Sulzer Muffin Monster 10000 Series, 10002-0008 Installation, Operating And Maintenance Instructions
Page 1
SULZER CONFIDENTIAL
EN
Grinder – 10000 Open Channel Series
Installation, Operating and Maintenance Instructions
www.sulzer.com
Rev. NC
3/2019A
Page 2
SULZER CONFIDENTIAL
EN: Grinder – Open Channel Series
DE: Zerkleinerer - Serie für offene Kanäle
EN: Declaration of Conformity
DE: Konformitatserklarung
FR: Declaration de Conformite
ES: Declaraci6n de Confirmidad
IT: Dichiarazione di conformita
NL: Overeenkomstigheidsverklaring
SV: Försäkran om överensstämmelse
NO: Samsva rserklmring
Fl: Vaatimustenmukaisuusvakuutus
RU: Заявление о соответствии
EN: Manufacturer/ Address:
DE: Hersteller I Adresse:
FR: Fabricant / A dresses:
ES: Fabricante / Direcci6n:
IT: Costruttore / lndirizzo:
NL: Fabrikant / Adres:
SV: Tillverkare / Adress:
NO: Produsent I Adresse:
Fl: Valmistaja / Osoite:
RU: Изготовитель/ Адрес
JWC Environmental / Unit 15, Daneside Business Park, River Dane Road, Congleton, Cheshire CW12 1UN
United Kingdom
EN: Name and address of the person authorised to compile the technical file to the authorities on request:
DE: Name und Adresse der Person, die berechtigt ist, das technische Datenblatt den Behorden auf Anfrage zusammenzustellen:
FR: Norn et adresse de la personne autorisee pour generer le fichier technique aupres des autorites sur demande:
ES: Nombre y direcci6n de la persona autorizada para compilar a pedido el archivo tecnico destinado a las autoridades:
IT: II nome e l'indirizzo delta persona autorizzata a compilare la documentazlone tecnica per le autorita dietro richiesta:
NL: Naam en adres van de persoon die geautoriseerd is voor het op verzoek samenstellen van het technisch bestand:
SV: Namn och adress på den person som är auktoriserad att på begäran utarbeta den tekniska dokumentsamlingen tili myndighe
terna:
NO: Navn og adresse pa den personen som har tillatelse tit a sette sammen den tekniske filen til myndighetene ved foresp0rsel:
Fl: Viranomaisten vaatiessa teknisten tietojen lomaketta lomakkeen valtuutetun laatijan nimi ja osoite::
RU: Ф.И.О и адрес лица, уполномоченного составлять техническую документацию no требованию органов власти:
Frank Ennenbach,
Director Product Safety and Regulations,
Sulzer Management AG,
Neuwiesenstrasse 15,
8401 Winterthur,
Switzerland.
EN: Declare under our sole responsibility that the products:
DE: Erklart eigenverantwortlich, daB die Produkte:
FR: Declarons sous notre seule responsabilite que les produits:
ES: Declaramos bajo nuestra exclusiva responsabilidad que los productos:
IT: Dichiariamo sotto la nostra esclusiva responsabilita che i prodotti:
NL: Verklaren geheel onder eigen verantwoordelijkheid dat de produkten:
SV: Forsakrar under eget ansvar att produkterna:
NO: Erkherer pa eget ansvar, at f0lgende produkter:
Fl: Vakuutamme yksinomaan omalla vastuullamme, etta seuraavat tuotteet:
RU: Заявляем со всей полнотой ответственности, что изделия:
FR: Broyeur - Gamme en canal
ES: Triturador de canal
IT: Trituratore - serie per canale aperto
NL: versnijdend
SV: Avloppskvarn - kanalutförande
NO: Avløpskvern – type åpen kanal
FI: Silppuri – avoin kanava mallit
RU: Дробилка канальной серии
Page 3
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SULZER CONFIDENTIAL
EN: To which this declaration relates are in conformity with the following standards or other normative documents
EN: As defined by ATEC Directive 2014/34/EU,
2012
NL: Zoals gedefinieerd door demachinerichtlijn
DE: Wie definiert in Maschinenrichtlinie
durch Richtlinie 2005/88/EG.
SV: Sasom definierats av Maskindirektiv
2005/88/EC.
FR: Comme definie par directive
2005/88/CE.
