Operating manual. Mobile Stone separator. Machine number : 93033

Transcription

1 Mobile Stone separator Model description: Stone separator Type : Stonefex 3000 E Machine number : Project number : AU13060 Year of manufacture : 2013

2 DANGER There is unawareness about the machine, its correct handling as well as possible sources of danger. Danger to person s lives. Danger of personal injury. Danger of damages to machine and environment. Before you execute any works at or with the machine, read the entire operating manual carefully! Only use the machine for its intended purpose! Attend all safety instructions, described in this operating manual. If you did not understand the operating manual or parts of it, inform your superior. Always operate the machine in awareness of hazards. NOTICE This operating manual consists of totally four handbooks: Safety instructions (chapter 1) Technical data (chapter 2 to 4) Operating manual (chapter 5 to 8) Maintenance manual (chapter 9 to 11) This operating manual is only considered to be complete, if all 4 handbooks are available completely, legible and in current condition. The operating manual is a component of the machine and it has to be made available for the personnel always. Page 2 of 70 Translation

3 Structure of the entire operating manual Safety instructions (separate handbook) 1. Safety Technical data (separate handbook) 2. Preface 3. Overview and intended use 4. Function Operating manual (this handbook) 5. EC-Conformity declaration 6. Transport, setting up and commissioning 7. Operation 8. Emergency Maintenance manual (separate handbook) 9. Maintenance / Cleaning 10. Error, cause, correction 11. Disassembly / Disposal Translation Page 3 of 70

4 Contents Operating manual 5. EC-Conformity declaration The most important laws and regulations Relevant EC-regulations Harmonised standards Laws Regulations BGV-Examinations (annually) Transport, setting up and commissioning Checking the delivery Demands against the manufacturer Claims against the freight forwarder Storage and packing Intermediate storage and wintering Transport Safety instructions for transport Transport regulations Prepare machine for transport Empty the machine...19 Secure the machine...20 Couple the machine onto a towing machine Setting up and commissioning Setting up the machine Decouple the machine from the towing vehicle...29 Prepare the machine for operation...30 Establish the readiness of operation Basics for operation Check free space below the machine Preparation for commissioning Safety instructions for preparing the commissioning...35 Checking the machine for stability...37 Checking the mechanics (at the machine switched off and secured against re-starting)...37 Checking the machine for working materials, running out uncontrollably...38 Checking the suction fan...39 Check the feeding belt...40 Check the engine compartment with diesel generator (option)...41 Checking the cooling openings in the switch cabinet...45 Page 4 of 70 Translation

5 Checking lines and electric cables...46 Checking the fuelling...47 Checking the safety devices First commissioning Operation Operating elements Operating elements for standard operation Operating elements for operation with diesel engine (option) Starting module for the diesel generator Types of operation Automatic operation Manual operation Operation of machine Commissioning - standard Commissioning diesel generator (option) Separation in operation type Automatic Separation in operation type Manual operation Switch off the machine Secure the machine Mechanically adjustable component Inclination of the separating device Energy breakdown Emergency Position of safety devices Personal damages Machine damages Index 68 Translation Page 5 of 70

6 5. EC-Conformity declaration Page 6 of 70 Translation

7 5.1. The most important laws and regulations With its individual components the mobile stone separator is a very complex machine, such that a whole series of different industrial fields and their respective regulations apply to such a machine. Therefore it is not recommendable listing all regulations here. This would restrict the overall clarity out of proportion to its value. The operator is responsible for observing all standards and regulations relevant for his areas Relevant EC-regulations REGULATION / STANDARD TITLE EDITION 2006/42/EG EC-regulation: Machines /108/EG EC-regulation: Electromagnetic compatibility 2004 Tab. 1: Relevant EC-regulations Harmonised standards HARMONISED STANDARD EN 349 EN TITLE Safety of machinery - Minimum gaps to avoid crushing of parts of the human body Safety of machinery - Human body measurements - Part 1: Principles for determining the dimensions required for openings for whole body access into machinery EDITION Translation Page 7 of 70

8 HARMONISED STANDARD TITLE EDITION EN EN 619 EN EN 842 EN 894 EN 953 EN 981 EN 1005 EN 1037 EN 1088 Safety of machinery - Ergonomic design principles - Part 1: Terminology and general principles Continuous handling equipment and systems - Safety and EMC requirements for equipment for mechanical handling of unit loads Safety of machinery - Reduction of risks to health from hazardous substances emitted by machinery - Part 1: Principles and specifications for machinery manufacturers Safety of machinery - Visual danger signals - General requirements, design and testing Safety of machinery - Ergonomics requirements for the design of displays and control actuators - Part 3: Control actuators Safety of machinery - Guards - General requirements for the design and construction of fixed and movable guards Safety of machinery - System of auditory and visual danger and information signals Safety of machinery - Human physical performance - Part 1: Terms and definitions Safety of machinery - Prevention of unexpected start-up Safety of machinery - Interlocking devices associated with guards - Principles for design and selection Page 8 of 70 Translation

