ACS MPS, APS, EPS, CPS, SPS User Manual

1000 Series Pipe Shredder
Models Covered:
APS, CPS, MPS, EPS, SPS
Part Number: MAN-EPS-0001
Bulletin Number: GRN4-610
GRN4-610 ii
Write Down Your Serial Numbers Here For Future Reference:
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We are committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice.
DCN No. ____________ © Copyright 2013 All rights reserved.
GRN4-610 iii
Shipping Info
Unpacking and Inspection
You should inspect your granulator for possible shipping damage.
Thoroughly check the equipment for any damage that might have occurred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc.
In the Event of Shipping Damage
According to the contract terms and conditions of the Carrier, the responsibility of the Shipper ends at the time and place of shipment.
Notify the transportation company’s local agent if you discover damage.
Hold the damaged goods and packing material for the examining agent’s inspection. Do not
return any goods before the transportation company’s inspection and authorization.
File a claim with the transportation company. Substantiate the claim by referring to the agent’s report. A certified copy of our invoice is available upon request. The original Bill of Lading is attached to our original invoice. If the shipment was prepaid, write us for a receipted transportation bill.
Advise customer service regarding your wish for assistance and to obtain an RMA (return material authorization) number.
If the Shipment is Not Complete
Check the packing list as back-ordered items are noted on the packing list. You should have:
! Granulator
! Bill of lading
! Packing list
! Operating and Installation packet
! Electrical schematic and panel layout drawings
! Component instruction manuals
Re-inspect the container and packing material to see if you missed any smaller items during unpacking.
If the Shipment is Not Correct
If the shipment is not what you ordered, contact the shipping department immediately. For immediate assistance, please contact the correct facility located in the technical assistance section of this manual. Have the order number and item number available. Hold the items until you receive shipping instructions.
GRN4-610 iv
Returns
Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department.
Credit Returns
Prior to the return of any material, authorization must be given by the manufacturer. A RMA number will be assigned for the equipment to be returned.
Reason for requesting the return must be given.
ALL returned material purchased from the manufacturer returned is subject to 15% ($75.00 minimum) restocking charge.
ALL returns are to be shipped prepaid.
The invoice number and date or purchase order number and date must be supplied.
No credit will be issued for material that is not within the manufacturer’s warranty period and/or in new and unused condition, suitable for resale.
Warranty Returns
Prior to the return of any material, authorization must be given by the manufacturer. A RMA number will be assigned for the equipment to be returned.
Reason for requesting the return must be given.
All returns are to be shipped prepaid.
The invoice number and date or purchase order number and date must be supplied.
After inspecting the material, a replacement or credit will be given at the manufacturer’s discretion. If the item is found to be defective in materials or workmanship, and it was manufactured by our company, purchased components are covered under their specific warranty terms.
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Table of Contents
CHAPTER 1:! SAFETY ................................................................ 6!
1-1! How to Use This Manual ............................................................................................. 6!
Safety Symbols Used in this Manual ..................................................................... 6!
General Safety Regulations ................................................................................................... 9!
1-2! Responsibility .............................................................................................................. 9!
1-3! Warnings and Precautions ........................................................................................ 10!
CHAPTER 2:! FUNCTIONAL DESCRIPTION ........................... 15!
2-1! Models Covered in This Manual ................................................................................ 15!
2-2! General Description & Typical Features ................................................................... 15!
2-3! Safety Features ......................................................................................................... 30!
CHAPTER 3:! INSTALLATION .................................................. 34!
3-1! Uncrating the Equipment ........................................................................................... 34!
3-1! Electrical Connections ............................................................................................... 35!
3-2! Initial Start-up ............................................................................................................ 36!
CHAPTER 4:! OPERATION ....................................................... 38!
4-1! Start-up ..................................................................................................................... 38!
4-2! Operation Procedures ............................................................................................... 38!
4-3! Shut-down ................................................................................................................. 39!
CHAPTER 5:! MAINTENANCE ................................................. 40!
