Sulzer Muffin Monster™– 40002 Installation, Operating And Maintenance Instructions
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- Installation, Operating And Maintenance Instructions
40002_Inline_and_Channel_Series_EN_20201208_V01.docx i
EN: Declaration of Conformity DA: Overensstemmelseserklæring TR: Uygunluk beyanıe
DE: Konformitätserklärung FI: Vaatimustenmukaisuusvakuutus BG: Декларация за съответствие
FR: Déclaration de Conformité PL: Deklaracja zgodności RO: Declaraţie de conformitate
ES: Declaración de Confirmidad HU: Megfelelõségi nyilatkozat SR: Izjava o usaglašenosti
PT: Declaracão de conformidade EL: Δήλωση εναρμόνισης LV: Atbilstības deklarācija
IT: Dichiarazione di conformità ET: Vastavusdeklaratsioon LT: Atitikties deklaracija
NL: Overeenkomstigheidsverklaring CS: Prohlášení o shod RU: Заявление о соответствии
SV: Försäkran om överensstämmelse SL: Izjava o skladnosti HR: Izjava o suglasnosti
NO: Samsvarserklæring SK: Vyhlásenie o zhode
EN: Manufacturer / Address: DA: Producent / Adresse: TR: Üretici / Adres:
DE: Hersteller / Adresse: Fl: Valmistaja / Osoite: BG: Производител / Адрес:
FR: Fabricant / Adresses: PL: Producent / Adres: RO: Producător / Adresa:
ES: Fabricante / Direccion: HU: Gyártóv/vCím: SR: Proizvođač / Adresa:
PT: Fabricante / Endereço: EL: Κατασκευαστής / Διεύθυνση: LV: Ražotājs / Adrese:
IT: Costruttore / lndirizzo: ET: Tootja / Aadress: LT: Gamintojas / Adresas:
NL: Fabrikant / Adres: CS: Výrobce / Adresa: RU: Изготовитель / Адрес
SV: Tillverkare / Adress: SL: Proizvajalec / Naslov: HR: Proizvođač/Adresa:
NO: Produsent / Adresse: SK: Výrobca / Adresa:
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 Behörden auf Anfrage zusammenzustellen:
FR: Nom et adresse de la personne autorisée pour générer le fichie technique auprès des autorités sur demande:
ES: Nombre y dirección de la persona autorizada para compilar a pedido el archivo técnico destinado a las autoridades:
PT: Nome e endereço da pessoa autorizada a compilar o ficheir técnico para as autoridades, caso solicitado:
IT: Il nome e l’indirizzo della persona autorizzata a compilare la documentazione tecnica per le autorità 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 till myndigheterna:
NO: Navn og adresse på den personen som har tillatelse til å sette sammen den tekniske file til myndighetene ved forespørsel:
DA: Navn og adresse på den person, der har tilladelse til at samle den tekniske dokumentation til myndighederne ved anmodning om
dette:
FI: Viranomaisten vaatiessa teknisten tietojen lomaketta lomakkeen valtuutetun laatijan nimi ja osoite:
PL: Nazwisko i adres osoby upoważnionej do przygotowania dokumentacji technicznej w przypadku, gdy jest ona wymagana przez
władze:
HU: A hatóságok kérésére a műszaki adatokat tartalmazó akta összeállítására meghatalmazott személy neve és címe:
EL: Όνομα και διεύθυνση του ατόμου που είναι εξουσιοδοτημένο για τη σύνταξη του τεχνικού φακέλου προς τις αρχές επί τη απαιτήσει:
ET: Isiku nimi ja aadress, kelle pädevuses on koostada nõudmise korral ametiasutustele tehnilist dokumentatsiooni:
CS: Jméno a adresa osoby oprávněné vytvořit, na vyžádání ze strany úřadů, soubor technické dokumentace:
SL: Ime in naslov osebe, pooblaščene za zbiranje tehničnih podatkov za pooblaščene organe na zahtevo:
SK: Meno a adresa osoby oprávnenej na zostavenie technického súboru pre úrady na požiadanie:
TR: Yetkili makamlara istek üzerine teknik dosyayı hazırlamaya yetkili olan kişinin adı ve adresi:
BG: Име и адрес на лицето, упълномощено да състави техническия документ за властите при поискване:
RO: Numele şi adresa persoanei autorizate să completeze dosarul tehnic pentru autorităţi la cerere:
SR: Ime i adresa lica ovlašćenog za sastavljanje tehničkog dokumenta za nadležnu instituciju u slučaju zahteva:
LV: Tās personas uzvārds un adrese, kura pilnvarota sagatavot tehnisko dokumentāciju pēc uzraugošo iestāžu pieprasījuma:
LT: Asmens, įgalioto valdžios institucijoms pareikalavus sudaryti techninę bylą, vardas, pavardė ir adresas:
RU: Ф.И.О и адрес лица, уполномоченного составлять техническую документацию по требованию органов власти:
HR: Ime i adresa ovlaštene osobe za sastavljanje tehničke dokumentacije nadležnoj instituciji u slučaju zahtjeva:
Frank Ennenbach, Director Product Safety and Regulations Sulzer Management AG, Neuwiesenstrasse 15, 8401 Winterthur,
Switzerland
40002_Inline_and_Channel_Series_EN_20201208_V01.docx ii
EN: We declare under our sole responsibility that the product to which this manual and declaration relates are in conformity with the
following standards or other normative documents.
