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Borger Classic HPL Series Operating Instructions Manual

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Operating Manual
Börger Multicrusher
Classic
Series HPL
www.boerger.de
www.boerger.com

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  • Page 1 Operating Manual Börger Multicrusher Classic Series HPL www.boerger.de www.boerger.com...
  • Page 2 France Börger France S.A.R.L. Phone +33 (0) 3 / 88515468 9 rue des Prés +33 (0) 3 / 88515413 67670 Wittersheim E-mail info@borger.fr France Internet www.borger.fr Great Britain/ Börger UK Ltd. Phone +44 (0) 1902 / 798977 Ireland East Wing - Old School +44 (0) 1902 / 798979 Watling St.
  • Page 3 Product Specifications Unit: Product group: Multicrusher Type: HPL 200, HPL 300, HPL 300 N Precise product specifications for your unit, with the exception of control units, can be found in the data sheet enclosed with this operating manual. Manufacturer’s address: Company: Börger GmbH Address:...

  • Page 4: Table Of Contents

    Table of Contents Table of Contents General information...................... 8 Introduction........................8 Notes on copyrights and property rights................8 Information for the operator..................... 9 Training and instruction....................10 Sample training topics....................10 Safety..........................13 General information....................... 13 Notes on signs and symbols..................13 Proper use........................
  • Page 5 Table of Contents 3.1.5 Shaft seal........................55 3.1.6 Intermediate chamber (quench)..................56 3.1.7 Designs, mounting positions..................57 3.1.8 Pipe connections on inlet and outlet................59 3.1.9 Units / drive options....................... 60 3.1.10 Options and accessories....................62 Operating principle......................63 Technical data........................ 64 3.3.1 Dimensions........................
  • Page 6 Table of Contents Maintenance and repairs..................123 Machine care....................... 125 6.1.1 Cleaning the outside....................126 6.1.2 Pressure relief......................127 6.1.3 Internal cleaning......................129 Maintenance and inspection..................132 6.2.1 Maintenance and inspection plan................132 6.2.2 Lubricant fill level and changing the lubricants............135 Repairs........................
  • Page 7 Table of Contents Appendix........................194 Data sheet........................194 Wear parts........................194 Assembly drawing....................... 198 9.3.1 HPL 200........................198 9.3.2 HPL 300 / HPL 300 N....................199 9.3.3 HPL gear unit....................... 199 Spare parts list......................200 9.4.1 Tools / installation aid....................204 Parallel keys........................

  • Page 8: General Information

    General information General information Introduction This operating manual is an important aid for the correct and safe operation of the Börger machine. It contains important information for operating the Börger machine in a safe, proper and economical manner. Adhering to these instructions will help avoid associated dangers, reduce repair costs and downtimes and increase the reliability and service life of the Börger machine.

  • Page 9: Information For The Operator

    General information Information for the operator The operating manual is an integral part of the Börger machine. The operator is responsible for making the operating personnel aware of this manual. Additionally, the operator is obligated to ensure the notice and observance of national regulations for accident prevention and environmental protection, plus the notice and observance of super- vision and reporting duties taking special operational aspects into...

  • Page 10: Training And Instruction

    General information Training and instruction As the operator, you are obligated to inform and, if necessary, instruct your operating personnel in regard to the applicable legal and accident prevention regulations, as well as the available safety equipment on the Börger machine. This obligation also applies to all other safety equipment on and around the Börger machine.
  • Page 11 General information 2. Operating the Börger machine — Using the operating elements on the Börger machine — Explanation of the operating manual for operating personnel — Specific experiences in using the Börger machine — Troubleshooting / dealing with malfunctions ___________________________________________________ ___________________________________________________ ___________________________________________________ ___________________________________________________...
  • Page 12 General information Confirmation of training Training topic Date: Trainer: Trainer signature: Surname, first name Signature www.boerger.de / www.boerger.com BA-Classic HPL_EN, 24.01.2024...

  • Page 13: Safety

    Safety Safety General information The Börger machine has been developed and constructed according to current state-of-the-art technology and recognized safety guidelines in observance of the valid safety regulations in the country of manufacture. However, operation of the Börger machine may endanger the operating person and cause damage to the Börger machine or other material assets in the following circumstances: —...
  • Page 14 Safety NOTICE! Indicates a possible hazardous situation or unsafe, dangerous work processes that may lead to damage to the machine or sur- rounding area. NOTE! Offers useful information on safe and proper operation. Arrow symbols describe work and/or operational steps. These steps must be carried out in the sequence of the numbering.

  • Page 15: Proper Use

    Safety Proper use The Multicrusher is a macerating unit used for preventing block- ages in a system and preventing damage to downstream machines (especially to pumps) caused by solids in the medium. The unit can process coarse materials in the flow medium such as wood and plastic parts, PET bottles, fabric strips, skin strips, small bones, potatoes, apples, turnips etc., toiletries, leaves, hay/straw, paper, cardboard and similar materials and plaited fiber materials...
  • Page 16 Safety Proper use includes compliance with the instructions — on safety, — on operation and control, — on repairs and maintenance, specified in this operating manual. Any other use or use over and above these specifications is deemed as improper use. The operator of the Börger machine is solely liable for any resulting damage.

  • Page 17: Residual Risk

    Safety Residual risk Even when all safety instructions are adhered to, there are residual risks involved in operating the Börger machine as detailed below. All persons that work on and with the Börger machine must be aware of these residual risks and observe the associated instruc- tions to avoid accidents or damage caused by these residual risks.
  • Page 18 Safety DANGER! Risk of fatal injury due to electric power! There is an immediate risk of fatal electric shock if live com- ponents are touched. Damage to the insulation of the indi- vidual components can be fatal. — Have all work on the electrical equipment performed by skilled electricians.
  • Page 19 Safety DANGER! Risk of injury due to rotating parts! Moving parts can cause severe injury. — Do not reach into rotating parts or handle rotating parts when the machine is in operation. — Never open protective covers when in operation. —...
  • Page 20 Safety WARNING! Risk of serious injuries caused by liquid spouting out or escaping gases! Gases or liquids may escape uncontrollably from seals and screw connections. Especially when flange connections are released and maintenance openings are opened, pressurized liquid can spout out at the cover. Never loosen connections when the unit is pressurized.
  • Page 21 Safety CAUTION! Health hazard due to residues of dangerous medium inside and on the Börger machine! There is an increased health hazard from contact with the medium and contaminated components. Generally, the following applies: — When using dangerous or health-endangering media, take all necessary safety measures when performing work on the Börger machine.

  • Page 22: Qualifications For Operating Personnel

    Safety Qualifications for operating personnel WARNING! Personnel with insufficient qualifications represent a hazard! Insufficiently qualified personnel are not able to assess the risks when using the machine and expose themselves and others to the risk of serious or fatal injuries. —...
  • Page 23 Safety Manufacturer Certain work may be carried out by manufacturer’s qualified per- sonnel only. Other personnel is not authorized to carry out this work. To have this work carried out, please contact our customer service. Mechanics Mechanics have completed professional training or are able to pro- vide evidence of having completed further training which enables them to perform the special tasks mentioned in these instructions on the system and its components.
  • Page 24 Safety Qualified electricians Qualified electricians have completed professional training in elec- trical engineering or are able to provide evidence of having com- pleted further training which enables them to perform the special tasks mentioned in these instructions on the electrical system and its components.

  • Page 25: Personal Protective Equipment

    Safety Personal protective equipment Personal protective equipment serves to protect personnel from adverse effects to safety and health whilst working. Staff must wear personal protective equipment whilst carrying out various work on the plant. The individual sections of these instructions make specific reference to the requirements.

  • Page 26: Securing The Machine Against Restart

    Safety Securing the machine against restart WARNING! Risk of fatal injury if the plant is switched back on uncon- trolledly or without authorization! Switching the Börger machine on without authorization or uncon- trolledly can cause serious injuries. — Before switching back on, make sure that all safety devices are fitted and fully functional and that staff are not at any risk.

  • Page 27: Description Of The Safety Equipment

    Safety Description of the safety equipment WARNING! Risk of fatal injury if safety devices are not fully functional! Non-functional or overridden safety devices may cause severe injuries, including death. — Check whether all safety devices are functional and correctly installed before starting work with the machine. —...

  • Page 28: Covering Of The Rotating Cutting Unit

    Safety 2.8.2 Covering of the rotating cutting unit When installed correctly, the cutting blades rotate inside a com- pletely sealed casing. Therefore, the manufacturer is not required to provide additional safety equipment for the cutting unit. However, the Multicrusher must only be switched on when the connections on the inlet and outlet are established and the Ä...