9 HARMONISED STANDARD EN ISO 4413 EN ISO 7731 EN ISO TITLE Hydraulic fluid power - General rules and safety requirements for systems and their components Ergonomics - Danger signals for public and work areas - Auditory danger signals Safety of machinery - General principles for design - Risk assessment and riskreduction EDITION EN ISO Ergonomics of the thermal environment - Methods for the assessment of human responses to contact with surfaces - Part 1: Hot surfaces EN ISO Safety of machinery - Safety-related parts of control systems - Part 1: General principles for design EN ISO Safety of machinery - Safety-related parts of control systems - Part 2: Validation EN Safety of machinery - Emergency stop - Principles for design EN ISO EN ISO /A1 EN ISO /A1 Safety of machinery - Safety distances to prevent hazard zones being reached by upper and lower limbs Safety of machinery - Permanent means of access to machinery - Part 1: Choice of fixed means of access between two levels - Amendment 1 Safety of machinery - Permanent means of access to machinery - Part 2: Working platforms and walkways - Amendment Translation Page 9 of 70

10 HARMONISED STANDARD TITLE EDITION EN ISO /A1 EN EN Safety of machinery - Permanent means of access to machinery - Part 3: Stairs, stepladders and guard-rails - Amendment 1 Safety of machinery - Electrical equipment of machines - Part 1: General requirements Degrees of protection provided by enclosures (IP code) EN Electromagnetic compatibility (EMC) - Part 6-2: Generic standards - Immunity for industrial environments EN Electromagnetic compatibility (EMC) - Part 6-4: Generic standards - Emission standard for industrial environments EN EN Safety of machinery - Indication, marking and actuation - Part 2: Requirements for marking Preparation of instructions - Structuring, content and presentation Tab. 2: Harmonised standards Page 10 of 70 Translation

11 Laws LAW TITLE EDITION 1.GPSGV 3.GPSGV 9.GPSGV Tab. 3: Laws First regulation for law of safety of units and products (regulation about putting electrical resources on the market for use within determined tension limits - 1. GPSGV) Third regulation for law of safety of unit and products, regulation for information of machine noise - 3. GPSGV Ninth regulation for law of safety of units and products (regulation of machines - 9. GPSGV Regulations REGULATION TITLE EDITION BGV A1 BGV A8 Accident prevention regulation Policy of prevention Accident prevention regulation Qualification of safety and healthy cover at the work place BGV B3 Accident prevention regulations - Noise 2005 Tab. 4: Regulations The above mentioned national regulations can be consulted as an underpinning of the proof of the Annex I of the EC-regulation Machines. Translation Page 11 of 70

12 BGV-Examinations (annually) According to the 9th regulation of the Machine and Safety Law annual testing of the machine safety is legally specified to be carried out by a specialist. Further details on this can be found in the Accident prevention regulation BGV A1, A3, A8, D8, BGR500 T2.9. The responsible specialist can be requested from: Komptech Umwelttechnik Deutschland GmbH Carl-Zeiss-Str. 2 D Oelde [t] (+49) [f] (+49) info@komptech.de Page 12 of 70 Translation

13 6. Transport, setting up and commissioning This chapter describes all measures and needs, to be fulfilled, to prepare the machine for operation. All machines of the company Komptech Umwelttechnik GmbH are carefully checked for damages and completeness before shipment. As far as this is possible due to shipping reasons, our stationary treatment plants are provided completely assembled and ready for operation Checking the delivery NOTICE The delivery can be incomplete. Complaints regarding missing parts or damages can only be accepted by the manufacturer, if a check of the delivery is executed promptly. 1. Check the entire delivery immediately after receipt, resp. the transfer of risk. Check the machine / delivery immediately after receipt for completeness (according to delivery note), damages, transport damages and availability of operating manual. Translation Page 13 of 70

14 Demands against the manufacturer If the machine / delivery is incomplete, damaged or without operating manual, get in touch with the seller immediately. If you recognize damages, document these photographically if possible Claims against the freight forwarder If you notice transport damages at the packaging or the machine, get in touch with the delivering forwarder promptly. Document damages photographically, if possible. Store the packaging for a possible check / inspection by the freight forwarder Storage and packing The packing material used by the manufacturer serves to avoid damages during a transport / shipment. avoid damages during storage. guarantee a safe storage. If the original package is not available anymore, then request a packing company with specialists put the consignment onto an appropriate basis transistionally (e.g. pallet). contact the manufacturer and clear any questions regarding the package, resp. transport insurance. Page 14 of 70 Translation

15 Intermediate storage and wintering WARNING Danger due to improper handling of lubricants, cleaning agents and preservatives. Personal damages due to skin contact and/or breathing in can arise. Wear the personal protection equipment. Read the corresponding safety data sheets. NOTICE The manufacturer cannot be held liable for damages, resulting from improper storage. The optimal service life of the machine cannot be achieved. Clean the machine thoroughly before storage. Prior to storage execute lubrication and conservation works. 2. Only store the machine/material within surroundings, protecting from influences of weather. Attend all descriptions of the chapter Maintenance and repair in the handbook Maintenance manual. Translation Page 15 of 70

