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2020 -05 -12
*WBV .X RP. 003 .E N XR C10 0Q D SI K*
WBV.XRP.003.EN XRC100QD SIK V6.0
Oper at in g I nstr u cti on s
XRipper ®
XRC100QD + SIK
Operating Instructions
XRipper®
XRC100QD + SIK
2020-05-12
FOR PARTS AND SERVICE, CONTACT
WBV.XRP.003.EN XRC100QD SIK V6.0
(717) 761-7884
(800) 733-7884
sales@envirep.com
www.envirep.com
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Summary of Contents for Vogelsang XRipper XRC100QD/320
- Page 1 2020 -05 -12 *WBV .X RP. 003 .E N XR C10 0Q D SI K* WBV.XRP.003.EN XRC100QD SIK V6.0 Oper at in g I nstr u cti on s XRipper ® XRC100QD + SIK Operating Instructions XRipper® XRC100QD + SIK FOR PARTS AND SERVICE, CONTACT (717) 761-7884 (800) 733-7884...
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Page 2: Issuer
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 ®... -
Page 3: Table Of Contents
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 ............................ - Page 4 T able of contents 8.1.2 Pressurisable buffer fluid tank (optional) ...................35 8.1.3 Buffer fluid – type ........................36 8.1.4 Buffer fluid – amount ........................36 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 Gearbox ............................38 8.3.1 Gear oil - grade ........................38...
- Page 5 T able of contents 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.
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Page 6: User Information
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. -
Page 7: Explanation Of Symbols
User i nformatio n Explanation of symbols The following symbols and signal words are used in this manual: 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. -
Page 8: Machine Versions Described Here
User i nformatio n 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. -
Page 9: Overview Drawing
User i nformatio n Overview drawing Hoisting gear with cross beam (provided by customer) Drive (geared motor) XRipper gearbox housing Seal chamber Cartridge mechanical seal, at gearbox side Wear plates, at gearbox side XRipper rotor Wear plates, cover side Bearing unit Housing unit Fig. -
Page 10: Specifications
Specifications Specifications Series XRC100QD/size Max. permissible pressure [bar] Blade widths [mm] 5.5 / 7.9 Max. permissible torque [Nm] Max. throughput* [m³/h] 140** 222** 310** 480** 690** XRipper chamber length [mm] Ambient temperature range [°C] 0 - 45 Weight*** [kg] 300*** 320*** 340*** 360***... -
Page 11: Name Plate
Specifications Name plate Fig. 2: Name plate The name plate (1) contains the following details: QR code Product Design (Series) Year of Serial number manufacture Weight Part number Address Vogelsang, GERMANY WBV.XRP.003.EN XRC100QD SIK V6.0... -
Page 12: Ec Declaration
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. -
Page 13: Safety
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: produktsicherheit@vogelsang.info... -
Page 14: Personnel Qualification
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. ... -
Page 15: Intended Use
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. 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. -
Page 16: Main Switch, Maintenance And Repair Switch
Safety 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. -
Page 17: Warning And Safety Stickers On The Machine
Safety 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. •... - Page 18 Safety (example only, the position of the stickers can vary depending on the size) Before machine start-up, operating instructions must be VAU.133 read! VAU.116 Caution: risk of hand injuries! VAU.138 Buffer fluid tank Before carrying out maintenance and repair work, pull VAU.012 the maintenance and repair switch.
