Page 1
O P E R AT I N G M A N U A L H 8 0 S E R I E S Operating Manual H 80 Series Virtus Equipment 9120 Centerlinks Commerce DR., Unit 4 Fort Myers, FL 33912 Virtus Equipment 9120 Centerlinks Commerce Dr., Unit 4...
Safety measures at the application site _________________________________ 29 4.13 Fire fighting agents __________________________________________________ 29 4.14 Cleaning agents _____________________________________________________ 29 4.15 Conduct in case of an emergency ______________________________________ 29 4.16 Classification of specific safety advice __________________________________ 30 Page 2 Virtus Equipment 2023, All rights reserved...
Page 3
Safety measures at the application site __________________________________ 30 4.13 Fire fighting agents ___________________________________________________ 30 4.14 Cleaning agents _____________________________________________________ 30 4.15 Conduct in case of an emergency _______________________________________ 30 4.16 Classification of specific safety advice___________________________________ 31 VIRTUS 2023, All rights reserved Page 2...
Page 4
Lubrication intervals: _______________________________________________________ 56 8.7.2 Check lubricant quality ______________________________________________________ 56 8.7.3 Replacing or refilling lubricant ________________________________________________ 56 8.7.4 List of lubricants ___________________________________________________________ 58 Mounting and dismounting the DOKO tensioning element ____________________ 59 VIRTUS 2023, All rights reserved Page 3...
Page 5
Storage, disposal, transportation __________________________________ 84 10.1 Storage _____________________________________________________________ 84 10.2 Disposal ____________________________________________________________ 84 10.3 Transportation _______________________________________________________ 84 Hydraulic Maintenance__________________________________________ 86 Customer service and spare parts orders ___________________________ 88 Spare Parts Lists ________________________________________________ 89 VIRTUS 2023, All rights reserved Page 4...
Page 6
Rotor assembly no pulley side ________________________________________ 102 Hydraulic Unit _________________________________________________ 103 14.1 Hydraulic Diagram __________________________________________________ 103 14.2 Spare parts list hydraulic unit _________________________________________ 104 14.3 Hydraulic Unit ______________________________________________________ 105 Clarification for Personal Training _________________________________ 106 ADDITION _____________________________________________________ 107 VIRTUS 2023, All rights reserved Page 5...
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 2023, All rights reserved Page 6...
Noise level: Without noise equipment, Approx. 110 Depends on plant location and in dB(A): type of grinding material! With noise equipment depends on in dB(A): type of soundproof Dimensions: See Layout drawing VIRTUS 2023, All rights reserved Page 7...
Page 9
Noise level: Without noise equipment, Approx. 110 Depends on plant location and in dB(A): type of grinding material! With noise equipment depends on in dB(A): type of soundproof Dimensions: See Layout drawing VIRTUS 2023, All rights reserved Page 8...
Page 10
Noise level: Without noise equipment, Approx. 110 Depends on plant location and in dB(A): type of grinding material! With noise equipment depends on in dB(A): type of soundproof Dimensions: See Layout drawing VIRTUS 2023, All rights reserved Page 9...
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...
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 2023, All rights reserved Page 11...
(see Contract of sale). Any other work or design will differ from the specified requirements. VIRTUS America will not be held responsible. The specified requirements also include all information found in the owner’s manual such as maintenance and service.
Page 14
New excerpts or additions to the owners’ manual must always be replaced to include any safety requirements or environmental re- quirements. All safety or caution signs must be visual and easy to read. VIRTUS 2023, All rights reserved Page 13...
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.
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 2023, All rights reserved Page 15...
Therefore it is necessary to actually determine if the noise level is directly coming from the machine or another accessory equipment. VIRTUS EQUIPMENT offers the following equipment to reduce the noise levels; Two piece soundproof box ( one piece stationary, one piece moveable ) also available with soundproof hopper.
Danger of crushing when closing the granulator upper section. Activity: Maintenance work. Possible Serious injury can result. consequences: Preventative When closing the granulator upper section, measures: ensure that no persons are in the danger area. VIRTUS 2023, All rights reserved Page 17...
Page 19
Danger of pulling in caused by running "V"- belts. Activity: All activities. Possible Hair, jewellery etc. can be pulled into the consequences: machine. Serious injury can result. Preventative Never dismount "V"-belt protection and measures: window. VIRTUS 2023, All rights reserved Page 18...
All activities. Possible Serious injury or death. consequences: Preventative It must be guaranteed that failure of an measures: Emergency Stop button is displayed and leads to an immediate stop of the machine. VIRTUS 2023, All rights reserved Page 19...
