VECOPLAN VAZ 800 XL SP User manual

Operation Manual
Shredder
VAZ 800 XL SP
Order no.:
Machine no.:
Date:
Year of construction:
10495
10495 020
2007-11-08
2007
VECOPLAN AG
Vor der Bitz 10
Gewerbegebiet Eichenstruth
D-56470 Bad Marienberg
Telephone [phone]
Fax [phone]
E-Mail: [e-mail]
http://www.vecoplan.de

Contents
2
Copyright
Copyright of this operation manual remains the property of
the company VECOPLAN AG
This operation manual is intended for the installation, operation and
monitoring personnel of the plant operator.
It contains regulations and drawings of a technical nature, which may
not be duplicated either in whole or in part, distributed or evaluated
without authorisation for the purposes of competition, or communicated
to others.
Copyright by
VECOPLAN AG
Vor der Bitz 10
Gewerbegebiet Eichenstruth
D-56470 Bad Marienberg
Federal Republic of Germany
VECOPLAN AG

Contents
3
Manufacturer's Declaration
in the sense of the EC Machine Directive 98/37/EC,
in the latest version
We hereby declare that the construction of
Shredder VAZ 800 XL SP
in theform supplied by us, is intended for installation in a machine
and/or for putting together with other machines to form a machine
and that its commissioning is prohibited to the extent that it could be
established that the machine into which this machine is to be
installed corresponds to the provisions of the EC directive in the
following 98/37/EC; EMC Directive2004/108/EC and the low voltage
directive 2006/95/EEC.
Bad Marienberg, 2007-11-08
Vecoplan AG
Vor der Bitz 10 Postfach 1260
D-56470 Bad Marienberg D-56464 Bad Marienberg
Industriegebiet Eichenstruth
Tel. [phone]
Irene Scheidweiler
Executive Board
Wolfgang Lipowski
Board of Directors

Contents
4
1 Contents
1Contents............................................................................................................................................4
2General..............................................................................................................................................8
2.1 Note to the Operator.................................................................................................................... 8
2.2 Usage as Stipulated.................................................................................................................... 8
2.3 VECOPLAN -Quality Control ...................................................................................................... 9
3Safety...............................................................................................................................................10
3.1 Symbols.....................................................................................................................................10
3.1.1 Occupational Safety...............................................................................................................10
3.2 Occupational Safety Instructions ................................................................................................11
3.2.1 Organisational Measures .......................................................................................................11
3.2.2 Selection and Qualification of Personnel; Fundamental Obligations........................................11
3.3 Safety Instructions for Specific Operating Phases.......................................................................12
3.3.1 Normal Operation...................................................................................................................12
3.3.2 Special Work such as Upkeep Work, Rectifying Faults and Waste Disposal ...........................13
3.4 Instructions on Particular Types of Risk......................................................................................15
3.4.1 Electrical Energy....................................................................................................................15
3.4.2 Gas, dust, steam and smoke..................................................................................................16
3.4.3 Hydraulics, Pneumatics..........................................................................................................16
3.4.4 Oils, Greases and other Chemical Substances.......................................................................16
3.5 Mobile Machines........................................................................................................................17
3.6 Safety distances.........................................................................................................................18
3.7 Safety Locks..............................................................................................................................19
3.8 Protective Devices .....................................................................................................................20
3.9 Dangerous Area.........................................................................................................................20
3.10 Residual Risks...........................................................................................................................23
3.11 Personal Protective Equipment...................................................................................................23
4Technical Data.................................................................................................................................24
4.1 Machine Model Code .................................................................................................................24
4.2 Machine/Plant Rating.................................................................................................................24
4.2.1 Functional Data......................................................................................................................24
4.2.2 Dimensions and Weight .........................................................................................................24
4.2.3 Main drive..............................................................................................................................25
4.2.4 Hydraulic unit.........................................................................................................................25
4.3 Tightening Moment of the Screw, Except Fixing Screws for Reducing Tools and Counter Knife..26
4.3.1 Tightening Torques of Screw Connection of Reducing Tools..................................................26