FI: Maaritetty naissa normeissa: Konedirektiivi
on muutettu direktiivilla 2005/88/EY.
ES: Como se establece en Directiva
FI: Maaritetty naissa normeissa: Konedirektiivi
дополненная 2005/88/ЕС.
.
DE: Auf die sich diese Erklarung bezieht, den folgenden und/oder anderen normativen Dokumenten entsprechen
FR: Auxquels se refere cette declaration sont conformes aux normes ou a d'autres documents normatifs
ES: Objeto de esta declaraci6n, estan conformes con las siguientes normas u otros documentos normativos
IT: Ai quali questa dichiarazione si riferisce sono conformi alla seguente norma o ad altri documenti normativi
NL: Waarop deze verklaring betrekking heeft, zijn in overeenstemming met de volgende normen of andere normatieve
documenten
SV: Som omfattas av denna forsakran ar i overensstammelse med foljande standarder eller andra regelgivande dokument NO:
Som dekkes av denne erkla:!ringen, er i samsvar med f0lgende standarder eller andre normative dokumenter
Fl: Joihin tama vakuutus liitty, ovat seuraavien standardien seka muiden saantбamaaraavien asiakirjojen mukaisia
RU: К которым применимо данное заявление, соответствуют следующим стандартам или нормативным документам.
Machinery Directive 2006/42/EC, EMC-Directive
2004/108/EC, Low Voltage Directive 2014/35/EU,
Outdoor Noise Directive 2000/14/EC amended by
2005/88/EC, EN 13463, IEC 80097-36, IEC
8009-37, Directive 2009/125/EC, EU No. 547-
2006/42/EG, EMV-Richtlinie 2004/108/ EG,
Niederspannungsrichtlinie 2014/35/ EU, Richtlinie
2000/14/EG uber Gerauschemisssionen geandert
Machines2006/42/CE, directive CEM
2004/108/CE, directive Basse tension
2014/35/UE, Directive sur le bruit exterieur
2000/14/CE, amendee par la directive
sabremaquinaria 2006/42/EC, Directiva EMC
2004/108/EC, Directiva sabre bajo voltaje
2014/35/UE, Directiva sabre el ruido 2000/CE
enmendada por 2005/88/CE.
IT: Come definito in Direttiva Macchina
2006/42/CE, Direttiva CEM 2004/108/CE,
Direttiva Bassa tensione 2014/35/UE, Direttiva
sull'emissione acustica ambientale 2000/14/CE
modificata dalla direttiva 2005/88/ CE
2006/42/EC, EMC-Directive 2004/108/EC,
laagspanningsrichtfijn
2014/35/EU, Geluidsemissierichtlijn 2000/14/ EG
gewijzigd door 2005/88/EG.
2006/42/EG, EMC-direktiv 2004/108/
EG, Direktiv om lagspanning 2014/35/EU,
Utomhusbullerdirektivet 2000/14/EC andrat av
2006/42/EY, EMC-direktiivi 2004/108/EY,
Matalajannitedirektiivi
2014/35/EU, Ulkona kaytettavien laitteiden
melupaastoja koskeva direktiivi 2000/14/EY, jota
2006/42/EY, EMC-direktiivi 2004/108/EY,
Matalajannitedirektiivi
2014/35/EU, Ulkona kaytettavien laitteiden
melupaastoja koskeva direktiivi 2000/14/EY, jota
on muutettu direktiivilla 2005/88/EY.
RU: В соответствии с директивой по
механическому оборудованию 2006/42/
ЕС, директивой по электромагнитной
совместимости 2004/108/ЕС, директивой
по низковольтным устройствам 2014/35/EU,
Директива по внешнему шуму 2000/14/ЕС,
EN ISO 12100-1, EN ISO 12100-2
.