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Page 19: Transport, Storage
T ransport, storage Transport, storage 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: •... -
Page 20: Storage
T ransport, storage 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. -
Page 21: Assembly
Asse mbl y Assembly 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,... -
Page 22: Wall-Mounted Frame On The Face Side With Guide Rail
Asse mbl y 6.1.1 Wall-mounted frame on the face side with guide rail Install the wall-mounted frame (1) on a flat, level and uncracked concrete surface and align it centrally 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), ... -
Page 23: Wall-Mounted Frame On Side With Guide Rail
Asse mbl y 6.1.2 Wall-mounted frame on side with guide rail Install the wall-mounted frame (1) on a flat, level and uncracked concrete surface. Insert the guide rail (2) as far as possible into the wall-mounted frame (1) and fasten with anchor rods (3). -
Page 24: Lowering And Pulling Up The Xripper
Asse mbl y Lowering and pulling up the XRipper WARNING Risk of crushing or concussion due to falling machine! The XRipper may start to sway or topple when it is lifted or set down. For safe lowering and pulling up of the XRipper, observe the following: •... -
Page 25: Without Guide Rail With Mounting On The Side
Asse mbl y 6.2.2 Without guide rail with mounting on the side To lower, carefully insert the slide rail (6) of the XRipper on both sides into the wall-mounted frame (1). 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. -
Page 26: Moving The Buffer Fluid Tank Upwards (Optional)
Asse mbl y Moving the buffer fluid tank upwards (optional) Chap. "Seal chamber" The pressurisable buffer fluid 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. -
Page 27: Flow Direction
Asse mbl y Flow direction The XRipper is principally 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. -
Page 28: Drive
Asse mbl y Drive The technical specifications for the drive system to be installed are determined by the machine’s specifications Chap. "Specifications". In addition, also read and observe the following: "Technical information for the drive system to be installed" "System requirements - Electrical drive technology"... -
Page 29: Hydraulic Drive
• 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. -
Page 30: System Control
Asse mbl y Connection The following diagram shows the connection of two hydraulic motors operated in parallel in relation to the flow direction. Fig. 14: Connection of two hydraulic motors operated in parallel System control We recommend our control that is specially designed for use with the XRipper in order to provide trouble-free operation and maximum performance and service life of the XRipper. -
Page 31: Start-Up
Start-up Start-up Personnel for start-up and operation We recommend starting up the machine in the presence of persons who are responsible for further operation of the machine. Functional test WARNING Risk of injury due to sharp-edged, rotating XRipper rotors! Accidentally inserting parts of the body into the XRipper chamber when the machine is running can result in cuts, amputation or the person being dragged in, due to the sharp-edged, rotating XRipper rotors. - Page 32 Start-up Checklist before start-up Safety Have you taken action to ensure that the XRipper rotors are not accessible during operation? Are the main switch and maintenance and repair switch easy to reach? Installation Are the wall bracket and extension rails properly installed? Drive ...
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Page 33: Maintenance
Mai ntena nce Maintenance 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. Before maintenance and repair work, secure the maintenance and repair switch against being turned on again, for example by means of a padlock. -
Page 34: Fig. 15: Seal Chamber Design With Plug
Mai ntena nce Air buffer When adding 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. -
Page 35: Pressurisable Buffer Fluid Tank (Optional)
Mai ntena nce 8.1.2 Pressurisable buffer fluid tank (optional) The pressurisable buffer fluid tank (hereinafter referred to as "the tank") with manual air pump provides a constant, defined seal chamber pressure (seal chamber pressure = tank pressure). The tank ensures that the seal chamber is monitored reliably. Topping up the buffer fluid ... -
Page 36: Buffer Fluid - Type
Mai ntena nce Trouble indication Possible signs of malfunctions in the sealing system after the running-in period: • Severe contamination of the buffer fluid in the tank • Buffer fluid escaping (tank is empty) • Increase in buffer fluid level (tank is full) Buffer fluid characteristics •... -
Page 37: Replacing The Buffer Fluid
Mai ntena nce Replacing the buffer fluid 8.2.1 Draining and filling the seal chamber (plug) Before draining, read and follow Chapter 8: Chap. "Lowering and pulling up the XRipper" 1. Pull up the XRipper. 2. Remove the top plug. 3.... -
Page 38: Draining And Filling The Seal Chamber (Buffer Fluid Tank)
Mai ntena nce 8.2.2 Draining and filling the seal chamber (buffer fluid tank) Before draining, read and follow this chapter: Chap. "Moving the buffer fluid tank upwards" Chap. "Lowering and pulling up the XRipper" 1. Use the buffer fluid tank to release the pressure from the seal chamber. 2.... -
Page 39: Gear Oil Change
Mai ntena nce 8.3.3 Gear oil change Before a gear oil change, read and follow these chapters: Chap. "Lowering and pulling up the XRipper" 1. Pull up the XRipper. For optional seal chamber designs with a pressurisable buffer fluid tank, observe the following notice: If the XRipper needs to be moved, e.g. -
Page 40: Oils And Lubricants
Mai ntena nce Oils and lubricants 1 Standard Vogelsang oil for XRipper gearbox and seal chamber BSS.006 Part number Description EP (Extreme Pressure) gear oil Trade name (Fuchs) Titan Gear MP 90 Characteristics Test acc. to SAE class 90 (85W-90) - Page 41 Mai ntena nce ATTENTION If a mechanical seal ring made of Duronit is used in the sealing system, the damage loading step for the seal chamber oil must be 12. 3 Alternative oils for the seal chamber BSS.014 Part number Description Mineral oil based hydraulic and lubricating oil Trade name (Fuchs)
- Page 42 Mai ntena nce 4 Oils for the electronically monitored seal chamber BSS.021 Part number Description Fully synthetic EP industrial gear oil based on selected polyglycols (PAG) Trade name (Fuchs) Renolin PG 100 Characteristics Test acc. to ISO VG DIN 51519 Kinematic viscosity DIN EN ISO 3104 at 40 °C...
