Virtus L Series Manual

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Manual L Series

VIRTUS EQUIPMENT

311 Era Drive

Northbrook, IL 60062

Phone: +1-847-2917-2100

www.Virtus-Equipment.com

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Page 1 Manual L Series VIRTUS EQUIPMENT 311 Era Drive Northbrook, IL 60062 Phone: +1-847-2917-2100 www.Virtus-Equipment.com...
Page 2: Table Of Contents
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 © VIRTUS EQUIPMENT 2018 All rights reserved Page 2...
Page 3 Mounting the main bearing ___________________________________________________ 46 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 © VIRTUS EQUIPMENT 2018 All rights reserved Page 3...
Page 4 Customer service and spare parts orders ____________________________ 66 Spare Parts List L 60 _____________________________________________ 67 Spare Parts List L 60+ ____________________________________________ 69 ClARIFICATION FOR PERSONal TRAINING __________________________ 76 Electrical Connection ____________________________________________ 77 DIMENSIONS OF STANDARD MACHINE _____________________________ 78 © VIRTUS EQUIPMENT 2018 All rights reserved Page 4...
Page 5: Information On This Instruction Manual
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! © VIRTUS EQUIPMENT 2018 All rights reserved Page 5...
Page 6: Technical Data
Machine weight: In kg Electrical connection data: markings are attached to the machine Noise level: Without noise equipment, Depends on plant location and in dB(A): type of grinding material! © VIRTUS EQUIPMENT 2018 All rights reserved Page 6...
Page 7 Machine weight: In kg Electrical connection data: markings are attached to the machine Noise level: Without noise equipment, Depends on plant location and in dB(A): type of grinding material ! © VIRTUS EQUIPMENT 2018 All rights reserved Page 7...
Page 8: General Information
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...
Page 9: General Safety Advice
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. © VIRTUS EQUIPMENT 2018 All rights reserved Page 9...
Page 10: Use In Accordance With The Regulations
(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.
Page 11 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. © VIRTUS EQUIPMENT 2018 All rights reserved Page 11...
Page 12: Liability And Responsibility
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.
Page 13: Structural Changes, Spare Parts, Accessories
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. © VIRTUS EQUIPMENT 2018 All rights reserved Page 13...
Page 14: Noise Levels And Noise Control Measures
PART A: Basic machine Shredder L 60; L60+ 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).
Page 15: Remaining Risks
Tripping over cables and other objects lying Type of danger: around. All activities. Activity: Serious injury can result. Possible consequences: Lay cables in accordance with the Preventative regulations. Keep work station clean and tidy. measures: © VIRTUS EQUIPMENT 2018 All rights reserved Page 15...
Page 16: Electrical Dangers
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. © VIRTUS EQUIPMENT 2018 All rights reserved Page 16...
Page 17: Dangers Caused By The Control System
Type of danger: Damage to hearing. All activities. Activity: Possible Diminished hearing, headaches, impaired balance, and deterioration of concentration. consequences: Reduce noise emissions by taking suitable Preventative measures. Wear ear protection. measures: © VIRTUS EQUIPMENT 2018 All rights reserved Page 17...
Page 18: Dangers Caused By Vibration
Serious injury or death can result. Possible consequences: Never make the protective devices Preventative ineffective. Check the protective devices measures: regularly for proper functioning according to the specifications given in this operation manual. © VIRTUS EQUIPMENT 2018 All rights reserved Page 18...
Page 19: Protective Devices
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. © VIRTUS EQUIPMENT 2018 All rights reserved Page 19...
Page 20: Safety Device For Hopper
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. © VIRTUS EQUIPMENT 2018 All rights reserved Page 20...
Page 21: Splash Guard
Safety markings are attached to the machine. If one of these markings becomes detached or is no longer recognisable, it must be replaced. You can order new markings at specialist shops or from us (see Customer service and spare parts orders). © VIRTUS EQUIPMENT 2018 All rights reserved Page 21...
Page 22: Authorized Persons