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Installation, Operating and Maintenance Instructions
SULZER CONFIDENTIAL
Grinder – 10000 Open Channel Series
ATE
X Warning Statements ...................................................................................... 1
TABL
E OF CONTENTS
Nameplate Details ..................................................................................................... 2
Safety and hazard warnings .................................................................................... 3
GENERAL INFORMATION ........................................................................................ 5
Limitation of Use ............................................................................................... 5
INSTALLATION .......................................................................................................... 7
Inspection & Safety Recommendations ............................................................ 7
System Design & Installation ............................................................................ 7
STORAGE .................................................................................................................. 7
WARNING / CONTROL DEVICE .............................................................................. 8
NOISE LEVELS ......................................................................................................... 9
EXPLOSIVE PRODUCTS / HAZARDOUS ATMOSPHERES .................................... 9
LUBRICATION .......................................................................................................... 9
START-UP PROCEDURE ....................................................................................... 10
DISMANTLING ADVICE ......................................................................................... 11
CLEANING / INSPECTION ..................................................................................... 11
RE-ASSEMBLY ADVICE ........................................................................................ 12
EXTENDED SHUTDOWN ....................................................................................... 12
MAINTENANCE ...................................................................................................... 13
Allowable Wear Tolerances ........................................................................... 14
TROUBLESHOOTING ............................................................................................. 14
Figures
1 Grinder ........................................................................................................................ 5
2 Grinder Installation ...................................................................................................... 9
3 Rotation ..................................................................................................................... 10
4 Top Cover and Gears ............................................................................................... 13
5 Cutter Wear ............................................................................................................... 14
Tables
1 Lubr
icants ................................................................................................................. 13
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1 Installation and Operating Instructions
SULZER CONFIDENTIAL
Grinder – 10000 Open Channel Series
ATEX Warning Statements
1. Where a grinder is to be installed in a potentially explosive atmosphere ensure that this has been
specified at the time of purchase and that the equipment has been supplied accordingly and displays an
ATEX nameplate or is supplied with a certificate of conformity. If there is any doubt as to the suitability of
the equipment please contact Sulzer before commencing with installation and commissioning.
2. Process liquids or fluids must be kept within -20°C – 40°C, otherwise the surface of grinder or system
components may become an ignition source due to temperature rises. Where the process liquid
temperature is less than 90 ºC the maximum surface temperature will not exceed 90 ºC provided the
grinder is installed, operated and maintained in accordance with this manual.
3. Cavities that could allow the accumulation of explosive gases have been designed out of the system.
However, any accumulation of gases or material should be fully purged before any work is carried out on
the grinder or system. The grinder should not be operated without liquid influent and no ignition sources
to be present.
4. Electrical installation and maintenance work should only be carried out by suitably qualified and
competent persons and must be in accordance with relevant electrical regulations.
5. If there is a risk of an accumulation of explosive gases or dust, proper ventilation must be performed,
removing all gases and dust.
6. When fitting drives, couplings, and guards to a grinder unit it is essential that these are correctly fitted,
aligned and adjusted in accordance with the installation instructions. Failure to do so may result in
sparking due to unintended mechanical contact, or temperature rises due to mechanical or electrical
overload.
7. Failure to operate or maintain the grinder and ancillary equipment in line with the manufacturer’s
instructions may lead to premature and potentially dangerous failure of components. Regular inspection,
and where necessary, replacement of bearings, seals, other wearing parts and lubrication is essential.
8. The grinder and its components have been designed to ensure safe operation within the guidelines
covered by legislation. Accordingly, Sulzer has declared the machine safe to use for the duty specified as
defined by the Declaration of Conformity that is issued with this instruction manual and the conditions as
specified in the Limitation of Use. The use of replacement parts that are not manufactured by or approved
by Sulzer may affect the safe operation of the grinder and it may therefore become a safety hazard to
both operators and other equipment. In these circumstances the Declaration provided will become invalid.
The guarantee referenced on the Terms and Conditions of Sale will also be invalidated.
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2 Installation and Operating Instructions
SULZER CONFIDENTIAL
Grinder – 10000 Open Channel Series
Nameplate Details
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3 Installation and Operating Instructions
SULZER CONFIDENTIAL
Non-compliance may result in personal injury.
Electrical connection should only be made using equipment suitable for both rating and
environment. Where any doubts exist regarding the suitability of equipment, Sulzer
Earthing points will be provided on electric drives (if supplied) and it is essential that
these are correctly connected. The electrical installation should include appropriate
to work on.
By the nature of the equipment and its operating environment the grinder can be an
extremely dangerous machine. It is vital that operators are conversant with these
off and padlocked.
During installation and maintenance, attention must be paid to the safe handling of all
Grinder – 10000 Open Channel Series
Safety and Hazard Warnings
Presence of dangerous voltage.
