Intimus DISINTEGRATOR DIS 150 User manual

intimus DIS 150/230
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intimus International GmbH Tel.: [phone]
Bergheimer Str. 6-12, D-88677 Markdorf Fax: [phone]
Internet: www.intimus.com E-Mail: [e-mail]
OPERATING MANUAL
FOR DISINTEGRATOR
INTIMUS DIS 150/230
Machine type :
Machine no. :
Year of construction :
Drive motor :
Motor no. :
Motor output :
550
HM 1798-17
2017
VEM
1437848002170
64,0kW
Operating voltage : 400 V
Control voltage : 230 V
Frequency : 50 Hz
Circuit diagram : See appendix
Accessories : -
94601 1 09/17

intimus DIS 150/230
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intimus International GmbH Tel.: [phone]
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Important !
Please read this manual through thoroughly
before initial commissioning, and comply with the
safety instructions!
The operating manual contains important
information for operation, maintenance, care and
safety of the machine to guarantee the
best possible preservation of your
investment.
Subject to changes in design, features and
accessories in the interests of
on-going developments. It is therefore not
possible to derive any claims from the
data, illustrations and descriptions contained
in the manual.
Subject to errors.

intimus DIS 150/230
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intimus International GmbH Tel.: [phone]
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Contents Page
1 Foreword 6
1.1 Supplied technical documentation 6
1.2 Factory number 6
1.3 Declaration of conformity 6
2 Description and proper use of the cutting mill 8
2.1 Description of the cutting mill 8
2.2 Proper purpose 9
2.3 Improper purpose 9
3 Safety instructions 10
3.1 General safety instructions 10
3.2 Safety symbols 10
3.3 Safety clothing 10
3.4 Requirements made of the operating staff 10
3.5 Initial commissioning 11
3.6 Cleaning 11
3.7 Maintenance 11
3.8 Emergency-off function 11
3.9 Remaining dangers 11
4 Electrical equipment of the cutting mill 12
4.1 Electrical safety 12
4.2 Electrical connection 12
4.3 Electrical circuit diagram 13

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intimus International GmbH Tel.: [phone]
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5 Transport and erection of the cutting mill 14
5.1 General transport information 14
5.2 Weight, dimensions 14
5.3 Erection and assembly 15
5.4 Erection site 15
5.5 Removing the preservative 15
5.6 Taking the cutting mil into storage 15
6 Safety devices 16
6.1 Mechanical opening device 16
7.2 Electrical limit switch 16
7 Operating the cutting mill 17
7.1 First steps 17
7.2 Switching the machine on and off 17
7.3 Opening the cutting mill 18
7.4 Closing the cutting mill 18
7.5 Lubrication of the cutting mill 19
7.6 Maintenance 19

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8 Handling the sieve 20
8.1 Fitting and removing the sieve 20
8.2 Cleaning the sieve 20
9Handling the knifes 21
9.1 Fitting and removing the knifes 21
9.2 Sharpening the blades 22
10 Tightening the V-belts 23
11 Replacement parts lists 24
11.1 Cutting mill 24
11.2 Cutting chamber 25
11.3 Rotor assembly 26
11.4 Electric assembly 28
12 Error identification 29
13 Attachment 30

intimus DIS 150/230
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intimus International GmbH Tel.: [phone]
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1 Foreword
Congratulations on your purchase of a intimus cutting mill
Model intimus DIS 150/230
Only original intimus replacement parts respectively purchased parts complying with the original state may
be used.
Guarantee claims are only valid if no changes are made to the original state of the cutting mill.
We assume no liability for damage caused by failure to comply with these instructions or by inappropriate
behaviour.
This technical manual may not be duplicated or passed on to third parties, either totally or partially.
1.1 Supplied technical documentation
The following documentation was supplied together with the machine:
Operating manual for the cutting mill, including
-Electrical circuit diagram
-Replacement parts lists
-Operating manual for the purchased parts (motor, safety switch, ...)
1.2 Factory number
The machine number is located on the nameplate on the right of the upper part.
This machine number must be stated when making any technical inquiries.
1.3 Declaration of conformity
Valid accident prevention regulations for the plastics industry VBG 4, VBG 5, VBG 22 and valid standards
DIN EN 292 Parts 1+2, DIN EN 953, DIN EN 954 Part 1, DIN EN 1050, DIN EN 1088, DIN EN 12012-1, DIN
VDE 0113 Part 1 and DIN VDE 0113 have been taken into consideration.
EC Machine Directive (2006/42/EC)