5-1! Preventative Maintenance Schedule ......................................................................... 40!
5-2! Preventative & Corrective Maintenance ................................................................... 41!
CHAPTER 6:! TROUBLESHOOTING ....................................... 59!
6-1! Introduction ............................................................................................................... 59!
CHAPTER 7:! APPENDIX .......................................................... 61!
7-1! Technical Specifications ............................................................................................ 61!
7-3! Drawings and Diagrams ............................................................................................ 62!
7-4! Spare Parts List ......................................................................................................... 69!
7-5! Technical Assistance ................................................................................................ 72!
Parts and Service Department ............................................................................ 72!
Sales and Contracting Department ..................................................................... 72!
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Chapter 1: Safety
1-1 How to Use This Manual
Use this manual as a guide and reference for installing, operating, and maintaining your granulator. The purpose is to assist you in applying efficient, proven techniques that enhance equipment productivity.
This manual covers only light corrective maintenance. No other maintenance should be undertaken without first contacting a service engineer.
The Functional Description section outlines models covered, standard features, and safety features. Additional sections within the manual provide instructions for installation, pre­operational procedures, operation, preventive maintenance, and corrective maintenance.
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup of the granulator. We can also provide the assistance of a factory-trained technician to help train your operator(s) for a nominal charge. This section includes instructions, checks, and adjustments that should be followed before commencing with operation of the granulator. These instructions are intended to supplement standard shop procedures performed at shift, daily, and weekly intervals.
The Operation chapter includes a description of electrical and mechanical controls, in addition to information for operating the granulator safely and efficiently.
The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service. Preventive maintenance sections are included to ensure that your granulator provides excellent, long service.
The Troubleshooting chapter serves as a guide for identification of most common problems. Potential problems are listed, along with possible causes and related solutions.
The Appendix contains technical specifications, drawings, schematics, parts lists, and available options. A spare parts list with part numbers specific to your machine is provided with your shipping paperwork package. Refer to this section for a listing of spare parts for purchase. Have your serial number and model number ready when ordering.
Safety Symbols Used in this Manual
The following safety alert symbols are used to alert you to potential personal injury hazards. Obey all safety messages that follow these symbols to avoid possible injury or death.
DANGER indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation or practice that, if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation or practice that, if not avoided, may result in minor or moderate injury or in property damage.
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Figure 1: Safety Tags and warning features
Hazard Alert Symbol
Description/Explanation
Preventative Maintenance
High Voltage Hazard. The electrical enclosure is supplied with 3-phase electrical power. Use caution when using or maintaining this product.
Every six months inspect all electrical connections for secure attachment. For further information see the Maintenance Chapter in this manual
Hands could be exposed to a crushing movement.
Every month inspect the shears/blades for any type of wear. For further information see the Maintenance Chapter in this manual.
When equipped with belts and sheaves, hands could become entangled.
Every month inspect the belt(s) for any type of wear. For further information see the Maintenance Chapter in this manual.
Hands can become entangled or cut if they enter the danger zone of gears or cutting shears
Every month inspect the shears/blades for any type of wear. For further information see the Maintenance Chapter in this manual.
The unit can produce continuous noise above 85 dBA and/or produce projectiles under normal operating conditions.
Always wear eye and ear protection when the machine is in operation or performing maintenance.
A person could be exposed to a crushing movement if walking around or under machine that is open/suspended for moving.
Always be aware of your surroundings and do not walk underneath a suspended machine.
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Mandatory Symbol
Description/Explanation
Read Operators Manual. This equipment must be operated and maintained by properly trained personnel. The information contained within this manual must be read and understood prior to operating this equipment.
Lock Out. This equipment is operated with 3-phase electrical power. Therefore, when performing any maintenance operations we recommend following the local standards for performing a lock-out/tag-out procedure.
Wear Safety Gloves. This equipment operates with sharp blades and rotors. We recommend that technicians use safety gloves while performing maintenance to protect hands from being exposed to these sharp surfaces.
