Virtus L Series User manual

VIRTUS EQUIPMENT
311 Era Drive
Northbrook, IL 60062
Phone: [phone]
www.Virtus-Equipment.com
Manual L Series

PART A: Basic machine
Shredder
L 60; L60+
©VIRTUS EQUIPMENT 2018 All rights reserved
Page 2
Table of Contents
1Information on this instruction manual ________________________________5
2Technical data_____________________________________________________6
3General Information ________________________________________________8
3.1 Copyright______________________________________________________________8
3.2 Application ____________________________________________________________8
3.3 Safety_________________________________________________________________8
3.4 Inspection of goods _____________________________________________________8
4General safety advice_______________________________________________9
4.1 Safe operation of the machine ____________________________________________9
4.2 Use in accordance with the regulations ___________________________________10
4.3 Liability and Responsibility______________________________________________12
4.4 Structural changes, spare parts, accessories_______________________________13
4.5 Operation manuals from other manufacturers ______________________________13
4.6 Noise levels and noise control measures __________________________________14
4.7 Work stations _________________________________________________________14
4.8 Remaining risks _______________________________________________________15
4.8.1 Mechanical dangers ________________________________________________________ 15
4.8.2 Electrical dangers __________________________________________________________ 16
4.8.3 Dangers caused by the control system __________________________________________ 17
4.8.4 Thermal dangers ___________________________________________________________ 17
4.8.5 Dangers caused by noise ____________________________________________________ 17
4.8.6 Dangers caused by vibration__________________________________________________ 18
4.8.7 Dangers caused by materials and substances ____________________________________ 18
4.8.8 Danger caused by manipulation of the protective devices ___________________________ 18
4.9 Protective devices _____________________________________________________19
4.9.1 Safety device for housing flap _________________________________________________ 19
4.9.2 Safety device for hopper _____________________________________________________ 20
4.9.3 Splash guard ______________________________________________________________ 21
4.9.4 Safety markings____________________________________________________________ 21
4.10 Authorized persons___________________________________________________22
4.11 Personal protective gear ______________________________________________23
4.12 Safety measures at the application site __________________________________24
4.13 Fire fighting agents___________________________________________________24
4.14 Cleaning agents _____________________________________________________24
4.15 Conduct in case of an emergency_______________________________________24
4.16 Classification of specific safety advice __________________________________25

PART A: Basic machine
Shredder
L 60; L60+
©VIRTUS EQUIPMENT 2018 All rights reserved
Page 3
5Description of the machine _________________________________________26
5.1 Grinding material in feed________________________________________________26
5.1.1 In feed hopper _____________________________________________________________ 26
5.2 Machine (Standard execution) ___________________________________________27
5.3 Drive_________________________________________________________________28
5.4 Rotor and knives ______________________________________________________29
5.5 Discharge of grinding material ___________________________________________31
5.6 Control panel _________________________________________________________31
6Initial startup_____________________________________________________32
6.1 General Advice ________________________________________________________32
6.2 Requirements at the application site ______________________________________33
6.3 Unloading and installing the machine _____________________________________34
6.4 Electrical connection___________________________________________________35
6.5 Machine check prior to initial start-up _____________________________________37
7Operation________________________________________________________38
7.1 Machine checks before switching on the machine___________________________38
7.2 Switch on machine_____________________________________________________38
7.3 Switch off machine_____________________________________________________39
7.4 Manual in feed of grinding material _______________________________________39
8Maintenance _____________________________________________________40
8.1 Safety advice__________________________________________________________40
8.2 Maintenance plan ______________________________________________________40
8.3 Checking the protective devices _________________________________________41
8.4 Cleaning the machine __________________________________________________42
8.5 Replacing the gearbox motor ____________________________________________43
8.6 Replacing the rotor ____________________________________________________43
8.6.1 Dismounting the rotor _______________________________________________________ 43
8.6.2 Mounting the rotor __________________________________________________________ 44
8.7 Replacing the main bearings ____________________________________________45
8.7.1 Dismounting the main bearings________________________________________________ 45
8.7.2 Mounting the main bearing ___________________________________________________ 46
8.8 Lubricating the main bearings ___________________________________________47
8.8.1 Lubrication intervals: ________________________________________________________ 47
8.8.2 Check lubricant quality_______________________________________________________ 47
8.8.3 Replacing or refilling lubricant _________________________________________________ 47
8.8.4 List of lubricants____________________________________________________________ 49