  • Page 29: Intermediate Chamber

    Safety 2.8.4 Intermediate chamber The intermediate chamber with safety plug separates the hydraulic part of the Multicrusher from the Multicrusher gear unit. It is used for monitoring the integrity of the mechanical seals on Multi- crushers with single-acting mechanical seals. Overflowing caused by penetrating flow medium indicates that the mechanical seals must be replaced immediately in order to prevent the flow medium from entering the gear unit.

  • Page 30: Markings And Signs

    Safety Markings and signs The symbols and information signs below are located in the work area. They refer to the immediate environment in which they are attached. WARNING! Danger due to illegible signage! Over time, stickers and signs can get soiled or become illegible due to other reasons, so that dangers are not recognized and necessary operating instructions cannot be observed.
  • Page 31 Safety Meaning: Nameplate according to directive 2006/42/EC (machinery directive) Location: In a clearly visible position on the Multicrusher Different address possible, e.g. when delivered through a subsidiary. CE marking not applicable for incomplete machines where only a declaration of incorporation may be delivered, and in certain other cases. Meaning: Grounding (bore hole for ground screw or terminal) Location:...

  • Page 32: Markings And Signs To Be Attached By The Operator

    Safety 2.10 Markings and signs to be attached by the operator The flow direction for which the Multicrusher was designed is already indicated at the plant by appropriate adhesive labels. The operator is obligated to label any changes in flow direction Ä...

  • Page 33: Safety Instructions For Operating Personnel

    Safety 2.11 Safety instructions for operating personnel The Börger machine may only be operated while it is in perfect working condition and only for its intended purpose, in a safe and risk-conscious manner having regard to this operating manual. All malfunctions must be rectified immediately, especially those affecting safety.

  • Page 34: General Work On The Börger Machine

    Safety 2.11.1 General work on the Börger machine NOTE! Work on the Börger machine! — Work on the Börger machine may only be carried out by trained, reliable personnel. — Personnel in training or requiring instruction, as well as per- sons currently in vocational training, may only operate the Börger machine under the constant supervision of an experi- enced staff member.
  • Page 35 Safety Further operating manuals / supplementary operating manuals You must completely read the separate operating manuals and/or supplemen- tary operating manuals for components and/or special versions. Pay particular attention to all instructions — on safety, — on operation and control, —...

  • Page 36: Work On The Electrical System

    Safety NOTE! Adhere to the prescribed intervals for regular maintenance and inspections or those specified herein and in the oper- ating manuals of the components. — Suitable workshop equipment as well as specified special tools are essential for carrying out maintenance work. Ä...
  • Page 37 Safety DANGER! Risk of fatal injury due to electric power! There is an immediate risk of fatal electric shock if live com- ponents are touched. Damage to the insulation of the indi- vidual components can be fatal. — Have all work on the electrical equipment performed by skilled electricians.
  • Page 38 Safety Operating manuals of electronic parts Pay particular attention to all instructions — on safety, — on operation and control, — on repairs and maintenance, — in the operating manuals of electronic parts in the appendix. NOTE! Adhere to the prescribed intervals for regular maintenance and inspections of the electrical system and/or components or to those intervals specified herein and in the operating manuals of the components.

  • Page 39: Safety Instructions For Maintenance And Rectifying Malfunctions

    Safety 2.12 Safety instructions for maintenance and rectifying malfunctions WARNING! Risk of injury due to inadequate troubleshooting, mainte- nance and repair work! Inadequate troubleshooting, maintenance and repair work can lead to severe injury and significant material damage. — To the extent necessary, amply secure the surrounding area when performing maintenance.
  • Page 40 Safety WARNING! Risk of fatal injury if safety devices are not fully functional! Non-functional or overridden safety devices may cause severe injuries, including death. — Check whether all safety devices are functional and correctly installed before starting work with the machine. —...
  • Page 41 Safety NOTICE! Risk of damage caused by frost! Frost can cause damage to the Börger machine. — Protect the Börger machine and its connections against frost. NOTICE! Improper cleaning of the Börger machine can lead to mal- functions and damage! —...
  • Page 42 Safety NOTICE! There is a danger of considerable material damage if the limits are not complied with! Failure to comply with the limits can cause permanent damage to the Börger machine and its components. — The values may neither exceed nor fall below the limits speci- fied in Ä...
  • Page 43 Safety NOTE! When using frequency converters Due to their working principle, frequency converters generate leakage current. — For proper operation of a frequency converter at a residual current device, the use of an AC/DC sensitive residuaI cur- rent device (type B) according to EN50178/VDE0160 is required due to the DC component of the leakage current.

  • Page 44: Information On Special Dangers

    Safety 2.13 Information on special dangers 2.13.1 Oil, grease and other chemical substances ENVIRONMENT! Danger due to incorrect handling of environmentally haz- ardous substances! Inappropriate handling of environmentally hazardous substances, especially incorrect disposal, can cause significant damage to the environment. —...

  • Page 45: Product Description

    Product Description Product Description Construction of the Börger machine Components Macerator Intermediate chamber Gear unit BA-Classic HPL_EN, 24.01.2024 www.boerger.de / www.boerger.com...
  • Page 46 Product Description Construction Quick-release cover Multicrusher casing Connection flange (inlet, outlet) Cutting unit Timing gear Oil sight glass Breather, oil filler for gear unit Oil drain for gear unit Two shafts with parallel axes; drive shaft can optionally be at position 0 or 1 Cutting chamber shaft seal Intermediate chamber (quench)

  • Page 47: Quick-Release Cover

    Product Description 3.1.1 Quick-release cover — This cover enables easy access to the interior of the casing and to all parts subject to wear in the Börger machine. — The pipes on the inlet and outlet can remain connected. — The quick-release cover can be removed after loosening the four ring nuts (2).
  • Page 48 Product Description HPL 300 N Depth — HPL 300 N The welded casing is equipped as standard with an internal casing protection plate towards the gear unit and one towards the quick- release cover. The casing protection plates are each equipped with a counter blade.

  • Page 49: Cutting Unit

    Product Description 3.1.3 Cutting unit Example: HFL Multicrusher Construction and function On the hexagonal shaft (S), which is pushed over the carrier shaft (W), there are cutting blades (M) and spacer rings in alternating sequence. Several blade designs and constructions are available for Börger Multicrushers.
  • Page 50 Product Description Cutting unit versions Blade types Installation of directional blades in respect of shaft rotation Coarse cutting output, Type G 10 teeth Direction of rotation: – Direction of rotation: – Fine cutting output, Type F 16 teeth Direction of rotation: – Direction of rotation: –...
  • Page 51 Product Description Blade thicknesses Blade thickness approx. 4 mm (0.16 ") Code 4 Series — HAL — HAN Blade thickness approx. 5 mm (0.20 ") Code 5 Series — HPL — HCL Blade thickness approx. 6 mm (0.24 ") Code 6 Series —...
  • Page 52 Product Description Arrangement The arrangement of the blades depends on the properties of the flow medium and the desired cutting performance: — Individual blades (Code E) For the finest possible cutting result — Blades in blocks of two (Code B) For a higher flow rate with a coarser cutting result In exceptional cases blocks of three blades...
  • Page 53 Product Description Alignment The blades or blocks of blades on any given shaft can be arranged in radial alignment with each other as follows: — Parallel (code p)   For optimum intake performance for coarse solids such as potatoes, turnips, apples —...
  • Page 54 Product Description The number of blades is dependent upon the construction depth of Ä Chapter 6.3 “Repairs” on page 144 the Multicrusher casing. Cutting unit code: Coarse, 10 teeth Fine, 16 teeth Very fine, 16 teeth Coarse, 8 double teeth Special geometry Shaft rotates counter-clockwise –L...

  • Page 55: Multicrusher Gear Unit

    Product Description 3.1.4 Multicrusher gear unit — The two shafts of the Multicrusher mounted on one side of the carrier gear unit drive the cutting units. — The carrier gear unit of the Multicrusher functions as a gear reducer. The rotary motion of the drive shaft is transferred to the "short shaft"...

  • Page 56: Intermediate Chamber (Quench)

    Product Description 3.1.6 Intermediate chamber (quench) NOTICE! Risk of damage to the gear unit when the intermediate chamber is closed tightly! When the vent hole is closed tightly or has become blocked, emerging medium from the working chamber cannot escape through the intermediate chamber and will penetrate the gear unit if the mechanical seal is defective.

  • Page 57: Designs, Mounting Positions

    Product Description 3.1.7 Designs, mounting positions NOTE! Fill holes and breathers Depending on the Börger machine and the mounting position, the positions of the oil sight glass, breathers, fill holes and drain holes for the gear unit and the intermediate chamber can vary. —...
  • Page 58 Product Description Mounting position M3 — Upside-down — Feet upwards — Horizontal shafts Example: Classic FL series Mounting position M5 — Turned 90° to the left — Feet to the right — Horizontal shafts Example: Classic FL series Mounting position M6 —...