The operator must make sure that only authorized personnel work on the machine. The operator is responsible for the safety of third persons in the working area of the machine. © VIRTUS EQUIPMENT 2018 All rights reserved Page 22...
Page 23: Personal Protective Gear
Maintenance of gearbox motor. Maintenance of cutting knives. Knife sharpening. If necessary, protect yourself with breathing equipment (in addition to the air suction device) before inhaling substances harmful to the health. © VIRTUS EQUIPMENT 2018 All rights reserved Page 23...
Page 24: Safety Measures At The Application Site
The EMERGENCY STOP must be activated in all situations whereby injury or damage could result! Reoperation:  Eliminate cause of Emergency Stop.  Unlock EMERGENCY STOP BUTTON.  Acknowledge fault. The machine is now ready for operation again. © VIRTUS EQUIPMENT 2018 All rights reserved Page 24...
Page 25: Classification Of Specific Safety Advice
HINT Indicates a possibly harmful situation. If you do not take avoiding action, the machine could be damaged. Indicates application tips and other particularly useful in- formation. © VIRTUS EQUIPMENT 2018 All rights reserved Page 25...
Page 26: Description Of The Machine
In feed hopper The grinding material in feed ensues via an in feed hopper, which is formed so that the grinding material can be delivered correctly and safely. Illustration: Standard hopper © VIRTUS EQUIPMENT 2018 All rights reserved Page 26...
Page 27: Machine (Standard Execution)
PART A: Basic machine Shredder L 60; L60+ Machine (Standard execution) Illustration: (1) Base frame (2) Housing flap (3) Gear box motor (4) Control panel (5) Hand winch (6) Hopper (7) Discharge area © VIRTUS EQUIPMENT 2018 All rights reserved Page 27...
Page 28: Drive
The drive of the rotor ensues by means of an electric helical gear motor. The motor is flanged on the rotor and fixed on the base frame. Please observe the operation manual from the manufacturer! Illustration: Drive Motor © VIRTUS EQUIPMENT 2018 All rights reserved Page 28...
Page 29: Rotor And Knives
The rotor construction, the type of knife mounting and the number of knives have all been exactly matched to your task allocation. Illustration: (1) Rotor knife (2) Stator knife © VIRTUS EQUIPMENT 2018 All rights reserved Page 29...
Page 30 The rotor is arranged on roller bearings, which are situated outside the housing. Gearbox motor is attached to the rotor axis. The rotor is dynamically counter balanced and has vibration-free concentricity. © VIRTUS EQUIPMENT 2018 All rights reserved Page 30...
Page 31: Discharge Of Grinding Material
Normally the ground material will be discharged by a box. Options: Discharge with conveyor Control panel Illustration: Control panel (1) Main switch (2) Emergency stop (3) Ampere meter (4) Control lights (5) Start button (6) Stop button (7) Reset button © VIRTUS EQUIPMENT 2018 All rights reserved Page 31...
Page 32: Initial Startup
Check the oil level of the gear box, before operating the machine. Please observe the operation manual from the manufac- turer! WARNING Fill oil into the hydraulic tank. Please observe the operation manual from the manufac- turer! © VIRTUS EQUIPMENT 2018 All rights reserved Page 32...
Page 33: Requirements At The Application Site
• The machine may not be operated within range of static discharges or strong magnetic fields as this could lead to faults in the machine control system. © VIRTUS EQUIPMENT 2018 All rights reserved Page 33...
Page 34: Unloading And Installing The Machine
Do not use blocks to place underneath the machine, use instead metal strips in order to prevent buckling of the base frame. Make sure that an even distribution of weight is achieved on all the points of support. © VIRTUS EQUIPMENT 2018 All rights reserved Page 34...
Page 35: Electrical Connection
Voltage, current, frequency and protection are marked on the Type plate. The voltage tolerance is ± 10%.  For machines which have not been pre-wired by VIRTUS , the electrical connection is to be carried out in accordance with the enclosed Wiring diagram in the terminal box.
Page 36 HINT If running in the wrong direction, reconnect the motor con- nection immediately. Damage to the machine will result from operation in the wrong direction. © VIRTUS EQUIPMENT 2018 All rights reserved Page 36...
Page 37: Machine Check Prior To Initial Start-Up
11. If necessary, check the temperature of the ground material. 12. Monitor the ammeter. This displays the present current consumption and in this way gives information on the load of the machine. © VIRTUS EQUIPMENT 2018 All rights reserved Page 37...
Page 38: Operation