PART A: Basic machine
Shredder
L 60; L60+
©VIRTUS EQUIPMENT 2018 All rights reserved
Page 4
8.9 Working on the cutting knives ___________________________________________50
8.9.1 Replacing and checking the cutting knife mountings _______________________________ 50
8.9.2 Checking the condition of the cutting knives ______________________________________ 51
8.9.3 Dismounting the rotor knives__________________________________________________ 52
8.9.4 Dismounting the rotor knife holders_____________________________________________ 53
8.9.5 Dismounting the stator knives _________________________________________________ 55
8.9.6 Mounting the rotor knife holders _______________________________________________ 56
8.9.7 Mounting the rotor knives ____________________________________________________ 57
8.9.8 Mounting the stator knives____________________________________________________ 58
8.9.9 Sharpening cutting knives ____________________________________________________ 60
8.9.10 Setting the cutting knives_____________________________________________________ 61
8.9.11 Transporting and storing the cutting knives_______________________________________ 62
9Troubleshooting __________________________________________________63
9.1 Machine blocks or switches itself off______________________________________63
9.2 Rotor does not grip bulky material________________________________________63
9.3 Overheating of the grinding material ______________________________________63
9.4 Unusual vibrations_____________________________________________________63
9.5 Extreme cutter wear____________________________________________________64
9.6 Bearings too hot_______________________________________________________64
9.7 Cutting gap alters during operation_______________________________________64
9.8 Shredder does not start_________________________________________________64
9.9 Shredder blocks when under load ________________________________________64
9.10 Frequent switching off of grinding material in feed device __________________64
10 Storage, disposal, transportation __________________________________65
10.1 Storage_____________________________________________________________65
10.2 Disposal ____________________________________________________________65
10.3 Transportation_______________________________________________________65
11 Customer service and spare parts orders____________________________66
12 Spare Parts List L 60_____________________________________________67
13 Spare Parts List L 60+____________________________________________69
14 ClARIFICATION FOR PERSONal TRAINING __________________________76
15 Electrical Connection ____________________________________________77
16 DIMENSIONS OF STANDARD MACHINE _____________________________78

PART A: Basic machine
Shredder
L 60; L60+
©VIRTUS EQUIPMENT 2018 All rights reserved
Page 5
1 INFORMATION ON THIS INSTRUCTION MANUAL
Author: VIRTUS EQUIPMENT
No part of this operation manual may be reproduced, distributed
or used in any shape or form, stored in a data processing system
or translated into another language without written permission.
This operation manual serves to help you to get to know your
machine and how to make use of its application possibilities in
accordance with the regulations.
The operation manual contains important information on how to
operate the machine safely, correctly and economically. Following
this advice will help you to avoid danger, minimize repair costs
and down times and to increase the reliability and durability of the
machine.
Before you begin to work on and with the machine, please read
the operation manual thoroughly. Only after you have read and
understood the contents of this operation manual may you begin
work on and with the machine. Keep this operation manual at the
application site for future reference.
References to chapters, plans and other documents as well as
key markings are written in italics.
Instructions on handling are marked in this way.
The machine is designed in modular system and offers a wide
spectrum of variations to do justice to your expectations.
This operation manual is divided into three parts:
1. Part A: Information of the basic machine.
2. Part B: Plans, operation manuals for systems from other manufac-
turers etc.
Should you wish to order further operation manuals, please quote
the machine number.
We wish you every success with your new machine!