Lock out – Tag out notification
Follow lockout procedures before connection / removing supply power.
should be consulted before proceeding.
isolating equipment to ensure that the grinder, drive and motor, or grinder motor is safe
Operation and Maintenance Instructions prior to working with the machine.
When servicing the grinder, be certain that the main isolator is
Serious injury could result from accidental start-up.
Keep clear of rotating components.
NEVER inspect or work on or near the cutter chamber without first isolating and locking
the grinder.
Auto-restart of rotating components may occur after power loss if the mains isolator is
not off.
items. Where a grinder or its components weigh in excess of 20 kg (45 lb) it is required
that suitable lifting tackle should be used to ensure that personal injury or damage to
components does not occur.
Suspended load. Do not stand under the grinder during installation / removal.
Relieve line pressure before opening pipe flanges.
Wear safety shoes when handling components.
Sharp edges. Wear safety gloves when handling grinder cutters and spacers.
Wear eye protection when cleaning components.
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4 Installation and Operating Instructions
SULZER CONFIDENTIAL
To minimise the risk of sparking or temperature rises due to mechanical or electrical
rical equipment and is capable of being locked in the OFF
position. All control and safety devices must be fitted, operated and maintained in
The grinder must rotate in the correct direction for proper operation. This must be
out. Failure to observe this may lead to mechanical or electrical overload.
Grinder – 10000 Open Channel Series
All electrical equipment, including control and safety devices, should be suitably rated
for the environment in to which they are installed
overload the following control and safety devices should be fitted. The control system
will shut the grinder down if the motor current or temperature exceed specified limits or
a jam of the cutter stack occurs. This includes a system that reverses the machine in
order to clear any such jam. An isolator switch will disconnect all electrical supply to the
motor and ancillary elect
accordance with the manufacturer’s instructions.
checked on installation and commissioning and after any maintenance has been carried
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5 Installation, Operating and Maintenance Instructions
SULZER CONFIDENTIAL
Model
Weight (Kg)*
IP55 1.5kW
IP55 2.2kW
IP55 1.5kW
IP55 2.2kW
IP68 1.5kW
IP68 2.2kW
29
46
15
31
31
36
Motor Only
IP55 1.5Kw
IP55 2.2kW
IP68 1.5kW
IP68 2.2kW
22
32
46
84
Description
Twin-shafted grinder with cutters and spacers enclosed in a cast iron
Intended Use
Particle size reduction of municipal / industrial sewage waste
Maximum Flow Rate
41.4 m3/hr
Maximum Process
6 bar as limited by shaft seals
Anticipated Level of
Applicable local, federal and area safety rules, regulations and
Special Physical
N/A
Personnel Affected
Installers, electricians, operators, maintenance personnel
Figure 1 Grinder
Grinder – 10000 Open Channel Series
GENERAL INFORMATION
The grinder reduces solids in sewage (Figure 1).
A separate control panel provides grinder controls.
Model Cutter Stack Height (mm)
10002-0008 185
10002-0008 125
*less drive
Drive Assembly Weights (Kg)
Integrated Reducer Only
Limitation of Use
Pressure
Training, Ability &
Experience
Requirements
Limits of the Machine
housing meeting various standards, speed reducer, electric motor and
motor controller
Personnel Information
guidelines; discipline-specific apprenticeship/training
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6 Installation, Operating and Maintenance Instructions
SULZER CONFIDENTIAL
Temperature
Operation: -5° C to +40° C
Humidity
IP66
Elevation
3048 metres above sea level
Space
Grinder: 483mm x 305mm x 1041mm
Clearance Required
150mm over motor fan cover
Clearance Required
610mm above
Electrical
120V/1PH/60HZ to 575V/3PH/60HZ
Water
N/A
Hydraulic
N/A
Connection to Other
Two (2) dry-contact relays indicating grinder Run and Fail conditions
Grinder – 10000 Open Channel Series
Environmental Limits
Storage: -40° C to +65° C
Space Limits
Requirements
for Operation
for Maintenance
Equipment
Controller: 457mm H x 406mm W x 254mm for IP66 enclosure
914mm in front of controller
914mm on left or right side of grinder
914mm in front of controller
Interface Limits
220V/1PH/50HZ to 400V/3PH/50HZ
for remotely located monitoring operation powered by foreign sources
1-2
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7 Installation and Operating Instructions
SULZER CONFIDENTIAL
Grinder – 10000 Open Channel Series
INSTALLATION
Inspection & Safety Recommendations
In common with other items of process plant a grinder must be installed correctly to ensure
satisfactory and safe operation. The grinder must also be maintained to a suitable standard.