  • Page 59: Pipe Connections On Inlet And Outlet

    Product Description 3.1.8 Pipe connections on inlet and outlet In most cases, two-shaft Börger machines are equipped with pipe connectors on the inlet and outlet that have been specially designed for the different applications and mounting conditions. The inlet and outlet can be equipped with the same or different pipe connectors.

  • Page 60: Units / Drive Options

    Product Description Double bend upwards — connection towards the front, back, top, bottom or side Intake hopper on the inlet — For highly viscous but still fluid material, a 90° turned Börger machine can be equipped with an intake hopper on the inlet instead of a pipe con- nector 3.1.9 Units / drive options...
  • Page 61 Product Description Overhead mounted drive assembly (piggyback) Börger-Multicrusher V-belt pulley / chain drive V-belt (up to five belts, depending on the drive) or chain drive V-belt/chain guard Drive (with gear reducer in this example) Base frame Pipe connector (short, straight pipe connector with flange in this example) Motor plate Unit with hydraulic drive Börger-Multicrusher...

  • Page 62: Options And Accessories

    Product Description 3.1.10 Options and accessories NOTE! Special equipment A variety of special equipment and additional accessories are available for the safe operation of the Börger machine according to its application. Ä Chapter 8 “Accessories” on page 191 You will find explanations referring to the special equipment and any delivered accessories in the appendix.

  • Page 63: Operating Principle

    Product Description Operating principle Inlet of flow medium with coarse materials Blades of the drive shaft Blades of the short shaft with intake and reversing effect Outlet of flow medium with shredded parts   The Börger Multicrusher is a dual-shaft grinder that has been con- structed according to the principle of the successful Börger rotary lobe pump.

  • Page 64: Technical Data

    Product Description Technical data Börger machines are configured individually for the application requirements. This leads to a wide range of variations that have been optimized for specific applications. Therefore, only the data of some of the standard versions can be listed here as examples. Detailed specifications for your Börger machine or unit can be found in the data sheet and the individual dimensional drawing sent when the machine was ordered.
  • Page 65 Product Description Dimensions without attachment parts (HPL 200, HPL 300) Dimensions approx. [mm] approx. [inch] HPL 200 HPL 300 HPL 200 HPL 300 3.58 5.79 5.71 7.87 4.57 4.57 37.5 1.48 2.56 67.5 2.66 3.74 8.46 10.63 20.28 22.44 15.55 15.55 9.84 9.84...
  • Page 66 Product Description Multicrusher without attachment parts - HPL 300 N www.boerger.de / www.boerger.com BA-Classic HPL_EN, 24.01.2024...
  • Page 67 Product Description Dimensions without attachment parts (HPL 300 N) Dimensions HPL 300 N approx. [mm] approx. [inch] 14.3 15.5 10.0 ÆR HPL 300 N approx. [kg] approx. [lb] Weight BA-Classic HPL_EN, 24.01.2024 www.boerger.de / www.boerger.com...
  • Page 68 Product Description Pipe connectors The pipe connectors are designed according to the dimensional drawing created for the order. We deliver short, straight pipe con- nectors as standard, with flanges (selectable) according to: — DIN EN 1092-1, type 11 — ANSI/ASME B 16.5 RF Class 150. www.boerger.de / www.boerger.com BA-Classic HPL_EN, 24.01.2024...
  • Page 69 Product Description Dimensions A and B in [mm] (approx.) Type: HPL 200 HPL 300 Standard: DIN/EN ANSI/ASME DIN/EN ANSI/ASME Dimension: DN 100 (4") DN 125 (5") DN 150 (6") DN 200 (8") When using two 2 mm (.08") gaskets, + 4 mm must be added to the specified B dimensions and + 2 mm to the speci- fied A dimensions.
  • Page 70 Product Description Dimensions A and B - HPL 300 N HPL 300 N HPL 300 N Type: approx. [mm] approx. [inch] Standard: DIN/EN ANSI/ASME DIN/EN ANSI/ASME Dimension: DN 100 (4") — — 30.5 — — DN 125 (5") 30.1 32.9 DN 150 (6") 28.1 30.9...
  • Page 71 Product Description Base frame Base frame HPL 200, HPL 300, HPL 300 N Base frame Dimensions approx. [mm] approx. [inch] 35.0 16.5 31.9 17.5 approx. [kg] approx. [lb] Weight Complete unit The dimensions can be found in the specific dimensional drawing created for the order.

  • Page 72: Performance Data And Maximum Loads

    Product Description 3.3.2 Performance data and maximum loads Multicrusher The specification of the rated capacity for which the Multicrusher was actually configured can be found in the data sheet. General limits: Speed n [rpm] Operating pressure Flow rate Multicrusher Recom- Permitted Min.
  • Page 73 Product Description Sludge up to 1% DS or very well flowing materials Water or materials similar to water Pipe connections NOTICE! Risk of damage due to incorrectly installed pipe system! Börger machines are robust, and are constructed for use with high loads.
  • Page 74 Product Description Example: Classic FL series Forces and torques on metal pipe connectors (short, straight pipe connectors) Forces N max Torques Nm max Pipe nominal Value: diameter (mm) (total) (total) Valid for Börger 100, 125, 150, 7000 9200 7000 13514 1500 1300 1800...

  • Page 75: Transportation, Storage And Installation

    Transportation, Storage and Installation Transportation, Storage and Installation Transportation WARNING! Risk of fatal injury due to suspended loads! Loads can swing and fall during lifting operations. This can cause severe injury, including death. — Never stand under or within the swinging range of suspended loads.
  • Page 76 Transportation, Storage and Installation Tool: Hoists Be sure to read and follow all instructions: — on safety, — on operation and control, Ä Chapter 2.12 — on installation, repairs and maintenance. “Safety instructions for maintenance and rectifying malfunc- tions” on page 39 Observe the specifications in the hoist instructions, especially for the inclination angle allowed.

  • Page 77: As-Delivered Condition

    Transportation, Storage and Installation — Overhead mounted drive assemblies can be transported safely using the method shown here, for example. As-delivered condition Be sure to read and follow all instructions: — on safety, — on operation and control, — on installation, repairs and maintenance. Ä...

  • Page 78: Storage And Interim Storage

    Transportation, Storage and Installation Storage and interim storage 4.3.1 Storage NOTICE! Risk of damage caused by frost! Frost can cause damage to the Börger machine. — Protect the Börger machine and its connections against frost. NOTICE! Inadequate maintenance can result in malfunctions and damage! —...
  • Page 79 Transportation, Storage and Installation Always adhere to the following storage conditions for the Börger machine: — The storage room must be evenly ventilated and free of dust and vibrations — The relative humidity must be below 65% and the temperature between 15 °C and 25 °C (59 °F and 77 °F) —...
  • Page 80 Transportation, Storage and Installation If the device was stored for two years or more, or if the storage conditions detailed above could not be met: Be sure to read and follow all instructions: — on safety, — on operation and control, Ä...

  • Page 81: Interim Storage

    Transportation, Storage and Installation 4.3.2 Interim storage For the interim storage of a used Börger machine, the fol- lowing applies: Be sure to read and follow all instructions: — on safety, — on operation and control, Ä Chapter 2.12 — on installation, repairs and maintenance. “Safety instructions for maintenance and rectifying malfunc- tions”...
  • Page 82 Transportation, Storage and Installation Further operating manuals / supplementary operating manuals You must completely read the separate operating manuals and/or supplemen- tary operating manuals for components and/or special versions. Pay particular attention to all instructions — on safety, — on operation and control, —...

  • Page 83: Preparation For Installation

    Transportation, Storage and Installation 4.4.1 Preparation for installation NOTICE! Risk of material damage due to non-compliance with the operating manuals for accessories! Non-compliance with supplementary operating manuals for spe- cial equipment or accessories can lead to damage to the Börger machine.
  • Page 84 Transportation, Storage and Installation Be sure to read and follow all instructions: — on safety, — on operation and control, Ä Chapter 2.12 — on installation, repairs and maintenance. “Safety instructions for maintenance and rectifying malfunc- tions” on page 39 Check all specifications in the technical data sheet and only install the Multicrusher if it is suitable for the intended applica- tion.
  • Page 85 Transportation, Storage and Installation Base frame Attach the Börger machine to a solid, rigid surface. Drive Connect the Börger machine which is installed on a Börger base frame or a suitable rigid surface to a suitable drive. Observe the appropriate speed and sufficient torque, and take all necessary parameters into account, such as viscosity and the solid content of the medium.
  • Page 86 Transportation, Storage and Installation PL / HPL Pipe connectors - Seals / Fastening screws Seal Fastening screw Torque max. Steel (8.8) — 25 Nm O-ring — 18 ft-lbs M8x25 (M8x30) — 3.5 mm (0.14") Stainless steel — Hexagon socket head cap screw, DIN EN ISO 4762 —...

