operator MUST remain on the platform to observe and
remove any non-bottle waste.
9. The conveyors can be stopped and started using the Conveyor Red and Green
buttons. ALWAYS stop Feed conveyor first. All plastic bottles, Aluminium cans,
bottle openers, and any metal or rock or dense non bottle product MUST be
removed from the conveyor. Failure to do so can cause severe damage to the
machine.
10.To shut down the machine turn Feed conveyor Off and then Main Conveyor Off
using the red conveyor stop buttons and then allow crusher to continue
running for 20 seconds and then turn crusher off using red Crusher button.
11.Some machines may have an optional foot switch installed to stop and start
both conveyors simultaneously.
12.EMERGENCY STOP – Only use the emergency stop for an emergency.
If the emergency stop is used to shut the machine down in normal operation it
will turn off the crusher and conveyer together and the crusher will shut down
while there is glass in the crushing process. This will probably require clearing
before the machine can restart.
The Waste Tray located at base of conveyor, must be continually monitored and
emptied as required. Failure to do so will damage cleats on the conveyor. The
waste can be tipped onto the conveyor and crushed as needed.
fig 4

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Bottle Jam
1. The crusher motor is protected by a high current protection device that is
configured to shut down the crusher in the event of a restriction or blockage
caused by a bottle jam or a foreign object that has not been removed from the
conveyor by the operator.
2. In the event of such shut down a properly trained person will need to apply the
LOCK OUT procedure fig 5. to open the chute and/or access panel Fig 6. and
remove the blocked material.
3. Once the material has been removed and the crusher mechanism is freely
rotating, then LOCK OUT procedure fig 5. can be reversed and once the crusher
is operating properly the Conveyors can be restarted for normal operation.
Fig 5

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fig 6
Conveyor Jam
1. In the event of a jam or blockage on either of the conveyors, the VFD control unit
will shut down the affected conveyor only. The crusher will remain running to
ensure that it completes its crushing process and does not become blocked.
2. It is likely that the offending material causing the blockage is easily seen and can
be removed by the operator. The VFD automatically resets after 30 seconds so
that the conveyor can be restarted using the green conveyor button.
3. In the event that the conveyor blockage is not immediately visible, then after 5-10
seconds (to ensure crusher is empty) the crusher should be shut down using the
red crusher button.
4. The Chute and/or access panel will need to be opened and jammed material
removed.
CHUTE and HOUSING CLEANING
1. If the bottles are not dry or partially full when crushed (which is often the case)
Then it is recommend to waterblast the chute, screenand main housing on a daily
basis or as required. This is to unclog the screen caused residual by damp sand.
2. Fit a wheely bin below the outlet chute and washing residual built up sand from
corners and side of housing and screen with a spray nozzle on a hose or water
blaster. After washing let dry and spray the mechanism and housings liberally
with WD40 or CRC corrosion protection product.
Filter Clean/Replacement
1. If visible dust is seen coming from the filter fig 7or main inlet, it is an indication
that the filter needs cleaning or the 1m3 bag is overfull.
ACCESS PANEL

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2. Primary filter clean can be achieved by rotating the cleaning bars on top of the
main filter cartridge.
3. The filter bin should be regularly emptied. The Fine powder is high value for paint
additive and should be kept in uncontaminated condition.
Fig 7
Bearing grease.
1. The machine is pre-greased in the factory.
2. If the machine makes an intermittent or consistent squeak the main bearings will
need greasing.
3. With the machine running pump grease into the grease nipple on the top of the
main bearing. Wait between each pump and when squeak stops give one more
pump. Do not over grease. Intermediate bearings are accessed by removing
panels on the motor Flange adapter. Fig 8.
fig 8.
Rotate Handle to Clean filter.
Remove bag and empty when it is
½ full in plastic bucket.

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4. As a rough rule of thumb you may find that you need to grease once every 50
bags.
Main Housing Access Interlock
1. An Interlock Switch is located on side of main housing. Fig 9. This is preset at
factory to isolate power to the main crusher motor. This is not intended to be
used instead of the Lock Out procedure. The Lockout procedure must be
followed and the interlock switch is back-up protection if someone breaches the
Lockout procedure. It is important that the functionality and adjustment of this
interlock is checked at regular intervals to ensure that it remains functional.
2.
fig 9.
Consumable Items
1. The GLAFS MAXI has specialised internal components which are made from
high tech abrasion resistant materials which eventually need replacing. These
parts are readily available for purchase from Expleco or your machine supplier.
The parts must be installed by a factory approved service technician.
2. The GLAFS MAXI can be configured to crush bottles to sand or cullet. It can also
crush cullet to sand.
3. PARTS CONFIGURATION AND REPLACEMENT
IMPORTANT! Ensure LOCK OUT procedure is followed
SAND CONFIGURATION
•12 x Oscillating Hammers replace with every 3rd screen
•Main Screen replace when worn thru.
•Top screen shroud replace with every 6th screen
•Main Bearing replace when noisy
•1m3 bags. PE Lined life dependent on handling. Avoid exposure to UV