DE: Wir erklären in alleiniger Verantwortung, dass das Produkt, auf das sich dieses Handbuch und diese Erklärung beziehen, den
folgenden Normen oder anderen normativen Dokumenten entspricht.
FR: Nous déclarons sous notre seule responsabilité que le produit auquel ce manuel et cette déclaration font référence est conforme aux
normes ou autres documents normatifs suivants.
ES: Por la presente, nosotros declaramos bajo nuestra exclusiva responsabilidad que el producto al que se refiere este manual y
declaración cumple con las siguientes normas u otros documentos normativos.
PT: Declaramos, sob nossa exclusiva responsabilidade, que o produto com o qual este manual e declaração estão relacionados se
encontra em conformidade com as seguintes normas ou outros documentos normativos.
IT: Dichiariamo sotto la nostra esclusiva responsabilità che il prodotto a cui si riferisce questo manuale e la presente dichiarazione sono
conformi ai seguenti standard o ad altri documenti normativi.
NL: Wij verklaren onder onze volledige verantwoordelijkheid dat het product, waar deze handleiding en verklaring bijhoren, voldoet aan
de volgende normen of andere normatieve documenten.
SV: Vi intygar på eget ansvar att produkten som denna bruksanvisning och försäkran gäller uppfyller följande standarder eller andra
normgivande dokument.
NO: Vi erklærer med vårt eneansvar at produktet som denne håndboken og erklæringen gjelder er i samsvar med følgende standarder
eller andre normative dokumenter.
DA: Vi erklærer under eneansvar, at det produkt, som denne manual og erklæring vedrører, er i overensstemmelse med følgende
standarder eller andre normgivende documenter.
Fl: Me vakuutamme yksinomaisena vastuullisena, että tuote, jota tämä käsikirja ja vakuutus koskee, vastaa seuraavia standardeja tai
muita ohjeellisia asiakirjoja.
PL: Deklarujemy na swoją wyłączną odpowiedzialność, że produkt, do którego odnosi się niniejsza instrukcja obsługi i deklaracja, jest
zgodny z poniższymi normami lub innymi aktami normatywnymi.
HU: Teljes felelősségünk tudatában kijelentjük, hogy a termék, amelyre a jelen kézikönyv és nyilatkozat vonatkozik, megfelel az alábbi
szabványoknak vagy egyéb normatív dokumentumoknak.
EL: Δηλώνουμε με αποκλειστική μας ευθύνη ότι το προϊόν στο οποίο αναφέρεται το παρόν εγχειρίδιο και η δήλωση βρίσκεται σε
συμμόρφωση με τα ακόλουθα πρότυπα ή άλλα κανονιστικά έγγραφα.
ET: Kinnitame oma ainuvastutusel, et toode, mida see juhend ja deklaratsioon käsitleb, on kooskõlas järgmiste standardite või muude
normdokumentidega.
CS: Prohlašujeme na naši výhradní odpovědnost, že produkt, ke kterému se vztahuje tento návod a prohlášení, je ve shodě s
následujícími normami nebo jinými normativními dokumenty.
SL: Izjavljamo pod lastno odgovornostjo, da je izdelek, na katerega se nanašata ta priročnik in izjava, skladen z naslednjimi standardi ali
drugimi normativnimi dokumenti.