Contents
5
4.3.2 Tightening Torques of Screw Connection for Counter Knife....................................................26
4.4 Electrical Connections................................................................................................................27
4.5 Noise Emission Values of a Reference Machine.........................................................................28
5Transporting....................................................................................................................................30
5.1 Dimensions and Weight (see Chapter "Technical Data").............................................................30
5.2 Instructions and Protective Measures for Transporting................................................................30
5.3 Hoisting Gear, Lifting Eye Bolts..................................................................................................30
5.4 Check on Acceptance by the Receiver .......................................................................................31
5.5 Packaging, Insulation.................................................................................................................31
5.6 Report and Document Transport Damage..................................................................................31
5.7 Storage Location, Storage Period, Protective Measures.............................................................31
6Installation.......................................................................................................................................32
6.1 General Instructions...................................................................................................................32
6.2 Installation Conditions................................................................................................................32
6.3 Hoisting Gear.............................................................................................................................33
6.4 Installation..................................................................................................................................33
6.4.1 Fitting.....................................................................................................................................34
6.5 After Installation .........................................................................................................................35
6.6 Electrical Plant...........................................................................................................................36
6.7 Removal.....................................................................................................................................37
7Commissioning...............................................................................................................................38
7.1 Instructions ................................................................................................................................38
7.2 Before commissioning................................................................................................................38
7.3 During Commissioning ...............................................................................................................39
7.4 Idle Operation and Locking Mechanism Test without Material.....................................................40
7.4.1 Idle Operation Test.................................................................................................................40
7.4.2 Locking Mechanism Tests......................................................................................................41
7.5 Mechanical Test Running with Material.......................................................................................42
8Operation.........................................................................................................................................44
8.1 Normal Operation.......................................................................................................................44
8.2 Stopping the Machine/Plant........................................................................................................44
8.3 Conduct in Case of Disruptions ..................................................................................................44
8.3.1 Safety Cut-Off........................................................................................................................44
8.4 Operational Safety .....................................................................................................................45
8.5 Operator controls.......................................................................................................................46
8.5.1 Control cabinet.......................................................................................................................46
8.6 For information on Allen Bradly programmer logic control (PLC) see "Appendix" section circuit
diagram (CPU 1747-L532).......................................................................................................................47

Contents
6
8.6.1 Troubleshooting.....................................................................................................................48
8.6.2 Switching on Again after Fault................................................................................................49
8.7 Damage during Guarantee Period..............................................................................................49
9Maintenance....................................................................................................................................50
9.1 Maintenance and Inspection.......................................................................................................50
9.1.1 Instructions............................................................................................................................50
9.1.2 General advice hydraulic system............................................................................................52
9.1.3 Recommended Hydraulic Oil Type.........................................................................................53
9.1.4 Adjusting the Hydraulic System..............................................................................................53
9.1.5 Maintenance and Inspection List............................................................................................54
9.2 Lubricating and Checking the Bearings.......................................................................................57
9.2.1 Checking the Bearings...........................................................................................................57
9.2.2 Lubricating Points ..................................................................................................................58
9.2.3 Lubricant Storage...................................................................................................................59
9.3 Maintenance..............................................................................................................................60
9.3.1 Note.......................................................................................................................................60
9.3.2 V-Belt Drive............................................................................................................................61
9.3.3 Tension and Replace V-ribbed belt.........................................................................................62
9.3.4 Removing and Fitting Pulley...................................................................................................64
9.3.5 Changing the Reducing Tools ................................................................................................65
9.3.6 Replace Counter Knife...........................................................................................................68
9.3.7 Changing the Screen .............................................................................................................70
9.3.8 Ram guides: Replacing of guide rollers ..................................................................................71
9.3.9 Replacement of guide rails.....................................................................................................73
9.3.10 Replacing the Seals at the Ram Front....................................................................................75
9.3.11 Replacing the Seal at the Back Wall.......................................................................................77
9.3.12 Repair Work on the Machine/Plant.........................................................................................78
10 Spare Parts Holding and Customer Service..................................................................................79
10.1 Spare Parts Holding...................................................................................................................79
10.2 Designation................................................................................................................................80
10.3 Name of Components ................................................................................................................81
10.4 Spare and Replacement Parts List.............................................................................................81
10.4.1 Machine body ........................................................................................................................82
10.4.2 Counter knife .........................................................................................................................83
10.4.3 Screen...................................................................................................................................83
10.4.4 Rotor......................................................................................................................................84
10.4.5 Reducing tool.........................................................................................................................86
10.4.6 Ram.......................................................................................................................................87