Wear ear and eye protection. This unit may produce loud and continuous noise and may produce projectiles.
Pneumatic or hydraulic equipment. Pneumatic or hydraulic equipment must be kept at a safe pressure.
Do not reach into unit. Reaching into a unit is prohibited while the unit is in operation and may cause serious injury.
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General Safety Regulations
This machine uses knives for the performance of its intended use. Consequently, it can be a dangerous machine to operate and maintain unless these safety regulations are followed.
These regulations should be read, understood and periodically reviewed by all personnel involved in any way with this machine.
Never operate or remove any machine components that are secured by wrench-type fasteners unless the motor is electrically locked out and the rotor is motionless.
Never operate the machine or jog the rotor unless the cutting chamber covers, discharge chute, or any guards or covers are in place and secure. Do not circumvent the safety interlocks.
Prior to clearing a jam or performing any maintenance, the motor should be turned off and electrically locked out. Be sure that the rotor has come to a stop. Hands must not be inserted into the machine to clear the jam.
Do not extend any part of the body into feed roll openings or discharge area unless the motors are electrically locked out and the rotor and feed rolls are motionless.
Never extend fingers through holes in screen.
Be sure that the v-belts are properly aligned and that tension is at its maximum.
Extreme care should be taken to see that all bolts are properly tightened at all times. During the operation of the machine, rotor knife bolts may come loose. Although fine threads are used on the rotor knife bolts because vibration does not easily loosen them, you should inspect the tightness of the bolts frequently.
This machine is designed for the granulation of plastic materials. Do not feed any other materials into the machine.
1-2 Responsibility
These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine.
All personnel engaged in the use of the machine should become familiar with its operation as described in this manual.
Proper operation of the machine promotes safety for the operator and all workers in its vicinity.
Becoming familiar with materials, inspection, speed limitations, screens, and guard maintenance and total user responsibility will assist you in learning potential areas in need of observation for danger.
Each individual must take responsibility for observing the prescribed safety rules as outlined. All caution, warning and danger signs must be observed and obeyed. All actual or potential danger areas must be reported to your immediate supervisor.
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1-3 Warnings and Precautions
Our granulators are designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes.
To avoid possible personal injury or equipment damage when installing, operating, or maintaining this granulator, use good judgment and follow these safe practices:
! LEARN AND OBEY your company’s safety policy regarding granulating
equipment.
! MOVING OR LIFTING THE GRANULATOR: Although our equipment is built
and engineered for great ruggedness in operation, care must be taken when moving the machine along the floor or lifting it. Damage may occur to sheet metal covers, electrical cabinets, or small brackets if pressure is applied to them when moving the granulator. When lifting the granulator, be certain of total machine weight and the capability of the lifting equipment. (See the Granulator Specification Sheets for machine weights and dimensions.)
! GRANULATOR LOCATION: Adequate area for routine maintenance should be
provided in order to open the machine for knife, screen, or cleanout service. Proper service area clearances also should allow people who are working on the machine to be clearly visible to others, thereby reducing the potential safety hazards.
! SAFE HOUSEKEEPING: The work area must be kept clean and uncluttered during
periods of operation or maintenance. No hand tools or other metal objects should be left on or around the machine. Any tools or other metal objects that mistakenly fall into the hopper feed opening can cause severe damage to internal cutting chamber, rotor and screen components.
! SAFETY GLASSES OR A FACE SHIELD MUST ALWAYS BE WORN when
servicing or operating the machine. Although our machines are designed for the maximum in flyback control, caution must be used when operating near the hopper feed opening in order to guard against unexpected material flyback.
! EAR PROTECTION may be required when operating the machine during
granulation of very hard or noisy materials. The Occupational Safety and Health Act of 1970 has established guidelines for Permissible Noise Exposures (OSHA 1910.95) that should be followed.
! NEVER attempt to operate the granulator unless it is fully assembled with all guards
and interlocks in place and functional.