  • Page 87: Setup

    Transportation, Storage and Installation 4.4.2 Setup NOTICE! Risk of damage caused by frost! Frost can cause damage to the Börger machine. — Protect the Börger machine and its connections against frost. NOTICE! Sufficient air circulation at the drive! — Ensure that there is sufficient circulation of air around the drive;...
  • Page 88 Transportation, Storage and Installation NOTE! Base frame installation The nuts underneath the base frame must be accessible with a wrench from the front and back. If realignment is required or the machine is reinstalled on the base frame (e.g. following repairs or replacement), then it must be possible to hold the nuts in place with a wrench.

  • Page 89: Installing The Inlet And Outlet

    Transportation, Storage and Installation Other versions — Mobile units must be operated on a solid surface and be secured in place. Double-check this. — When installing special versions, check whether a supple- mentary operating manual is enclosed in the appendix and, if so, follow the instructions.

  • Page 90: Aligning The Unit

    Transportation, Storage and Installation Be sure to read and follow all instructions: — on safety, — on operation and control, Ä Chapter 2.12 — on installation, repairs and maintenance. “Safety instructions for maintenance and rectifying malfunc- tions” on page 39 Clean all connection flanges and all other connections before installation and ensure that they are not damaged.
  • Page 91 Transportation, Storage and Installation After the Börger machine is installed, in order to rule out damage caused by displacement, you must check the align- ment of the coupling on units mounted on a base frame that have gear motors. Be sure to read and follow all instructions: —...
  • Page 92 Transportation, Storage and Installation Be sure to read and follow all instructions: — on safety, — on operation and control, Ä Chapter 2.12 — on installation, repairs and maintenance. “Safety instructions for maintenance and rectifying malfunc- tions” on page 39 —...

  • Page 93: Electrical Connection

    Transportation, Storage and Installation 4.4.5 Electrical connection DANGER! Risk of fatal injury due to electric power! There is an immediate risk of fatal electric shock if live com- ponents are touched. Damage to the insulation of the indi- vidual components can be fatal. —...
  • Page 94 Transportation, Storage and Installation NOTE! When using frequency converters Due to their working principle, frequency converters generate leakage current. — For proper operation of a frequency converter at a residual current device, the use of an AC/DC sensitive residuaI cur- rent device (type B) according to EN50178/VDE0160 is required due to the DC component of the leakage current.

  • Page 95: Hydraulic Connection

    Transportation, Storage and Installation 4.4.6 Hydraulic connection DANGER! Risk of fatal injury due to hydraulic oil spurting out under pressure! Hydraulically actuated moving parts can cause severe injury. — Have all work on the hydraulic system performed by hydraulic specialists. —...

  • Page 96: Pto Shaft Connection

    Transportation, Storage and Installation 4.4.7 PTO shaft connection DANGER! Risk of injury due to rotating parts! Moving parts can cause severe injury. — Do not reach into rotating parts or handle rotating parts when the machine is in operation. — Never open protective covers when in operation. —...

  • Page 97: Checks Before Commissioning

    Transportation, Storage and Installation Be sure to read and follow all instructions: — on safety, — on operation and control, Ä Chapter 2.12 — on installation, repairs and maintenance. “Safety instructions for maintenance and rectifying malfunc- tions” on page 39 On versions with a PTO shaft drive, ensure that the drive side of the PTO shaft is properly connected to the drive.
  • Page 98 Transportation, Storage and Installation NOTICE! Inadequate maintenance can result in malfunctions and damage! — When the machine is stored for longer periods, rotate the shafts several times after about six months (or more often, depending on the storage conditions), according to Ä...

  • Page 99: Checking Readiness For Operation

    Transportation, Storage and Installation On used machines, remove any foreign bodies that may cause the rotating parts to jam. If this does not solve the problem, then removal and possibly replacement of the mechanical seals or rotating parts is necessary. Ä...
  • Page 100 Transportation, Storage and Installation — on installation, repairs and maintenance. Ä Chapter 2.12 “Safety instructions for maintenance and rectifying malfunc- tions” on page 39 — Ensure that the Börger machine is integrated into an emer- gency stop system, or, if such a system is not mandatory, that the shutdown device is adequately labeled.
  • Page 101 Transportation, Storage and Installation Check the fill level in the intermediate chamber. On standing versions, the quench fluid must reach halfway up the top shaft. Otherwise, the quench fluid (cf. data sheet) must be refilled. If there is much more fluid in the inter- mediate chamber than the optimum fill level when the mechanical seal is intact, some of the fluid should be drained off in order to prevent premature overflowing.

  • Page 102: Checking The Flow Direction

    Transportation, Storage and Installation 4.5.3 Checking the flow direction DANGER! Risk of injury due to rotating parts! Moving parts can cause severe injury. — Do not reach into rotating parts or handle rotating parts when the machine is in operation. —...
  • Page 103 Transportation, Storage and Installation Example: Standard drive with two-stage helical gear unit: View of quick-release cover: View of drive with drive shaft at the top Þ Required direction of rotation of the shaft / the fan Flow direction from right to left, when the upper shaft turns clockwise wheel when looking at the drive: counter-clockwise...
  • Page 104 Transportation, Storage and Installation If the direction of rotation and therefore the flow direction are incorrect, change the direction of rotation of the drive or switch the PTO shaft for versions with two drive shafts. Mark the selected flow direction on the Börger machine using the adhesive label provided.

  • Page 105: Operation

    Operation Operation WARNING! Risk of injury as a result of improper operation! Improper operation may cause severe injury and considerable material damage. — Prior to commissioning, ensure that all installation work is per- formed and completed as per the information and notes pro- vided in this manual.
  • Page 106 Operation NOTICE! Risk of severe material damage caused by running a Börger machine against closed valves! Running against closed valves may cause permanent damage to your Börger machine. — The Börger machine must not be run against closed valves. — Make sure that the pipes are open when the Börger machine is switched on, e.g.
  • Page 107 Operation ENVIRONMENT! Danger due to incorrect handling of environmentally haz- ardous substances! Inappropriate handling of environmentally hazardous substances, especially incorrect disposal, can cause significant damage to the environment. — Especially water-polluting materials such as grease and lubri- cating oil must not pollute the soil or enter the sewage system during installation, repair and maintenance work.

  • Page 108: Commissioning

    Operation Commissioning NOTICE! Risk of damage to the mechanical seal due to a lack of quench fluid! Risk of damage to the mechanical seal due to a lack of quench fluid! — The heat-absorbing quench fluid prevents the mechanical seal from running dry and captures any medium that enters the intermediate chamber due to leaks in the mechanical seal.
  • Page 109 Operation Switch on the drive of the Multicrusher at the same time as the pump (or the pumps or the gravity feed, depending on the system). If it is not possible to switch on the drive and pump simultaneously as recommended, then switch on the Multi- crusher first, followed immediately by the pump (or the pumps or the gravity feed).

  • Page 110: Complete Commissioning

    Operation 5.1.2 Complete commissioning The Börger machine can be operated properly when all functions run correctly and no leaks are detected. NOTE! Checklist for commissioning A checklist for commissioning the Börger machine can be found in the appendix. Ä Chapter 9.6 “Checklist for commissioning” on page 209 Continuous operation Be sure to read and follow all instructions: —...

  • Page 111: Downtimes

    Operation Downtimes Be sure to read and follow all instructions: — on safety, — on operation and control, Ä Chapter 2.12 — on installation, repairs and maintenance. “Safety instructions for maintenance and rectifying malfunc- tions” on page 39 Switch off the Börger machine (or the pumps or the gravity feed, depending on the system) at the same time.

  • Page 112: Emergency Shut-Down

    Operation Emergency shut-down NOTE! EMERGENCY STOP The EMERGENCY STOP button as an EMERGENCY STOP enables the immediate shut-down of the Börger machine. In cases of emergency, the Börger machine must be shut down as fast as possible, the energy supply must be switched off and pressure must be released.