1. Switch on the grinding material discharge device. 2. Switch on the Shredder (main switch to 1). Wait until the rotor has reached its full speed. 3. Switch on the grinding material in feed device (accessories). © VIRTUS EQUIPMENT 2018 All rights reserved Page 38...
Page 41: Checking The Protective Devices
• If defects occur during operation, stop the machine im- mediately and eliminate the defects! • Do not change or remove any protective devices. Do not put any protective devices out of action by modifying them. © VIRTUS EQUIPMENT 2018 All rights reserved Page 41...
Page 42: Cleaning The Machine
 Remove clinging grinding material residue using a suitable wood- en scraper.  Put the screen back into its working position and fasten with the mounting screws  Close the housing flaps  Machine can be started again © VIRTUS EQUIPMENT 2018 All rights reserved Page 42...
Page 43: Replacing The Gearbox Motor
 Carefully lift out the complete rotor using suitable lifting and stop- ping means.  Lay the rotor down in a safe location. Suitable for this are timber beams of appropriate size. © VIRTUS EQUIPMENT 2018 All rights reserved Page 43...
Page 44: Mounting The Rotor
 Attach the bearing housing (Pos) to the bearing seats using screws.  Put the gearbox motor onto the rotor axis  Put back the rotor mounting slot cover plates  Carry out a test run. © VIRTUS EQUIPMENT 2018 All rights reserved Page 44...
Page 45: Replacing The Main Bearings
 Loose the bearings cover mounting screws and take off the bear- ing cover.  Pull the bearing housing off with a pulling-off device.  Pull the bearing off the rotor axis using a pulling-off device. © VIRTUS EQUIPMENT 2018 All rights reserved Page 45...
Page 46: Mounting The Main Bearing
 Push the distance sleeve onto the rotor axis.  Put the gearbox motor onto the rotor axis  Put back the rotor cover plates  Carry out a test run. © VIRTUS EQUIPMENT 2018 All rights reserved Page 46...
Page 47: Lubricating The Main Bearings
Lubricating the main bearings An important requirement for high operational safety and long service life of the arrangement of bearings is the correct lubricant supply. Every VIRTUS machine is greased and checked in test runs before delivery. HINT Unsuitable lubricant, lubricant deficiency, excessive lubri- cation or impurities in the lubricant lead to overheating and thus extreme wear of the bearings.
Page 48 After washing out, the bearing must immediately be preserved using lubricant, in order to avoid corrosion.  Fill bearing with approved lubricant (see List of lubricants). © VIRTUS EQUIPMENT 2018 All rights reserved Page 48...
Page 49: List Of Lubricants
Zeller & Gmelin ZET GE Grease M 50 FAG L 71 ANTAR Petroles de ROLEXA l’Antlantique Holland, Beverol Beverol Multi Purpose Grease Italy, Agip AGIP Grease 33 FD Swede, NYNÄS Nynäs FI 3-42 © VIRTUS EQUIPMENT 2018 All rights reserved Page 49...
Page 50: Working On The Cutting Knives
Torque: Bolt type Grade 8.8 Grade 10.9 Grade 12.9 lbf ft lbf ft lbf ft 18.4 25.8 30.2 36.1 50.9 61.2 63.4 88.5 1000 1200 © VIRTUS EQUIPMENT 2018 All rights reserved Page 50...
Page 51: Checking The Condition Of The Cutting Knives
Therefore they should be checked regularly. Using blunt knives has the following consequences: • Decreased grinding capacity. • Increased current consumption of the drive motor. • Inexact cut. • Overheating of the ground material. © VIRTUS EQUIPMENT 2018 All rights reserved Page 51...
Page 52: Dismounting The Rotor Knives
 Loose the bolt using a high quality Allen key (10 mm). If necessary knock the Allen key lightly with a hammer to loose it.  Take out the knife fixing bolt, the washer and the knife © VIRTUS EQUIPMENT 2018 All rights reserved Page 52...
Page 53: Dismounting The Rotor Knife Holders
 Loose the bolt using a high quality Allen key (6 mm). If necessary knock the Allen key lightly with a hammer to loose it.  Take out the knife holder fixing bolts.  Remove the knife holder with the delivered Extractor. © VIRTUS EQUIPMENT 2018 All rights reserved Page 53...
Page 55: Dismounting The Stator Knives
Loose the knife fixing bolts using a high quality Allen key (10 mm). If necessary knock the Allen key lightly with a hammer to loose it.  Take out the knife fixing bolt, and the knife © VIRTUS EQUIPMENT 2018 All rights reserved Page 55...
Page 56: Mounting The Rotor Knife Holders
 Tighten the knife fixing bolts using a torque wrench. The required torque for the knife holder mounting bolts is 39 Nm (also see the table under Replacing and checking the cutting knife mountings). © VIRTUS EQUIPMENT 2018 All rights reserved Page 56...
Page 57: Mounting The Rotor Knives
