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Inspection and maintenance plan

WBV.XRP.003.EN XRC100QD SIK V6.0

10 Inspection and maintenance plan

Please note

•

Perform the specified inspection and maintenance work according to schedule.

•

Switch off the machine before commencing any inspection or maintenance work.

•

Observe the warning and safety notes;



Chap.

"Maintenance" and



Chap.

"Repairs".

•

Use only original spare parts or parts approved by Vogelsang.

•

Install spare parts correctly.

•

Once the work has been completed, reinstall and check any removed safety devices.

•

In order to avoid endangering any warranty claims, document all scheduled repair work in the service

plan.

10.1 Inspection schedule

10.1.1 After 20 operating hours

Part

Inspection

Machine mounting



Check that the screw connections fastening the machine are

tight.



Tighten any loose screw connections.

Part

Inspection

Machine



Check the machine for damage, dirt deposits and assembly

errors (visual inspection).



Restore the machine to its specified condition.



Check the machine for running noise and vibrations.



If you notice any unusual running noises or vibrations,

implement the appropriate measures



Chap.

"Help with

problems using the machine".



Check the machine for unusual levels of power consumption.



If you notice any abnormalities with regard to power

consumption, implement the appropriate measures



Chap.

"Help with problems using the machine".

10.1.2 Every 3 months

Part

Inspection

Machine



Check the machine for damage, dirt deposits and assembly

errors (visual inspection).



Restore the machine to its specified condition.



Check the machine for running noise and vibrations.



If you notice any unusual running noises or vibrations,

implement the appropriate measures



Chap.

"Help with

problems using the machine".



Check the machine for unusual levels of power consumption.



If you notice any abnormalities with regard to power

consumption, implement the appropriate measures



Chap.

"Help with problems using the machine".



Check the cutting performance (size-reduction ratio) of the

machine.



If the size-reduction ratio does not match the requirements,

implement the appropriate measures



Chap.

"Help with

problems using the machine".

Содержание XRipper XRC100QD/320

Страница 1: ...12 WBV XRP 003 EN XRC100QD SIK V6 0 1 61 2020 05 12 WBV X RP 003 E N XR C10 0Q D SI K WBV XRP 003 EN XRC100QD SIK V6 0 Operat ingI nstructi ons XRipper XRC100QD SIK FOR PARTS AND SERVICE CONTACT 717 761 7884 800 733 7884 sales envirep com www envirep com ...

Страница 2: ...he 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 tr...

Страница 3: ...ation 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 5 Transport storage 19 5 1 Transport 19 5 2 Storage 20 6 Assembly 21 6 1 Installing the SIK Sewer Integration Kit 21 6 1 1 Wall mounte...

Страница 4: ... 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 Inspec...

Страница 5: ...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 sid...

Страница 6: ...pair 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 Carr...

Страница 7: ... 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...

Страница 8: ... 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 wi...

Страница 9: ...isting 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 ...

Страница 10: ...roughput m 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 li...

Страница 11: ...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 ...

Страница 12: ...ing 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 ...

Страница 13: ... 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 ...

Страница 14: ...lt 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 perfo...

Страница 15: ...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 instru...

Страница 16: ...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 saf...

Страница 17: ...ne 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 ...

Страница 18: ...art 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 ...

Страница 19: ...d 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 a...

Страница 20: ...s 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 wi...

Страница 21: ...lling the SIK Sewer Integration Kit The XRipper wall mounted frame can be attached to the channel on the face side or on the side as required With a wall mounted frame on the face side the XRipper can be lowered into the channel via guide rails and pulled up again A wall mounted frame on the side may be fitted with or without guide rails depending on the depth of the channel Always observe the fol...

Страница 22: ...ntrally to the wall opening The dimensions stated must not be exceeded Dimension H XRipper chamber length 320 mm 480 mm 640 mm 800 mm 960 mm Chap Technical data 2 Insert the guide rail 2 into the wall mounted frame 1 as far as the stop and fasten with anchor rods 3 Join multiple guide rails together using a connector 4 Connector Wall opening Fig 5 Wall mounted frame on the face side with guide rai...

Страница 23: ... 2 as far as possible into the wall mounted frame 1 and fasten with anchor rods 3 Join multiple guide rails together using a connector 5 Fig 6 Wall mounted frame on side with guide rail 6 1 3 Wall mounted frame on side without guide rail 1 Install the wall mounted frame 1 on a flat level and uncracked concrete surface and fasten with anchor rods 3 Fig 7 Wall mounted frame on side without guide rai...

