UNTHA RS100-4-S User manual
Operating manual
RS100-4-S Translation of the ORIGINAL
CERTIFIED FINAL
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Table of contents
1.General information ...............................................................................................................4
1.1Purpose of the document .........................................................................................................4
1.2Storage.....................................................................................................................................4
1.3Your opinion counts! ................................................................................................................4
2.Product description ...............................................................................................................5
2.1Correct use...............................................................................................................................5
2.2Machine specific information....................................................................................................6
2.3General machine information ...................................................................................................6
2.4Description of function..............................................................................................................7
3.Basic safety information .......................................................................................................8
3.1Duties and liabilities .................................................................................................................8
3.2Basic safety symbols................................................................................................................9
3.3Symbols on the machine........................................................................................................10
4.Special safety information ..................................................................................................11
4.1Protective structures ..............................................................................................................11
4.2Safety mechanisms................................................................................................................11
4.3Informal safety measures.......................................................................................................12
4.4Acoustic warning signal..........................................................................................................12
4.4.1Signal horn at the control cabinet ......................................................................................12
4.5Personnel training ..................................................................................................................12
4.6Basic safety measures for normal operation..........................................................................12
4.7Basic safety measures for repair and maintenance...............................................................13
4.8Safety measures of electrical equipment ...............................................................................14
4.9Fire .........................................................................................................................................14
4.10Disposal..................................................................................................................................14
5.Transport...............................................................................................................................15
5.1Safety guidelines....................................................................................................................15
5.2Means of transport .................................................................................................................15
5.3Weight ....................................................................................................................................18
6.Setting up..............................................................................................................................19
6.1Safety guidelines....................................................................................................................19
6.2Maintenance area ..................................................................................................................19
6.3Operating positions ................................................................................................................20
7.Electric power source..........................................................................................................21
7.1Safety guidelines....................................................................................................................21
7.2Standard control cabinet set-up position................................................................................22
8.Commissioning ....................................................................................................................23
8.1Safety guidelines....................................................................................................................23
8.2Checking the emergency stop button ....................................................................................23
8.3Elements on the control box...................................................................................................24
8.4Control electrical connection (clockwise rotation field) ..........................................................25
8.5Control climate control unit.....................................................................................................25
8.6Shaft ventilation system .........................................................................................................25
9.Operation ..............................................................................................................................26
9.1Safety guidelines....................................................................................................................26
9.2What may not be shredded?..................................................................................................26
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9.3Material removal.....................................................................................................................26
9.4Turning on the machine .........................................................................................................27
9.5Turning off the machine .........................................................................................................27
9.6Automatic shut down mechanism for foreign matter..............................................................28
9.7Workplaces.............................................................................................................................29
9.8Spray unit ...............................................................................................................................30
9.9Inspection door.......................................................................................................................30
9.10Help with breakdowns and problems .....................................................................................31
10.Maintenance .........................................................................................................................32
10.1Safety guidelines....................................................................................................................32
10.2Maintenance overview ..........................................................................................................32
10.3Protective covers....................................................................................................................33
10.4Gear system maintenance .....................................................................................................34
10.5Spray unit ...............................................................................................................................36
10.6Cleaning the bulkhead spaces...............................................................................................36
10.7Greasing application ..............................................................................................................37
10.7.1Central lubrication ..............................................................................................................37
10.7.2Greasing of the motors.......................................................................................................39
10.8Belt tension.............................................................................................................................40
11.Repair and maintenance......................................................................................................41
11.1Safety guidelines....................................................................................................................41
11.2Cleaning and changing the exit screen..................................................................................41
11.3Changing the cutting mechanism...........................................................................................43
12.Final shut down and disposal.............................................................................................45
13.Points of integration ............................................................................................................45
14.Installation instructions.......................................................................................................45
15.Start up service and information........................................................................................46
Appendix
•Declaration of Incorporation
•
Layout
•
Spare part list
•
Cutting system plane and assembly sketch
•
Frequency inverter
•
Electrics (circuitry plans and function descriptions)
I C A
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1. General information
1.1Purpose of the document
This operation manual familiarizes the operative with:
•working methods
•
safety guidelines
•
operation
•
maintenance
1.2Storage
Always store the operation manual with the machine. The manual should always be instantly
accessible!