PART A: Basic machine
Shredder
L 60; L60+
©VIRTUS EQUIPMENT 2018 All rights reserved
Page 6
2 TECHNICAL DATA
L 60
Opening cutting chamber
Data in mm:
580x560
Rotor dimension:
Diameter in mm:
Width of cut in mm:
310
550
Rotor knives:
No. of rotor knives:
26
Stator knives:
No. of stator knives:
2
Rotor speed (50 Hz):
rpm
60
Width:
Data in mm:
1400
Length:
Data in mm:
1000
Height:
Data in mm:
2165
Drive motor:
Power in kW:
11
Screen:
Type and screen hole size
dependent on the
application and customer
requirements.
Machine weight:
In kg
150
Electrical connection data:
markings are attached to the machine
Noise level:
Depends on plant location and
type of grinding material!
Without noise equipment,
in dB(A):

PART A: Basic machine
Shredder
L 60; L60+
©VIRTUS EQUIPMENT 2018 All rights reserved
Page 7
L 60+
Opening cutting chamber
Data in mm:
580x560
Rotor dimension:
Diameter in mm:
Width of cut in mm:
310
550
Rotor knives:
No. of rotor knives:
26
Stator knives:
No. of stator knives:
2
Rotor speed (50 Hz):
rpm
60
Width:
Data in mm:
1400
Length:
Data in mm:
1000
Height:
Data in mm:
2165
Drive motor:
Power in kW:
11
Screen:
Type and screen hole size
dependent on the
application and customer
requirements.
Machine weight:
In kg
160
Electrical connection data:
markings are attached to the machine
Noise level:
Depends on plant location and
type of grinding material !
Without noise equipment,
in dB(A):

PART A: Basic machine
Shredder
L 60; L60+
©VIRTUS EQUIPMENT 2018 All rights reserved
Page 8
3 GENERAL INFORMATION
3.1 Copyright
VIRTUS EQUIPMENTholds the copyright for these operation
instructions, entrusted to the owner of the shredder for his
personal use. This contains technical instructions and drawings
which are not be copied complete or in part, distributed or used for
reasons of unauthorized competition or for informing others.
3.2 Application
The shredder is designed for size-reduction of plastic material
such as PE, PP, and PVC etc. The user is responsible for
consequences resulting from incorrect operation: This will lead to
the loss of the warranty as well as any compensation claims.
3.3 Safety The shredder has been constructed in accordance to the general
standards of technology and is fitted with safety devices to prevent
accidents that could endanger the life or health of the operator.
The company operating the unit is responsible for the compliance
to the safety regulations. We recommend staff training courses at
regular intervals subsequent to initial training during
commissioning.
3.4 Inspection of goods
The goods must be inspected by the purchaser to ensure that the
delivery is complete and free from damage during transport. In the
event of any queries VIRTUS must be informed with regard to
missing items or transport damage. In the event of actual transport
damage, written notification including photographs should be
made and sent to the transport company as well as sent to
VIRTUS immediately after delivery.

PART A: Basic machine
Shredder
L 60; L60+
©VIRTUS EQUIPMENT 2018 All rights reserved
Page 9
4 GENERAL SAFETY ADVICE
4.1 Safe operation of the machine
The machine is built according to the state of the art and
recognised safety regulations.
It is equipped with protective devices; however there is still the
threat of danger in case of incorrect conduct or misuse:
•for the health of the operator and that of other persons,
•for the machine,
•for the environment,
•for material assets belonging to the company and the operator.
All persons involved in:
•transportation and storage,
•start-up and shutdown,
•operation,
•setting and fitting
•maintenance and waste disposal...
of the machine must carefully read and take note of the following
advice. However, not only does the general safety advice listed in
this chapter need to be observed, but also the safety advice which
is added specifically in the other chapters.
Failure to heed this safety advice can lead to loss of all
compensation claims.
Furthermore, the existing rules and regulations for the prevention
of accidents as well as in house company working, operational
and safety regulations have to be observed.