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Konformitätserklärung
Certicate of Conformity
Attestation de Conformité
Certicado de Conformidad
Bezeichnung der Maschine:
Type of machine:
Description de la machine:
Descripcion de la máquina:
Modell / Model / Modèle / Modelo:
Typ / Type / Type / Tipo:
Artikel-Nr. / item number /
numéro d‘article / número de la pieza:
Serien-Nr. / serial number /
numéro de série / número de serie:
Baujahr / year of manufacture /
année de production / año de producción:
Spezialshredder
Special Shredder
Destructeur spécial
Destructora especial
Disintegrator intimus DIS 150/230
550
55010x
550A0x.000xx.Oxx
siehe Typenschild / see type plate / voir plaque
d‘identication / mirar la placa de identicación
Nationale Normen / national standards
normes national / normas nacional
DIN 45635 T1
Harmonisierte Normen / harmonized standards
normes harmonisées / normas armonizadas
EN ISO 12100:2011-03
EN ISO 13857:2008
EN 349:1993+A1:2008
EN 953:1997+A1:2009
EN 1088:1995+A2:2008
EN 12012-1:2007+A1:2008
EN 60204-1:2006+A1:2009
EN 61000-4-2:2009
EN 61000-4-5:2006
Hiermit wird bestätigt, dass vorgenanntes Produkt den Anforderungen der Maschinen-Richtlinie 2006/42/EG sowie der EMV-
Richtlinie 2004/108/EG einschließlich allen bis heute veröffentlichten Änderungen bzw. Nachträgen entspricht. Der oben beschriebene
Gegenstand der Erklärung erfüllt die Vorschriften der Richtlinie 2011/65/EU des Europäischen Parla-ments und des Rates vom 8. Juni
2011 zur Beschränkung der Verwendung bestimmter gefährlicher Stoffe in Elektro- und Elektronikgeräten. Das vorgenannte Produkt
entspricht folgenden harmonisierten bzw. nationalen Normen:
We do hereby certify that the above mentioned product meets the requirements set forth in EEC-Guidelines 2006/42 and EMC
2004/108/EEC including all changes and addendums to date thereto. The object of the declaration described above is in conformity with
Directive 2011/65/EU of the European Parliament and of the Council of 8 June 2011 on the restriction of use of certain hazardous
substances in electrical and electronic equipment. The above mentioned product meets the following harmonized and national
standards:
Nous Vous Confirmons que le produit cité ci-dessus correspond aux exigences des directives 2006/42/CEE ainsi qu’ à la directive
CEM 2004/108/CEE, ci-inclus toutes les modifications ainsi que tous les suppléments publiés jusqu’à ce jour. L‘objet de la déclaration
décrit ci-dessus est conforme à la directive 2011/65/UE du Parlement européen et du Conseil du 8 Juin 2011 sur la limitation de
l‘utilisation de certaines substances dangereuses dans les équipements électriques et électroniques. Le produit mentionné correspond
aux normes citées ci-après:
Confirmamos que los productos arriba citados cumplen las exigencias de las directivas 2006/42/CEE y CEM 2004/108/CEE, incluidas
todas las modificaciones publicadas hasta la fecha. El objeto de la declaración descrita anteriormente es conforme a la Directiva
2011/65/UE del Parlamento Europeo y del Consejo, de 8 de Junio del 2011, sobre restricciones a la utilización de determinadas
sustancias peligrosas en aparatos eléctricos y electrónicos. Los productos citados cor-responden con las siguientes normas:
2017/06
Javier Ortiz de Zárate
Geschäftsführer
Managing director
Directeur général
Director General
Postfach / p.o.box 1420
D-88672 Markdorf / Germany
CE-Bevollmächtigter / authorized person of CE / personne autorisée de la CE / persona autorizada por CE:
intimus International GmbH; Bergheimer Straße 6-12; D-88672 Markdorf / Germany

intimus DIS 150/230
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intimus International GmbH Tel.: [phone]
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Internet: www.intimus.com E-Mail: [e-mail]
2 Description and proper use of the cutting mill
2.1Description of the cutting mill
This cutting mill is intended for the crushing of............. HIPS, ABS, PP,…plastics and feuilles
with an output of max.................................................................................... 20 - 60 kg/h
for a sieve of....…....................................................................................................6 mm
The cutting mill consists essentially of upper housing, basic housing, infeed throat, support of the machine,
protection cover and electric motor according to the following picture.
Electric motor
Infeed throat
Basic housing
Protection cover
Support of he
machine
Upper housing