SK: Vyhlasujeme na vlastnú zodpovednosť, že produkt, ktorého sa týka tento návod a vyhlásenie, je v zhode s nasledujúcimi normami a
normatívnymi dokumentmi.
TR: Bu el kitabının ve beyanın konusu olan ürünün, aşağıdaki standartlara ve standartlara tabi diğer dokümanlara uygun olduğunu, tüm
sorumluluk bize ait olmak üzere beyan ederiz.
BG: Декларираме на собствена отговорност, че продуктът, за който се отнася това ръководство и тази декларация, е в
съответствие със следните стандарти или други нормативни документи.
RO: Declarăm pe propria răspundere că produsul la care fac referire acest manual şi această declaraţie este în conformitate cu
următoarele standarde sau alte documente normative.
SR: Na svoju isključivu odgovornost izjavljujemo da su proizvodi na koje se odnose ovaj priručnik i izjava u skladu sa sledećim
standardima ili drugim normativnim dokumentima.
LV: Vienīgi uz savu atbildību deklarējam, ka izstrādājums, uz kuru attiecas šī rokasgrāmata un deklarācija, atbilst šādiem standartiem un
citiem normatīvajiem aktiem.
LT: Deklaruojame savo atsakomybe, kad produktas, su kuriuo susijęs šis vadovas ir deklaracija, atitinka toliau nurodytus standartus ar
kitus norminius dokumentus.
RU: Под нашу полную ответственность заявляем, что продукт, к которому относится данное руководство и декларация,
соответствует следующим стандартам или другим нормативным документам.
HR: Izjavljujemo pod vlastitom odgovornosti da je proizvod na koji se ovaj priručnik i ova izjava odnose usklađen sa sljedećim normama
ili drugim normativnim dokumentima.
40002_Inline_and_Channel_Series_EN_20201208_V01.docx iii
EN: As defined by ATEX Directive 2014/34/EU, 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.
DE: Im Sinne der ATEX-Richtlinie 2014/34/EU Maschinenrichtlinie 2006/42/EG, EMV-Richtlinie 2004/108/EG, Niederspannungsrichtlinie
2014/35/EU, Lärmrichtlinie 2000/14/EG geändert durch 2005/88/EG.
FR: Tel que défini par la directive ATEX 2014/34/EU, Directive sur les machines 2006/42/CE, EMC-Directive 2004/108/CE, Directive
basse tension 2014/35/EU, Directive sur le bruit exterieur 2000/14/CE amendé par 2005/88/EC.
ES: Según se define en la Directiva ATEX 2014/34/UE, Directiva de Máquinas 2006/42/CE, DIRECTIVA EMC 2004/108/CE, Directiva de
Baja Tensión 2014/35/UE, Directiva 2000/14/CE modificada por 2005/88/CE.
PT: Conforme definido pela diretiva ATEX 2014/34/UE, diretiva de máquinas 2006/42/CE, Diretiva EMC 2004/108/CE, diretiva de baixa
tensão 2014/35/UE, diretiva ruído exterior 2000/14/CE alterada por 2005/88/CE.
IT: Come definito dalla direttiva ATEX 2014/34/EU, direttiva sulle macchine 2006/42/EC, Direttiva EMC 2004/108/EC, direttiva a bassa
tensione 2014/35/UE, direttiva sul rumore esterno 2000/14/EC modificata entro il 2005/88/EC.
NL: Zoals gedefinieerd in ATEX richtlijn 2014/34/EU, Machinerichtlijn 2006/42/EG, EMC-richtlijn 2004/108/EG, laagspanningsrichtlijn
2014/35/EU, buitenlawaai Richtlijn 2000/14/EG gewijzigd tegen 2005/88/EG.
SV: Enligt definitionen i ATEX-direktivet 2014/34/EU, maskin direktiv 2006/42/EG, EMC-direktiv 2004/108/EG, lågspännings direktivet
2014/35/EU, direktiv 2000/14/EG om buller, ändrat genom 2005/88/EG.
NO: Som definert av ATEX-direktiv 2014/34/EU, maskindirektiv 2006/42/EF, EMC-direktiv 2004/108/EF, lavspenningsdirektiv
2014/35/EU, direktiv om utendørs støy 2000/14/EF endret av 2005/88/EF.