PART A: Basic machine
Shredder
L 60; L60+
©VIRTUS EQUIPMENT 2018 All rights reserved
Page 10
4.2 Use in accordance with the regulations
The operational safety of the delivered machine is only
guaranteed for use in accordance with the regulations!
This regulation use is only achieved if the following points are
observed and fulfilled.
Manufacturing process and grinding material
The shredder is suitable exclusively for the grinding of material,
which corresponds to the agreed customer-specific specifications
in all points (see Contract of sale).
Any other work or design will differ from the specified
requirements. VIRTUS EQUIPMENT will not be held responsible.
The specified requirements also include all information found in
the owner’s manual such as maintenance and service.
Any change in the specifications or requirements must be brought
to the attention of VIRTUS .
Suction unit
If emissions occur during grinding of material, which exceed the
permissible legal values for contaminants in the air, the shredder
may only then be operated when the customer has installed a
suitable air suction device on site.
Safety device for the in feed hopper
In the case that your design of the shredder does not contain any
additional in feed device (e.g. nip roll feed device), the in feed
hopper must be safeguarded in a suitable way against persons
reaching in or falling in.
If, without our knowledge, the machine is installed "underground"
on site, it is deemed to be installation contrary to the intended
purpose. The attached manufacturer's declaration alone, stating
that the machine may not be operated without additional
measures
Connection of the Emergency Stop button
The machine may only be operated with the installed Emergency
Stop buttons. In case no Emergency Stop buttons have been
installed, an Emergency Stop button must be mounted on the
control cabinet, the second on the material in feed.

PART A: Basic machine
Shredder
L 60; L60+
©VIRTUS EQUIPMENT 2018 All rights reserved
Page 11
Miscellaneous:
•The working conditions and instructions specified in this
operation manual must be adhered to.
•The machine is not suitable for operation in an explosive
environment.
•Faults, which can impair safety, are to be reported immediately
and eliminated by a trained and skilled specialist.
•The machine may only be used in the industrial application
range.
General Requirements Safety Information
•The service and maintenance in this owner’s manual must be
performed on a regular basis.
•The machine is not designed for operation in a volatile
environment.
•Faults that could be a safety hazard must be reported
immediately and repaired by experienced personal.
•The machine must only be installed in an industrial type
building.
Known uses not in accordance with the regulations
Never grind materials, which do not correspond to the agreed
customer-specific specifications. If this occurs, there could be a
danger to persons and the possibility of the machine being
damaged.
Informal Safety Requirements
The owner’s manual should always be located near the machine.
New excerpts or additions to the owners’ manual must always be
inserted to include any safety requirements or environmental re-
quirements.
All safety or caution signs must be visible and easy to read.

PART A: Basic machine
Shredder
L 60; L60+
©VIRTUS EQUIPMENT 2018 All rights reserved
Page 12
4.3 Liability and Responsibility
The General Conditions of Sale and Delivery apply. These condi-
tions apply no later than the end of the contract. Liability and or
responsibility to seller do not apply to the following;
⚫Equipment is not properly used for its specific application.
⚫Non-conforming installation, commissioning or service of
the machines.
⚫Operation of the equipment without proper safety guards.
⚫Not conforming to the directions of the owners’ manual re-
garding transport, storage, installation, commissioning or
servicing the equipment.
⚫Any designs alterations on the machine.
⚫Any changes on the program logic which can alter the ma-
chine operation or electrical function.
⚫Changes in the logic function.
⚫Improper maintenance or servicing of the machines that
can lead to extraordinary wear
⚫Improper servicing of equipment
⚫Spontaneous crashes caused by foreign objects falling into
the machine or acts of God
We honour a 12 month guarantee valid after delivery under the
conditions that originally delivery or original parts from VIRTUS
EQUIPMENT are used or accepted for use in accordance with our
owner’s manual.
Otherwise the guarantee will be considered invalid. Excluded are
wear and tear parts such as knives, screens, drive belts, bearings,
etc.