  • Page 113: Malfunctions

    Operation Malfunctions WARNING! Risk of injury due to inadequate troubleshooting, mainte- nance and repair work! Inadequate troubleshooting, maintenance and repair work can lead to severe injury and significant material damage. — To the extent necessary, amply secure the surrounding area when performing maintenance.
  • Page 114 Operation NOTICE! Risk of severe material damage due to a delayed shut-down in the event of a malfunction! A delayed shut-down in the event of malfunction can cause per- manent damage to the Börger machine. — In the event of a malfunction, shut down the Börger machine and all upstream and downstream system components imme- diately until the cause has been rectified.
  • Page 115 Operation Fault Possible causes Fault elimination Flow rate of the Multicrusher under Shut-off devices not open / not open — Open shut-off devices the target value completely Pipes blocked — Clean the pipes — Agitate the substrate fed, if required (lumps which are too large regularly enter the pipe at once) Flow speed not optimized...
  • Page 116 Operation Fault Possible causes Fault elimination The Multicrusher does not shred / Flow speed not optimized — Adjust the pump speed or the does not shred optimally feed Speed of the Multicrusher not opti- — Adjust the speed mized Incorrect drive direction of rotation —...
  • Page 117 Operation Fault Possible causes Fault elimination Wear or damage to the blades — Replace blades and, if necessary, spacer rings — Determine and rectify the cause of the damage — Install a stone trap upstream, if necessary — Only use the Multicrusher for its intended purpose Wear or damage to a hexagonal shaft —...
  • Page 118 Operation Fault Possible causes Fault elimination Multicrusher blocked (e.g. current Pump (pumps / gravity feed) switched — Switch pump (pumps / gravity consumption of the electric motor on too early feed) on at the same time as or exceeds limit) Ä...
  • Page 119 Operation Fault Possible causes Fault elimination Cutting unit incorrectly installed — Install the cutting unit properly Ä Chapter 6.3.3 “Replacing the blades and spacer rings” Ä Chapter 6.3.4 on page 150 “Replacing the hexagonal shaft” on page 168 Drive output too low —...
  • Page 120 Operation Fault Possible causes Fault elimination Complete loss of quench fluid Unsuitable, quickly evaporating — Use suitable quench fluid quench fluid — Adhere to temperature limits Maintenance intervals exceeded — Adhere to maintenance intervals — Fill intermediate chamber — Exclude consequential damage to the seals by performing regular fill level checks and by checking the quality of the gear oil...
  • Page 121 Operation Fault Possible causes Fault elimination The Multicrusher does not start, or Drive not switched on, not installed — Establish the correct drive func- runs with difficulty after a down- correctly or defective tion by connecting it to the power time supply, installing it correctly etc.

  • Page 122: Measures Following On Demand Work

    Operation Measures following on demand work! Following completion of the work and before starting the unit, carry out the following steps: Be sure to read and follow all instructions: — on safety, — on operation and control, Ä Chapter 2.12 —...

  • Page 123: Maintenance And Repairs

    Maintenance and repairs Maintenance and repairs WARNING! Risk of injury due to inadequate troubleshooting, mainte- nance and repair work! Inadequate troubleshooting, maintenance and repair work can lead to severe injury and significant material damage. — To the extent necessary, amply secure the surrounding area when performing maintenance.
  • Page 124 Maintenance and repairs NOTE! Minimum requirements The instructions described in this chapter are to be under- stood as the minimum requirements. — Depending on the operating conditions, further work may be necessary to maintain the Börger machine in an optimum con- dition.

  • Page 125: Machine Care

    Maintenance and repairs Machine care Appropriate machine care helps to maintain the functionality of the Börger machine in the long term. In general, regular cleaning of dust and deposits from all surfaces is sufficient. CAUTION! Health hazard due to residues of dangerous medium inside and on the Börger machine! There is an increased health hazard from contact with the medium and contaminated components.

  • Page 126: Cleaning The Outside

    Maintenance and repairs ENVIRONMENT! Danger due to incorrect handling of environmentally haz- ardous substances! Inappropriate handling of environmentally hazardous substances, especially incorrect disposal, can cause significant damage to the environment. — Especially water-polluting materials such as grease and lubri- cating oil must not pollute the soil or enter the sewage system during installation, repair and maintenance work.

  • Page 127: Pressure Relief

    Maintenance and repairs 6.1.2 Pressure relief WARNING! Risk of serious injuries caused by liquid spouting out or escaping gases! Gases or liquids may escape uncontrollably from seals and screw connections. Especially when flange connections are released and maintenance openings are opened, pressurized liquid can spout out at the cover.
  • Page 128 Maintenance and repairs CAUTION! Health hazard due to residues of dangerous medium inside and on the Börger machine! There is an increased health hazard from contact with the medium and contaminated components. Generally, the following applies: — When using dangerous or health-endangering media, take all necessary safety measures when performing work on the Börger machine.

  • Page 129: Internal Cleaning

    Maintenance and repairs 6.1.3 Internal cleaning WARNING! Severe injury due to residual pressure! Despite having depressurized the Börger machine, it may be under residual pressure in the event of congestion or lump forma- tion in the medium. — Take extra care when removing the flange connections and maintenance openings to prevent accidents caused by the release of residual pressure.
  • Page 130 Maintenance and repairs ENVIRONMENT! Danger due to incorrect handling of environmentally haz- ardous substances! Inappropriate handling of environmentally hazardous substances, especially incorrect disposal, can cause significant damage to the environment. — Especially water-polluting materials such as grease and lubri- cating oil must not pollute the soil or enter the sewage system during installation, repair and maintenance work.
  • Page 131 Maintenance and repairs — Shut down the Börger machine and downstream and upstream Ä Chapter 5.3 “Downtimes” on page 111 system components. — Secure the Börger machine against unauthorized or uncon- Ä Chapter 2.7 “Securing the machine trolled reactivation. against restart” on page 26 Ä...

  • Page 132: Maintenance And Inspection

    Maintenance and repairs Maintenance and inspection 6.2.1 Maintenance and inspection plan NOTICE! Risk of material damage due to improper maintenance! — Also observe the maintenance intervals detailed in the oper- ating manuals for the drive gear unit, motor etc., which are included in the appendix.
  • Page 133 Maintenance and repairs weekly Checking the barrier fluid fill level — In the event of a malfunction: take appropriate measures Ä Chapter 5.5 “Malfunctions” on page 113 Checking the functions and flow rate — Take appropriate measures to eliminate the malfunction Ä...
  • Page 134 Maintenance and repairs yearly Checking the electrical system and control unit for integrity and proper function every 2 years / every 10,000 operating hours Ä Chapter 6.2.2 “Lubricant fill level and changing the lubricants” on page 135 Changing the lubricants NOTE! Observe the operating conditions! The oil change intervals apply to normal operating condi-...

  • Page 135: Lubricant Fill Level And Changing The Lubricants

    Maintenance and repairs 6.2.2 Lubricant fill level and changing the lubricants CAUTION! Health hazard due to residues of dangerous medium inside and on the Börger machine! There is an increased health hazard from contact with the medium and contaminated components. Generally, the following applies: —...
  • Page 136 Maintenance and repairs NOTE! Behavior of the quench fluid The level of quench fluid may not drop below the minimum indi- cated on the level indicator. — The quench fluid can rise to the rim of the fill hole due to its function and depending on the operating temperature.
  • Page 137 Maintenance and repairs ENVIRONMENT! Danger due to incorrect handling of environmentally haz- ardous substances! Inappropriate handling of environmentally hazardous substances, especially incorrect disposal, can cause significant damage to the environment. — Especially water-polluting materials such as grease and lubri- cating oil must not pollute the soil or enter the sewage system during installation, repair and maintenance work.
  • Page 138 Maintenance and repairs Checking the oil level and the quench fluid The intervals for changing the lubricants can vary significantly and be reduced considerably depending on the operating conditions, such as high levels of humidity, high temperatures, temperature variations, aggressive atmospheres etc. Be sure to read and follow all instructions: —...
  • Page 139 Maintenance and repairs PL / HPL Rotary lobe pump BLUEline (Classic) / Multicrusher Optimum fill level Design Gear unit Intermediate chamber (mounting position) Center of oil sight glass Top shaft, center to covered (upright) Completely filled Lower edge, test bore (vertical) Center of oil sight glass Top shaft, center to covered...
  • Page 140 Maintenance and repairs Correcting the lubricant fill levels If necessary, correct the fill level of the intermediate chamber, unless a seal leakage is to be assumed, and the fill level of the gear unit according to the following description. Be sure to read and follow all instructions: —...
  • Page 141 Maintenance and repairs Filling: Remove the closure from the fill hole. Fill the lubricant up to the optimum fill level having regard to the information in the lubricant list. Ä Chapter 9.9 “Lubricant list” on page 215 Properly close the fill hole with the closure removed previ- ously.
  • Page 142 Maintenance and repairs NOTE! Changing the lubricant Observe the detailed information and instructions on changing the lubricant as described in the lubricant list and in the data Ä Chapter 9.9 “Lubricant sheet regarding the lubricants used. list” on page 215 Changing the lubricants Be sure to read and follow all instructions: —...
  • Page 143 Maintenance and repairs PL / HPL Rotary lobe pump BLUEline (Legend) / Multicrusher Fill quantity Gear unit Intermediate chamber Design (mounting position) approx. [l] approx. [gal] approx. [l] approx. [gal] 0.61 0.30 (upright) 0.90 0.32 (vertical) 0.61 0.30 (upside-down) M5, M6 0.42 0.24 (turned 90°)

  • Page 144: Repairs

    Maintenance and repairs Repairs WARNING! Risk of injury due to inadequate troubleshooting, mainte- nance and repair work! Inadequate troubleshooting, maintenance and repair work can lead to severe injury and significant material damage. — To the extent necessary, amply secure the surrounding area when performing maintenance.