DA: Som defineret i ATEX-direktiv 2014/34/EU, maskindirektiv 2006/42/EF, EMC-direktiv 2004/108/EF, lavspændingsdirektiv
2014/35/EU, direktiv vedr. udendørs støj 2000/14/EF revideret ved 2005/88/EF.
FI: kuten ATEX-direktiivissä 2014/34/EU on määritelty, kone direktiivi 2006/42/EY, EMC-direktiivi 2004/108/EY, pien jännite direktiivi
2014/35/EU, ulkomelu direktiivi 2000/14/EY, sellaisena kuin se on muutettuna direktiivillä 2005/88/EY.
PL: zgodnie z definicją zawartą w dyrektywie ATEX 2014/34/UE Dyrektywa maszynowa 2006/42/WE, dyrektywa EMC 2004/108/WE,
dyrektywa niskonapięciowa 2014/35/UE, dyrektywa w sprawie hałasu na zewnątrz 2000/14/WE zmieniona dyrektywą 2005/88/WE,
dyrektywa 2009/125/WE.
HU: A 2014/34/EU,ATEX-irányelv, a 2006/42/EK gépekről szóló irányelv, a 2004/108/EK EMC-irányelv, a 2014/35/EU kisfeszültségű
irányelv és a kültéri zajkibocsátás 2005/88/EK irányelvvel módosított 2000/14/EK irányelve által meghatározottak szerint.
EL: όπως ορίζεται από την οδηγία 2014/34/ΕΕ του ΑΤΕΧ, οδηγία για τις μηχανές 2006/42/ΕΚ, EMC-Οδηγία 2004/108/ΕΚ, οδηγία για την
χαμηλή τάση 2014/35/ΕΕ, οδηγία 2000/14/ΕΚ για το θόρυβο, τροποποιήθηκε από το 2005/88/ΕΚ.
ET: Kooskõlas ATEX-direktiiviga 2014/34/EL, masinadirektiiviga 2006/42/EÜ, elektromagnetilise ühilduvuse direktiiviga 2004/108/EÜ,
madalpingedirektiiviga 2014/35/EL, välismüra direktiiviga 2000/14/EÜ, mida on muudetud direktiiviga 2005/88/EÜ.
CS: Podle definice ve směrnici ATEX 2014/34/EU, směrnici o strojních zařízeních 2006/42/ES, směrnici o elektromagnetické
kompatibilitě 2004/108/ES, směrnici o nízkém napětí 2014/35/EU, směrnici o venkovním hluku 2000/14/ES ve znění směrnice
2005/88/ES.
SL: Kot opredeljujejo Direktiva ATEX 2014/34/EU, Direktiva o strojih 2006/42/ES, Direktiva o elektromagnetni združljivosti 2004/108/ES,
Direktiva o nizki napetosti 2014/35/EU, Direktiva 2000/14/ES o emisijah hrupa v okolje, kot jo spreminja Direktiva 2005/88/ES.
SK: Ako je definované smernicou 2014/34/EU ATEX, smernicou 2006/42/EC o strojových zariadeniach, smernicou 2004/108/EC o
elektromagnetickej kompatibilite, smernicou 2014/35/EU o nízkom napätí, smernicou 2000/14/EC o hluku vo vonkajšom prostredí
zmenenou a doplnenou smernicou 2005/88/EC.
TR: ATEX Yönetmeliği 2014/34/AB, Makine Emniyeti Yönetmeliği 2006/42/AT, EMU Yönetmeliği 2004/108/AT, Alçak Gerilim
Yönetmeliği 2014/35/AB, Gürültü Yönetmeliği 2000/14/AT (yerine 2005/88/AT yürürlüğe girmiştir) doğrultusunda.
BG: Както е определено в Директива ATEX 2014/34/ЕС, Директива 2006/42/ЕО относно машините, Директива 2004/108/ЕО
относно ЕМС, Директива 2014/35/ЕС относно ниското напрежение, Директива 2000/14/ЕО относно шума на открито,
изменена с Директива 2005/88/ЕО.
RO: În conformitate cu Directiva ATEX 2014/34/UE, Directiva privind echipamentele tehnice 2006/42/CE, Directiva CEM 2004/108/CE,
Directiva privind tensiunea joasă 2014/35/UE, Directiva privind zgomotul exterior 2000/14/CE, modificată prin 2005/88/CE.