Following these recommendations will ensure that the safety of personnel and satisfactory
operation of the grinder is achieved.
When handling harmful or objectionable materials, adequate ventilation must be provided in
order to disperse dangerous concentrations of vapours. It is recommended that wherever
possible, Sulzer grinders should be installed with provision for adequate lighting, thus
ensuring that effective maintenance can be carried out in satisfactory conditions. With certain
product materials, a hosing down facility with adequate draining will simplify maintenance and
prolong the life of grinder components.
System Design & Installation
At the system design stage, consideration must be given to provision of filler plugs, and
the installation of non-return and/or isolating valves where applicable.
Handling
During installation and maintenance, attention must be paid to the safe handling of all
items. Where a grinder or its components weigh in excess of 20 kg (45 lb) it is
recommended that suitable lifting tackle should be used to ensure that personal injury
or damage to components does not occur.
Do not attempt to lift the grinder using only one lifting point. Extreme caution should
be observed for personnel safety when lifting heavy objects.
By design the cutters have sharp edges. Great care must be taken when handling. The
use of protective gloves is recommended.
STORAGE
Grinders are dispatched from our factory with the cutter chamber sprayed with a moisture
repellent coating and ready for immediate installation and operation.
Should the machine be stored or left stationary for any length of time it is recommended
that the cutter stack is re-sprayed with anti-rust lubricant and that the shafts are rotated
monthly.
Failure to do this may result in a higher frequency of reversals and in extreme cases the
machine to seize due to the tight running clearances of the individual cutting elements
during commissioning and initial start-up.
The controller should be stored in a controlled dry environment to prevent moisture buildup
causing corrosion of contactors and other metallic components.
The grinder is protected by a PLC control unit set to the correct
operating philosophy. Only PLCs supplied or approved by Sulzer should
be used. Failure to observe this requirement may cause premature
machine failure and could invalidate the warranty of the machine. It is
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8 Installation, Operating and Maintenance Instructions
SULZER CONFIDENTIAL
Grinder – 10000 Open Channel Series
also important that the PLC be correctly wired into the panel.
Before installing the grinder please ensure that all plugs and
inspection plates are replaced.
E
lectrical
Electrical connection should only be made using equipment suitable for both rating and environment.
Where any doubts exist regarding the suitability of equipment, Sulzer
should be consulted before proceeding.
arthing points will be provided on electric drives (if supplied) and it
E
is essential that these are correctly connected. The electrical
installation should include appropriate isolating equipment to ensure
that the grinder and drive assembly is safe to work on.
G
eneral safety
All guards and removable. Maintain-in-place covers must be in place and
securely fitted while the machine is running.
All nuts and bolts, securing flanges and base mounting fixtures must be checked for tightness
before operation.
If, when starting, the grinder does not appear to operate correctly, it must be shut down
immediately and the cause of the malfunction established before operations are
recommenced.
May contain substances from the ECHA SVHC Candidates List (REACH - Regulation (EC) No.
1907/2006).
Guards
In the interests of safety, all guards must be replaced after necessary adjustments have been made to the grinder.
ARNING / CONTROL DEVICE
W
Prior to operating the grinder, if any warning or control devices are fitted, these must be set
in accordance with their specific instructions.
Rotate grinder drive motor 1-5 minutes every 3 months if stored either by hand or by
applying power to the motor. Check for grinder drive lubricant leakage. Contact Sulzer if leakage
exceeds 6ml.
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9 Installation and Operating Instructions
SULZER CONFIDENTIAL
Attach 3-phase motor power
wiring
Use anchor bolts
channel.
Fill any gaps
channel wall
Flow
BE SURE TO USE BOTH LIFTING EYES
Figure 2 Grinder Installation
Grinder – 10000 Open Channel Series
Sulzer is not liable if local or international regulations are not followed or for damage caused
by wiring errors or improper shielding. Use lifting equipment rated for the weight of the grinder
minimum attached to all the grinder top cover lifting rings as shown to lift the grinder. Verify the
grinder flow arrows, located on the side of the grinder, point in the direction of flow.