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CULLET CONFIGURATION
•4 x Star Breakers.
•4 x Balance collars
•1 x Finger Rattler
Residual risks and Disposal
All parts of the machines are able to be recycled. There are no residual toxic or
hazardous substances or materials used in the manufacture of the machines. At the
end of the machines useful life it is important that the machine and its parts are
disposed of in an environmentally safe manner and in accordance with the local laws
in place at the time of disposal.

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Trouble Shooting
Trouble
Probable cause
Remedy
Squeak or Whistling Noise
1. Dry Bearing
2. Main Shaft Misalignment
1.Grease Bearing
2. Contact supplier and have
shaft re-aligned.
Unusual Vibration or
knocking sound
1. Main Shaft Misalignment
2. Damaged Hammers or
Flail Shaft
1. Contact supplier and have
shaft re-aligned.
2. Replace damaged
Hammer Set.
Crusher Motor Stops
1. Bearing Failure
2. Power Supply Inadequate
3. Extension cord too long.
4. Main Shaft Misalignment
as referred above.
5. Glass or Foreign Object
Blockage
1. replace main Bearing
2. Check Power Supply.
3. Use shorter or Heavy Duty
Extension.
4.Contact supplier and have
shaft re-aligned.
5. Clear Blockage
Conveyor and Crusher Stops
At same time
1. Glass or Foreign Object
Blockage
2. Bottle Jam in machine that
has then jammed conveyor
1. Clear Blockage
2. Clear Blockage
.
Dust is visible from inlet
and/or filter
1. Full Bag
2. Main Filter clogged
1. Change bag
3. Clean or replace main
filter.

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ELECTRICAL WIRING DIAGRAMS

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GUARANTEE
Expleco Limited guarantees this product from defects of materials and workmanship for a period of
twelve months from date of purchase provided that the product is used in accordance with the
recommendations set out in this instruction manual and with voltage and current limits set out on the
motor plate. Expleco Limited will at its own option make good, replace the complete machine (or
defective component) with the same or similar product, or provide credit for any product manufactured
or supplied by it, which proves to be defective within the limits set out above provided that always no
repairs, modifications or alterations to the product have been undertaken or attempted, other than by
the company or its authorised agents. Should the purchaser wish to make a claim under the
guarantee, the product should be returned pre-paid to the place of purchase.
To obtain the warranty the purchase receipt must be returned with the machine. This guarantee is in
addition to and does not take away from any rights available to the consumer under the Consumer
Guarantees Act.
A TWELVE MONTH GUARANTEE APPLIES TO THIS PRODUCT FOR INDUSTRIAL USE
BY PROPERLY TRAINED STAFF ONLY.
THE GUARANTEE IS APPLICABLE FROM THE ORIGINAL DATE OF INSTALLATION
TO OBTAIN THE WARRANTY THE PURCHASE RECEIPT MUST BE RETURNED WITH
THE MACHINE.
THE GUARANTEE EXCLUDES:
•DAMAGE, MALFUNCTION OR FAILURE DUE TO NEGLECT, MISUSE OR
ABUSE
•DAMAGE MALFUNCTION OR FAILURE DUE TO USE IN CONTINUOUS HEAVY
INDUSTRIAL APPLICATIONS BY STAFF WITHOUT PROPER TRAINING.
•DAMAGE, MALFUNCTION OR FAILURE DUE TO USE IN APPLICATIONS THAT
THE MACHINE IS NOT DESIGNED TO PERFORM AND/OR INGESTION OF ANY
MATERIAL OTHER THAN GLASS BOTTLES OR CULLET.
•CONSUMABLE COMPONENTS AND ACCESSORIES.
•REPAIRS, MODIFICATIONS, OR ALTERATIONS ATTEMPTED OR MADE TO
THE MACHINE BY OTHER THAN AN AUTHORISED AGENT.
Sales and Service Enquirys
www.expleco.com tel. [phone] mob [phone]
© This Instruction Manual is subject to copyright and must not be reproduced, copied or otherwise used in any
way or for any purpose without the consent in writing of Expleco Limited