Loosening of the cutting knife mountings caused by vibration. Activity: All activities. Possible Serious injury can result. consequences: Preventative Check the cutting knife mountings regularly measures: according to the instructions in this operation manual. VIRTUS 2023, All rights reserved Page 20...
Serious injury or death can result. consequences: Preventative Never make the protective devices measures: ineffective. Check the protective devices regularly for proper functioning according to the specifications given in this operation manual. VIRTUS 2023, All rights reserved Page 21...
The safety switch for the front door has a guard locking and can be only opened after the key switch “Door Open” at the panel is activated. The electrical time delay prevents that the machine can be opened before the machine comes to shutdown. VIRTUS 2023, All rights reserved Page 22...
A third safety switch is installed on the hinge of the screen holder. It prevents that the granulator can be started, when the screen holder is lowered. VIRTUS 2023, All rights reserved Page 23...
Page 25
PART A: Basic machine Granulator H 80 Series Illustration: Opened hopper/ upper section VIRTUS 2023, All rights reserved Page 24...
If machines are delivered on the request of the customer without drive motors, the operator is obliged to fit and mount the protective devices delivered together with the machine himself in line with the current legal safety regulations. Illustration: Shaft cover VIRTUS 2023, All rights reserved Page 25...
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. VIRTUS 2023, All rights reserved Page 26...
To secure the rotor against turning by knife change or other maintenance work, move the security interlock into the rotor. The interlock is secured by a safety switch what will provide damage to the lock caused by closing the housing VIRTUS 2023, All rights reserved Page 27...
The operator must make sure that only authorized person’s work on the machine. He is responsible for the safety of third persons in the working area of the machine. VIRTUS 2023, All rights reserved Page 28...
Screen replacement. Maintenance of "V"-belts. Maintenance of cutting knives. Knife sharpening. If necessary, protect yourself (in addition to the air suction device) with breathing equipment before inhaling substances harmful to the health. VIRTUS 2023, All rights reserved Page 29...
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 2023, All rights reserved Page 30...
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 2023, All rights reserved Page 31...
Additional in feed device If your machine has an optional in feed device such as roller feeder or conveyor belt please refer to the additional information about the accessories in the appendix. VIRTUS 2023, All rights reserved Page 32...
"V"-belts by means of tensioning screws. The "V"-belt pulley is attached with a special tensioning element to the motor shaft. Illustration: Drive Motor Please observe the operation manual from the manufacturer! VIRTUS 2023, All rights reserved Page 34...
Granulator upper section (opened) In addition, an anti-winding device is also integrated on the granulator upper section. This prevents foil strips, for example, becoming wrapped around the rotor axis and thus causing operational faults. VIRTUS 2023, All rights reserved Page 35...
The design of the rotor has a significant influence on the quality of the grinding process and it's results. The rotor construction, the type of knife mounting and the number of knives have all been exactly matched to your task allocation. VIRTUS 2023, All rights reserved Page 36...
Page 38
The deflection wedge and the block knives ensure that larger pieces of grinding material e.g. lumps, foil rolls etc. can be ground and do not cause blockage of the rotor. Illustration: Deflection wedge (3.Stator knife) VIRTUS 2023, All rights reserved Page 37...
The screen is replaceable and can be taken out through the open housing flap of the granulator lower section. VIRTUS 2023, All rights reserved Page 38...
Illustration: By-pass flap If a material blower is installed in your plant configuration, please observe the additional information for work with and on the material blower in Part B: Accessories. VIRTUS 2023, All rights reserved Page 39...
The granulator upper section and the screen support can be opened with a hydraulic system for maintenance work and cleaning. It is connected with the lower part by means of a joint. Illustration: (1) Hydraulic Unit (2) Hydraulic Controls VIRTUS 2023, All rights reserved Page 40...
(4) Two hand switch start 1 and 2 The hydraulic unit is set ready for operation at VIRTUS. Normally adjustment work is not necessary. On the control arm you have 2 buttons (Start) and 2 switches (hopper open/close and screen open/close).
Insulation for the tropics is also necessary. • 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 2023, All rights reserved Page 42...
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 2023, All rights reserved Page 43...
The voltage tolerance is ± 10%. For machines, which have been supplied none pre-wired by VIRTUS the electrical connection, is to be carried out in accord- ance with the enclosed Wiring diagram in the terminal box. When doing this, the regulations of the local electricity authority are to be adhered to.
Page 46
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 2023, All rights reserved Page 45...
14. Open the air regulating flap on the by-pass Discharge of grinding material flap far enough so that the trough is completely emptied (do not open further!). VIRTUS 2023, All rights reserved Page 46...