SR: Kao što je definisano ATEX Direktivom 2014/34/EU, Direktivom o mašinama 2006/42/EK, Direktivom o EMK 2004/108/EK, Direktivi
za električne uređaje niskog napona 2014/35/EU, Direktivi o emisiji buke opreme koja se koristi na otvorenom prostoru 2000/14/EK
koju zamenjuje 2005/88/EK.
LV: Saskaņā ar ATEX direktīvu 2014/34/ES, Mašīnu direktīvu 2006/42/EK, EMS direktīvu 2004/108/EK, Zemsprieguma
direktīvu 2014/35/ES, Trokšņu direktīvu 2000/14/EK, kas grozīta ar 2005/88/EK.
LT: Kaip apibrėžta ATEX direktyvoje 2014/34/ES, Mašinų direktyvoje 2006/42/EB, EMC direktyvoje 2004/108/EB, Žemos įtampos
direktyvoje 2014/35/ES, Išorinio triukšmo direktyvoje 2000/14/EB, iš dalies pakeistoje 2005/88/EB.
RU: Как определено директивой ATEX 2014/34/EU, Директива о машиностроении 2006/42/EC, EMC-Directive 2004/108/EC,
Директива о низком напряжении 2014/35/EU, Директива об уличном шуме 2000/14/EC с поправками к 2005/88/EC.
HR: U skladu s Direktivom ATEX 2014/34/EU, Direktivom o strojevima 2006/42/EZ, Direktivom EMC 2004/108/EZ, Direktiva o
niskonaponskoj opremi 2014/35/EU, Direktivom o vanjskoj buci 2000/14/EZ dopunjenoj s 2005/88/EZ.
EN ISO 12100-1, EN ISO 12100-2, IEC 80079-36, IEC 80079-37
Gregory B. Queen, President
JWC Environmental Inc.
11-12-2019
Installation and Operating Instructions
40002 Inline and Channel Series
40002_Inline_and_Channel_Series_EN_20201208_V01.docx iv
Table of contents
ATEX warning statements (refer to nameplate to check if applicable) ...................................... 1
Nameplate details ............................................................................................................................. 2
Safety and hazard warnings ............................................................................................................. 3
General information .......................................................................................................................... 4
Intended use ..................................................................................................................................... 4
Limitation of use................................................................................................................................ 5
Torque settings ................................................................................................................................. 6
Safety recommendations .................................................................................................................. 6
Noise levels ...................................................................................................................................... 7
Lubrication ........................................................................................................................................ 7
Handling ........................................................................................................................................... 7
Use of items not approved or manufactured by Sulzer ...................................................................... 7
Inspection / Storage .......................................................................................................................... 7
Installation ........................................................................................................................................ 9
Earth bonding [explosion-proof grinders only] ................................................................................. 10
Electrical installation ....................................................................................................................... 11
Guards ............................................................................................................................................ 11
Warning / Control device ................................................................................................................. 11
Start-up procedure .......................................................................................................................... 11
Dismantling advice .......................................................................................................................... 12
Cleaning / Inspection ...................................................................................................................... 13
Re-assembly advice ....................................................................................................................... 13
Extended shutdown ........................................................................................................................ 13
Maintenance ................................................................................................................................... 14
Lubrication table ............................................................................................................................. 15
Allowable wear tolerances .............................................................................................................. 15
Troubleshooting .............................................................................................................................. 15
Installation and Operating Instructions
40002 Inline and Channel Series
40002_Inline_and_Channel_Series_EN_20201208_V01.docx 1
ATEX warning statements (refer to nameplate to check if applicable)
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.
3. 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.
4. If there is a risk of an accumulation of explosive gases or dust, proper ventilation must be
performed before and during operation, removing all gases and dust.
5. 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.
6. 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.
For unit specific ATEX grinder arrangement drawings, please use the following table to ensure you
have the correct unit drawing for reference.