1.3Your opinion counts!
Dear Readers!
Our operating manuals are constantly updated. Suggestions and comments are very welcome and
help us to make them as clear, comprehensive and user-friendly as possible.
¤
¤¤
¤2011 Anton Unterwurzacher Maschinenbau GmbH
Moldanstr. 141, A-5431 Kuchl
Tel.: 0043 (0) 6244-7016
All rights reserved.
Reproduction of the complete document, or excerpts thereof,
only permissible with the explicit authorisation of UNTHA!
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2. Product description
2.1Correct use
The operational safety of the machines delivered can only be guaranteed when the machine is
correctly used. The correct and intended use for which safety can be guaranteed is:
Shredding of waste
Description: a) Rubber Tyres (after debeading) and other rubber products (eg fan belts).
b) Waste timber and transport crates.(1m³ a week)
c) Vegetation and organic material
d) Industrial and Domestic Plastics (like rags, car or truck oil filters,
mattresses)
e) Electronic equipment and household appliances (1pc. per month)
f) Chemical waste (plastic chemical containers) (2pcs. per week)
g) Paper, cardboard and document destruction
Dimension: a) Ø < 500 mm at car tyres, Ø < 800 mm at truck tyres
b) max. 1000 x 500 x 1000 mm
e) max. 800 x 600 x 1000
f) max. 800 ltrs.
Condition: a) truck tyres have to be debeaded
e) sorted out
f) dry and clean
Type of infeed: belt conveyor on site
Evacuation: directly into container
Daily operating hours: < 5 hours
Notice:
- The machine has to be fed in that way, so that the machine can shred it unproblematic (without
reversions)
- Hardened steel parts (like bearings, bars etc.) must be removed prior to shredding from the
electronic equipment and household appliances as well as metallic items.
- Solid unhardened steel shafts bigger then Ø8mm have to be removed as well (like coils, trafo etc).
- If bigger steel shafts get into the shredder they may be shredded with the risk of causing damage
and increased wear to the cutting unit and the screen.
Condition on site
Place of installation: inside a hall, under a roof
Ambient temperature: +2°C to +40°C
Humidity: 10 to 100 %
Sea level: 1720 m above sea level
Power supply: 400 V, tolerance -10% / +7%
50 Hz, tolerance +/-1%
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•Title________________________________
_
_________
_
•Machine type ________________________________
_
_
_
•Serial number________________________________
_
_
_
•Power [kW]________________________________
_
___
_
•
Cutting mechanism inlet [mm]
_
____________________
_
•Year of manufacture
_
____________________________
_
•
Country of origin________________________________
_
RS100-4-S
RS104485
2 x 55
1200 x 1020
06 / 2011
AUSTRIA
Shredder
Dimension of the plant see layout in the appendix!
•
If the machine is used for purposes other than the above-stated correct use, safe operation can
no longer be guaranteed.
•
For a duly application of the machine it is absolutely necessary to observe all safety signs in the
operating manual and on the machine!
•
If the machine is used for purposes other than the above-stated correct use, the operators and
not the manufacturers shall be held responsible for any damage or injury to persons or property!
2.2Machine specific information
2.3General machine information
Machine specifications RS100-4-S
Power [kW] 2 x 55
Main shaft rev count [RPM] approx. 20
Additional shaft rev count [RPM] approx. 21
Noise levels (DIN 45635-31)
Work place noise level (LpA,1m)approx. 86 dB (A)
Noise level (LWA)approx. 98 dB (A)
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•After feeding the material (A) into the hopper (B) it is consumed (without assistance) into the
cutting chamber system where it is pre and secondary shredded in one step.
•Material which does not fall immediately through the screen (C) is taken by the main cutters
(D) and taken up (preshredding).
•
When preshredded material is caught from the side cutters (E), a secondary shredding step
takes place (secondary shredding)
•Additionally the material is shredded at the transition from the main to the side cutting system.
The final product are exactly defined homogenous final granules (F).
•The shafts of the cutting system are driven by two electric motors (G) and a 3-stage gear
system (H).
2.4Description of function
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A basic prerequisite for the safe handling and problem free operation of this machine is familiarity
with the basic safety guidelines and regulations. All personnel working on and with the machines
should be aware of these operation guidelines, and in particular the safety guidelines. Additionally,
the safety rules and regulations valid for the place of operation should be observed, in the interests
of accident prevention.