16 6.3. Transport In this chapter the necessary measures to transport, set up and commission the machine safely, are described Safety instructions for transport DANGER The machine is unsuitable for transporting humans and materials. Personal damage and death can result. Prior to every transport secure, that no persons stay on or in the machine. Prior to every transport secure, that no foreign material is on or in the machine. DANGER During transport, materials can fall down from the machine or be catapulted out of it. Personal damage and death can result. Prior to every transport secure that no separations are on or in the machine. Prior to every transport secure that the machine is secured against re-starting. Page 16 of 70 Translation

17 DANGER For the transport of the machine, a perfect condition for traffic is required. Personal damages and death can result. Prior to every transport check the braking unit, illumination unit and signal devices for their perfect function. Prior to every transport check the tyre pressure (8 bar). WARNING Screws and nuts adapt themselves under load and set after a certain period of time. So the screwing connection can loose. Personal and machine damages can arise. Secure that the wheel nuts are tightened with a torque of 450Nm. At new machines check the torque of the wheel nuts after approx km. Check the torque of the wheel nuts after longer applications prior to a new transport of the unit. WARNING The personnel is not sufficiently qualified for a safe execution of machine transports. Personal and machine damages can arise. Only engage personnel specifically qualified with the machine s transport. Secure that local transport conditions and regulations are observed. Observe the regulations of the road traffic code (StVO). Translation Page 17 of 70

18 WARNING The machine s transport requires the compliance of minimum requirements on the route. Personal and machine damages can arise. Familiarize with the machine s transport dimensions. Familiarize with the machine s transport weight. Only drive on roads proved and appropriate for transport. NOTICE Secure that the axle- and braking system between towing vehicle and trailer coordinate with each other. In the case of non-attention we cannot take over any guarantee or warranty for damages caused by this. 3. Execute a coordination between axle- and braking system Transport regulations NOTICE Secure that the machine s transport is executed professionally and aware of dangers. In the case of non-attention we cannot accept any guarantee or warranty claims in the case of occurring damages. Attend all transport instructions of the operating manual. 4. Attend the regulations of accident prevention Prepare machine for transport Here the measures, to be carried out are described, so you can transport the machine safely. Page 18 of 70 Translation

19 DANGER Danger of falling down when using ladders. Personal damage and death can result. Do only put ladders onto the machine if this is not operating. Do only use ladders, not showing any visible damages. Secure that the underground is suitable for setting up a ladder. NOTICE The features of the machine and so possible options are listed in the handbook "Technical data in chapter Equipment of the machine. Empty the machine NOTICE When stopping the machine, there are differences, depending on the type of operation. In operation Manual all belts and blowing devices are stopped immediately. In operation type Automatic all belts and blowing devices are stopped systematically in reverse order to commissioning. We strongly recommend to empty the machine in operation type Automatic. Thus a complete emptying of the machine can be most likely guaranteed. Conditions: The machine is in working position (see chapter Setting up the machine, page 28). Translation Page 19 of 70

20 Then: Fig. 1: Operating panel - Empty the machine Press the button Stop (1). Standard Switch the key switch to position 0 and remove the key. Option Diesel generator Switch the key switch (4) to position 0 and remove the key. Switch the electro main switch (3) to position 0 / OFF. NOTICE Secure that no material is on the belts. Secure the machine DANGER Machine parts not secured can fold out or loose from the machine uncontrollably during transport. Personal damages and death can result. Prior to every transport secure that all transport safety devices had been installed. Page 20 of 70 Translation

21 Fig. 2: Loose the transport struts Loose the pins (1). Put the transport struts (2) onto the discharge belts. Standard manual winch: Fig. 3: Manual winch discharge belt Crank up the discharge belts onto the machine until the end position is achieved. Translation Page 21 of 70

22 Option manual-hydraulically: Fig. 4: Manual hydraulics discharge belt Fig. 5: Adjusting manual hydraulics POS Description 1 Adjusting lever 2 Lever position Folding on the belt 3 Lever position Folding out the belt Pump the discharge belts onto the unit until the end position is achieved. Page 22 of 70 Translation

23 Option electro-hydraulically: Fig. 6: Activation discharge belt stone and inert fraction Fig. 7: Activation discharge belt biomass combustible fraction Activate the jack switch (1 resp. 2) to the left and fold the discharge belts onto the machine until the end position is achieved. Fig. 8: Fix pins at the transport struds Hand the eyes of the transport struts into the bolts on both sides. Secure both sides with pins (1). Translation Page 23 of 70

24 Fig. 9: Remove exhaust hose Remove the exhaust hose (1) at the spout from the suction fan. Fig. 10: Sockets in engine compartment If necessary disconnect the external power supply (1) to the machine. If necessary disconnect electric connections (2+3) from the unit. Fig.: Additional socket at the rear If necessary disconnect the additional socket at the rear of the machine. Page 24 of 70 Translation