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2.2Proper purpose
The cutting mill is suitable only for crushing thermomer, elastomer and duromer plastics.
The works guarantee becomes null and void if any other materials are processed. The responsible operating
staff must be informed about the output capacity of the cutting mill and ensure that the machine does not
exceed the stated output limits.
2.3Improper purpose
No other kinds of material may be fed into the machine. If any other kinds of material are fed
into the machine, this can cause major accidents or damage to the cutting mill.
In addition, plastics containing additives such as flammable or corrosive substances etc. may not be crushed
with the cutting mill. The material being crushed may not be easily flammable or toxic.
Hollow bodies may not be pressurised and must be completely empty before being crushed.

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3 Safety instructions
3.1General safety instructions
The cutting mill has been manufactured using state-of-the-art engineering and technology and complies with
the valid safety requirements of EU directive 98/37/EG on the point in time of delivery. The accident
prevention regulations of the plastics industry VBG 4, VBG 5, VBG 22 and valid standards DIN EN 292
T1+T2, E DIN EN 954 T1, DIN VDE 0113 T1 and E DIN VDE 0113 valid at the point in time of delivery have
been taken into account in manufacturing the machine.
The cutting mill may only be started up when it is guaranteed that the machine into which the cutting mill is
possibly going to be installed also complies with the regulations of the national standards and the EU
directive (2006/42/EC).
The original state of the machine may not be changed. Safety devices may not be changed, removed
or bridged. All maintenance and repair work may only be carried out by qualified staff when the
machine is at a standstill and disconnected from the power supply.
3.2Safety symbols
Failure to comply with the sections of text marked in this way result in danger. Injuries are
possible. Damage to the mill and accessories is possible, special care is required.
This symbol marks instructions for correct execution of certain jobs of work, e.g. that the
work may only be carried out by an electrician.
Symbol for supplementary information and remarks.
3.3Safety clothing
When feeding plastic into the cutting mill and during maintenance and repair work, safety gloves, safety
boots and goggles must be worn.
3.4Requirements made of the operating staff
The operating staff at the machine must always use the personal safety gear prescribed by law and provided
by the employer. The staff responsible for operating and maintaining the machine must be trained and
suitable for these jobs of work. Precision and safety in machine checks must be guaranteed.
The responsible staff must have read and understood this operating manual.
There is an added risk of accidents during maintenance and servicing work. This is why all jobs of work must
be carried out with the machine at a standstill by experienced and skilled staff capable of taking the
necessary safety precautions for major maintenance work.
The machine may only be operated, maintained and repaired by trained staff. In particular, these people
must have read and understood the complete operating manual in the interests of all those involved. This is
the only way to guarantee safe, trouble free operation.

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3.5Initial commissioning
Remove the preservative (see chapter 5.5). Always wear safety gloves to prevent cuts and
injuries.
Initial commissioning only by a qualified fitter. Electrical connection by an electrician. Only
switch the cutting mill on when it is empty.
Open the cutting chamber (chapter 7.3) and check whether any foreign bodies, for example
tools or other items, have been left in the cutting chamber or intake opening. Close the
cutting chamber (chapter 7.4) again. Bring the cutting mill directly to its operating position.
3.6Cleaning
Observe the same safety precautions as for maintenance! Always open the cutting chamber
up to the trip dog. Switch off the cutting mill before cleaning, safeguard the main switch. Do
not use corrosive, easily flammable substances as cleaning agents. Wear safety gloves as
protection from cuts or injuries.
3.7Maintenance
To be carried out only by qualified staff (see also 3.4). Wear safety gloves. Switch machine
off, open the cutting chamber up to the trip dog, safeguard main switch.
After maintenance, fit all the safety devices back in their correct positions and check that
they function properly.
Check every week:
-State and proper fastening of the knifes
-Functions of the limit switches (only by the company electrician, see chapter 6)
-Condition of the sieve.
3.8Emergency-off function
In the case of an emergency, put the main switch in the "off" position immediately.
3.9Description of the safety closures
See chapter 6.
3.10 Remaining dangers
During operation of the cutting mill always wear safety gloves and goggles. Never keep
hands, head or other extremities into the infeed throat. Do not force in clogged or stranded
material with long parts (risk of back kicks). Always keep a foam or powder fire extinguisher
in clear visibility and in easy reach. Don’t keep the hands in the cutting chamber when
closing the upper part.