Prior to installation/commissioning.
heck external hardware as gasketed areas may have a tendency to loosen fasteners
• C
.
Retighten if loose.
heck paint for any slight damage and touch up if necessary. Standard Sulzer colour
• C
(RAL 5002).
(not provided) of
suitable size and
type for the
installation site
and any optional thermostat
for attaching the
frame to the
between the
frame and
NOISE LEVELS
The sound pressure level will not exceed 70 dB at one metre distance from the grinder. This
is based on a typical installation and does not necessarily include noise from other sources or
any contribution from building reverberation.
EXPLOSIVE PRODUCTS / HAZARDOUS ATMOSPHERES
In certain instances the product being pumped may well be of a hazardous nature. In these
installations consideration must be given to provide suitable protection and appropriate
warnings to safeguard personnel and plant.
LUBRICATION
At 10,000 hr intervals, bearings, gears and seal assembly inspection should take place along
with gear grease replenishment.
Under tropical or other arduous conditions, however, more frequent lubrication may be
necessary. It is therefore advisable to establish a suitable maintenance schedule or periodic
inspection to match service conditions.
Open channel grinders should be isolated from flow prior to servicing.
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10 Installation, Operating and Maintenance Instructions
SULZER CONFIDENTIAL
Figure 3 Rotation
Shafts
Motor
Flow
Grinder – 10000 Open Channel Series
S
TART-UP PROCEDURE
By the nature of the equipment and its operating environment the grinder can be an extremely dangerous machine. It is vital that operators are conversant with these Operation and Maintenance Instructions prior to working with the machine.
Verify there is no unauthorized personnel or materials near
the grinder.
U
se a control panel rated for the grinder motor voltage, amps,
frequency with a suitable power disconnect and overtemp
protection if the motor has a thermostat.
pply power to grinder with the control panel control switch.
A
heck for proper motor or shaft rotation (Figure 3). Disconnect
C
power and interchange any two motor leads if reversed.
Gradually apply flow. Verify reduction of solids.
Where applicable:
1. Check all installation hardware once the machine is installed in its correct operating position.
2. Check all electrical connections for continuity and earthing and that installation is
in accordance with relevant regulations and circuit diagrams.
3. Always ensure that machine is guarded in accordance with PD5304: 2000 Safety of
Machinery requirements before any attempt is made to operate.
4. On start-up check the direction of rotation of the cutters. The cutters should rotate
towards the centre when viewed from the inlet side.
5. Check that the grinder stops when the stop operation is activated.
6. Start up the machine and gradually start the feed system to the machine. Care should
be taken not to overburden the machine. Adjust feed to maintain only the smallest
practical reservoir of material in cutter stack.
7. After a further 10 minutes of running, stop the machine, switch off and lock the main
isolator. Check the tightness of all securing bolts. Recheck every 500 hours of operating
time.
8. Check the tightness of all cables and connections. Re-check every 500 hours of operating
time.
9. Observe manufacturer’s guidelines with regard to gearbox lubricant initial renewal and
subsequent intervals.
10. In the event of machine overload (jam), the controller is programmed to activate the following
11. After machine shutdown, relieve pressure, isolate, and lock off. Inspect machine,
pr
ocedure:-
I. Momentarily reverse rotation to clear the condition, then return to normal operation.
II. If overload re-occurs within 60 seconds, reverse rotation to clear the condition, then
return to normal operation.
III. If a third overload occurs within 60 seconds of the first, machine shuts down and
energises an alarm circuit.
remove any obstruction and reset the controller.
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11 Installation and Operating Instructions
SULZER CONFIDENTIAL
Grinder – 10000 Open Channel Series
12. The machine can now be re-started.
NEVER inspect or work on or near the cutter chamber without first isolating and locking the machine.
Use of items not approved or manufactured by Sulzer
The grinder and its components have been designed to ensure that the grinder will operate
safely within the guidelines covered by legislation. As a consequence, Sulzer has declared
the machine safe to use for the duty specified as defined by the Declaration of Conformity
that is issued with this instruction manual.
The use of replacement items that are not approved by or manufactured by Sulzer may affect the
safe operation of the grinder and it may therefore become a safety hazard to both operators and
other equipment. In these instances the declaration provided will therefore become invalid. The
guarantee referenced in the Terms and Conditions of Sale will also be invalidated if replacement
items are used that are not approved or manufactured by Sulzer.