25 Close the maintenance doors. Close the switch cabinet s doors. Prior to a transport on public roads clean the unit carefully. Couple the machine onto a towing machine Fix the bumper buffer device on both sides of the machine. Couple the machine onto an appropriate and proved towing vehicle. Fig. 11: Connection for compressed air & landing gear Connect the hoses for compressed air (1) onto the towing vehicle. Crank up the landing gear (2). Fig. 12: Electric connections Connect the cable for backlights (1). Connect the cable for the ABS-unit (2). Translation Page 25 of 70

26 Connect the cable for the illumination unit (3). Fig. 13: Release valve compressed air brake Activate the release valve (1) if the machine shall be moved without the towing machine. Fig. 14: Wheel chocks Remove the wheels chocks and fix these in the retainers (1) at both sides of the machine. Fig. 15: Parking brake Loose the parking brake by turning it anti-clockwise (1). DANGER Page 26 of 70 Translation

27 Prior to a transport on public roads secure the roadworthy and safe condition of the entire combination! Personal damages and death can result. Check the tyre air pressure, the wheel fixation, the function of the illumination unit, the function of the braking unit. Secure that no construction parts protrude over the admissible dimensions of the vehicle. Secure that transport safety devices are correctly installed. Translation Page 27 of 70

28 6.4. Setting up and commissioning Setting up the machine DANGER The machine can sink or overturn on not suiting underground (non-sufficient load bearing capacity or high inclination). Personal damages and death can result. Prior to the machine s assembly secure that an appropriate substructure is available on site. DANGER Within the scope of commissioning, works at electrics can be necessary at which the danger of an electric shock exists. Personal damages and death can result. Works at electrics must only be executed by authorized electro specialists. WARNING For the machine s commissioning, it is necessary that unit parts are folded down, whereby mechanical dangers arise. Personal and machine damages can arise. Prior to fold down the discharge belts secure that no one stays in the danger area of the machine. Wear the personal protection equipment. Page 28 of 70 Translation

29 WARNING For a safe commissioning it is necessary that all operating elements and machine parts are freely accessible. Personal and machine damages can result. Keep the safety distances necessary. Expel unauthorized persons out of the danger area. Secure that escape and emergency routes are not blocked. NOTICE The machine s features and so the possible options and their specifications are described in the handbook "Technical data in chapter Equipment of the machine Here the steps to be carried or are described to set up the machine for operation safely. Decouple the machine from the towing vehicle (Reverse order to description in chapter Prepare machine for transport, page 18) Tighten the parking brakes (cranking to the right). Put the wheel chocks behind the wheels on both sides. Disconnect the electric connections to the towing vehicle. Disconnect the connections of compressed air to the towing vehicle. Crank down the landing gear. Decouple the machine from the towing vehicle. Remove the bumper buffer device on both sides. Translation Page 29 of 70

30 DANGER The machine could have been damaged during transport so a safe operation is not guaranteed anymore. Personal damages and death can result. After setting up, check the machine for visible mechanic, electric or hydraulic damages. Inform the operator immediately if you recognized any damages. Do not execute any further works at or with the machine. Secure the machine against unintended starting. Prepare the machine for operation (Reverse order to description in chapter Prepare machine for transport, page 18) Loose the transport safety device on both sides at the discharge belt. Fold the discharge belt down from the unit. For this use the manual winch, the manual-hydraulics (option) resp. the electro-hydraulics (option). Fig. 16: Securing the discharge belts Hang the eyes of the transport struts into the bolts. Secure both sides with pins (1). Page 30 of 70 Translation

31 Connection exhaust hose Fig. 17: Connection exhaust hose Connect the flexible exhaust hose (1) to the span locks at the spouts of the suction fan. Direct the flexible exhaust hose (l= 3,300 mm) into a container (3) to be provided b the operator. The container has to have a minimum size of 30m³. Span the container covering net (2) over the container. The net has the dimensions: 3,500mm x 7,000mm. Translation Page 31 of 70

32 Establish the readiness of operation Electro-operation: DANGER When changing phases to adjust the machine, this can lead to an electric shock. Personal damages and death can result. Works at the electrics must only be executed by authorized electro-specialists. Connect the machine to the external power supply, sockets 63A/400V, if an operation with diesel generator is not planned. Operation with diesel generator (option): Switch on the battery disconnecting switch (option). Turn the electro main switch to position I / ON. Put the key into the lock for the electro-operation. Put the key into the ignition lock (option Diesel generatoroperation). The machine is now prepared for operation Page 32 of 70 Translation

33 Basics for operation Prior to commissioning, the machine and the personnel have to be prepared for a safe use. The following activities belong to this: Overhand product documentation When handing over the machine you also receive the operating manual according to the overhanding certificate. Check the completeness and confirm the receipt. Training of the personnel When the machine is handed over, the training on the machine is executed. The training must contain the following points: Safety instructions. Operating elements, functions of the machine. Carry out, check, change adjustments. Explanation for using the operating manual. Demand on using the operating manual. Execute regular safety checks. Translation Page 33 of 70