Страница 24: ...t see Weights Chap Specifications NOTICE If the XRipper is equipped with a pressurisable buffer fluid tank via a hose connection make sure that the hoses can move unhindered when lowering and pulling up The figures that follow are examples and depict the XRipper without a hose connection 6 2 1 With guide rail with mounting on the face side and on the side 1 To lower carefully insert the slide rail...

Страница 25: ...arefully insert the slide rail 6 of the XRipper on both sides into the wall mounted frame 1 2 Lower the XRipper slowly and carefully Before pulling up the XRipper make sure that the slide rails can move freely and are not blocked by foreign matter Fig 9 Lowering and pulling up without guide rail side mounting ...

Страница 26: ...uid tank 1 is shipped separately from the XRipper Before lowering and starting up the XRipper move the tank upwards using the hose extension 2 supplied and mount it in a readily visible location The hose extension must be installed so it rises at all times Fig Moving the buffer fluid tank upwards Fig 10 Moving the buffer fluid tank upwards ...

Страница 27: ...directional The flow direction is set by the installation of the XRipper rotors 1 and the ribs on the housing segments 2 The ribs must be located on the inlet side XRipper housing segments with ribs View of inlet side Fig 11 View of XRipper rotors in the XRipper housing Fig 12 Flow direction ...

Страница 28: ...6 doc 14 147 2 In addition also read and note the following Motor operating instructions Before connecting the geared motor electric motor with gearbox Check that the power supply is correct for the motor Check that the power feed and fuse protection are adequately dimensioned to allow for multiple rotation direction changes and peak loads within a short period of time Be sure to follow the cable ...

Страница 29: ...ssure and the permissible delivery rate Connect the overflow oil line in accordance with the manufacturer s instructions Replace hydraulic hose lines that show signs of damage or ageing Only use genuine Vogelsang hydraulic hose lines The date of manufacture of the hydraulic hose line is displayed on the pressing component of the connector The period of usage for the hydraulic hose line should not ...

Страница 30: ...ipper The control must at least fulfil PL c in accordance with EN ISO 13849 The load circuit provided for the XRipper must be suitable for heavy starting A soft starter is sufficient for soft starting A star delta connection is not suitable for the XRipper Mains contactors for direct starting must be designed for utilisation category AC 4 The soft starter must be suitable for high starting current...

Страница 31: ...efore switching on the machine for functional tests make sure that there are no persons in the danger area Functional test procedure 1 Switch the main switch to OFF 2 Check the XRipper chamber for foreign matter and remove it before the functional test 3 Switch the main switch to ON and carry out the test for example checking the direction of rotation 7 2 Safety distance WARNING Risk of injury due...

Страница 32: ...be set for the soft starter if present Is the soft starter if present dimensioned and configured correctly Units should be suitable for heavy starting Is the motor connected correctly to the hydraulic lines if applicable documents provided by the motor manufacturer Buffer chamber XRipper gearbox Are the optional buffer chamber assemblies correctly installed Are they correctly adjusted Is the buffe...

Страница 33: ...mber are loosened or the buffer fluid tank cover is opened working materials may spray out under high pressure Personnel must wear suitable protective clothing Before maintenance and repair work release the seal chamber pressure To protect against fluids spraying out open the seal chamber and the gearbox carefully and slowly Where appropriate cover the valves or screws to be removed with a cloth o...

Страница 34: ... buffer fluid leave an air buffer 2 above it about 1 cm distance between the oil level and the bearing seal housing The air buffer prevents the seal chamber fluid from building up an unacceptably high pressure due to thermal expansion Fig 15 Seal chamber design with plug ...

Страница 35: ... upper coupling of the upper housing while holding the union nut securely so that the lower coupling does not come undone 3 Top up the buffer fluid in the tank The tank must be up to one quarter full 4 Close the tank and use a manual air pump or a compressed air supply outlet to set the required tank pressure to 0 5 bar Replacing the XRipper rotors and Cartridge mechanical seal replacement Relieve...

Страница 36: ...Ripper operation 8 1 3 Buffer fluid type To ensure optimum functioning of the mechanical seal we recommend using the oil grades listed in Chap Oils Please check your order confirmation to determine whether the seal chamber on your machine is filled with an oil grade other than that specified in this chapter Use only the oil specified on your order confirmation ATTENTION To prevent premature wear o...

Страница 37: ...ulling up the XRipper 1 Pull up the XRipper 2 Remove the top plug 3 Undo the lower screw plug 2 and drain the buffer fluid Fig Draining and filling the seal chamber 4 Screw the lower screw plug back in tightening torque 60 Nm 5 Fill the seal chamber Chap Buffer fluid grade and Buffer fluid quantity 6 Reinstall the screw plug 7 Lower the XRipper Fig 17 Draining and filling the seal chamber ...