This machine has been manufactured using and incorporating the latest technology and
acknowledged rules of technical safety. Nevertheless, use of the machine can entail physical and
fatal injury to the operator, or third parties, damage to the machine itself and to other property. This
machine may only be used…
•For the correct purpose for which it was built.
•
When all technical and safety criteria have been completely satisfied.
3. Basic safety information
This operation manual contains important guidelines for the safe use of the machine.
3.1Duties and liabilities
Guarantee and liability claims for damage or injury, to persons or property, are invalid if one or more
of the following were cause for the fatalities, injuries or damage:
•
Incorrect use of the machine (see 2.1).
•
Inappropriate and incorrect installation, starting up, operation or maintenance of the machine.
•
Operation of the machine by unqualified or unauthorised personnel.
•
Operation of the machine when safety devices are defective, or when safety devices and
protective appliances have been incorrectly installed or are not functioning correctly, if at all.
•
Ignoring the information in the manual on transport, positioning, starting up, operation, repair and
maintenance of the machine.
•
Unauthorised structural changes are made to the machine.
•
Insufficient checking/observation of machine parts subject to wear.
•
Inappropriate and incorrect repair work.
•
Missing or insufficient removal of shredded material from the exit screen.
•
Repair and disassembly work is carried out during the guarantee period by non-UNTHA
personnel or persons not explicitly authorized by the manufacturers.
•
The effects of the presence of foreign matter, catastrophes and acts of God.
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Danger: This symbol indicates immediate danger to the life and
physical wellbeing of human beings.
Ignoring this warning can lead to everything from serious
damage to your health to life-threatening injuries.
Caution: This symbol indicates a potentially dangerous situation.
Ignoring this warning can lead to injury or damage to property.
Information: Tips and useful information for using the machine.
These tips help you optimise your use of all the functions of the
machine.
Important: This symbol offers important instructs on how to
handle the machine correctly.
Ignoring this information can lead to problems with the machine
and its environment.
3.2Basic safety symbols
This operators’ manual uses the following symbols and names for dangers and risks:
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Danger:
Do not mount on the shredder / screw conveyor / conveyor belt!
Note:
Read the operating instructions (including Annex) carefully
before start-up of the equipment. It is important that all details of
the instructions are well understood as they cover important
information about safe and proper handling and trouble-free
operation of the shredder.
Note:
People standing near the shredder must wear safety helmet,
safety goggles, hearing protection and breathing masks!
Danger:
Putting the fingers through the exit screen is strictly forbidden!
Danger:
Looking and reaching into the hopper during operation is strictly
forbidden!
Warning:
Warning - harmful or irritating substances.
This machine is not designed for shredding flammable or toxic
materials.
3.3Symbols on the machine
The following warnings and information are to be found on the machine:
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4. Special safety information
4.1Protective structures
Every time before the machine is started up, all protective structures and mechanisms should be
correctly in place and in perfect working order.
Protective structures and mechanisms can only be disabled or removed in the following situations:
•
Standstill (complete shutdown).
•
Prevention of start up is ensured (e.g. the main switch is padlocked).
4.2Safety mechanisms
Ensure free access and eye contact to safety switches and mechanisms at all times!
Main switch on the control box
•
Cuts the power supply to the shredder.
•
Can be locked in the „OFF“ position.
Lock the main power switch in the “OFF” position:
•
for repair and maintenance work.
•
If starting up could be dangerous.
EMERGENCY STOP button
•
Stall the shredder.
•
Press button in dangerous situations:
shredder then comes to a halt.
•
Reset by pulling the red button out and
acknowledge the fault report by press the ACK
button at the display.
Safety switch
•
Opening monitored safety covers during operation
causes the shredder to stop.
Main switch
EMERGENCY STOP button
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4.3Informal safety measures
•In addition to the operation manual, all generally valid regulations and other local and corporate
regulations for accident prevention and environmental protection should be easily accessible and
observed in their entirety.
•
All safety information and danger warnings on the machine should be kept legible and be
renewed if necessary!
4.4Acoustic warning signal
The safety is only ensured, if the warning signal is intact. Therefore:
•
Before start working, check if the warning signal is correct installed and functional.