34 Check free space below the machine WARNING Garbage or screenings under the machine can be drawn into the machine again, or be set on fire due to the motor s heat emission. Machine damages or errors in process can arise. Clean the working area under the machine regularly. Fig. 18: Free space below the machine Keep the grey-marked area (1) under the unit free of screenings and contamination. Check this daily. Keep the orange-marked area (2) under the unit free of screenings and contamination. Secure this especially during the machine s operation. This is the area of sucking fresh air of the pressure fan. Keep the red-marked area (3) under the discharge belts free of screenings and contamination permanently. Secure this especially during the machine s operation Preparation for commissioning In the following chapters the control and maintenance works usually necessary before works, are described. Page 34 of 70 Translation

35 In the lubrication and maintenance manual you find an additional tablet at which the periods (intervals) of controls are described. Safety instructions for preparing the commissioning DANGER Checking and maintenance works are always combined with mechanic and electric dangers. Personal damages and death can result. Execute maintenance, repair and adjusting works only at the machine switched off and secured against unauthorized re-starting. DANGER Damaged or worn-out cables and hydraulic lines lead to a substantial danger due to high pressures and strong electric current. Personal damages and death can result. Do not commission the machine if you recognized damaged or worn-out cables or hydraulic lines. Secure the machine against unauthorized switching on. Inform the operator. DANGER Repair works at hydraulics and electrics contain a special danger due to high pressures and strong electric current. Personal damages and death can result. Works at the machine s hydraulics and electrics must exclusively be executed by qualified specialists. Translation Page 35 of 70

36 DANGER Danger of falling when using ladders. Personal damages and death can result. Do only put ladders onto the machine, if this does not operate. Do only use ladders, not showing any visible damages. Secure that the underground is suitable for setting up a ladder. In the case of diesel generator operation (option): DANGER The diesel generator s exhaust gases contain products, harmful to health. Personal damages and death can result. Let the diesel engine only run in a well-ventilated surrounding area. If necessary lead the exhaust gases out of the working surroundings with an appropriate suction device. WARNING Cooling water level, water and / or oil cooler heat up substantially during operation. Personal damages due to burnings or scaldings can arise. Check the level of cooling liquid of the water as well as the oil cooler only when the engine is switched off. Attend the period of cooling down the liquid and the coolers after switching off the machine Wear the personal protection equipment. Page 36 of 70 Translation

37 WARNING Open the maintenance flaps during operation or abandonment stage of the fans. Biomass or stones can be discharged out of the machine uncontrollably due to the air flow. Only open the maintenance flaps if the fans are switched off and stand still. Wear the personal protection equipment. Checking the machine for stability Secure that the machine has not sinked into the underground. Secure that the machine stands horizontally. Secure that the parking brake is tightened. Secure that the wheel chocks are positioned behind the wheels. Secure that there s no contamination or screening under the machine Checking the mechanics (at the machine switched off and secured against re-starting) Secure that no foreign bodies are within the expansion chamber or on the conveyor belt. Secure that the screwing connections are firmly tightened. Secure that the machine does not show any visible damages. Translation Page 37 of 70

38 Checking the machine for working materials, running out uncontrollably Secure that the machine does not show any leakages in the hydraulic system. Secure that the machine does not show any leakage of oil. Secure that the machine does not show any loss of fuel (Diesel). Secure that the machine does not show any loss of cooling liquid. Page 38 of 70 Translation

39 Checking the suction fan DANGER The suction fan has a very large gyrating mass and sharp-edged machine parts. Personal damages and death can arise. Secure that the suction fan is switched off and does not turn anymore. After switching off the suction fan wait for 2-3 minutes to secure that all parts have grinded to a halt. Secure that the suction fan cannot be switched on as long as works are executed at this part. Fig. 19: Check suction fan Secure that the cooling opening of the motor (1) is not contaminated. Secure that no foreign bodies are in the exhaust opening (3) of the suction fan. Loose the screws of the maintenance door (3) and secure that the interior (5) does not show any contamination. Loose the screws of the suction fan s (2) maintenance flaps and open this. Translation Page 39 of 70

40 Fig. 20: Suction fan, opened Check the interior for contamination and remove this contamination. Check the feeding belt Fig. 21: Maintenance flap, feeding belt Loose the securing screw (1). Open the maintenance flap (2). Fig. 22: Feeding belt - cleaning Check the interspace (1) for contamination and remove this. Page 40 of 70 Translation

41 Check the engine compartment with diesel generator (option) NOTICE The engine is a construction group. For this construction group an additional manufacturer documentation can be found in the annex Operating manuals of manufacturers. Attend the statements in the manufacturer documentation. Fig. 23: Unlock cooler door Unlock the lockings (1) of the cooler door with the machine key and fold out the door. Fig. 24: Cooler pre-screen Secure that the cooler pre-screen (1) is not contaminated. If necessary clean the cooler pre-screen (1). Open the span locks (2) and remove the cooler pre-screen for cleaning. Translation Page 41 of 70

42 Secure that the cooler is not contaminated. Close the cooler door after an executed check and / or cleaning. Fig. 25: Motor door Unlock the motor door (1) with the machine key and open the door. Fig. 26: Diesel generator Clean the motor free of contamination. Fig. 27: Motor for pressure fan Secure that the cooling opening of the electro-motor (1) is not contaminated. Page 42 of 70 Translation