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4 Electrical equipment of the cutting mill
4.1Electrical safety
In the case of malfunctions, interrupt the power supply immediately and secure it to prevent
the machine being switched on again. Only use the fuses stated in the circuit diagram.
Connection, maintenance and servicing should only be carried out by an electrician.
4.2Electrical connection
Operating voltage : 400 V
Control voltage : 230 V
Frequency : 50 Hz
Drive motor : VEM
Motor output : 4,0 kW
Rated speed : 1455 rpm
The electrical connection should generally be carried out by an electrician. The motors are supplied by
intimus ready mounted. The works guarantee becomes null and void when the motors are mounted by the
customer.
The motors are connected up according to the operating manual of the motor manufacturer. The machine
must be grounded, with the cable cross section for grounding corresponding to the power lead.
When wiring the machine, pay attention to the direction of rotation of the rotor. When the machine is slowing
down, when looking at the motor the fan blade must turn clockwise. In addition, the direction of rotation is
marked by an arrow on the motor respectively on the safety hood.
These jobs of work may only be carried out by qualified staff. The connections must be
completed carefully. Errors can pose a mortal danger. The connection regulations of the
responsible power utility company must be observed.
In addition, the operating and installation instructions of the suppliers are to be observed!
-Connect up the machine according to the circuit diagram.
-Ground the machine (upper infeed throat) and check the grounding. The protective conductor cross
section should be the same as the main lead but not larger than 16 mm².
-For star-delta starting, set max. 58% of the rated motor current at the motor protection switch.
-Check safety fasteners.

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Star-delta starting:
Set max. 58 % of the rated motor current at the motor protection switch.
Power lead as per VDE specification (DIN VDE 0113 T1 respectively EN 60204).
The minimum cable cross sections for the motor outputs listed below are:
Comply with the following when making the connection:
Motor output
kW
Operating voltage
400 V, 50 Hz
Lead cross section
mm²
1.5
3,40 A
1.5
2.2
4,85 A
1.5
3.0
6,65 A
1.5
4.3Electrical circuit diagram
See appendix.

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5 Transport and erection of the cutting mill
5.1General transport information
Guarantee or compensation claims are null and void when the damage has been caused by improper
transport, improper handling or erection of the rotary cutter.
Examine the cutting mill for any signs of transport damage immediately after transport, have any such
damage acknowledged in writing by the carrier, inform the insurance company and the supplier.
Transport of the cutting mill on a pallet by forklift
Fasten the cutting mill on the pallet with tension straps. Insert the forks completely.
Ensure that the mill is not top-heavy on the pallet. Move the forklift at the lowest speed,
only lift the load as far as absolutely necessary.
5.2Weight, dimensions
Cutting mill weight approx. 230 kg, without pallet.

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5.3Erection and assembly
Some types of infeed throats have to be fixed on the upper part with 4 screws M6 x 12 DIN 151-8.8. Ensure
that the interiour walls of the infeed throat flush with the interiour walls of the upper part. At protruding edges
material can get jammed.
After assembly, check as follows:
-Check all fixing screws
-Check all safety fasteners, and remove any foreign bodies from the cutting chamber.
Check electric system (only by an electrician)
-Operating voltage using a voltmeter
-Electrical fuses
-Check electric cables for any signs of damage
-Check connections
-Check safety closures (when the closure flap is open, it must not be possible to switch on the rotary
cutter)
After assemby has been completed, check whether the rotor can be turned by hand (always
wear gloves). The knifes may not knock into each other. The cutting gap should be approx.
0,1-0,2 mm.
5.4Erection site
The machine can directly be erected on the floor of the workshop, if this shows an appropriate bearing
surface. A solid bearing surface is the most important mark of a good foundation. By this any deformation of
the machine will be avoided.
The following points must be observed at the erection site of the machine:
-A constant temperature must be guaranteed. It should not be under +5°C or above +50°C.
-The humidity may not exceed 85% continuously.
-The emergency-off (main switch) of the cutting mill must be freely accessible
5.5Removing the preservative
Blank parts such as rotor, blade, inside parts of the housing etc. are covered with preservative before
delivery. This preservative is wiped off with a clean, dry cloth. Do not use any rough materials. Never use
compressed air or pressurised liquids.
Caution, it is easy to cut yourself on the knifes! Always wear safety gloves. Comply with all
the accident prevention regulations!
5.6Taking the cutting mill into storage
The cutting mill is to be stored in a dry room. Protect from the damp, from a corrosive atmosphere and from
temperatures below +5°C and above +50°C.