 Check whether the cutting gap is correct and whether the cut- ting knives do not collide as the rotor turns. Rotor knives from VIRTUS are reversible and have four symmetrical cutting edges. This makes it possible to turn the knives and only to sharp- en after every fourth knife change.
Page 58: Mounting The Stator Knives
The required torque for all knife mounting bolts M12 is 120Nm The required torque for all knife adjusting bolts M16 is 295Nm (also see the table under Replacing and checking the cutting knife mountings). © VIRTUS EQUIPMENT 2018 All rights reserved Page 58...
Page 59  Check whether the cutting gap is correct and whether the cut- ting knives do not collide as the rotor turns. Stator knives from VIRTUS are reversible and have two symmetrical cutting edges. This makes it possible to turn the knives and only to sharp- en after every second knife change.
Page 60: Sharpening Cutting Knives
L 60; L60+ 8.9.9 Sharpening cutting knives Shredder rotor knives from VIRTUS have four cutting edges. This means they can be turned three times. After that they should be replaced with new ones. Stator knives can be turned two times and can be resharpened as long as you can fix them with the long hole.
Page 61: Setting The Cutting Knives
Serious injury, in particular to hands and fingers, can re- sult. Wear protective gloves. Rotor knives for the L series shredder don’t have to be adjusted. All adjustments have to be done with the stator knives. To simplify knife setting and shorten standstill periods when replacing the knives, VIRTUS stator knives have four adjusting screws, two for pulling two for pushing the knife.
Page 63: Troubleshooting
9.4.1 Rotor out of balance. Weigh knives, balance rotor. 9.4.2 Bearing damage. Check bearings, replace bearings if necessary. 9.4.3 Anti vibration pads defective Check mounting pads and renew these if necessary. © VIRTUS EQUIPMENT 2018 All rights reserved Page 63...
Page 64: Extreme Cutter Wear
Reduce feed quantity of the grinding material, tor. correct setting, replace fuse. 9.10 Frequent switching off of grinding material in feed device Possible causes Remedy required 9.12.1 Current relay switches off. Correct setting. © VIRTUS EQUIPMENT 2018 All rights reserved Page 64...
Page 65: Storage, Disposal, Transportation
Also use suitable stopping means and pay attention to the gravity centre location. Do not step under the suspended load. Wear a protective helmet in addition to your basic protec- tive gear. © VIRTUS EQUIPMENT 2018 All rights reserved Page 65...
Page 66: Customer Service And Spare Parts Orders
Phone: +1-847-291-1800 www.Virtus-Equipment.com The easiest way to order your spare parts is to copy the spare parts list and to fill in the order amount after the re- spective spare part. © VIRTUS EQUIPMENT 2018 All rights reserved Page 66...
Page 67: Spare Parts List L 60
Fixing bolt DIN912 M8x50-12.9 80011121 Torque arm plate 21256700 Torque arm 21257100 Fixing bolt DIN931 M24x125-12.9 80040363 Washer DIN433-24 80040442 Spring washer DIN127-24 80040441 Fixing nut DIN934 M24-10 80040366 Fixing bolt DIN933 M16x60-12.9 80010010 © VIRTUS EQUIPMENT 2018 All rights reserved Page 67...
Page 68 Stator knife cover plate 21252000 Mounting plate for cover plate 21257800 Fixing Bolt DIN912 M12x65 – 12.9 80011270 Fixing Bolt DIN912 M16x50 – 12.9 80011291 Electrical parts Control panel Safety switch AZ15ZVRK-1476-1 © VIRTUS EQUIPMENT 2018 All rights reserved Page 68...
Page 69: Spare Parts List L 60
Fixing bolt DIN912 M8x50-12.9 80011121 Torque arm plate 21256700 Torque arm 21257100 Fixing bolt DIN931 M24x125-12.9 80040363 Washer DIN433-24 80040442 Spring washer DIN127-24 80040441 Fixing nut DIN934 M24-10 80040366 Fixing bolt DIN933 M16x60-12.9 80010010 © VIRTUS EQUIPMENT 2018 All rights reserved Page 69...
Page 70 Stator knife cover plate 21252000 Mounting plate for cover plate 21257800 Fixing Bolt DIN912 M12x65 – 12.9 80011270 Fixing Bolt DIN912 M16x50 – 12.9 80011291 Electrical parts Control panel Safety switch AZ15ZVRK-1476-1 © VIRTUS EQUIPMENT 2018 All rights reserved Page 70...
Page 76: Clarification For Personal Training
This is to certify that I have attended an in company training for service and operation of the shredder and understand all safety regulations. Further to this I have read and understand the owners’ manual. City Date Printed name Signature © VIRTUS EQUIPMENT 2018 All rights reserved Page 76...
Page 77: Electrical Connection
PART A: Basic machine Shredder L 60; L60+ ELECTRICAL CONNECTION The machine should be wired by a qualified electrician. Please refer to the wiring diagram. © VIRTUS EQUIPMENT 2018 All rights reserved Page 77...

This manual is also suitable for:

L 60