Vogelsang XRipper XRC100QD/320 User manual

Operating Instructions
XRipper®
XRC100QD + SIK
2020-05-12
WBV.XRP.003.EN XRC100QD SIK V6.0
1/61
2020-05 -12
*WBV.XRP.003.E N XRC100Q D SI K*
WBV.X RP.003.EN XRC100QD SIK V6.0
Operating Instructi ons
XRipper®
XRC100QD + SIK
FOR PARTS AND SERVICE, CONTACT
[phone]
[phone]
[email protected]
www.envirep.com

Issuer
2
WBV.XRP.003.EN XRC100QD SIK V6.0
Original operating instructions
Issuer
Issuer
Vogelsang GmbH & Co. KG
Holthöge 10-14
49632 Essen/Oldb.
Phone: [phone]
Fax: [phone]
www.vogelsang.info
[e-mail]
In the absence of express, written authorisation from the issuer, the reproduction or partial reproduction of
this document in any form is prohibited.
We reserve the right to make technical modifications to the diagrams and information presented in this
document in the event that such modifications become necessary for the enhancement of the machine.
© 2020 Vogelsang GmbH & Co. KG
Registered trademarks of Vogelsang
In selected countries, Vogelsang®, RotaCut®, HiFlo®, ACC®, CFC®, BioCrack®, XTill®, EnergyJet®, BioCut®,
CC-Serie®, PreMix®, ProTerra®, VarioCrop® and XRipper® are registered trademarks of Vogelsang GmbH &
Co. KG, Essen/Oldb., Germany.
All rights reserved, including graphics and images.
The registered trademarks are not always marked with an ® symbol in this document.

Table of contents
WBV.XRP.003.EN XRC100QD SIK V6.0
3
Dear customer,
in every one of our products, you will see the entirety of our competence and our power of innovation at
work. Each product is developed and built so that you can work more successfully.
We call it quite simply: ENGINEERED TO WORK
If you want to know more about our company or put forward requests or suggestions, a wealth of information
can be found at www.vogelsang.info
Table of contents
Issuer ........................................................................................................................................................... 2
Table of contents ........................................................................................................................................ 3
1User information ............................................................................................................................... 6
1.1 Using the operating instructions ..................................................................................................... 6
1.2 Presentation convention ................................................................................................................. 6
1.3 Explanation of symbols .................................................................................................................. 7
1.4 Machine versions described here ................................................................................................... 8
1.5 Overview drawing .......................................................................................................................... 9
2Specifications.................................................................................................................................. 10
2.1 Name plate ...................................................................................................................................11
3EC declaration ................................................................................................................................. 12
4Safety ............................................................................................................................................... 13
4.1 Operator’s responsibilities .............................................................................................................13
4.2 Personnel qualification ..................................................................................................................14
4.3 Fields of activity ............................................................................................................................14
4.4 Intended use .................................................................................................................................15
4.5 General safety notes .....................................................................................................................15
4.6 Main switch, maintenance and repair switch ..................................................................................16
4.6.1 EMERGENCY STOP shutdown (main switch) ..........................................................................16
4.6.2 Maintenance and repair switch .................................................................................................16
4.7 Warning and safety stickers on the machine ..................................................................................17
5Transport, storage .......................................................................................................................... 19
5.1 Transport ......................................................................................................................................19
5.2 Storage .........................................................................................................................................20
6Assembly ......................................................................................................................................... 21
6.1 Installing the SIK (Sewer Integration Kit) .......................................................................................21
6.1.1 Wall-mounted frame on the face side with guide rail .................................................................22
6.1.2 Wall-mounted frame on side with guide rail ..............................................................................23
6.1.3 Wall-mounted frame on side without guide rail .........................................................................23
6.2 Lowering and pulling up the XRipper .............................................................................................24
6.2.1 With guide rail with mounting on the face side and on the side .................................................24
6.2.2 Without guide rail with mounting on the side .............................................................................25
6.3 Moving the buffer fluid tank upwards (optional) ..............................................................................26
6.4 Flow direction................................................................................................................................27
6.5 Drive .............................................................................................................................................28
6.5.1 Electric drive ............................................................................................................................28
6.5.2 Hydraulic drive .........................................................................................................................29
6.6 System control ..............................................................................................................................30
7Start-up ............................................................................................................................................ 31
7.1 Functional test ..............................................................................................................................31
7.2 Safety distance .............................................................................................................................31
8Maintenance .................................................................................................................................... 33
8.1 Seal chamber................................................................................................................................33
8.1.1 Plugs .......................................................................................................................................33