The material blower is installed properly and Part B: Accessories. the air regulating flap on the suction trough is set so that the grinding material can be completely sucked away. VIRTUS 2023, All rights reserved Page 47...
If in your design of machine an additional in feed device is installed, please observe the additional information for work with and on the in feed device Part B: Accessories. VIRTUS 2023, All rights reserved Page 48...
• 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 2023, All rights reserved Page 50...
Open the hopper by using the hydraulic system, by pushing the start buttons of the 2 hand switch on the control arm. ( Selector switch 1 at HOPPER and selector switch 2 at OPEN) VIRTUS 2023, All rights reserved Page 51...
Tighten the connecting bolts between the granulator lower section and the granulator upper section. Switch of the hydraulic via key switch on the control panel Deactivate the key switch “DOOR OPEN” Machine can be started again. VIRTUS 2023, All rights reserved Page 52...
Pivot the screen support into the working position using the hy- draulic system and fasten with the mounting screws Close the granulator upper section (see Closing the granulator). Rotate in the threaded spindle completely Machine can be started again VIRTUS 2023, All rights reserved Page 53...
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 2023, All rights reserved Page 54...
(see, Mounting and dismounting TAPER-LOCK tensioning ele- ment). Pull on "V"-belts and adjust the "V"-belt tension force ( see Retensioning and relaxing the "V"-belt). Attach the "V"-belt cover. Carry out a test run. VIRTUS 2023, All rights reserved Page 55...
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 58
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 2023, All rights reserved Page 57...
The length of the thread allows maximum utilization of the tensioning screws. Tightening torque of the screws: 395Nm VIRTUS 2023, All rights reserved Page 59...
If the tensioning elements only have to be dismounted for the first time after a longer period, you should spray corrosion solvent into the slit and into the open screw holes and allow this to react for a sufficient amount of time. VIRTUS 2023, All rights reserved Page 60...
Then try to loosen the tensioning element by tightening the threaded screws again using the torque wrench. Keep repeating this process until the tensioning element becomes loose. Remove the tensioning element. VIRTUS 2023, All rights reserved Page 61...
TAPER-LOCK tensioning element. The disks must be dismounted for certain maintenance work. 8.9.1 Table for the tightening torque of the screws Tensioning Screws- Screw details element (Type) Tightening torque in Nm Number Size (BSW) 4040 " VIRTUS 2023, All rights reserved Page 62...
Tighten screws alternately until bush is loosened in hub and as- sembly is free on the shaft. Remove assembly from shaft. VIRTUS 2023, All rights reserved Page 63...
Pivot the screen support downwards, by pushing the start buttons of the 2 hand switch on the control arm. ( Selector switch 1 at SCREEN and selector switch 2 at OPEN) VIRTUS 2023, All rights reserved Page 64...
Page 66
1 at SCREEN and selector switch 2 at CLOSE) Fasten the screen support by using the mounting screws. Close the housing flap. Deactivate the key switch “DOOR OPEN” Granulator can be started again. VIRTUS 2023, All rights reserved Page 65...
Compare determined value with the value in the above table. If the value lies below the lowest tolerance limit, the "V"-belt must be retensioned. If the value lies above the highest tolerance limit, the "V"-belt must be relaxed. VIRTUS 2023, All rights reserved Page 66...
Loosen the front and rear tensioning screw. Relax the "V"-belt by shifting the drive motor. Put new "V"-belt in. Tension the "V"-belt (see Retensioning and relaxing the "V"-belt). Mount the "V"-belt cover. VIRTUS 2023, All rights reserved Page 67...
(2) Knife mounting screws Open the granulator (see Opening the granulator ). Safeguard the rotor against torsion. Loosen the knife mounting screws. Take out the knife capping and knives. VIRTUS 2023, All rights reserved Page 69...
Check whether the cutting gap is correct and whether the cut- ting knives do not collide as the rotor turns. Stator knives from VIRTUS have two symmetrical cutting edges. This makes it possible to turn the knives and only to sharp- en after every second knife change.
By taking these measures, the service life of the cutting knives can be increased. Set the cutting knives (see mounting the cutting knives). Mount the cutting knives (see mounting the cutting knives). VIRTUS 2023, All rights reserved Page 71...
Page 73
PART A: Basic machine Granulator H 80 Series Illustration: Resharpening plan S-rotor knife VIRTUS 2023, All rights reserved Page 72...
Page 74
PART A: Basic machine Granulator H 80 Series Illustration: Resharpening plan stator knife VIRTUS 2023, All rights reserved Page 73...