Страница 38: ...e extension must be brought in along with the buffer fluid tank 3 Undo the lower screw plug 2 and drain the buffer fluid Fig Draining the seal chamber 4 Screw the lower screw plug back in tightening torque 60 Nm 5 Fill the seal chamber Chap Buffer fluid grade and Buffer fluid quantity 6 Reinstall the hose connection 7 Lower the XRipper and move the buffer fluid tank upwards 8 Top up the buffer flu...

Страница 39: ...or maintenance the hose extension may need to be brought in along with the buffer fluid tank Fig Draining gear oil 2 Loosen the top screw plug 1 for venting 3 Loosen the lower screw plug 2 drain the gear oil and collect it 4 Screw the lower screw plug back in tightening torque 60 Nm Fig 18 Draining gear oil Fig Topping up gear oil 5 Fill the gearbox 1 Chap Gear oil grade and Gear oil quantity Adhe...

Страница 40: ...IN 51519 Kinematic viscosity at 40 C at 100 C 220 mm s 26 7 mm s DIN EN ISO 3104 Flash point 260 C DIN ISO 2592 Pour point 42 C DIN ISO 3016 Water hazard class Slightly hazardous to waters when using BSS0021 oil for the XRipper gearbox the maintenance interval for inspection and gear oil change may be doubled Chapter Maintenance plan Part number BSS 010 Description Medical white oil water white no...

Страница 41: ...ic viscosity at 40 C at 100 C 46 mm s 6 9 mm s DIN EN ISO 3104 Flash point 210 C DIN ISO 2592 Pour point 24 C DIN ISO 3016 Damage loading step 12 Water hazard class Slightly hazardous to waters Part number BSS 016 Description Biodegradable environmentally friendly multigrade hydraulic oil based on rape seed oil as per ISO 15308 type HETG Trade name Fuchs Hydraulic oil 40 N Characteristics Test acc...

Страница 42: ...sed on selected polyglycols PAG Trade name Fuchs Renolin PG 46 Characteristics Test acc to ISO VG 46 DIN 51519 Viscosity index 203 DIN ISO 2909 Kinematic viscosity at 40 C 46 mm s DIN 51562 Flash point 240 C DIN ISO 2592 Damage loading step 12 Water hazard class Slightly hazardous to waters 5 Lubricant for the bearing with mechanical seal Part number BSS 002 Description Lithium soap grease with a ...

Страница 43: ...tive clothing Before maintenance and repair work release the seal chamber pressure To protect against fluids spraying out open the seal chamber and the gearbox carefully and slowly Where appropriate cover the valves or screws to be removed with a cloth or similar item ATTENTION Before installing stainless steel bolts and stainless steel nuts Clean threads and contact surfaces Apply anti seize past...

Страница 44: ... seals need to be replaced depressurise the seal chamber if it is pressurised 2 Undo the hexagon nut 2 and the hexagon socket set screw 3 3 Undo the hexagon nut 4 4 Pull the functional unit out of the housing unit 6 using appropriate hoisting gear with a cross beam 1 and secure the O ring 5 to prevent it from falling out Fig 20 Attaching the functional housing unit ...

Страница 45: ...crushing hands or fingers due to rapid lowering of the functional unit Lower the functional unit slowly using the hoisting gear carefully guiding the XRipper rotors into the housing unit 3 Reinstall the hexagon nuts 4 To prevent tilting of the XRipper housing unit install the hexagon nuts in a crosswise pattern and tighten them manually to 45 Nm Make sure the O ring is seated correctly 4 Tighten t...

Страница 46: ...k 3 Vogelsang part no IBA2555 1 Leave the functional unit attached to the hoisting gear 2 Undo the cylinder head bolts 1 and remove them from the bearing unit 2 3 Affix the mounting rack to the machine s support surface The support surface must be flat 4 Mount the functional unit on the mounting rack and tighten the cylinder head bolts finger tight Fig 21 Fastening the functional unit on the mount...

Страница 47: ...ipper rotors are dismounted the machine s centre of gravity shifts After undoing the connection of the threaded rods and XRipper rotors and before raising the gearbox unit slightly undo the bolts 8 and move the supports 9 as far as they go in the direction of the motor Before raising the XRipper with the new rotors return the supports to their original position 2 Re hang the hoisting gear in the e...

Страница 48: ... lifting device into the XRipper rotors and hook the lifting arms securely into the groove in the XRipper rotor 7 Tighten the hexagon head bolts 11 8 Lift the XRipper rotors 5 and remove O rings 4 at cover side 9 Remove tensioning elements 6 and the spring washer units 7 and reuse them for the new XRipper rotors Notice XRipper rotors The XRipper rotors can each be rotated through 180 and put in ea...