Table of contents
4
WBV.XRP.003.EN XRC100QD SIK V6.0
8.1.2 Pressurisable buffer fluid tank (optional) ...................................................................................35
8.1.3 Buffer fluid – type .....................................................................................................................36
8.1.4 Buffer fluid – amount ................................................................................................................36
8.2 Replacing the buffer fluid...............................................................................................................37
8.2.1 Draining and filling the seal chamber (plug) ..............................................................................37
8.2.2 Draining and filling the seal chamber (buffer fluid tank) .............................................................38
8.3 Gearbox ........................................................................................................................................38
8.3.1 Gear oil - grade ........................................................................................................................38
8.3.2 Gear oil - quantity ....................................................................................................................38
8.3.3 Gear oil change .......................................................................................................................39
8.4 Oils and lubricants ........................................................................................................................40
9Repair .............................................................................................................................................. 43
9.1 Conversion and spare parts ..........................................................................................................43
9.2 Functional unit ..............................................................................................................................44
9.2.1 Dismounting the functional unit from the housing unit ...............................................................44
9.2.2 Reinstalling the functional unit ..................................................................................................45
9.2.3 Mounting the functional unit on the mounting rack ....................................................................46
9.3 XRipper rotors...............................................................................................................................47
9.3.1 Releasing the XRipper rotors from the gearbox housing ...........................................................47
9.3.2 Dismounting XRipper rotors .....................................................................................................48
9.3.3 Installing the XRipper rotors .....................................................................................................49
9.4 Wear plates ..................................................................................................................................50
9.4.1 Dismounting wear plates ..........................................................................................................50
9.4.2 Reinstalling wear plates ...........................................................................................................51
9.4.3 Replacing the bearing unit .......................................................................................................52
9.4.4 Replacing the Cartridge mechanical seal .................................................................................53
10 Inspection and maintenance plan .................................................................................................. 55
10.1 Inspection schedule .................................................................................................................55
10.1.1 After 20 operating hours .........................................................................................................55
10.1.2 Every 3 months ......................................................................................................................55
10.1.3 Every 12 months ....................................................................................................................56
10.1.4 After prolonged shutdown periods...........................................................................................56
10.2 Maintenance plan ....................................................................................................................57
10.2.1 Every 12 months ....................................................................................................................57
10.2.2 Before prolonged shutdown periods ........................................................................................57
11 Troubleshooting .............................................................................................................................. 58
11.1 Troubleshooting .......................................................................................................................58
11.2 Help .........................................................................................................................................58
12 Putting out of operation and disposal............................................................................................ 59
13 Service plan ..................................................................................................................................... 60