JWC/Sulzer unit drawings & ATEX certification data
Drawing no. Unit description ATEX zone
10000-CD-ATEX-S 10K Inline Series Muffin Monster Gas & Dust
10002-CD-ATEX-S 10K Channel Series Muffin Monster Gas & Dust
30002-SC2-ATEX-S 3-SHRED Series Muffin Monster Gas & Dust
30004T-CD-ATEX-S 30K Inline Series Muffin Monster Gas & Dust
30005-CD-ATEX-S 30K Channel Series Muffin Monster Gas & Dust
40002-CD-ATEX-S 40K Channel Series Muffin Monster Gas & Dust
40002-IL-CD-ATEX-S 40K Inline Series Muffin Monster Gas & Dust
40002-SC2-ATEX-S 4-SHRED-Series Muffin Monster Gas & Dust
CMD-XDS2.0-ATEX-S CMD-XDS2.0 Channel Monster Series Gas Only
CMD-XDM2.0-ATEX-S CMD-XDM2.0 Channel Monster Series
Gas Only
CDD-XDS2.0-ATEX-S CDD-XDS2.0 Channel Monster Series Gas Only
CDD-XDM2.0-ATEX-S CDD-XDM2.0 Channel Monster Series Gas Only
CDD-XDS2.5-ATEX-S CDD-XDS2.5 Channel Monster Series Gas Only
CDD-XDM2.5-ATEX-S CDD-XDM2.5 Channel Monster Series Gas Only
Installation and Operating Instructions
40002 Inline and Channel Series
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Nameplate details
II Equipment Group - Surface
2/3 ATEX Category – High Protection
G/D Gas/Dust
Ex Explosion Proof
h Mechanical Equipment, assigned protection group per EN80079-36
IIB/IIIC Gas/Dust Group
T Temperature Class
Gb/Dc Equipment Protection Level (Gas-1, Dust-22)
Channel Monster
Gas Only
Non ATEX
Muffin Monster
Gas & Dust
Installation and Operating Instructions
40002 Inline and Channel Series
40002_Inline_and_Channel_Series_EN_20201208_V01.docx 3
Safety and hazard warnings
Presence of dangerous voltage.
Non-compliance may result in personal injury.
Lock out – Tag out notification. Electrical hazard – non-compliance may
result in personal injury.
Keep clear of rotating components.
Auto-restart of rotating components may occur after power loss if the
main isolator is not off.
Suspended load. Do not stand under the grinder during installation /
removal.
Wear safety shoes when handling components.
Sharp edges. Wear safety gloves when handling grinder cutters and
spacers.
Wear eye protection when cleaning components.
The grinder must rotate in the correct direction for proper operation. This
must be checked on installation and commissioning and after any
maintenance has been carried out. Failure to observe this may lead to
mechanical or electrical overload.
Installation and Operating Instructions
40002 Inline and Channel Series
40002_Inline_and_Channel_Series_EN_20201208_V01.docx 4
General information
The grinder reduces solids in sewage. A separate control panel
provides grinder controls.
Model Cutter stack height (mm)
40002-0018/18B 450 mm
40002-0024/24B 600 mm
40002-0032/32B 800 mm
Model Weight (kg)* Model Weight (kg)*
40002-0018 410 kg 40002-18B300 690 kg
40002-0024 530 kg 40002-24B300 810 kg
40002-0032 660 kg 40002-24B400 860 kg
40002-24B450 950 kg
40002-32B500 1190 kg
*less drive
Drive assembly weights (kg)
Reducer only Motor only
IP55 IP68 IP55 IP68
7.5 kW 7.5 kW 7.5 kW 7.5 kW
90 kg 108 kg 66 kg 215 kg
Intended use
The 40002 inline and open channel series grinder has been designed for the economical and
reliable particle reduction for commercial, industrial and municipal sewage.