43 Fig. 28: Cover of cooler Secure that there is enough cooling liquid in the cooler. Fig. 29: Check motor oil level Check the oil level by means of a dipstick (1). The filling level has to be over the mark of minimum quantity. Fig. 30: Filling opening for motor oil If necessary refill motoroil. Translation Page 43 of 70

44 Fig. 31: Water pre-separator Check whether the water pre-separator (1) in the fuel line has to be emptied. If necessary empty the water pre-separator. Fig. 32: Air filtercontamination display Check whether the air filter s contamination display (1) shows a red stripe. Clean or replace the air filter (filter element) if a red stripe is shown. WARNING Dirt in the generator can inflame or cause a shortcircuit. Personal damages due to burnings can arise. Check the generator s protection cover for contamination regularly. Clean the generator s protection cover if this is contaminated. Page 44 of 70 Translation

45 Fig. 33: Protection cover of the generator Check the generator s protection cover (1) for contamination. Clean the generator s protection cover, if this is contaminated. Close the motor door after an executed check and / or cleaning. Checking the cooling openings in the switch cabinet Fig. 34: Switch cabinet Cooling openings Check the cooling openings (1) at the switch cabinet. Clean the cooling openings (1), if this is contaminated or change the filter elements. Translation Page 45 of 70

46 Checking lines and electric cables DANGER Repair works at hydraulics and electrics contain a special danger due to high pressures and strong electric current. Personal damages and death can result. Works at the machine s hydraulics and electrics must exclusively be executed by qualified specialists. Secure that all hose connections lay freely and must not be squeezed. Lay free squeezed hose lines. Check hose lines laid open for damages. Page 46 of 70 Translation

47 Checking the fuelling ATTENTION In the case of a tank not filled completely, the possibility of condensation water in the tank exists. Condensation water can lead to corrosion rust in the tank. By and by this can lead to a leakage in the tank resp. to motor damages. At the end of the working day, fill up the tank completely. In the case of a longer stand still oft he unit it is absolutely necessary that the tank is filled completely. Fig. 35: Operating panel Checking the filling Check the fuel level (Diesel). Proceed as follows: Put the electro main switch (1) to position I / ON. Put the ignition key into the ignition lock (3) and turn it to position 1. Record the current filling level at the fuel gauge. After recording, switch all switches (1) and all keys to position 0, resp. OFF. Remove the key and store it safely. Refill the necessary fuel quantity (Diesel). Translation Page 47 of 70

48 Checking the safety devices Fig. 36: Safety devices Secure that all safety devices are available, undamaged and not manipulated. Check the function of all safety devices at the machine switched on. Press the EMERGENCY-STOP-SWITCH (unlocking by turning in clockwise direction). Turn the electro main switch to the left in position 0 / OFF. The machine has to stop operation immediately after activating a safety device. The lamp Error lights up in the operating panel after activating a safety device First commissioning For the first commissioning request a mechanic from the retailer or manufacturer. Page 48 of 70 Translation

49 Komptech Umwelttechnik Deutschland GmbH Carl-Zeiss-Str. 2 D Oelde [t] (+49) [f] (+49) info@komptech.de Translation Page 49 of 70

50 7. Operation The following points are described in this chapter, The operating elements, involved at the machine, which types of operation are available and how the machine is started and shut down Operating elements Fig. 37: Position of operating elements All operating elements (1) can be found at the rear, left side of the machine. Fig. 38: Division Operating panel The operating panel is divided into the following parts: POS Description 1 Operating elements for the operation with diesel generator (option). Page 50 of 70 Translation

51 2 EMERGENCY-STOP SWITCH 3 Operating elements for standard operation. 4 Electro-main switch Operating elements for standard operation Fig. 39: Operating elements Normal operation (1) Jack switch for Cleanfix -function (option) Serves the possibility to activate an intermediate cleaning of the cooler by the Cleanfix-fan (only with equipment diesel generator) (2) Selector switch (manual operation) Serves to pre-select the drives, to be started in operating type Manual operation. (3) Turning regulator for pressure fan Serves for adjusting the fan power of the pressure fan. (4) Stop-Button Serves for stopping the drives in the operating types Automatic-, resp. Manual operation. (5) Turning regulator for feeding belt Serves for adjusting the speed (0.5m/s to 1.4 m/s of the feeding belt). Translation Page 51 of 70

52 (6) Start-Button Serves for starting the unit in operation types Automatic-, resp. Manual operation. (7) Key switch Serves for choosing the operation type Automatic-, resp. Manual operation. (8) Control light Operation (green) Blinking - Machine is in start-, resp. stop sequence. Cont. light - Machine has started up and ready for operation. (9) Control light Error (red) Lights up in cases of errors at the drive motors. Lights up, if an EMERGENCY-STOP-SWITCH has been pushed Operating elements for operation with diesel engine (option) Fig. 40: Operating elements Diesel generator (option) (1) Starting module for the diesel generator (2) Tank display Shows the filling level in the Diesel tank. The maximum tank volume is approx. 300 litres. Page 52 of 70 Translation