Page 75
PART A: Basic machine Granulator H 80 Series Illustration: Resharpening plan flat knife deflection wedge VIRTUS 2023, All rights reserved Page 74...
The cutting gap is set using the knife gap of the rotor knives in the knife-setting device. Illustration: Cutting gap Knife gap Stator knife Rotor kife Rotor-cutting circle VIRTUS 2023, All rights reserved Page 75...
Page 77
Unscrew the setting screw of the knife so far that the feeler gage is gently squeezed. Tighten the counter nut. Set all the setting screws as described. Check the knife gap at the end of setting and correct if required. VIRTUS 2023, All rights reserved Page 76...
Page 78
(3) Cover plate HINT In operating state, the granulator heats up and expands unevenly. Therefore, if the knife gap is too small this can lead to machine damage caused by the knives colliding. VIRTUS 2023, All rights reserved Page 77...
Fix lifting equipment so that the wedge cannot fall down after re- moving the fixing bolts Remove the fixing bolts from the deflection wedge on the backside of the upper machine section Take out the deflection wedge VIRTUS 2023, All rights reserved Page 79...
Page 81
The cover plate prevents both damage to the rear surface of the housing and material leaving the granulator through bolt holes. The cover plate is only supplied with the unit if the granulator is intended for operation without the deflection wedge. VIRTUS 2023, All rights reserved Page 80...
Material rubs against the housing Fit anti-winding device. wall. 9.3.6 Insufficient cooling. Fit water-spraying device, increase air intake (larger suction fan). 9.3.7 Suction fan rotates in wrong direc- Check connection, if required reverse polarity. tion. VIRTUS 2023, All rights reserved Page 81...
9.5.2 Knife finish. Check knife and sharpen or replace if necessary. 9.5.3 Wrong cutting angle. Modify cutting angle after consulting VIRTUS service department. 9.5.4 Wrong cutting angle. Check cutting gap and set according to the instruc- tions in this operation manual.
Reduce feed quantity of the grinding material, tor. correct setting, replace fuse. 9.12 Frequent switching off of grinding material in feed device Possible causes Remedy required 9.12.1 Current relay switches off. Correct setting. VIRTUS 2023, All rights reserved Page 83...
10.3 Transportation WARNING Suspended load. Falling loads can cause serious injury or death. Only use a crane or forklift truck, which is suitable for the weight and dimensions of the loads. VIRTUS 2023, All rights reserved Page 84...
Page 86
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 2023, All rights reserved Page 85...
The system may only be filled with new oil after this has been done. This is necessary to prevent gumming of the valves. VIRTUS 2023, All rights reserved Page 86...
Page 88
MOBIL Mobil DTE 24 Mobil DTE 17 Drucköl HLP 32 - C Hydrauliköl HLPD 32 TEXACO Rando Oil HD A - 32 Rando Oil HD AZ - 32 Alcor Oil DD 32 VIRTUS 2023, All rights reserved Page 87...
Phone: +1-239-219-1500 Parts@Virtus-Equipment.com 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 2023, All rights reserved Page 88...
Page 93
PART A: Basic machine Granulator H 80 Series 1.5KW/460V-60HZ/110V 80001886 1.5KW/415V-50HZ/110V 80050316 1.5KW/415V-50HZ/220V 80050149 Electrical parts Safety switch ZS336 80005600 Control panel VIRTUS 2023, All rights reserved Page 92...
Page 94
20195200 φ15 20195300 φ16 20195400 Φ20 20195500 Φ25 20195600 Φ30 Bearing Bearing housing SN236 20159100 Bearing 22236/W33 80002970 Bearing Cover A 20159200 Bearing Cover B 20159300 Bearing Cover C 20159500 Sealing 80004050 VIRTUS 2023, All rights reserved Page 93...
This is to certify that I have attended an in company training for service and operation of the granulator and understand all safety regulations. Further to this I have read and understand the owners’ manual. City Date Printed name Signature VIRTUS 2023, All rights reserved Page 106...
ADDITION Documentation Main Drive Granulator (PART B) Delivery documentation ATTENTION: The wiring schematics are located in the control panel in the event that the control panel is a part of the delivery VIRTUS 2023, All rights reserved Page 107...
Page 109
Virtus Equipment 9120 Centerlinks Commerce Dr., Unit 4 Fort Myers, FL 33912 239-219-1500 Parts@Virtus-Equipment.com www.Virtus-Equipment.com...
Need help?
Do you have a question about the H 80 Series and is the answer not in the manual?
Questions and answers