Table of contents
WBV.XRP.003.EN XRC100QD SIK V6.0
5
Table of figures
Fig. 1: Overview drawing .............................................................................................................................. 9
Fig. 2: Name plate.......................................................................................................................................11
Fig. 3: Positions of the warning and safety labels ........................................................................................17
Fig. 4: Transport aid (example only) ............................................................................................................19
Fig. 5: Wall-mounted frame on the face side with guide rail .........................................................................22
Fig. 6: Wall-mounted frame on side with guide rail .......................................................................................23
Fig. 7: Wall-mounted frame on side without guide rail ..................................................................................23
Fig. 8: Lowering and pulling up on guide rail ................................................................................................24
Fig. 9: Lowering and pulling up without guide rail (side mounting) ................................................................25
Fig. 10: Moving the buffer fluid tank upwards...............................................................................................26
Fig. 11: View of XRipper rotors in the XRipper housing................................................................................27
Fig. 12: Flow direction .................................................................................................................................27
Fig. 13: Vent screw on the gearbox (removing the seal) ..............................................................................28
Fig. 14: Connection of two hydraulic motors operated in parallel ..................................................................30
Fig. 15: Seal chamber design with plug .......................................................................................................34
Fig. 16: Pressurisable buffer fluid tank .........................................................................................................35
Fig. 17: Draining and filling the seal chamber ..............................................................................................37
Fig. 18 Draining gear oil ..............................................................................................................................39
Fig. 19: Topping up gear oil .........................................................................................................................39
Fig. 20: Attaching the functional/housing unit...............................................................................................44
Fig. 21: Fastening the functional unit on the mounting rack..........................................................................46
Fig. 22: Fastening of XRipper rotors and gearbox housing...........................................................................47
Fig. 23: Disassembly of XRipper rotors using lifting arms ............................................................................48
Fig. 24: Fastening the cover-side wear plates ..............................................................................................50
Fig. 25: Fastening the wear plates at the gearbox side ................................................................................50
Fig. 26: Orientation of wear plates relative to XRipper rotors ......................................................................51
Fig. 27: Disassembly sequence for the bearing unit .....................................................................................52
Fig. 28: Cartridge mechanical seal with installation/disassembly tool ...........................................................53
Fig. 29: O-ring and support ring disassembly/assembly ...............................................................................54
Relevant documents
• Dimension sheet/drawing
• Spare parts list
• Characteristic curve
• Technical information on drive system
• Technical information on safety/monitoring devices
• EC declaration
Read and adhere to the information and instructions in the relevant documents.

User information
6
WBV.XRP.003.EN XRC100QD SIK V6.0
1 User information
1.1 Using the operating instructions
These instructions contain information concerning operating elements, handling, start-up and maintenance
and repair work, as well as the relevant specifications.
The operating instructions are a component of the machine.
IMPORTANT
READ CAREFULLY BEFORE USE
Read the operating instructions thoroughly. All of the points presented in these instructions must be
understood and observed by those persons responsible for the installation, operation, maintenance and
repair of the machine.
Vogelsang does not accept any liability for damage resulting from failure to comply with these operating
instructions.
KEEP FOR FUTURE REFERENCE
Please keep the manual ready at hand to ensure easy access to the necessary information at all times.
Additional copies of the manual are available upon request. 
1.2 Presentation convention
Presentation
Meaning
•
Listing
 
Sublisting
1. 
2.
Carry out these actions in the described sequence
 Fig. "Caption"
Reference to a figure for additional information
 Chapter "Chapter heading"
Reference to a chapter for additional information
 Table "Table caption"
Reference to a table for additional information
"Relevant document"
Reference to a document for additional information
 Technical support
Contact our technical support

User information
WBV.XRP.003.EN XRC100QD SIK V6.0
7
1.3 Explanation of symbols
The following symbols and signal words are used in this manual:
1 If personal protective equipment is needed to work with and on the machine, that is indicated
by the following symbols:
Indicates that protective gloves must be worn for subsequent tasks.
Indicates that protective goggles must be worn for subsequent tasks.
Indicates that safety shoes must be worn for subsequent tasks.
2 This symbol draws attention to the use of tools:
Tools, mounting devices and resources required for the following work tasks.
3 General notices and information about environmental protection are marked by these symbols:
NOTE
Refers to further information and useful notes.
ENVIRONMENTAL PROTECTION
Refers to measures to be observed to prevent damage to the environment.

User information
8
WBV.XRP.003.EN XRC100QD SIK V6.0
4 Safety notes are introduced by these symbols and words:
CAUTION
Refers to a dangerous situation in which failure to comply with the safety note could result in light injuries.
WARNING
Refers to a dangerous situation in which failure to comply with the safety note could result in death or serious
injuries.
DANGER
Refers to an (extremely) dangerous situation in which failure to comply with the safety note will result in
death or serious injuries.
RISK OF ELECTRIC SHOCK
Touching live parts leads to dangerous electrocution.
This can result in electric shock, burns or death.
ATTENTION
Refers to possible damage to machinery or property as a result of failure to comply with this note.
1.4 Machine versions described here
The "Installation" chapter contains important assembly instructions and warning and safety notes that the
operator must always comply with.
The following optional machine versions are described in the "Installation" chapter:
Machine version
Chapter reference
• With SIK (Sewer Integration Kit)
 Chapter "Installation"
• With the following drive options:
 Chapter "Drive"
 Electric drive
 Hydraulic drive
• With or without system control
 Chapter "System control"