Страница 49: ...d bolts 6 Reinstall the clamping elements and spring washer units on the cover side 7 Grease the O rings on the cover side and fix them in place in the XRipper rotors 8 Using the lifting device place the XRipper rotors on the shaft ends in pairs Make sure the XRipper rotors are lying flush and are correctly aligned on the wear plates Chap Assembling the wear plates 9 Reinstall the tensioning eleme...

Страница 50: ... Cover side Undo the nuts from the bolts 1 and dismount the wear plates 2 and 3 Fig 24 Fastening the cover side wear plates Gearbox side Dismount the O ring 1 undo the bolts with microencapsulation 2 and dismount the wear plates 3 and 4 Fig 25 Fastening the wear plates at the gearbox side ...

Страница 51: ...tes in the reverse order of disassembly 2 Arrange the wear plates so their cutting direction 1 is the opposite of the cutting direction of the XRipper rotor blades 2 3 Tighten the wear plate bolts and screws to a tightening torque of 20 Nm Fig 26 Orientation of wear plates relative to XRipper rotors ...

Страница 52: ...ts 1 and remove wear plates 2 and 3 2 Undo the cylinder head bolts 5 and remove the bearing unit 4 from the mounting rack 3 Mount the new bearing unit on the mounting rack using the cylinder head bolts 5 4 Re install the wear plates 2 and 3 using the hexagon head bolts 1 Fig 27 Disassembly sequence for the bearing unit ...

Страница 53: ...s 1 from the Cartridge mechanical seal 8 Attach the installation disassembly tool A and screw the cylinder head bolts 2 into the extracting boreholes of the Cartridge mechanical seal 9 Pull out the Cartridge mechanical seal evenly using the three hexagon head bolts 3 10 Carefully remove the burrs on the keyway in the shaft and clean the Cartridge mechanical seal seat in the XRipper gearbox housing...

Страница 54: ...r and the Cartridge mechanical seal 15 Chap Reinstalling the wear plates 16 Put the gearbox unit back in place and restore the connection of the threaded rods and XRipper rotors Chap Installing the XRipper rotors 17 Dismount the functional unit from the mounting rack Chap Mounting the functional unit on the mounting rack 18 Top up the gear oil 19 Fill the seal chamber 20 Chap Reinstalling the func...

Страница 55: ...1 Check the machine for running noise and vibrations 2 If you notice any unusual running noises or vibrations implement the appropriate measures Chap Help with problems using the machine 1 Check the machine for unusual levels of power consumption 2 If you notice any abnormalities with regard to power consumption implement the appropriate measures Chap Help with problems using the machine 10 1 2 Ev...

Страница 56: ... worn housing parts Part Inspection Wear parts 1 Check the wear parts rotors and wear plates for wear visual inspection 2 Rotate any worn rotors 180 or replace them 3 Replace any worn wear plates 10 1 4 After prolonged shutdown periods Part Inspection Buffer fluid tank 1 Check the level in the tank 2 Top up the buffer fluid if necessary 1 Check the tank pressure 2 Restore the rated pressure in the...

Страница 57: ...amber Part Maintenance Gearbox 1 Change the gear oil 10 2 2 Before prolonged shutdown periods Part Maintenance Machine 1 Clean the machine thoroughly removing any deposits and residual water 2 Protect the machine from frost 3 Protect wetted parts from corrosion Environmentally friendly disposal Dispose of all working materials and other materials in an environmentally friendly manner ...

Страница 58: ...on Check the electrical equipment Drive C Motor speed too low during variable frequency drive operation Install external fan increase motor speed System control Frequency converter operation D Oil level in the XRipper gearbox is not OK Chap Gearbox Maintenance E Operational fluctuations in the seal chamber Chap Seal chamber Maintenance F Cartridge mechanical seal damage Replacing the Cartridge mec...

Страница 59: ...rs worn Check the rotors for wear and rotate them 180 or replace them 12 Putting out of operation and disposal 1 Disconnect the XRipper from the power supply Observe notices and safety notes Chap Installation Chap Drive 2 Drain off the working materials Drain the gear oil from the XRipper gearbox Observe notices and safety notes Chap Gear oil inspection and change Drain the buffer fluid from the b...

Страница 60: ... 0 13 Service plan In order to avoid endangering any warranty claims document all scheduled repair work in the service plan Serial number _________________________ Activity as per maintenance plan Operating hour meter Throughput rate Date Signature ...

Страница 61: ...ogelsang 7966 State Route 44 Ravenna Ohio 44266 330 296 3820 Main Number 330 296 4113 Fax sales vogelsangusa com e mail www vogelsangusa com website FOR PARTS AND SERVICE CONTACT 717 761 7884 800 733 7884 sales envirep com www envirep com ...

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