53 (3) Temperature switch Shows the cooling liquid s temperature. In the case of a too high temperature, the diesel engine is switched off automatically. Starting module for the diesel generator Fig. 41: Starting module (1) Counter for operating hours (LCD-display) Shows the operating hours of the display. (2) Ignition lock The ignition lock has three switching positions: 0 = Off 1 = Ignition 2 = Motor start (3) Control light (red) Does not occupy any function. (4) Control light for water temperature (red) The control light for water temperature lights up if the ignition key is turned to position 1 and goes out afterwards. If the cooling liquid s temperature is too high, the control lamp lights up. In the case of a too high cooling liquid temperature the diesel generator is switched off automatically. Translation Page 53 of 70

54 (5) Control light for motor oil pressure (red) The control light for the motor oil pressure lights up if the ignition key is turned to position 1 and then passes over to continuous light. It expires directly after starting the engine. If the motor oil pressure is too low, the control lamp lights up continuously. In the case of too low motor oil pressure, the diesel engine is switched off automatically. (6) Control light for battery charge (red) The charge control lamp lights up if the ignition key is in position 1 in the ignition key. The light goes out immediately after starting the engine. In the case of a defective alternator or a torn V-belt, the control lamp lights up and the diesel engine switches off. (7) Control light for ignition (green) The control light for the ignition blinks if the ignition key is turned to position 1. The diesel generator must not be started until it has passed over to a continuous light. The control light for the ignition goes out after starting the diesel engine Types of operation In this chapter the different operation types are described. The description includes the functions, contained in the separate operation types and the dependencies on the service conditions. Selecting the operation type is executed with the key switch described in chapter Operating elements for standard operation, page Automatic operation The Automatic operation is the standard operation type of the machine. Page 54 of 70 Translation

55 Here it is secured that the machine is started and stopped (emptied) in the technologically correct order. Furthermore it is secured that the machine is switched off systematically in cases of error. Moreover the variable machine components are pre-adjusted so the best possible separation result is achieved in medium operation. These adjustments are based on the experiences gained during the machine s development Manual operation The machine s operation in operation type Manual operation can be necessary, if the type of the feeding material changes, the consistency (e.g. humidity of material) changes or the separation result shall be influenced specifically. In the operation type Manual operation all machine components can be started / stopped and partially controlled separately from each other. In the case of error (breakdown of a machine component) the machine is not stopped automatically in this operation type. The choice of this operation type can be necessary when machine components have to be put into a certain position for maintenance or repair works. Translation Page 55 of 70

56 7.3. Operation of machine Here the following points are described: How to commission the machine systematically. How to start the separation process. How to carry out the necessary machine adjustments. How to stop the machine systematically. The following steps must only be executed, if all descriptions of chapter Setting up and commissioning, page 28 have been transformed. WARNING Danger for persons, staying unauthorized in the machine s danger area. Personal damages due to movable machine parts or discharged material can arise. Secure that only authorized persons stay in the separate danger areas. Only operate the machine if no unauthorized persons stay in the danger area. Stop operating the machine if unauthorized persons enter the corresponding danger area. Wear the personal protection equipment. Page 56 of 70 Translation

57 Commissioning - standard Fig. 42: Operating panel - Commissioning Standard Switch the electro main switch (1) to position I / ON. Put the selector switch (5) to position 0. Put the key into the key switch (4) and turn the key to the right to position Automatic. Press the key Start (2) The machine is now being started up systematically. During this time the lamp Operation (3) lights up. When the lamp Operation (3) passes over to a continuous light, the unit is ready for operation. Translation Page 57 of 70

58 Commissioning diesel generator (option) Fig. 43: Operating panel - Commissioning Diesel generator (option) Put the electro main switch (1) to position I / ON. Put the selector switch (6) to position 0. Put the key into the key switch (5) and turn the key to the right to position Automatic. Put the key into the starting module (2) to position 1. Put the key in the starting module (2) to position 2 and start the diesel generator. Press the key Start (3)- The machine is now being started up systematically. During this time the light Operation (4) is blinking. If the light Operation (4) passes over to a continuous light, the unit is ready for operation Separation in operation type Automatic If the operation type Automatic has been selected, then the machine is ready for operation immediately after commissioning according to chapter Commissioning - standard (page 57) or chapter Commissioning diesel generator (option) (page 58). Page 58 of 70 Translation

59 Separation in operation type Manual operation If you selected the operation type Manual operation, all machine components must be commissioned separately. Start the diesel generator (if option available). Fig. 44: Operating panel - commissioning Manual operation 1 Secure that the turning regulator (8) and (9) are adjusted to Minimum". Put the key into the key switch (6) and turn the key to the left to position Manual. Choose the component you want to commission with the selector switch (7). With the functioning scheme you can see what component you are choosing. The positions 6 and 7 of the selector switch (7) are not occupied as standard. The position 0 is the initial position of the selector switch (7) for commissioning in Manual operation. Choose the machine component to be commissioned with the selector switch (7). Press the button Start (4) The machine component is now started up systematically. During this time the light Operation (5) is blinking. Translation Page 59 of 70