  • Page 145: Notes On Repair Work

    Maintenance and repairs 6.3.1 Notes on repair work Be sure to read and follow all instructions: — on safety, — on operation and control, Ä Chapter 2.12 — on installation, repairs and maintenance. “Safety instructions for maintenance and rectifying malfunc- tions”...

  • Page 146: Opening And Closing The Quick-Release Cover

    Maintenance and repairs 6.3.2 Opening and closing the quick-release cover WARNING! Severe injury due to residual pressure! Despite having depressurized the Börger machine, it may be under residual pressure in the event of congestion or lump forma- tion in the medium. —...
  • Page 147 Maintenance and repairs All parts on the Börger machine that are subject to wear are accessible after the quick-release cover has been removed. Be sure to read and follow all instructions: — on safety, — on operation and control, Ä Chapter 2.12 —...
  • Page 148 Maintenance and repairs Remove the cover-side casing protection plate (4). Clean the interior of the Börger machine. Ä Chapter 6.1.3 “Internal cleaning” on page 129 Closing the quick-release cover: Check the O-ring (6). Replace the O-ring (6) if it shows signs of damage.
  • Page 149 Maintenance and repairs NOTE! Replacing the casing protection plate If the cover-side casing protection plate is damaged, make sure that you use a suitable new casing protection plate. — The counter blades differ in size for the blade thicknesses 5 mm (.20'') and 8 mm (.31'') and the casing protection plates are not interchangeable on the Multicrusher, unlike the rotary lobe pump.

  • Page 150: Replacing The Blades And Spacer Rings

    Maintenance and repairs 6.3.3 Replacing the blades and spacer rings DANGER! Risk of injury due to rotating parts! Moving parts can cause severe injury. — Do not reach into rotating parts or handle rotating parts when the machine is in operation. —...
  • Page 151 Maintenance and repairs Hexagon socket head cap screw Counter blade Sealing washer Drive shaft Cover disk Short shaft O-ring Blades, spacer rings on the drive shaft Hexagonal shaft Blades, spacer rings on the short shaft Gear-side casing protection plate Rotor / hexagonal shaft (tightening torques) Tightening torques Fastening screw Counter bearing with...
  • Page 152 Maintenance and repairs Tightening torques Fastening screw Counter bearing with Pump / Multicrusher Counter bearing (rotor) mechanical seal Size approx. [in-lbs] approx. [in-lbs] (hexagonal shaft) approx. [in-lbs] Thread Stainless Steel Stainless Steel Stainless Steel (10.9) steel (10.9) steel (10.9) steel M 12 M 12 M 16...
  • Page 153 Maintenance and repairs NOTE! Sequence of the blades and spacer rings Before removing the blades [M1, M2], make sure that the neces- sary sequence of the blades and spacer rings (arranged in blocks, arranged individually), the radial alignment of the blades with each other (parallel or offset) and the installation direction of the blade tips that corresponds to the direction of rotation have been recorded so they can be reinstalled correctly.
  • Page 154 Maintenance and repairs a) HPL 200, blade thickness 8 mm (.31''), 6 blades per shaft Blade types G, F or S, 8 mm (.31'') Gear-side counter blade Blade type R, 8 mm (.31'') Cover-side counter blade Spacer ring 8.5 mm (.33'') (6x on AW, 5x on KW) Spacer ring 8.25 mm (.32'') (1x on KW) www.boerger.de / www.boerger.com...
  • Page 155 Maintenance and repairs b) HPL 200, blade thickness 5 mm (.20''), 9 blades per shaft Blade types G, F or S, 5 mm (.20'') Gear-side counter blade Blade type R, 5 mm (.20'') Cover-side counter blade Spacer ring 6 mm (.24'') (9x on AW, 8x on KW) Spacer ring 5.5 mm (.22'') (1x on KW) BA-Classic HPL_EN, 24.01.2024...
  • Page 156 Maintenance and repairs c) HPL 300, blade thickness 8 mm (.31''), 9 blades per shaft Blade types G, F or S, 8 mm (.31'') Gear-side counter blade Blade type R, 8 mm (.31'') Cover-side counter blade Spacer ring 8.5 mm (.33'') (8x on AW, 8x on KW) Spacer ring 8.25 mm (.32'') (1x on AW, 1x on KW)
  • Page 157 Maintenance and repairs d) HPL 300, blade thickness 5 mm (.20''), 14 blades per shaft Blade types G, F or S, 5 mm (.20'') Gear-side counter blade Blade type R, 5 mm (.20'') Cover-side counter blade Spacer ring 6 mm (.24'') (13x on AW, 13x on KW) Spacer ring 5.5 mm (.22'') (1x on AW, 1x on KW)
  • Page 158 Maintenance and repairs Arranged in blocks of two (code B) The alignment must be parallel or offset — Check before removing the blades! Parallel alignment (code p) Offset alignment (code v) www.boerger.de / www.boerger.com BA-Classic HPL_EN, 24.01.2024...
  • Page 159 Maintenance and repairs e) HPL 200, blade thickness 8 mm (.31''), 6 blades per shaft, blocks Blade types G, F or S, 8 mm (.31'') Gear-side counter blade Blade type R, 8 mm (.31'') Cover-side counter blade Spacer ring 8.5 mm (.33'') (6x on AW, 5x on KW) Spacer ring 8.25 mm (.32'') (1x on KW) BA-Classic HPL_EN, 24.01.2024...
  • Page 160 Maintenance and repairs f) HPL 200, blade thickness 5 mm (.20''), 9 blades per shaft, blocks Blade types G, F or S, 5 mm (.20'') Gear-side counter blade Blade type R, 5 mm (.20'') Cover-side counter blade Spacer ring 6 mm (.24'') (9x on AW, 8x on KW) Spacer ring 5.5 mm (.22'') (1x on KW) www.boerger.de / www.boerger.com...
  • Page 161 Maintenance and repairs g) HPL 300, blade thickness 8 mm (.31''), 9 blades per shaft, blocks Blade types G, F or S, 8 mm (.31'') Gear-side counter blade Blade type R, 8 mm (.31'') Cover-side counter blade Spacer ring 8.5 mm (.33'') (8x on AW, 8x on KW) Spacer ring 8.25 mm (.32'') (1x on AW, 1x on KW)
  • Page 162 Maintenance and repairs h) HPL 300, blade thickness 5 mm (.20''), 14 blades per shaft, blocks Blade types G, F or S, 5 mm (.20'') Gear-side counter blade Blade type R, 5 mm (.20'') Cover-side counter blade Spacer ring 6 mm (.24'') (14x on AW, 12x on KW) Spacer ring 5.5 mm (.22'') (2x on KW) www.boerger.de / www.boerger.com...
  • Page 163 Maintenance and repairs Tool: Torque wrench Be sure to read and follow all instructions: — on safety, — on operation and control, — on installation, repairs and maintenance. Ä Chapter 2.12 “Safety instructions for maintenance and rectifying malfunc- tions” on page 39 —...
  • Page 164 Maintenance and repairs Pull the blades [M] and the spacer rings [D] off the hexagonal shafts (5) one after the other. Thoroughly clean all parts and the cutting chamber before reinstalling removed parts. Check all removed parts for wear and only reuse them if they are undamaged.
  • Page 165 Maintenance and repairs The casing protection plates are fitted with counter blades [GS]. As standard, the gear-side casing protection plate (6) is mounted so that the counter blade [GS] is oriented around the short shaft (i.e. the shaft that is not connected to the drive).
  • Page 166 Maintenance and repairs Use new O-rings (4) and coat them depending on their resist- ance, e.g. with oil or flushing agent. 10. Use new cover disks (3) if required. 11. In each case, push on the cover disk (3) with the O-ring (4) correctly fitted into the groove so that the recess points towards the parallel key [PF].
  • Page 167 Maintenance and repairs 15. Check that the installed blades run smoothly. The easiest way of doing this is by turning the drive shaft clockwise with an appropriate amount of force using a hexagon socket wrench or a ratchet. NOTE! Troubleshooting when checking for smooth running. A spacer ring that is too thin and in an incorrect position can have the result that the blades of the drive shaft and the short shaft do not have the required distance to each other...