PART A: Basic machine
Shredder
L 60; L60+
©VIRTUS EQUIPMENT 2018 All rights reserved
Page 13
4.4 Structural changes, spare parts, accessories
For reasons of safety, remodelling and/or modifications to the
machine, in particular to the electrical devices, are only
permissible by arrangement with the manufacturer!
Replace faulty parts immediately. Only use original spare parts or
spare parts from other manufacturers, which correspond to the
original spare parts with regards to function, stress and safety.
This applies in particular for reasons of EMC (electro-magnetic
compatibility) for electrical components.
The use of unsuitable parts can impair resistance to relays and
increase the emission of relays!
If parts are replaced which are relevant for safety, they must be
checked afterwards for proper function.
Only use accessories, which have been approved by the
manufacturer. Use of accessories can change how the machine
works. You must therefore observe the additional advice for your
work and your safety. Read Part B: Accessories, before you
commission the machine.
4.5 Operation manuals from other manufacturers
Integrated in the machine are systems from other manufacturers.
When working on or with these systems, please observe the
advice in the operation manuals from the respective manufacturer.
These operation manuals are enclosed with the machine
documentation.

PART A: Basic machine
Shredder
L 60; L60+
©VIRTUS EQUIPMENT 2018 All rights reserved
Page 14
4.6 Noise levels and noise control measures
The L series shredder standard design is without a sound proof
enclosure.
The noise level of the shredder at idle speed is approximately 85
dB (A).
Especially by rigid materials soundproofing is recommended due
to a noise level of up to 120 dB (A) when in operation.
In order not to exceed the noise level of 85 dB (A) is the purchaser
required to provide soundproofing.
The noise level can be affected by foundation static or dynamic,
aux. blowers etc. or other additional equipment. Therefore it is
necessary to actually determine if the noise level is directly coming
from the machine or accessory equipment.
VIRTUS EQUIPMENT offers the following equipment to reduce
the noise levels;
⚫Two piece soundproof box (one piece stationary, one piece
moveable) also available with soundproof hopper.
⚫Walk-in type soundproof enclosure.
CAUTION
The user or purchaser is responsible for compliance with
the instructions and procedures!
4.7 Work stations
During normal operation, the work station is the station at the in
feed of the grinding material.
For maintenance work, the whole area around the machine is at
your disposal.

PART A: Basic machine
Shredder
L 60; L60+
©VIRTUS EQUIPMENT 2018 All rights reserved
Page 15
4.8 Remaining risks
The machine is constructed so that you are able to operate it
safely. Structurally non-avoidable dangers are prevented as well
as possible by the protective devices. A certain remaining risk
does however always remain! Being aware of these remaining
risks of the machine will help you to structure your work more
safely and in so doing to avoid accidents.
To avoid danger, please observe in addition the specific safety
advice in the individual chapters.
4.8.1 Mechanical dangers
Type of danger:
Danger of crushing by heavy parts falling
down or falling over.
Activity:
Unloading and transporting the machine or
machine components.
Possible
consequences:
Serious injury could result.
Preventative
measures:
Wear personal protective gear. Follow the
instructions in this Operation manual.
Type of danger:
Danger of cutting caused by sharp cutting
knives, even when the rotor is stationary.
Activity:
Knife replacement, knife setting, and knife
sharpening, other maintenance work.
Possible
consequences:
Serious injury, particularly to hands and
fingers can result.
Preventative
measures:
Wear personal protective gear. Follow the
instructions in this Operation manual.
Type of danger:
Danger of crushing when opening/closing the
maintenance doors on the front side of the
machine.
Activity:
Maintenance work.
Possible
consequences:
Serious injury can result.
Preventative
measures:
Ensure that no persons are in the danger
area while closing the door.
Type of danger:
Tripping over cables and other objects lying
around.
Activity:
All activities.
Possible
consequences:
Serious injury can result.
Preventative
measures:
Lay cables in accordance with the
regulations. Keep work station clean and tidy.

PART A: Basic machine
Shredder
L 60; L60+
©VIRTUS EQUIPMENT 2018 All rights reserved
Page 16
Type of danger:
Danger of crushing, cutting and amputation
caused by run-down of the rotor.
Activity:
Maintenance work.
Possible
consequences:
Serious injury or death can result.
Preventative
measures:
The maintenance doors must always be
tightly locked during operation. Do not make
the run down safety devices ineffective by
using technical aids or other manipulations.
Never check by hand whether the rotor has
come to a stop.
4.8.2 Electrical dangers
Danger:
Direct or indirect contact with live parts in the
terminal box.
Activity:
Maintenance work, start-up.
Possible
consequences:
Serious injury or death.
Preventative
measures:
Only trained electricians may only carry out
all work on the electrical equipment.
If work is necessary on parts, which conduct
dangerous voltage, a second person should
be called in who can break the power supply
in case of emergency.
The yellow-marked lines conduct voltage
even when the machine is switched off (main
switch to 0).
Only use original safety fuses with stipulated
intensity of current.
Faulty electrical components must be
replaced immediately.
If faults occur in the electrical energy supply,
switch machine off immediately.
The terminal box must be locked during
operation. Before opening the terminal box:
Main switch to 0.