•
Never decommission the warning signal.
4.4.1 Signal horn at the control cabinet
Before the machine start, a warning signal sounded.
4.5Personnel training
Only trained and authorized personnel are permitted to work with the machine. Areas of
responsibility for operating and maintaining the machine have to be clearly determined. Trainee and
apprentice personnel can only work on and with the machine under the supervision of an
experienced member of staff!
4.6Basic safety measures for normal operation
•
Only trained and authorized personnel familiar with the operation manual, and who know how to
adhere to the manual’s guidelines, are permitted to work with the machine.
•
The machine may only be operated when all safety mechanisms and structures are in place and
are in perfect working order!
•
The operating company must fit an appropriate safety device, which meets the industrial health
and safety regulations, to prevent anyone from reaching into the cutting system.
•
The machine may only be operated with a hopper, underframe and a safety guard underneath
the machine! The machine and the equipment must be bolted together fix.
•
The operating company must fit start-up warning signal if the shredder is driven by a higher-
ranking control system.
•
The operating company must fit an appropriate lighting of the work area, which meets the
industrial health and safety regulations.
•
The operating company must eliminate sources of danger caused by the integration of the
shredder into a system! The unit into which the shredder is integrated must be subjected to a
safety inspection (including an analysis of dangers and an evaluation of risks).
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•Before starting the machine, be sure that no-one can be endangered by the machine as it starts
up!
•
If the warning signal sounded (signal horn), all persons had to leave the danger area, not to be
endangered by the automatic starting machine.
•
The operating personnel should notify defects which could be dangerous immediately. If danger
is threatened (f. i. injury) the operation has to be stopped and is only allowed to be restarted after
removal of the defects.
•
The machine should be checked for outward signs of damage, and the safety mechanisms and
structures to be checked for ‘perfect working order’ status, at least once a day!
•
Materials to be shredded should be released before being loaded into the machine and may not
be held. Otherwise the materials entering the shredder can lash out and cause injury to hands
and arms (protective work gloves must be worn)!
•
Do not look into the hopper or the loading opening during the shredding process. Pressurised
and stressed materials in the machine can throw out splinters at great speeds, causing eye and
facial injuries (protective goggles must be worn)!
•
Don’t reach into the machine from above. Clothing can be seriously damaged and limbs, fingers,
hands and arms badly injured by contact with the cutting system!
•
Don’t reach throuh the holes of the exit screen with the fingers! Cause of heavy injurys of the
fingers.
•
Do not try to remove material that has already been fed into the hopper!
•
Shredded material must be continually removed.
•
Do not reach into the shredded material! Pointed or sharp edged materials can cause serious
injury to fingers, hands and arms!
•
In case of risks due to the shredded material, the relevant industrial health and safety regulations
for the individual area of operation must be followed.
•
The machine may not be climbed upon!
•
All persons in the working area of the machine have to wear personal protective equipment.
4.7Basic safety measures for repair and maintenance
•
Obey the prescribed interval guidelines for maintenance and inspections!
•
Repair and maintenance to be done on the shredder may only be carried out by trained and
authorised personnel!
•
Suitable protective equipment must be carried! These must correspond to the working
regulations!
•
Before starting repair or maintenance work, turn off the main power switch and make it
inaccessible with a padlock, the key to which must be kept by the persons authorized to carry
out the repair or maintenance work!
•
Make sure that the machine is empty and no material is inserted before starting maintenance or
repair works.
•
To avoid falls, it is absolutely necessary to use a working platform, according to the instructions
for accident prevention, at maintenance- and service works.
•
When replacing heavy machine parts, only use suitable and fault-free means of lifting and weight
bearing!
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•Before starting repair or maintenance work, ensure that all parts with which you may come into
contact, have cooled down to room temperature!
•
Do not hit with tool on hardened parts (as cutting system) because, otherwise, splinters can fly
away!
•
Depending on the dust formation, the machine must be cleaned to prevent hazardous dust/air
mixtures (risk of explosion) from developing inside.
•
Thoroughly clean the area around the machine daily when the machine is switched off.
(Deposited dust could lead to dangerous situations if whirled up). If this cleaning process is not
carried out, the development of an ex-zone 22 (explosion risk) around the machine is possible!