  • Page 168: Replacing The Hexagonal Shaft

    Maintenance and repairs 6.3.4 Replacing the hexagonal shaft DANGER! Risk of injury due to rotating parts! Moving parts can cause severe injury. — Do not reach into rotating parts or handle rotating parts when the machine is in operation. — Never open protective covers when in operation. —...
  • Page 169 Maintenance and repairs NOTE! Inspection of the condition of the hexagonal shaft Only in rare exceptional cases , the hexagonal shaft must be replaced. However, regular inspections of the condition of the hexagonal shaft are recommended. Ensure that there is no excessively large play between the blades and the hexagonal profile.
  • Page 170 Maintenance and repairs Be sure to read and follow all instructions: — on safety, — on operation and control, Ä Chapter 2.12 — on installation, repairs and maintenance. “Safety instructions for maintenance and rectifying malfunc- tions” on page 39 — Shut down the Börger machine and downstream and upstream Ä...
  • Page 171 Maintenance and repairs Check the O-rings (5) on the rotating seal holding bushes and Ä Chapter 6.3.5 replace them when necessary, see “Replacing the mechanical seal” on page 172. NOTE! Börger GmbH recommends: — Always replace the O-rings as well in this situation. Check all removed parts for wear and only reuse them if they are undamaged.

  • Page 172: Replacing The Mechanical Seal

    Maintenance and repairs 6.3.5 Replacing the mechanical seal O-ring Lip seal Rotating seal holding bush Gear-side casing protection plate Keyway Stationary seal holding bush Seal faces Parallel key O-ring Shaft Tool: Multitool [M] www.boerger.de / www.boerger.com BA-Classic HPL_EN, 24.01.2024...
  • Page 173 Maintenance and repairs Be sure to read and follow all instructions: — on safety, — on operation and control, Ä Chapter 2.12 — on installation, repairs and maintenance. “Safety instructions for maintenance and rectifying malfunc- tions” on page 39 — Shut down the Börger machine and downstream and upstream Ä...
  • Page 174 Maintenance and repairs In each case, unscrew the rotating seal holding bush (2) using the special tool (M) and pull it off the shaft. Removing the parallel key Unscrewing the rotating seal Rotating seal holding bushes - holding bush removing the seal faces Remove the seal face (4) with O-ring (5) out of the corre- sponding rotating seal holding bush (2).
  • Page 175 Maintenance and repairs NOTICE! Risk of material damage due to incorrect handling of mechanical seals! Make sure not to damage the sealing surfaces of the new seal faces. — The sealing surfaces must be clean and should not be scratched. 12.
  • Page 176 Maintenance and repairs 15. Press both remaining seal faces (4) with O-rings (5) into the stationary seal holding bushes (8) using the push-in tool for mechanical seals (M). Press the mechanical seals into the Press the mechanical seals into the Screw in the rotating seal holding rotating seal holding bushes (2) stationary seal holding bushes (8)
  • Page 177 Maintenance and repairs NOTICE! Risk of material damage due to insufficient or excessive pre-tension of mechanical seals! Risk of consequential damage if the rotating seal holding bushes are installed incorrectly. The pre-tension on the seal faces required for a correct seal is generated by the correct setting of the rotating holding bush.
  • Page 178 Maintenance and repairs 18. Insert the parallel key (9) so that it fits into the groove of the rotating seal holding bush (2) and the keyway of the shaft (3). The side of the parallel key must fit into the rotating seal holding bush with the nib upwards.
  • Page 179 Maintenance and repairs 22. Install the blades and spacer rings in accordance with Ä Chapter 6.3.3 “Replacing the blades and spacer rings” on page 150. Check that the blades run smoothly: — If a rotating seal holding bush is screwed in too far, the collar of the hexagonal shaft rubs against the gear-side casing protection plate and the shaft can only turn with difficulty.

  • Page 180: Replacing The Gear-Side Casing Protection Plate

    Maintenance and repairs 6.3.6 Replacing the gear-side casing protection plate O-ring f. rotating seal holding bush Drive shaft Countersunk screw Short shaft Gear-side casing protection plate Counter blade Jacking thread Be sure to read and follow all instructions: — on safety, —...
  • Page 181 Maintenance and repairs Remove the blades and spacer rings in accordance with Ä Chapter 6.3.3 “Replacing the blades and spacer rings” on page 150. Ä Chapter Remove the hexagonal shaft in accordance with 6.3.4 “Replacing the hexagonal shaft” on page 168. Unscrew the countersunk screws (2) from the gear-side ®...
  • Page 182 Maintenance and repairs 10. Attach the hexagonal shaft, see Ä Chapter 6.3.4 “Replacing the hexagonal shaft” on page 168. 11. Install the blades and spacer rings, cover disks with new O- rings and hexagon socket head cap screws with new sealing washers and tighten the hexagon socket head cap screws with the torque specified in Ä...

  • Page 183: Modifications For Changing The Flow Direction

    Maintenance and repairs 6.3.7 Modifications for changing the flow direction DANGER! Risk of injury due to rotating parts! Moving parts can cause severe injury. — Do not reach into rotating parts or handle rotating parts when the machine is in operation. —...
  • Page 184 Maintenance and repairs Required directions of rotation of the shafts depending on the flow direc- tion: View of quick-release cover / counter bearing cover: — Flow direction from right to left View of quick-release cover / counter bearing cover: — Flow direction from left to right NOTE! Observe the direction of rotation! The tips of the directional blade types G, F and S must always...
  • Page 185 Maintenance and repairs Be sure to read and follow all instructions: — on safety, — on operation and control, Ä Chapter 2.12 — on installation, repairs and maintenance. “Safety instructions for maintenance and rectifying malfunc- tions” on page 39 — Shut down the Börger machine and downstream and upstream Ä...

  • Page 186: Other Repairs

    Maintenance and repairs 6.3.8 Other repairs If repairs to your Börger machine are required that are not covered by the described repair and maintenance measures, we recom- mend contacting Börger customer service. The factory can only accept repair orders if a completed safety cer- tificate / declaration of decontamination accompany the device submitted for repair, as well as any necessary safety data sheets for the medium and / or cleaning agent.

  • Page 187: Measures Following Repair And Maintenance Work

    Maintenance and repairs 6.3.10 Measures following repair and maintenance work! Following completion of the work and before starting the unit, carry out the following steps: Be sure to read and follow all instructions: — on safety, — on operation and control, Ä...

  • Page 188: Queries

    Maintenance and repairs 6.3.11 Queries Börger machines are easy to maintain. We hope that we have clearly described all the relevant operating steps in this operating manual. Nevertheless, Börger machines are customized and developed for the specific requirements of the operator so that not all questions can be fully answered in a general operating manual.

  • Page 189: Disposal

    Disposal Disposal Environmental protection ENVIRONMENT! Danger due to incorrect handling of environmentally haz- ardous substances! Inappropriate handling of environmentally hazardous substances, especially incorrect disposal, can cause significant damage to the environment. — Especially water-polluting materials such as grease and lubri- cating oil must not pollute the soil or enter the sewage system during installation, repair and maintenance work.

  • Page 190: Metals

    Disposal Metals Sort and separate different metal types. Dispose of these metals according to the legal requirements through authorized waste disposal companies/authorities. Electrical and electronic waste Electrical and electronic waste must be disposed of separately. Electrical and electronic waste must not be disposed of with domestic waste.

  • Page 191: Accessories

    Accessories Accessories The range of accessories supplied by Börger GmbH is as multi- faceted as the areas of application for Börger machines. If your Börger machine was delivered with accessories, the corresponding operating manuals can generally be found in the appendix or in the packaging of the units, if delivered as originally packed.

  • Page 192: Monitoring Equipment

    Accessories Monitoring equipment 8.3.1 Dry run protection with conductivity sensor In a correctly installed Multicrusher, direct frictional heat is not gen- erated when dry running for a short period. Frictional heat or spark formation as a result of incorrect mainte- nance and repair work, due to foreign bodies or adhesive solids that have penetrated the unit, could however –...

  • Page 193: Flow Monitoring Devices

    Accessories Pressure monitoring devices of different manufacturers offer pro- tection from damage due to overpressure. The Börger machine or system can thus be switched off when a preset pressure is exceeded, or other measures for reducing the pressure can be carried out.

  • Page 194: Appendix

    Appendix Appendix Data sheet Data sheet The data sheet is enclosed separately with the operating manual. The data sheet contains all relevant data for your Börger machine or unit. — Especially consider the operating conditions and limits mentioned in the data sheet.
  • Page 195 Appendix Replacing the blades and spacer rings Pos. no. Designation Quantity 9.1a, 9.2a Blade for drive shaft 6 / 9 / 14 9.1b, 9.2b Spacer ring for drive shaft 6 / 9 / 8 / 13 / 14 9.1c, 9.2c Spacer ring for drive shaft, narrow 0 / 1 9.1d...
  • Page 196 Appendix Replacing the mechanical seals Pos. no. Designation Quantity Mechanical seal — 2 x seal face — 2x O-ring O-ring for quick-release cover O-ring for rotating seal holding bush O-ring for cover disk Sealing washer Hexagon socket head cap screw for fastening the cutting unit to the shaft Sealing washer Replacing the casing protection plates Pos.
  • Page 197 Appendix NOTE! Spare parts orders! The data below are required: — Serial number — see nameplate — Type code — according to data sheet (Important! - comparison with serial number!) Börger GmbH will then obtain the information for the appropriate spare parts for you from the production documents of your machine.