60 When the lamp Operation (5) has passed to a continuous light, the machine component is ready for operation. Start all machine components to be commissioned according to this scheme. Fig. 45: Operating panel - Commissioning Manual operation 2 For the separating operation you have to commission the machine components 1 to 5. Adjust the pressure fan s (1) power with the turning regulator (8 in Fig. 44). Adjust the feeding belt s (5) speed with the turning regulator (9 in Fig. 44). Not until all machine components have been commissioned, the machine is ready for operation. Page 60 of 70 Translation

61 Switch off the machine DANGER When operating with diesel engine (option) the power supply is not interrupted until the diesel generator is switched off. Personal damages and death can result. Always finish the switch off procedure of the machine with switching off the diesel engine. Fig. 46: Operating panel Switch off machine Operation type Automatic Stop the material feed on the feeding belt. Press the button Stop (1). The machine shuts down all components systematically now. The control light Operation (2) goes out when all components are shut down. Operation type Manual operation Stop the material feed on the feeding belt. Wait until the machine is empty. Press the button Stop (1). All activated machine components are stopped. Translation Page 61 of 70

62 The control light Operation (2) goes out Secure the machine Fig. 47: Operating panel Secure the machine Standard operation Put the key switch (1) to position 0. Remove the key and store it safely. Put the electro main switch (2) to position 0 / OFF. Option Diesel generator Put the key switch (1) to position 0. Remove the key and store it safely. Put the electro main switch (2) to position 0 / OFF. Turn the ignition key at the starting module (3) to position 0. Remove the ignition key and store it safely. Page 62 of 70 Translation

63 7.4. Mechanically adjustable component NOTICE A corresponding experience is required to use the mechanical adjustment possibilities so the separation result is affected positively. Without corresponding experience the separation result can get worse. 5. If possible use only the adjustments made at the plant Inclination of the separating device Due to adjusting the inclination, the air flow is changed in the expansion chamber. Thus the separation and its result can be affected. Fig. 48: Inclination of separating device Loose the screwings of the adjusting lever (1). Get the adjusting lever (1) to the desired, new position. Screw on the adjusting lever (1). Translation Page 63 of 70

64 7.5. Energy breakdown In the case of an energy breakdown, the machine shuts down completely. For a new operation the machine has to be commissioned again as described in chapter Commissioning - standard (page 57) resp. Commissioning diesel generator (option) (page 58). Page 64 of 70 Translation

65 8. Emergency DANGER The machine can be switched on again, although the danger or the source of it is not eliminated yet. Danger to life due to switching on the machine uncontrollably. Secure the machine against unauthorized re-starting. Fix corresponding warning signs at the operating panel. Inform the personnel on site about the reason of switching off Position of safety devices Fig. 49: Safety devices Translation Page 65 of 70

66 Personal damages If, in cases of emergency, danger to life and health of persons exists, execute the following actions: Press EMERGENCY-STOP-SWITCH. Take precautions against early re-starting of the machine. As far as necessary, take measures for First Aid resp. for danger or damage defence. Execute emergency call (rescue service, fire brigade, police) or engage someone with executing. Inform the supervising personnel/superior and the machine s operator immediately. Do not unlock the EMERGENCY-STOP-SWITCH until the danger is over and the source, resp. cause is found and eliminated. Page 66 of 70 Translation

67 Machine damages If, in cases of emergency, the danger of machine damages exists or this already occurred, execute the following actions: Press EMERGENCY-STOP-SWITCH. Take precautions against an early re-start of the machine. Inform the supervising personnel/superior and the machine s operator immediately. Only eliminate damages, which you were authorized for by the operator and you are specially qualified for. Do not unlock the EMERGENCY-STOP-SWITCH until the danger is over and the source, resp. cause is found and eliminated. Translation Page 67 of 70

68 Index Air filter 44 Automatic operation 54 BGV - Examinations 12 Bumper buffer device 25 Checking the delivery 13 Checks before commissioning 37 Commissioning 48 Cooler pre-screen 41 Cooling water filling 43 Counter for operating hours diesel generator53 EC-regulations 7 Empty 19 Exhaust hose 31 Free space under the machine 34 Fuel pump 44 Fuel tank 47 Generator 45 Harmonised standards 7 Laws 11 Laws and regulations 7 Maintenance manual 3 Manual hydraulics 22 Manual operation 55 Manual winch 21 Motor oil level 43 Operating elements 50 Operating manual 3 Regulations 11 Safety devices 48 Safety instructions 3 Secure the machine 20 Setting up 28 Storage and packing 14 Suction fan 39 Switch off the machine 61 Technical data 3 Transport 16 Water pre-separator 44 Page 68 of 70 Translation

69 Translation Page 69 of 70

70 Komptech Umwelttechnik Deutschland GmbH Carl-Zeiss-Str. 2 D Oelde [t] [f] [e] info@komptech.de Komptech GmbH Kühau 37 A-8130 Frohnleiten [t] [f] [e] info@komptech.com All rights reserved - Rev.2 - Print : 01/2015 Translation : BA_Steinabscheider_3BA_02_en