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6 Safety devices
The electrical safety closure may never be bridged or dismantled. Improper handling can
cause major accidents!
The safety closure of the cutting mill safeguards the cutting chamber and protects the operating and
maintenance staff from dangerous operating conditions. It consists of the following devices:
6.1Mechanical opening device
The mechanical opening device (knob + closure flap + knob) delays the opening of the machine. It may
never be removed or changed. It ensures that the rotor has finished moving before the upper part can be
swivelled open.
6.2Electrical limit switch
This limit switch prevents any access to the closure screws of the cutting chamber and the sieve frame.
The machine can be stopped using the main switch in every operating mode and condition.
Limit switch with actuator

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7 Operating the cutting mill
7.1First steps
Electrical connection only by electrician. Check operating voltage. Ground the rotary
cutter. Check the safety closures.
The motor is mounted by intimus. The works guarantee is null and void if the customer mounts the
motor.
Comply with the operating manual issued by the motor manufacturer.
Check the cutting mill for foreign bodies.
Only start the machine in no-load state.
Check all safety elements.
7.2Switching the machine on and off
Switch the mill on as follows:
1. Main switch to position 1
2. Push green button (release key, green lamp is on)
3. Start cutting mill by press key 1
The cutting mill must be fed with material quickly and evenly. The best grinding performance is reached
when there is a constant flow of grinding material. Do not "overfeed" the cutting mill.
If the rotor stops because of too much material, proceed as follows:
1. Stop cutting mill using the off switch (0)
2. Put main switch in position 0.
3. Open machine upper part (see 7.3).
4. Clean grinding chamber thoroughly.
5. Close mill again in reverse order.
6. The company electrician should unlock the motor protection switch if this was triggered automatically.
7. Put main switch in position 1
8. Start mill

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7.3Opening the cutting mill
Proceed as follows to open the machine:
1. Switch machine off.
2. Switch main switch off and secure it.
3. Wait until the rotor has finished moving.
4. Loosen the knob of the collecting bin and put out the bin, this activates the limit switch. The knobs for the
upper part and the sieve frame are now accessible, loosen the knobs.
5. Swivel the upper part and the infeed throat backwards by hand. The sieve frame can be swivelled
downwards, the sieve can be put out.
7.4Closing the cutting mill
1. Clean the machine
2. Swivel the sieve frame with sieve up (see chapter 8.1) and fasten with knob.
Swivel upper part until closed, checking that the grinding housing is clean and that no granulate
can get jammed.
3. Lock upper part with the second knob.
4. Put in the collecting bin.
5. Screw in knob of the collecting bin.
Hebel
Knob
collecting bin
Knob upper
part

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7.5Lubrication of the cutting mill
Only use the grease stated in the lubrication section. Never mix several grades of grease. Grease used on
delivery: OKS 420
(The following grease may be used: “SHELL”-Alvania EP2, “BP”-LS EP2 , “ESSO”-Beacon EP2 and
“TEXACO” –Multifak EP1). The grease is to be renewed completely after 20,000 operating hours at the latest
or after 4 years. Lubricate the electric motors according to the manufacturer's instructions.
Always arrange for the company machine fitter to proceed with lubrication!
Lubrication intervals
Lubricating the
No. of operating
hours
rotor bearing
every 2000 h
motor bearing
acc. manufacturer
closure spindle
oil every week
7.6Maintenance
All tasks stated below may only be performed by a qualified machine fitter.
Lubrication see lubrication table.
To be checked every week:
-Cutting rails
-Check wear of safety curtain
V-belt tension and wear should be checked once a month.

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8 Handling the sieve
8.1Fitting and removing the sieve
Always wear protective gloves for these tasks!
-Open machine as described in chapter 7.3.
-Loosen knob screws, hold sieve frame and then swivel downwards.
-Reach under the sieve and unhook it.
-Take sieve out to the front.
-When fitting the sieve, ensure that the sieve frame contact surfaces are clean.
8.2Cleaning the sieve
Always wear safety gloves for these jobs of work! Only brush the sieve clean. Never use
compressed air. Press jammed parts through from behind.
Sieve
Sieve chase