! OBSERVE all danger, warning, caution and safety labels on the equipment.
! Upon completion of any machine maintenance, be certain ALL SAFETY GUARDS
AND COVERS are securely and properly fastened prior to resuming machine operation. All fasteners must be in place and properly tightened. ANY
SHORTCUTS MAY RESULT IN INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT.
! NEVER wear any loose fitting clothes, neckties, or dangling items such as earrings,
belts, or shoestrings. Jewelry, such as wristwatches, bracelets, or rings should NEVER be worn. Long hair must be tied back or placed in a tight fitting hairnet. NEVER lean against or rest hands or feet on the granulator when it is in operation or open for maintenance. NEVER stand on the granulator when it is in operation.
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! ROTATION OF MOTORS: The correct rotating direction for the granulator motor
is clearly marked on the machine. Always check for proper rotation of motors. Incorrect rotation direction can cause severe damage.
! ELECTRICAL GROUNDING: All electrical equipment on the granulator must be
grounded in accordance to all local codes and Article 250 of the National Electric Code.
! ALWAYS DISCONNECT AND LOCKOUT the main electrical power to the
granulator before performing any service.
! SAFETY INTERLOCKS MUST NOT BE BYPASSED. The mechanical and
electrical safety interlocks ensure the safety of personnel. They should never be tampered with or removed for ANY reason. They should be checked frequently by a qualified mechanic for proper operation.
! NEVER modify the machine configuration or any individual component without
written notice from the factory.
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Remaining Risks
The machine is constructed so that you are able to operate it safely. Non-avoidable dangers are prevented as greatly as possible by the protective devices. Remaining risks always exist. Please be aware of the risks described below as this will help operators/staff avoid accidents. To further avoid danger, please adhere to all advice provided in the operational manual.
Mechanical Dangers
Type of Danger
Activity
Possible Consequences
Preventative Measures
Crushing due to heavy parts falling down or over.
Unloading/transporting the machine and/or components.
Serious injury.
Wear personal protective gear and follow the instructions provided in the operational manual.
Cutting caused by sharp knives—even when the rotor is stationary.
Knife replacement, knife setting, knife sharpening, and other maintenance.
Serious injury— particularly to the hands and fingers.
Wear personal protective gear and follow the instructions provided in the operational manual.
Crushing when opening/closing the doors on front side of machine.
Maintenance.
Serious injury.
Ensure no persons are in the danger area while closing the door.
Tripping over cables and other surrounding objects.
All activities.
Serious injury.
Lay cables in accordance with regulations.
Keep work station clean and tidy.
Crushing, cutting, amputation caused by run­down of the rotor.
Maintenance.
Serious injury or death.
The maintenance doors must always be tightly locked during operation.
DO NOT make the run-down safety devices ineffective by using technical aids or other manipulations.
NEVER use hands to check if the rotor has stopped.
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Type of Danger
Activity
Possible Consequences
Preventative Measures
Direct/indirect contact with live parts in terminal box.
Maintenance; start-up.
Serious injury or death.
Only trained electricians may carry out work on the electrical equipment.
If work is necessary on parts that could conduct dangerous voltage, a second person should be present to break the power supply in case of an emergency.
The yellow-marked lines conduct voltage even when the machine is switched OFF.
Only use original safety fuses with stipulated intensity of current.
Faulty electrical components must be replaced immediately.
If faults occur in electrical energy supply, switch the machine OFF immediately.
The terminal box must be locked during operation. Before opening the terminal box turn main switch to 0.
Failure of the Emergency Stop Function.
All activities.
Serious injury or death.
There must be a guarantee that the machine will be stopped immediately upon failure of an Emergency Stop button.
Fire/explosion caused by throwing dangerous objects (i.e. spray cans) into the shredder.
Grinding.
Serious injury or death.
Only grind material that corresponds to the agreed customer-specific specifications.
Damage to hearing.
All activities.
Diminished hearing, headaches, impaired balance, and deterioration of concentration.