  • Page 198: Assembly Drawing

    Appendix Assembly drawing The assembly drawing shows the positions of the spare parts as Ä Chapter 9.4 “Spare parts list” on page 200. described in 9.3.1 HPL 200 www.boerger.de / www.boerger.com BA-Classic HPL_EN, 24.01.2024...

  • Page 199: Hpl 300 / Hpl 300 N

    Appendix 9.3.2 HPL 300 / HPL 300 N 9.3.3 HPL gear unit BA-Classic HPL_EN, 24.01.2024 www.boerger.de / www.boerger.com...

  • Page 200: Spare Parts List

    Appendix Spare parts list WARNING! Risk of injury when using unsuitable spare parts! The use of unsuitable spare parts can cause malfunctions which can lead to severe injury, including death, and to significant mate- rial damage. — Only use suitable spare parts. —...
  • Page 201 Appendix Quantity HPL... Pos. Item description Gear casing PL Gear casing cover Casing, PL Quick-release cover 9.1a Blade, 8 mm, drive shaft 9.1b Spacer ring, 8.5 mm, drive shaft 9.1c Spacer ring, 8.25 mm, drive shaft HPL 300 — 9.1d Spacer ring, 5.5 mm, drive shaft HPL 300 —...
  • Page 202 Appendix Quantity HPL... Pos. Item description O-ring, PL 25.1 25.2 Gasket, PL O-ring for cover O-ring for rotating seal holding bush, 54x4 mm O-ring for cover disk, 54x4 mm O-ring for stationary seal holding bush, 80x3 mm Lip seal with dust protection lip, DIN 3760 form AS, 45x70x10 mm 1 / 2 1 / 2 DUO double lip seal, 55x80x10 mm...
  • Page 203 Appendix Quantity HPL... Pos. Item description Sealing washer, 21x26x1.5 mm, for oil sight glass ½" for 90° turned version 0 / 1 0 / 1 Sealing washer, A17x23x1.5, DIN 7603 Breather G⅜" Snap ring DIN 472 - 110x4 Screw plug for gear unit, G1A, DIN 908 Sealing washer A17x23x1.5, DIN 7603 (for pos.

  • Page 204: Tools / Installation Aid

    Appendix 9.4.1 Tools / installation aid General work on the Börger machine NOTE! Adhere to the prescribed intervals for regular maintenance and inspections or those specified herein and in the oper- ating manuals of the components. — Suitable workshop equipment as well as specified special tools are essential for carrying out maintenance work.
  • Page 205 Appendix NOTE! Adhere to the prescribed intervals for regular maintenance and inspections of the electrical system and/or components or to those intervals specified herein and in the operating manuals of the components. — The electrical system may only be opened, maintained and repaired by qualified electricians, while having proper regard to the attached electric circuit diagrams.
  • Page 206 Appendix Standard tools Tools for electrical work — These tools shall comply with the international standard IEC 60900 (identical to EN 60900 for Europe and DIN EN 60900 for Germany). — The standard applies to “Insulated and insulating hand tools” used for live working and work near live parts, with voltage ratings up to 1000V AC or 1500V DC.
  • Page 207 Appendix Special tools Hammer drill — A hammer drill is a power tool to drill holes into mineral mate- rial, e.g. stone or concrete. Through the impact, the cutting edge of the drill pulverizes the material Hoists Lifting and slinging gear must be designed and dimensioned ade- quately according to the particular hazard and the loads occurring during transport.
  • Page 208 Appendix Torque wrench — A torque wrench is a hand-held fastening tool, with which a defined torque can be applied to a connecting element (screw or nut), so as to ensure the required clamping force between the connecting components even at maximum operating forces.

  • Page 209: Parallel Keys

    Appendix Parallel keys The following parallel key lengths must be adhered to and checked. NOTICE! Risk of material damage when operated with an incorrect or damaged parallel key! Imprecise parallel key lengths can lead to misalignment of the rotating holding bush and can cause mechanical damage to the Börger machine or to the complete unit.
  • Page 210 Appendix Customer: Börger order confirmation no.: Machine number: Type code: Your project: Order number: Commissioning date: Delivery date: Carried out by: Checked by: Test point (date/signature) (date/signature) 1 Operating manual and appendices read and understood Application data and operating parameters according to data sheet correspond to application 3 Base frame fixed correctly to solid, even surface Coupling alignment within the permitted tolerance, coupling...

  • Page 211: Eu Declaration Of Conformity / Eu Declaration Of Incorporation

    Appendix EU Declaration of Conformity / EU Declaration of Incorporation 9.7.1 EU Declaration of Conformity Börger GmbH | Benningsweg 24 | 46325 Borken-Weseke | Germany We hereby declare that the following products: Product description: Multicrusher Type descriptions: HAL, HAN, HPL, HCL, HFL, HLA Version: Classic, Protect, Select Serial number:...

  • Page 212: Eu Declaration Of Incorporation

    Appendix 9.7.2 EU Declaration of Incorporation Börger GmbH | Benningsweg 24 | 46325 Borken-Weseke | Germany We hereby declare that the following products: Product description: Multicrusher Type descriptions: HAL, HAN, HPL, HCL, HFL, HLA Version: Classic, Protect, Select Serial number: from 1000 0000 Year of manufacture: from 2018...

  • Page 213: Declaration Of Conformity / Uk - Declaration Of Incorporation

    Appendix UK - Declaration of Conformity / UK - Declaration of Incorporation 9.8.1 UK - Declaration of Conformity Börger GmbH | Benningsweg 24 | 46325 Borken-Weseke | Germany We hereby declare that the following products: Product description: Multicrusher Type descriptions: HAL, HAN, HPL, HCL, HFL, HLA Version: Classic, Protect, Select...

  • Page 214: Declaration Of Incorporation

    Appendix 9.8.2 UK - Declaration of Incorporation Börger GmbH | Benningsweg 24 | 46325 Borken-Weseke | Germany We hereby declare that the following products: Product description: Multicrusher Type descriptions: HAL, HAN, HPL, HCL, HFL, HLA Version: Classic, Protect, Select Serial number: from 1000 0000 Year of manufacture: from 2018...

  • Page 215: Lubricant List

    Appendix Lubricant list Lubricant list — The lubricant list is enclosed separately with the operating manual. Area of validity — Unless subject to special agreements, the lubricant list applies to all standard Börger pump versions, Powerfeed units, macerating units, Biose- lect units and submersible mixers.

  • Page 216: Technical Data (Maintenance)

    Appendix 9.12 Technical data (maintenance) 9.12.1 Lubricants - fill levels NOTE! Lubricant list and data sheet! Observe the detailed information and instructions on changing Ä Chapter 9.9 the lubricant as described in the lubricant list “Lubricant list” on page 215 and in the data sheet regarding the lubricants used.
  • Page 217 Appendix PL / HPL Rotary lobe pump BLUEline (Classic) / Multicrusher Optimum fill level Design Gear unit Intermediate chamber (mounting position) Center of oil sight glass Top shaft, center to covered (upright) Completely filled Lower edge, test bore (vertical) Center of oil sight glass Top shaft, center to covered (upside-down) M5, M6...

  • Page 218: Tightening Torques (Guidelines)

    Appendix 9.12.2 Tightening torques (guidelines) Rotor / hexagonal shaft (tightening torques) Tightening torques Fastening screw Counter bearing with Pump / Multicrusher Counter bearing (rotor) mechanical seal Size approx. [Nm] approx. [Nm] (hexagonal shaft) approx. [Nm] Thread Stainless Steel Stainless Steel Stainless Steel (10.9) steel...

  • Page 219: Anchor Bolts - Setup

    Appendix PL / HPL Pipe connectors - Seals / Fastening screws Seal Fastening screw Torque max. Steel (8.8) — 25 Nm O-ring — 18 ft-lbs M8x25 (M8x30) — 3.5 mm (0.14") Stainless steel — Hexagon socket head cap screw, DIN EN ISO 4762 —...

  • Page 220: Index

    Index Index Checklist for commissioning ... . . 209 Commissioning ..... . . 108 Accessories .
  • Page 221 Index Cover ......28 Inspection ......132 Inspection plan .
  • Page 222 Index Operation ......105 Other repairs ..... . . 186 Commissioning .
  • Page 223 Index Safety equipment ..... . . 27 Coupling guard ..... . 28 Repairs .
  • Page 224 Index Tools ....... . 204 Training ....... 10 Training topics .

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