User information
WBV.XRP.003.EN XRC100QD SIK V6.0
9
1.5 Overview drawing
1
Hoisting gear with cross beam
(provided by customer)
2
Drive (geared motor)
3
XRipper gearbox housing
4
Seal chamber
5
Cartridge mechanical seal, at
gearbox side
6
Wear plates, at gearbox side
7
XRipper rotor
8
Wear plates, cover side
9
Bearing unit
10
Housing unit
Fig. 1: Overview drawing

Specifications
10
WBV.XRP.003.EN XRC100QD SIK V6.0
2 Specifications
Series XRC100QD/size
320
480
640
800
960
Max. permissible pressure [bar]
2
Blade widths [mm]
5.5 / 7.9
Max. permissible torque [Nm]
500
Max. throughput* [m³/h]
140**
222**
310**
480**
690**
XRipper chamber length [mm]
320
480
640
800
960
Ambient temperature range [°C]
0 - 45
Weight*** [kg]
300***
320***
340***
360***
380***
* in optimal installation conditions
** The throughput is based on water as the medium
*** Inc. submersible motor
Dimensions
For the machine's dimensions: see "Dimension sheet"
Characteristic lines
For the machine's characteristic lines (curve charts), see "Characteristic line"

Specifications
WBV.XRP.003.EN XRC100QD SIK V6.0
11
2.1 Name plate
Fig. 2: Name plate
The name plate (1) contains the following details:
QR code
Product
Design (Series)
Serial number
Year of
manufacture
Weight
Part number
Address Vogelsang, GERMANY

EC declaration
12
WBV.XRP.003.EN XRC100QD SIK V6.0
3 EC declaration
(sample printout)
Declaration of installation
for an incomplete machine according to Machinery Directive 2006/42/EC; annex II B
Manufacturer: Vogelsang GmbH & Co. KG
Holthöge 10-14
49632 Essen/Oldb.
GERMANY
We declare that this delivery concerns the following machine which is not complete. The machine must
not be put into service until the machinery into which this incomplete machine is incorporated is in
conformity with the Machinery Directive 2006/42/EC.
Product: XRipper
Machine type: XRC, XRC+SIK, XRG
The following basic health and safety requirements according to Annex I of the Machinery Directive
(2006/42/EC) are applied and observed:
1.1.2; 1.1.3; 1.1.5; 1.5.4; 1.5.13; 1.6.1; 1.7.1.1; 1.7.3; 1.7.4
Applied harmonised standards:
DIN EN ISO 12100:2010
DIN EN ISO 14118:2018
DIN EN 349:1993+A1:2008
DIN EN ISO 13857:2008
The special technical documents according to annex VII B have been prepared and can be obtained if
necessary.
The person or entity authorised to compile the technical documentation is:
Vogelsang GmbH & Co. KG; Holthöge 10-14; 49632 Essen/Oldb., GERMANY
The manufacturer is obligated to electronically forward the relevant technical documentation for the partly
completed machine to national authorities upon justified request.
49632 Essen, 2018-05-24
Harald Vogelsang (Managing Director)

Safety
WBV.XRP.003.EN XRC100QD SIK V6.0
13
4 Safety
This section gives you an overview of important safety aspects needed to ensure optimum protection of
personnel and to ensure safe and trouble-free operation.
Failure to comply with the instructions and safety information specified in this manual may result in serious
hazards.
In the event of any abnormalities and/or signs relating to the safety of the product supplied by Vogelsang,
please contact us without delay via:
[e-mail]
4.1 Operator’s responsibilities
The machine is used commercially. The operator of the machine is therefore subject to the statutory
occupational safety regulations.
In addition to the safety information provided in this manual, the relevant safety, accident prevention and
environmental protection requirements for the area in which the machine is used must be complied with.
The following applies in particular:
• The operator shall ensure that all persons who handle the machine have read and understood this
manual. If necessary, the operator shall train personnel and inform them of possible hazards. To help
keep track of training, we recommend creating a training log.
• The operator shall clearly regulate and define responsibilities for transport, installation, start-up,
operation, maintenance, repair, cleaning, troubleshooting, shutdown and disposal.
• The operator must take appropriate safety measures as required by the nature of the media, such as
acidic or alkaline media, or high media temperatures > 60 °C.
The operator is responsible for ensuring that the machine is always in perfect technical condition.
The following therefore applies:
• The operator shall ensure that maintenance intervals described in this manual are complied with and
are documented in the service plan.
• The operator shall have all safety devices checked at regular intervals to ensure that they are fully
functioning and complete.