Reduce noise levels by taking suitable measures and wear ear protection.
Instable machine due to vibration.
All activities.
Serious injury.
Install the machine according to the instructions in the operational manual.
Loose cutter/bed knife mountings due to vibration.
All activities.
Serious injury.
Check the cutter/bed knife mountings regularly.
Inhalation of grinding dust.
All activities.
Respirator disease, etc.
Mount a suitable air suction device. DO NOT blow out grinding dust when cleaning the machine.
Crushing, cutting, amputation caused by manipulation of protective devices.
All activities.
Serous injury or death.
Never make the protective devices ineffective; check the devices regularly for proper function.
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For further information on granulator safety, installation, and operation, see the American
National Standard for Plastics Machinery!Granulators, Pelletizers, and Dicers Used for Size Reduction of Plastics!Construction, Care, and Use. ANSI B151.11-1982.
We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration. We expect you, as a user, to abide by the foregoing recommendations in order to make operator safety a reality.
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Chapter 2: Functional Description
2-1 Models Covered in This Manual
This manual covers the1000 Series pipe shredder which includes models APS, CPS, MPS,
EPS and SPS. The 1000 Series pipe shredder is designed for size-reduction of plastic pipes made of PE, PP, and PVC etc. The user is responsible for consequences resulting from incorrect operation: This will lead to the loss of the warranty as well as any compensation claims.
2-2 General Description & Typical Features
Mechanical section
After the machine has been switched on, a hydraulically controlled feeding unit pushes the pipe onto the slow-running rotor. The in feed is controlled according to the load of the motor. The pipes can be fed horizontally and without precutting into the feeding trough of the pipe shredder by a forklift or optionally with a loading device. The feeding trough has a hydraulically operated cover, which is closed after it is filled with material. A hydraulic ram system is than pushing the material towards the rotor. The ram consists of a double­acting telescopic cylinder and the pusher itself, which is a heavy durable welding construction. The pusher is moving on 3 sets of high performance guide roller skids. Those adjustable skids are running on 3 independent guide rails. The trough is built with tough steel profiles and all safety features are according latest CE-standards for work safety. The pipe should be placed horizontally in the feeding trough mounted next to the cutting chamber. Attention must be paid that this material does not contain any metal parts. The guarantee does not cover any damage to the machine as a result of metal parts being fed into the machine. The pipe in the feeding trough is shredded by the rotating knives on the rotor. This shredding process is finished when the hydraulic cylinder has reached its full stroke and the pusher is at the end position. The 1000 series shredder is equipped with an E style rotor using a standard square, concave cutter blocks. These cutters make light work of the heaviest pieces. Importantly, the design allows efficient cutting of material, rather than hammering as well as reduced heat build-up and degradation of material. The cutter blocks have four corners so they can be easily turned once a corner has worn away. The projection of the cutter can be easily adjusted to match the aggressiveness of the shredder with the customer’s material by adding or removing thin shims on the cutters holder. The housing is a rigid welded and very compact construction. Upper and lower part of the housing are bolted together and this makes maintenance work very convenient. The housing is sitting on a base frame, which allows easy installation of a discharge conveyor.
Due to the compact design this machine can only be used for screen-less operations! The heavy-duty outboard bearings mounted on the 1000 series shredders minimize the risk of contamination of the recycled materials and also minimize the risk of dust penetrating the bearings and make a rotor change easier. Power is transmitted from the electromotor by V-belts to the gearboxes, which are mounted directly on the shaft end on either side of the rotor. In combination with the elastically supported torque arm this construction will reduce stress to both motor and gear. The dual drive will further ensure that all loads are evenly distributed into the rotor.