DISMANTLING ADVICE
When servicing the grinder, be certain that the main isolator is tagged out / locked out. Serious injury could result from accidental start-up.
1. Disconnect wiring at motor(s) terminal box(es) and tag leads for identification.
2. Isolate the grinder from influent.
3. If necessary, the grinder may be completely removed from installation using the
recommended lifting equipment.
4. Replace the cutter stack with the maintenance screen if required.
5. When dismantling cutters and spacers, take careful note of the position and orientation of
eac
h component.
CLEANING / INSPECTION
It is important to periodically inspect the grinder (timeframe dependent on usage).
1. Steam clean and disinfect all parts of the unit excluding motor, seal assemblies, gear
drive unit and bearings.
2. Remove any gasket material from joint faces.
3. Housings should be cleaned thoroughly.
4. Inspect all parts for excessive wear and replace if necessary.
5. Sealed bearings cannot be re-greased, replace if necessary.
6. Inspect gears for wear and damage and replace if necessary.
7. All cutters and spacers must be clean and free from cracks or excessive wear.
8. Shafts should be clean and any burrs filed off for easier stacking. Inspect shafts for
excessive wear of hexagonal portion. Replace if necessary.
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12 Installation, Operating and Maintenance Instructions
SULZER CONFIDENTIAL
Grinder – 10000 Open Channel Series
RE-ASSEMBLY ADVICE
1. Lubricate all bores, shafts and seals on re-assembly.
2. Lubricate gears on re-assembly with the specified lubricant.
3. Re-connect wiring at motor(s) terminal box(es) using tag leads for identification.
4. Re-open system isolation valves.
5. On completion of assembly, run through the ‘initial start-up’ procedure.
EXTENDED SHUTDOWN
CAUTION – electrical, cutting, lifting risk is possible
A
ttach lifting equipment and remove the grinder.
nsure the machine is adequately supported prior to steam cleaning, excluding the
E
drive assembly.
oat interior and cutters with rust inhibitor.
C
P
lace the grinder into storage. See STORAGE.
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13 Installation and Operating Instructions
SULZER CONFIDENTIAL
Ormskirk
Lithium Complex 559*
Ironsides Lubricant Ltd
Silicon Valve Grease*
0250/0077
Rust inhibitor
Solent
SOL-732-0620K Spray*
General / Protectant
WD-40 Company
WD-40 Aerosol Lubricant*
* O.E.M. (Original Equipment Manufacturer)
Figure 4
Top Cover and Gears
Drive
Gears
Grinder – 10000 Open Channel Series
MAINTENANCE
Remove and lock out supply power
After first 3 months, then every 6 months or if sludge/scum not reduced properly.
• Check cutters for wear, edges should not be rounded. (See Allowable Wear
Tolerances).
• Check cutter stack tightness.
If loose or worn, refer to TROUBLESHOOTING.
Every 12 months routine maintenance should be carried out.
• Check cutter stack tightness and cutters for wear. (Replace if necessary).
• Remove drive assembly, then remove top and bottom covers. If top or bottom seals
housings are contaminated with effluent, replace seals.
• Prior to refitting top and bottoms covers, fit new gaskets.
Every 5 years: (See Figure 4)
• Remove drive assembly, top cover and old grease.
• Inspect gears for damage or wear, replace if necessary, then replenish grease. See Table 1
Lubricants.
Table 1 Lubricants
Manufacturer Lubricant
Gear grease (Do not mix) 200 grams
O-Ring grease
Assembly
Page 19
14 Installation and Operating Instructions
SULZER CONFIDENTIAL
Part No.
O/D
Thickness
Symptom
Check
Figure 5 Cutter Wear
Grinder – 10000 Open Channel Series
Allowable Wear Tolerances
31016 0.20mm MAX zero wear
31017 0.63mm MAX
TROUBLESHOOTING
Solids not reduced.
Loose cutter stack.
The unit must be stripped down.
0.75mm per side at edge of cutter.
See Figure 5
Cutter rotation.
Cutters for wear.
Cutter stack tightness.
Grinder motor drive train.
Seal cartridges for damage
Cutters for wear.
Lock nuts loose.
Excessive noise, vibration or reversals
Motor overload.
Drive gears for wear.
Seal cartridges for contamination.
Solids overloading.
Cutters for wear.
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