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Page 43: Repair
Conversion and spare parts Modifications or changes to the machine are only permissible after consultation with Vogelsang. Only accessory parts approved by Vogelsang or genuine spare parts may be used. The use of other parts invalidates the guarantee for any resulting damage. -
Page 44: Functional Unit
Repair Functional unit 9.2.1 Dismounting the functional unit from the housing unit 1. If XRipper rotors or Cartridge mechanical 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.... -
Page 45: Reinstalling The Functional Unit
Repair 9.2.2 Reinstalling the functional unit Fig. "Attaching the functional/housing unit" 1. Thoroughly clean the contact surfaces between the functional unit and the housing unit (6). 2. Grease the O-ring (5) and press it onto the contact surface. Make sure that the O-ring adheres. WARNING Risk of 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... -
Page 46: Mounting The Functional Unit On The Mounting Rack
Mounting the functional unit on the mounting rack In order to replace the XRipper rotors or the seals, the functional unit must be mounted on the mounting rack (3) (Vogelsang part no. IBA2555). 1. Leave the functional unit attached to the hoisting gear. -
Page 47: Xripper Rotors
Repair XRipper rotors 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. 9.3.1 Releasing the XRipper rotors from the gearbox housing 1.... -
Page 48: Dismounting Xripper Rotors
Repair 9.3.2 Dismounting XRipper rotors Dismount the XRipper rotors using the lifting device (10) (Vogelsang part no. IBA2556). 5. Slightly loosen the hexagon head bolts (11) in the lifting device so that the lifting arms can move. 6. Insert the lifting device into the XRipper rotors and hook the lifting arms securely into the groove in the XRipper rotor. -
Page 49: Installing The Xripper Rotors
Repair 9.3.3 Installing the XRipper rotors Fig. Fastening of XRipper rotors and gearbox housing Fig. Disassembly of XRipper rotors using lifting arms 1. Thoroughly clean the contact surfaces of the XRipper rotors and bearing units. 2. Lightly grease the ends of the shafts. 3.... -
Page 50: Wear Plates
Repair Wear plates 9.4.1 Dismounting wear plates 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). -
Page 51: Reinstalling Wear Plates
Repair 9.4.2 Reinstalling wear plates 1. Reinstall the wear plates 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. -
Page 52: Replacing The Bearing Unit
Repair 9.4.3 Replacing the bearing unit 1. Remove the nuts from the hexagon head bolts (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.... -
Page 53: Replacing The Cartridge Mechanical Seal
Repair 9.4.4 Replacing the Cartridge mechanical seal Cartridge mechanical seal – installation/disassembly tool:: Vogelsang part no. WKZ0455 (A) Pos. 2 and 3 are included in part no. WKZ0455. Perform the steps as described above: Chap. "Dismounting the functional unit from the housing unit"... -
Page 54: Fig. 29: O-Ring And Support Ring Disassembly/Assembly
Repair 13. Grease the O-ring (5) and support ring (6), push them onto the shaft and fix them in place. Fig. 29: O-ring and support ring disassembly/assembly 14. Before installing the XRipper rotor, thoroughly clean the contact surfaces of the XRipper rotor and the Cartridge mechanical seal. -
Page 55: 10 Inspection And Maintenance Plan
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. •... -
Page 56: 10.1.3 Every 12 Months
Inspection and mainte na nce plan 10.1.3 Every 12 months Part Inspection Machine mounting 1. Check that the screw connections fastening the machine are tight. 2. Tighten any loose screw connections. Part Inspection Housing parts 1. Check the housing parts for wear (visual inspection) 2.... -
Page 57: 10.2 Maintenance Plan
Inspection and mainte na nce plan 10.2 Maintenance plan 10.2.1 Every 12 months Part Maintenance Seal chamber 1. Replace the buffer fluid in the seal chamber. Part Maintenance Gearbox 1. Change the gear oil. 10.2.2 Before prolonged shutdown periods Part Maintenance Machine 1.... -
Page 58: Troubleshooting
T roubleshooting 11 Troubleshooting 11.1 Troubleshooting Help Troubleshooting Chap. "Help" • XRipper stops after starting, will not start A, B • XRipper stops during operation A, B • XRipper rotates, but does not cut • Cutting performance is insufficient •... -
Page 59: 12 Putting Out Of Operation And Disposal
Putti ng out of operation and disposal Observe notices and Possible cause Possible remedy safety notes Chap. Foreign matter jammed in "Opening the QD cover" Clean the XRipper chamber and XRipper rotors between the XRipper rotor and the instructions after (XRipper rotor blades) blades, blocking them that... -
Page 60: 13 Service Plan
Service pla n 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/ Date Signature Throughput rate WBV.XRP.003.EN XRC100QD SIK V6.0... - Page 61 FOR PARTS AND SERVICE, CONTACT (717) 761-7884 (800) 733-7884 sales@envirep.com www.envirep.com Vogelsang 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 WBV.XRP.003.EN XRC100QD SIK V6.0...
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