Contents
7
10.4.7Main drive..............................................................................................................................89
10.4.8 Hydraulic system (structural component 6).............................................................................90
10.5 Spare Parts and Customer Service Addresses...........................................................................91
10.6 Our Representative Offices........................................................................................................92
11 Appendix.........................................................................................................................................94
11.1 Maintenance Tools and Accessories ..........................................................................................94
11.2 List of Separate Documentation..................................................................................................94
12 Trip coupling...................................................................................................................................95
12.1 Operational Safety .....................................................................................................................95
12.2 Design .......................................................................................................................................95
12.3 Operation...................................................................................................................................95
12.4 Troubleshooting.........................................................................................................................96
12.5 Adjusting the contaminant detection proximity switch..................................................................97
12.6 Measures after the machine has been shut down by the contaminant detection..........................98
13 Index................................................................................................................................................99

General
8
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2 General
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2.1 Note to the Operator
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The operating instructions from this operation manual must be
observed, because:
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Only with the knowledge of this operation manual can errors to the
machine/plant be avoided and faultless operation be guaranteed.
Pos:1.5 /01_AL/01 _Hinweis andenBetreiber/Allg/FürSchädenundBetriebsstörungen @2 7\mod7510_2.doc@ 3 161 69
VECOPLAN accepts no liability for damage and operational
disruptions arising from the non-observation of this operation
manual!
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Pos:1.7 /01_AL/01 _Hinweis andenBetreiber/Allg/Sollten sicht rotzd em ei nm al Sc hwie ri gkeit en @ 27\mod751 1_2. doc @ 31 619 5
Nevertheless, should you encounter any difficulties, please turn to our
Customer Service or Spare Parts department or one of our
representative agents. They will be happy to help you (see Chapter
"Spare Parts Holding and Customer Service").
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2.2 Usage as Stipulated
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The machine/plant is exclusively provided for the following purpose:
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Pos:5/01_AL/XXX_Verw endungs zweck/ZK/10495020 @100\mod_1194429484171_2.doc@1241985
- for reducing of nappies from production waste
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Any further usage is deemed not to be as stipulated. VECOPLAN is not
liable for damage incurred as a result; solely the user bears the risk for
this.
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Pos:7.3 /01_AL/02_BestimmungsgemäßeV erwendun g/Allg/Die Maschine/Anlage istnachdemz ur Zeit @27\mo d75 13 _ 2.doc @3 1 63 51
The machine/plant is constructed in accordance with the state of
the art at the time and the acknowledged safety regulations at the
time it is supplied and is operationally safe.
Nevertheless, risk to life and limb of the user or third parties or
effects on the machine and other investment goods can arise if it is
not used expertly, by untrained personnel or not used as stipulated.
Included under usage as stipulated is the observance of the
operation manual and keeping to the inspection and maintenance
conditions.
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General
9
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2.3 VECOPLAN -Quality Control
Pos:9.2 /01_AL/03 _VECOPLAN -Qualität s kont rolle/All g /Die M aschin e/A nla ge wir d bei VECOPLA N kom plett @32 \mo d10 8 93_2. d oc @ 3163 77
The machine/plant will be completely assembled and the individual
parts operationally checked at the VECOPLAN site.
The complete machine/plant will furthermore be subjected to
VECOPLAN quality control.
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Safety
10
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3 Safety
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3.1 Symbols
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3.1.1 Occupational Safety
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Warning!
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You will find this symbol next to all occupational safety
instructions in this operation manual for which there is risk to life
and/or limb. Observe these instructions and conduct yourself
particularly carefully in these cases.
Forward all occupational safety instructions to other users as well.
As well as the instructions in this operation manual, the generally
valid safety and accident prevention regulations must be
considered.
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Caution -Equipment Damage!
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This symbol is found in places in this operation manual
which are to be specially noted so that the guidelines,
regulations, instructions and the correct working
procedures observed, and so damage and destruction
of the machine and/or other parts of the plant are also
prevented.
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Note
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This is where you will find information or notes.
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