They are suitable for processing the following material:
Clear and wastewater for sewage containing solids and fibrous material
Faecal matter
Sludge
Sewage
Installation and Operating Instructions
40002 Inline and Channel Series
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Limitation of use
Limits of the machine
Description Twin-shafted grinder with cutters and spacers enclosed in a cast
iron housing meeting various standards, speed reducer, electric
motor and motor controller
Intended use Particle size reduction of municipal / industrial sewage waste
Maximum flow rate 40002-1812 inline – 612 m3/hr
40002-2412 inline – 727 m3/hr
40002-2416 inline – 999 m3/hr
40002-2418 inline – 1249 m3/hr
40002-3220 inline – 1558 m3/hr
40002-0018 open channel – 207 m3/hr
40002-0024 open channel – 327 m3/hr
40002-0032 open channel – 477 m3/hr
Maximum process
pressure 6 bar
Personnel information
Anticipated level of
training, ability and
experience
Applicable local, federal and area safety rules, regulations and
guidelines; discipline-specific apprenticeship/training
Special physical
requirements
N/A
Personnel affected Installers, electricians, operators, maintenance personnel
Environmental limits
Temperature Operation: -5° C to +40° C
Storage: -40° C to +65° C
Humidity IP68
Elevation 1000 metres above sea level
Space limits
Clearance required for
operation
150mm over motor fan cover
914mm in front of controller
Clearance required for
maintenance
610mm above
914mm on left or right side of grinder
914mm in front of controller
Installation and Operating Instructions
40002 Inline and Channel Series
40002_Inline_and_Channel_Series_EN_20201208_V01.docx 6
Interface limits
Electrical 575V/3PH/60HZ
400V/3PH/50HZ
Water N/A
Hydraulic N/A
Connection to other
equipment
Two (2) dry-contact relays indicating grinder Run and Fail
conditions for remotely located monitoring operation powered by
foreign sources
Torque settings
Torque settings (nm)
10K grinder
Thread 8.8 ZP 18-8 SST Cutter stack locking nuts
M6 12 8.7
M8 30 21.2
M10 55 42
1 in. 170
30K, 40K, CMD, CDD grinder
1/4 in. 8.5
5/16 in. 14.9
3/8 in. 26.7
1/2 in. 58
9/16 in. 75.9
5/8 in. 124.7
1-1/2 in. 224
Safety recommendations
In common with other items of process plant a grinder must be installed correctly to ensure
satisfactory and safe operation (refer to the Installation section). The grinder must also be
maintained to a suitable standard (refer to the Maintenance section). Following these
recommendations will ensure that the safety of personnel and satisfactory operation of the grinder is
achieved.
Then handling harmful or objectional materials, adequate ventilation must be provided in order to
disperse dangerous concentrations of vapours. It is recommended that where possible, Sulzer
grinders should be installed with provision for adequate lighting, thus ensure 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.
Installation and Operating Instructions
40002 Inline and Channel Series
40002_Inline_and_Channel_Series_EN_20201208_V01.docx 7
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.
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.
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.
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 and the Intended Use
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.
Inspection / Storage
Report container damage to the carrier and Sulzer.
Contact Sulzer or representative for missing, loose, or damaged parts.
All equipment should be stored in a controlled dry environment to prevent corrosion or damage to
components.
Grinders are dispatched from our factory with the cutter chamber sprayed with a moisture repellent
coating and ready for immediate installation and operation.
Installation and Operating Instructions
40002 Inline and Channel Series
40002_Inline_and_Channel_Series_EN_20201208_V01.docx 8
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 for 1-5 minutes
every 3 months either by hand or applying power to the drive motor. Check for grinder drive
lubricant leakage. Contact Sulzer is leakage exceed 6ml.
Failure to do the above may cause the machine to seize due to the tight running clearances of the
individual cutting elements during commissioning and initial start-up.
Prior to installation/commissioning:
Check external hardware as gasketed areas may have a tendency to loosen fasteners.
Retighten if loose (refer to Torque settings).
Check paint for any slight damage and touch up if necessary. Standard Sulzer colour (RAL
5002).
Installation and Operating Instructions
40002 Inline and Channel Series
40002_Inline_and_Channel_Series_EN_20201208_V01.docx 9
Installation
Electrical, mechanical and maintenance work should only be performed by suitably
qualified and competent persons and must be in accordance with relevant electrical and
mechanical regulations.
Fill any gaps
between the frame
and channel wall
Attach 3-phase motor power
Flow
Use all lifting eyes
Frame (In Channel)
Channel Installation
Use all lifting eyes
Attach 3-phase motor power
Inline Installation Horizontal Installation
Flow
Installation and Operating Instructions
40002 Inline and Channel Series
40002_Inline_and_Channel_Series_EN_20201208_V01.docx 10
Earth bonding [explosion-proof grinders only]
The grinder and associated motor are equipped with threaded studs for installations requiring single
point earth bonding. Use a cable meeting local wiring requirements and attach it to the two earth
bonding lugs located on the motor housing and grinder top cover.
Typical earth bonding points for grinder and drive. To be connected to local
earthing points on installation. To be carried out by suitably qualified installation
contractor and following local country requirements and legislation. Earth
bonding cables not supplied.
ATEX RATED MOTOR
ATEX RATED
SPEED REDUCER
Installation and Operating Instructions
40002 Inline and Channel Series
40002_Inline_and_Channel_Series_EN_20201208_V01.docx 11
Electrical installation
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 also important that the PLC be correctly wired into the panel (refer to
the Controller Manual if controller is supplied).