Safety
14
WBV.XRP.003.EN XRC100QD SIK V6.0
4.2 Personnel qualification
Instructed person
Has been instructed by the operator to perform the tasks for which the instructed person is responsible and
has been informed of possible hazards in the event of improper behaviour.
Qualified technical personnel
Are able, due to their specialist training, skills, experience and knowledge of the relevant regulations, to
perform the work for which they are responsible, and are able to identify and avoid possible hazards
independently.
Qualified electrician
Is able, due to his or her specialist training, skills, experience and knowledge of the relevant standards and
regulations, to perform work on electrical systems, and is able to identify and avoid possible hazards
independently.
Handling the machine improperly can result in serious injuries and property damage.
For this reason, all activities must be performed by qualified personnel only.
Only persons who can be expected to perform their work reliably shall be permitted as personnel. Persons
whose ability to respond is impaired, for example due to drugs, alcohol or medication, are not approved.
4.3 Fields of activity
• The activities described in this manual may be performed by instructed persons unless explicit
mention is made of a special qualification that is necessary.
• If activities may only be performed by qualified technical personnel, this fact will be clearly stated in
this manual. Safety devices may only be connected and checked by qualified technical personnel.
• Electrical work and work on the electrical system may only be performed by qualified electricians.
Vogelsang must always be consulted prior to any system-specific activities that are not described in this
manual. 
Training in the activities described in this manual may be provided by Vogelsang on request. 

Safety
WBV.XRP.003.EN XRC100QD SIK V6.0
15
4.4 Intended use
The Vogelsang XRipper (referred to hereinafter as the “machine”) is a twin-shaft cutter.
The counter-rotating XRipper rotors are positioned on the two shafts.
The XRipper + SIK (Sewer Integration Kit)
• is designed for installation in sewers, to shred the disruptive matter contained in the wastewater, such
as textiles, wood or plastic waste, and to break up clumps and entangled material.
• is designed for submersed applications.
The XRipper is configured for the medium to be shredded as specified by the customer.
For a different medium, or if the XRipper was not configured for a specific application, test runs will be
carried out with the medium in use. In some cases the XRipper must be reconfigured.
In addition to these specifications, the specifications in  Chap. "Specifications" must be complied with as
well.
The machine is NOT intended for use as follows:
Use in potentially explosive atmospheres
Any other use is contrary to the intended purpose. Vogelsang is not liable for any damage resulting
from incorrect use.
4.5 General safety notes
WARNING
Risk of injury due to sharp-edged rotors!
If the rotors are freely accessible or fall off, the sharp blades can result in cuts.
• Personnel must wear suitable protective clothing.
• Note and comply with the transport instructions.
WARNING
Risk of injury due to rotating, sharp-edged rotors!
Accidental contact with the rotating rotors when the machine is running can result in cutting injuries,
amputation or the person being dragged in.
• The customer must take action to ensure that the rotors are not accessible during operation. Safety
distances according to DIN EN ISO 13857 must be adhered to in order to rule out the possibility of
anyone entering the danger area.
• Before maintenance and repair work, switch the machine OFF and secure it against being turned on
again.
• In the case of an XRipper with control, the control must fulfil performance level “c” or higher in
accordance with EN ISO 13849, in order to prevent unintentional starting.