•
After finishing repair and maintenance work, check that all safety structures and mechanisms are
in perfect working order!
4.8Safety measures of electrical equipment
•
Repare work on electrical equipment in the shredder may only be carried out by a qualified
electrician!
•
Check electrical equipment regularly for function and damages to assure perfect working order!
•
Damaged components, leads and cables must be replaced immediately!
•
The control box should be locked at all times! Access is only permitted to authorised persons
with a key!
•
Electrical equipment must never be hosed down with water!
4.9Fire
•
Disconnect the shredder from power before starting fire fighting measures!
•
Local fire control regulations must be observed!
•
Suitable fire extinguishers must be available. The operator must be familiar with handling the
extinguishing agent!
•
Information about suitable fire extinguishers and extinguishing methods must be obtained.
•
Special attention must be paid to the flammability of gear and hydraulic oils in the tank and the
lines.
4.10 Disposal
•
All work on the machine is subject to the legal directives on waste avoidance and to the correct
methods of recycling, salvaging and disposal!
•
Substances threatening water purity, such as:
Grease, engine and gear oil, hydraulic oil, cooling fluids, cleaning fluids containing solvents and
detergents
may not enter the ground or seep into the water and sewage systems! Such substances must be
stored in suitable containers, transported, collected and correctly disposed of!
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Advice: Before lifting with crane, you have to remove the hopper!
5. Transport
5.1Safety guidelines
To avoid damage to the machine and life-threatening injuries to persons during transit:
•Only qualified, authorised personnel may take on the task of transportation (see ch. 4.5)!
•
All means of lifting and load bearing points must comply with accident prevention regulations and
guidelines and be suitable for the task!
•
Attention must be paid to the weight of the machine in choosing a means of lifting, supporting,
lowering and load bearing points!
•
The transit routes must be limited, kept clear and signposted in such a way as to rule out the
possibility of unauthorised persons entering the danger area!
•
Transit may only take place with the machine in the standard upright position, thus neither laid
on its sides nor on its head. The shredder must be strapped down with belts in such a way as to
rule out any slipping.
•
After the transport all transport equipments had to be dismantled!
5.2Means of transport
All machines may only be lifted into position for transport or set up via crane.
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Hopper
Attachment points hopper
Use the attachment points of the hopper, according
to the figure, for transport.
Underframe
Attachment points underframe
Use the attachment points of the underframe,
according to the figure, for transport.
Exit screen
Attachment points exit screen
Use the attachment points of the exit screen,
according to the figure, for transport.
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Chute
Chute attachment points
Use the attachment points of the chute, according
to the figure, for transport.
Free bearing plate
Attachment point free bearing plate
Use the attachment point of the free bearing plate,
according to the figure, for transport.
Control cabinet
Attachment points control cabinet
Use the attachment points of the control cabinet,
according to the figure, for transport.
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5.3Weight
Value Unit
Machine 11000 kg
Hopper 800 kg
Underframe 1150 kg
Exit screen 400 kg
Chute 130 kg
Free bearing plate 360 kg
Control cabinet 1000 kg
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Standard feeding side
min. 2000 m
m
min. 1000 m
m
The operating company must fit an appropriate safety device, which meets the industrial health and
safety regulations, to prevent anyone from reaching into the cutting system.
6. Setting up
6.1Safety guidelines
•Only qualified, authorised personnel may bring the machines into the correct set up position (see
chapter 4.5)!
•
All connections (cables, tubes and pipes) must be installed in such a way as to rule out the
possibility of tripping up restricting free movement!
•
UNTHA Shredders are only suitable for indoor and covered usage; they must never come into
direct contact with dampness or wetness. In particular, the electrics must always be kept
completely dry!
•
The shredding machine may only be set up and operated on flat surfaces. If the ground is weak
or cannot support the machine, a concrete foundation block must be placed beneath the
shredder and, if necessary, bolted to the machine!
•
The place of operation must be a place where a temperature range of 0°C to +40 °C does not
drop below and exceed respectively.
•
Ensure, that the intake of the motors is not obstructed and air can circulate freely!
•
The operating company must fit an appropriate lighting of the work area, which meets the
industrial health and safety regulations.
6.2Maintenance area
Keep in mind that there has to be enough space designated around the machine for maintenance
work!
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