Before installing the grinder please ensure that all plugs and inspection plates are
replaced.
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. Earthing points will be provided on ATEX rated
electric drives (if supplied) and it 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.
Guards
In the interests of safety, all guards must be replaced after necessary adjustments
have been made to the grinder.
Warning / Control device
Prior to operating the grinder, if any warning or control devices are fitted, these must be set in
accordance with their specific instructions.
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.
Start-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 installation and operating instructions prior to working with the machine.
Verify there is no unauthorized personnel or materials near the grinder.
Use 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.
Apply power to grinder with the control panel control switch.
Installation and Operating Instructions
40002 Inline and Channel Series
40002_Inline_and_Channel_Series_EN_20201208_V01.docx 12
Check for proper motor or shaft rotation. Disconnect 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 local health and safety requirements.
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. Re-check 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
procedure:
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.
11. After machine shutdown, relieve pressure, isolate, and lock off. Inspect machine, remove any
obstruction and reset the controller.
12. The machine can now be re-started.
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.
Flow
Shafts Motor
Installation and Operating Instructions
40002 Inline and Channel Series
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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.
5. Inspect gears for wear and damage.
6. All cutters and spacers must be clean and free from cracks or excessive wear.
7. Shafts should be clean and any burrs filed off for easier stacking. Inspect shafts
for excessive wear of hexagonal portion.
Contact the Sulzer service department if any of the above requires replacement.
Re-assembly advice
1. Lubricate gears on re-assembly with the specified lubricant.
2. Re-connect wiring at motor(s) terminal box(es) using tag leads for identification.
3. Re-open system isolation valves.
4. On completion of assembly, run through the ‘initial start-up’ procedure.
Extended shutdown
For extended shutdown refer to the Inspection / Storage section.
Attach lifting equipment and remove the grinder
Installation and Operating Instructions
40002 Inline and Channel Series
40002_Inline_and_Channel_Series_EN_20201208_V01.docx 14
Maintenance
For service or parts please contact your Sulzer representative. DO NOT attempt service other than
that described in this section.
Remove and lock out supply power.
After first 3 months, then every 6 months or if solids not processed.
Check cutters for wear, (for inline units remove inspection
cover) edges should not be rounded. (See Allowable wear
tolerances).
Check cutter stack tightness.
If loose or worn, refer Troubleshooting.
Every 12 months routine maintenance should be carried out.
Check cutter stack tightness and cutters for wear.
Remove drive assembly, then remove top and bottom covers. If
top gear housing is contaminated with effluent, contact your local
Sulzer service centre.
Prior to refitting top and bottom covers, fit new gaskets.
Every 5 years:
Remove drive assembly, top cover and old grease (see figure).
Inspect gears for damage or wear, replace if necessary, then replenish
grease (see Lubrication table).
INSPECTION
COVER
Installation and Operating Instructions
40002 Inline and Channel Series
40002_Inline_and_Channel_Series_EN_20201208_V01.docx 15
Lubrication table
Manufacturer Lubricant
Gear grease (do not mix) 500 grams
Ormskirk Total Multis Complex EP2*
O-Ring grease
Ironsides Lubricant Ltd Silicon valve grease*0250/0077
Rust inhibitor
Solent SOL-732-0620K spray*
General and protectant
WD-40 Company WD-40 aerosol lubricant
* O.E.M. (Original Equipment Manufacturer)
Allowable wear tolerances
Description O/D Thickness
Spacer Maximal 0.20 mm zero wear
Cutter Maximal 0.63 mm 0.75 mm per side at edge of cutter
See figure below
Cutter Wear
Troubleshooting
Symptom Check
Solids not reduced
Cutter rotation
Cutters for wear
Cutter stack tightness
Grinder motor drive train
Loose cutter stack
The unit must be stripped down
Seal cartridges for damage
Cutters for wear
Lock nuts loose
Excessive noise, vibration or reversals Drive gears for wear
Seal cartridges for contamination
Motor overload Solids overloading
Cutters for wear
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Sulzer Muffin Monster™– 40002 Installation, Operating And Maintenance Instructions
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- Installation, Operating And Maintenance Instructions
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- English: Sulzer Muffin Monster™– 40002
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Sulzer Channel Monster™ – CDD-XDS2.0 Installation, Operating And Maintenance Instructions
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