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Control
The pusher feeds the rotor with as much material as it is able to process. Upon reaching 70-90 % of rated current, the feeding of the pusher will be stopped and automatically started again after the power consumption has fallen by 20 % in comparison with rated current. If the high current is applied for longer than 0.7 - 1.5 sec., the main drive motor switches off and runs back after about 3 sec. standstill time. The pusher plate also runs back whilst the rotor runs back. The drive motor then stops for another 3 sec. before starting again. The position of the pusher is controlled by an optical distance sensor. The in feed is controlled according to load. Duration of pauses and return as well as the current settings can be adjusted. Any alterations, however, should only be carried out after consulting the manufacturer.
Grinding Material In-feed
The grinding material can be fed into the shredder using the following methods:
Manual in-feed of the grinding material directly into the feeding trough.
Manual in-feed of the grinding material with the help of an additional in-feed
device (i.e. hydraulic feeding unit).
In-feed Hopper
The grinding material in-feed ensues via a feeding trough. The pipe can be placed easily in the feeding trough by a forklift.
Illustration:
Feeding trough
The feeding trough has a hydraulically operated cover, which is closed after it is filled with material. A hydraulic ram system is than pushing the material towards the rotor.
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Illustration:
(1) Stage cylinder (2) Cover (3) Lock (4) Pusher
Optional (not included in standard machine) the feeding trough can be equipped with a hydraulic feeding device.
Illustration:
(1) Base frame (2) Lower housing flap (3) Upper housing flap (4)Gear box (5) Drive motor (6) V-belt protection (7) Discharge conveyor
The machine housing is mounted on the base frame and the drive motor and the gear box are mounted on the machine housing. This design makes the machine compact.
3
1
4
1 2 7
3 4 6
5
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Drive
The drive of the rotor ensues by means of an electric motor via "V"-belts. The motor, which is mounted on sliding rails or a motor plate, can be adjusted for regulating the tension of the "V"-belts by means of tensioning screws. The "V"-belt pulley is attached with a special tensioning element to the motor shaft.
Illustration:
Drive
Please observe the operation manual from the manufacturer!
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Rotor and Cutters
The material is ground between the knives assembled on the rotor and the stator knives which are mounted in a fixed position in the machine lower section. All rotors are equipped with square knives. These knives make light work of the heaviest pieces. The knives have four corners, so that they can be easily turned once a comer has worn off. The design of the rotor has a significant influence on the quality of the grinding process and its results. The rotor construction, the type of knife mounting and the number of knives have all been exactly matched to your task allocation.
Illustration:
(1) Rotor knife (2) Stator knife (3) Discharge area
Due to the compact design this machine can only be used for screen-less operations! The rotor is accessible after opening the lower housing flap or the upper housing flap. The rotor is arranged on roller bearings, which are situated outside the housing. The "V"­belt pulley is attached by means of a taper bush to the rotor axis. The rotor is dynamically counter balanced and has vibration-free concentricity.
Discharge of grinding material
Illustration:
Conveyor belt discharge
2 1 3
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The ground material will be discharged by a conveyor belt.
Hydraulic pusher
The ram consists of a double-acting telescopic cylinder and the pusher itself, which is a heavy durable welding construction. The pusher is moving on 3 sets of high performance guide roller skids. Those adjustable skids are running on 3 independent guide rails. The position of the pusher is controlled by an optical distance sensor.
Illustration:
(1) Hydraulic stage cylinder (2) Guide roller (3) Guide rail (4) Pusher
Illustration:
(1) Pusher front plate (2) Guide rail
1
3 2 4 1 2
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Illustration:
(1) Distance sensor (2) Reflecting area
Control Panel
Illustration: Control panel
(1) Emergency STOP (2) Ampere meters (3) Elapsed hour counter (4) Part 1 (5) Part 2
1
2 2 3
4
1
5
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Illustration: Part 1
(1) Error lights (2) Control lights (3) Start buttons (4) Stop buttons (5) Control light hydraulic (6) Start/Stop switch hydraulic
Illustration: Part 2
(1) Error lights (2) Control lights (3) Star buttons (4) Stop buttons (5) Overload light shredder (6) Oil filter jam (7) Overload light Ram (8) Reset
1 5 6 2 7 3 8 4 1 2 3 4 5
6
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