PART A: Basic machine
Shredder
L 60; L60+
©VIRTUS EQUIPMENT 2018 All rights reserved
Page 17
4.8.3 Dangers caused by the control system
Type of danger:
Danger caused by failure of the Emergency
Stop function.
Activity:
All activities.
Possible
consequences:
Serious injury or death.
Preventative
measures:
It must be guaranteed that failure of an
Emergency Stop button is displayed and
leads to an immediate stop of the machine.
4.8.4 Thermal dangers
Type of danger:
Danger of fire and explosion caused by
throwing dangerous objects (e.g. spray cans)
into the shredder.
Activity:
Grinding.
Possible
consequences:
Serious injury or death can result.
Preventative
measures:
Only grind material which corresponds to the
agreed customer-specific specifications in all
points.
4.8.5 Dangers caused by noise
Type of danger:
Damage to hearing.
Activity:
All activities.
Possible
consequences:
Diminished hearing, headaches, impaired
balance, and deterioration of concentration.
Preventative
measures:
Reduce noise emissions by taking suitable
measures. Wear ear protection.

PART A: Basic machine
Shredder
L 60; L60+
©VIRTUS EQUIPMENT 2018 All rights reserved
Page 18
4.8.6 Dangers caused by vibration
Type of danger:
Instability of the machine caused by vibration.
Activity:
All activities.
Possible
consequences:
Serious injury can result.
Preventative
measures:
Install the machine according to the
instructions of this Operation manual and the
Assembly drawing.
Type of danger:
Loosening of the cutting knife mountings
caused by vibration.
Activity:
All activities.
Possible
consequences:
Serious injury can result.
Preventative
measures:
Check the cutting knife mountings regularly
according to the instructions in this operation
manual.
4.8.7 Dangers caused by materials and substances
Type of danger:
Inhalation of grinding dust.
Activity:
All activities.
Possible
consequences:
Diseases of the respiratory tract etc.
Preventative
measures:
Mount a suitable air suction device. Wear
breathing equipment if necessary.
When cleaning the machine do not blow out
grinding dust, use suction instead.
4.8.8 Danger caused by manipulation of the protective devices
Type of danger:
Danger of crushing, cutting and amputation.
Activity:
All activities.
Possible
consequences:
Serious injury or death can result.
Preventative
measures:
Never make the protective devices
ineffective. Check the protective devices
regularly for proper functioning according to
the specifications given in this operation
manual.

PART A: Basic machine
Shredder
L 60; L60+
©VIRTUS EQUIPMENT 2018 All rights reserved
Page 19
4.9 Protective devices
The machine may under no circumstances be operated without
these protective devices or with faulty or manipulated protective
devices.
4.9.1 Safety device for housing flap
Illustration:
Safety device for housing
flap
for hausd
The shredder can only be operated if the housing flap is fixed and
the screws are tightened. Otherwise the safety switch is activated.
If the housing flap will be opened during operation, the safety
switch is activated, thus switching off the machine.

PART A: Basic machine
Shredder
L 60; L60+
©VIRTUS EQUIPMENT 2018 All rights reserved
Page 20
4.9.2 Safety device for hopper
Illustration:
Safety device for hopper
Magnetventile
The hopper can be opened or pivoted upwards for maintenance
work and for cleaning. It is connected with the cutting chamber by
means of a joint.
It can be opened manually with the mounted hand winch.
Therefore the hopper is safeguarded against opening while
running.
If the hopper will be opened during operation, the safety switch will
be activated and the machine stops.