Safety
16
WBV.XRP.003.EN XRC100QD SIK V6.0
WARNING
Skin and eye irritation caused by contact with hazardous working materials or media!
All work on the machine can lead to contact with working materials or media.
• Personnel must wear suitable protective clothing.
• The operator must inform his or her staff about any potentially hazardous substances in working
materials or media.
ATTENTION
Stones or other hard objects in the medium result in heavy wear of or even damage to the XRipper.
ATTENTION
Risk of frost!
To protect the XRipper against damage caused by frozen medium, drain the XRipper when there is a risk of
frost.
ATTENTION
Pull up the XRipper during temporary shutdowns.
To prevent solid matter from blocking up the XRipper inlet and causing problems when starting it up again,
the XRipper must be pulled up for temporary shutdown.
4.6 Main switch, maintenance and repair switch
All-pole disconnection must be provided for the main switch and maintenance and repair switch.
4.6.1 EMERGENCY STOP shutdown (main switch)
For shutdown in the event of an emergency, an emergency stop must be present and freely accessible at all
times.
4.6.2 Maintenance and repair switch
To safely exclude the possibility of unexpected machine start-up, a maintenance and repair switch must be
installed in the immediate vicinity of the electric drive so that the electrical power can be safely isolated for
maintenance purposes.
The maintenance and repair switch must be secured in its OFF position to prevent it being switched back on
again, using a padlock for example.
WARNING
Qualified technical personnel must connect and check the safety devices on a regular basis for proper
function, especially after performing maintenance and repair work and before start-up.

Safety
WBV.XRP.003.EN XRC100QD SIK V6.0
17
4.7 Warning and safety stickers on the machine
Warning and safety stickers on the machine
• provide important information for the safe operation of the machine. Observing the stickers is for the
safety of persons who work with and on the machine.
• must remain legible, remove any contamination, if required.
• may not be removed and must be replaced immediately if damaged or lost.
Fig. 3: Positions of the warning and safety labels

Safety
18
WBV.XRP.003.EN XRC100QD SIK V6.0
(example only, the position of the stickers can vary depending on the size)
VAU.133
Before machine start-up, operating instructions must be
read!
VAU.116
Caution: risk of hand injuries!
VAU.138
Buffer fluid tank
VAU.012
Before carrying out maintenance and repair work, pull
the maintenance and repair switch.
VAU0107
Direction arrow (flow direction)
VAU0091
Warning: risk of injury due to being dragged in by
rotating XRipper rotors! Keep a safe distance!

Transport, storage
WBV.XRP.003.EN XRC100QD SIK V6.0
19
5 Transport, storage
5.1 Transport
Fig. 4: Transport aid (example only)
WARNING
Risk of crushing or concussion due to falling machine!
The machine may start to sway or topple when it is transported, loaded or set down. To ensure safe
transport, note the following:
• Loading and transporting may only be carried out by qualified technical personnel. In other words: The
operator of a crane or forklift must be able to show an appropriate authorisation.
• Cranes, hoisting gear and forklifts must be designed for the weight of the transport units. Weights: 
Chap. “Specifications”.
• Standing under raised loads is prohibited. Have all persons leave the danger area.
• When transporting the machine on vehicles, it must be secured against sliding and tipping.
• Permissible transport options for the machine:
 Bolted to a Euro-pallet
 Suspended with suitable hosting gear. Securely fasten the lifting tackle for hoisting gear.

Transport, storage
20
WBV.XRP.003.EN XRC100QD SIK V6.0
WARNING
Cutting injuries from the XRipper rotor blades during transport when lowering and pulling up (SIK)
and when changing the XRipper rotors!
When moving and positioning the machine manually, the XRipper rotors are freely accessible, so the sharp
blades of the XRipper rotors could cause cutting injuries.
Personnel must wear suitable protective clothing.
5.2 Storage
Long-term storage
of complete XRipper, individual O-rings and seal components
If not stored and handled properly, the physical characteristics of products made of rubber may change.
Possible consequences include excessive hardening, softening, lasting deformation, peeling, cracking or
other surface damage.
Long-term storage is possible under the following conditions (longer than 6 months to a maximum of 5
years):
• The storage area should be dry (relative humidity under 65%) and the temperature should be between
5 °C and 30 °C.
• The XRipper chamber can be sealed with a preservative that is suitable for the sealing material.
• The products should be protected against light, especially direct sunlight and strong artificial light with
a high proportion of ultraviolet.
After a storage period of five years or more and before start-up we recommend:
• Checking and renewing (if necessary) all wetted gaskets and rotary lobes
• Changing the gear oil