Klöckner BK-DH 500 SERIES Operating instructions

Operating manual 17.410+411

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Dateiname Firma Datum Rev

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DRUM CHIPPER

Type

BK-DH 500 x ....

BK-DH 700 x ....

BK-DH 850 x ....

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Contents

1 GENERAL COMMENTS ...................................................................................... 6

1.1 Preface................................................................................................................. 6

1.2 Intended purpose................................................................................................ 7

1.3 Copyright............................................................................................................. 7

2 SAFETY INSTRUCTIONS.................................................................................... 8

3 MACHINE DESCRIPTION ................................................................................... 11

3.1 Constructional design........................................................................................ 11

3.1.1 Rotor bearings .................................................................................................... 11

3.1.2 Feedroll carrier pivot..........................................................................................11

3.1.3 Lower feedrolls and bearings............................................................................ 11

3.1.4 Upper feedrolls and bearings ............................................................................ 11

3.1.5 Counter knife carrier .......................................................................................... 12

3.1.6 Rotor .................................................................................................................... 12

3.1.7 Hood .................................................................................................................... 12

3.1.8 Screen.................................................................................................................. 12

3.1.9 Feedroll carrier.................................................................................................... 12

3.1.10 Machine housing ................................................................................................ 12

3.1.11 Hydraulic plant.................................................................................................... 13

3.1.12 Motor plant .......................................................................................................... 13

3.1.13 Cradle support .................................................................................................... 13

3.1.14 Run-up device (if requested) ............................................................................. 14

3.1.15 Rotor hood locking device (if requested) ......................................................... 14

3.1.16 Rotor turning device (if requested) ................................................................... 15

3.1.17 Screen basket ..................................................................................................... 16

3.2 Functional description ....................................................................................... 17

3.2.1 Stock feed ...........................................................................................................17

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3.2.2 Chipping operation............................................................................................. 17

3.2.3 Material distribution ........................................................................................... 17

3.2.4 Overload protection............................................................................................ 17

3.2.5 Start and run up.................................................................................................. 18

3.2.6 Hydraulic functions ............................................................................................ 18

4 TRANSPORTATION AND STORAGE................................................................. 20

4.1 Transport rules and regulations........................................................................ 20

4.2 Transportation fixtures ...................................................................................... 21

4.3 Storage at site..................................................................................................... 21

4.4 Break down for chipment................................................................................... 21

4.5 Scope of supply.................................................................................................. 22

5 INSTALLATION ................................................................................................... 23

5.1 General comments ............................................................................................. 23

5.2 Set-up and preliminary alignment..................................................................... 24

5.3 Installation of hydraulic plant............................................................................ 24

5.4 Installation of lower feedroll drive..................................................................... 25

5.5 Final alignment ................................................................................................... 25

5.6 Counterknife carrier guide rail installation....................................................... 26

5.7 Installation of hydraulic cylinder for anvil........................................................ 26

5.8 Installation of motor and base........................................................................... 27

5.9 Installation of drive belt(s) and guard............................................................... 27

5.9.1 Applying and tensioning of V-belts................................................................... 28

5.10 Electrical installation.......................................................................................... 29

6 START-UP ........................................................................................................... 30

6.1 Preliminary checks............................................................................................. 30

6.2 Starting ................................................................................................................ 31

6.3 Subsequent checks............................................................................................ 31

7 OPERATING INSTRUCTIONS............................................................................. 32

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7.1 General comments ............................................................................................. 32

7.2 Operation of the machine .................................................................................. 32

7.3 Knife change (general) ....................................................................................... 33

7.3.1 Knife change ....................................................................................................... 33

7.3.1.1 Knife change ....................................................................................................... 35

7.3.1.2 Counter knife change with clamped anvils ...................................................... 36

8 INSPECTION AND MAINTENANCE.................................................................... 38

8.1 General comments ............................................................................................. 38

8.2 Maintenance and inspection list........................................................................ 39

8.3 Knives.................................................................................................................. 41

8.3.1 Knife grinding ..................................................................................................... 41

8.3.1.1 Grinding of knives .............................................................................................. 41

8.3.1.2 Grinding of counter knives ................................................................................ 42

8.3.2 Knife setting........................................................................................................ 43

8.3.3 Re- adjusting the jig ........................................................................................... 44

8.4 Hydraulic plant.................................................................................................... 44

8.4.1 Accumulator (only for hydraulic plant of the chipper) .................................... 44

8.4.1.1 Oil pressure p3.................................................................................................... 44

8.4.1.2 Gas pressure p1.................................................................................................. 45

8.4.2 System pressure................................................................................................. 46

8.4.3 Oil tank ................................................................................................................ 46

8.4.4 Filter..................................................................................................................... 46

8.4.5 Hydraulic hoses.................................................................................................. 47

8.4.6 Pipework.............................................................................................................. 47

8.5 Gear motors ........................................................................................................ 47

8.6 Electrical motors................................................................................................. 47

8.7 Couplings ............................................................................................................ 47

8.8 Belt drive ............................................................................................................. 47

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8.8.1 V-belt.................................................................................................................... 47

8.8.2 Flat belts.............................................................................................................. 48

8.9 Chain drive .......................................................................................................... 48

8.10 Rotor wear plates (optional) .............................................................................. 49

8.11 Feedrolls.............................................................................................................. 49

8.12 Screen.................................................................................................................. 50

8.13 Lubrication .......................................................................................................... 50

9 TROUBLE SHOOTING ........................................................................................ 51

9.1 Problems with the chip quality.......................................................................... 51

9.2 Problems with the machine ............................................................................... 52

9.3 Problems with the hydraulic plant .................................................................... 53

9.4 Problems with the belt drive.............................................................................. 54

10 TECHNICAL DATA .............................................................................................. 55

10.a Machine no.: 17.410/20 + 17.411/20................................................................. 55

11 KEEPING OF SPARE PARTS ............................................................................. 59

12 SPARE PART DRAWINGS AND LISTS.............................................................. 60

13 APPENDIX ........................................................................................................... 61

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1 GENERAL COMMENTS

1.1 Preface

This manual is written for the personnel responsible for the operation and mainte-

nance of the BRUKS-KLÖCKNER-drum chipper.

The complete manual should be kept near the machine.

The manual contains important details concerning the operation of the drum chipper

and it is very important that the appropriate personnel is fully familiar with this man-

ual.

We strongly recommend the reading of this manual prior to installation, start-

up or operation; damage caused by disregarding these instructions is not cov-

ered by warranty.

Should you experience any problems, we ask you to contact our service or parts de-

partment or one of our representatives, who will be pleased to assist you.

This manual covers only the drum chipper.

In the interest of product improvement, we reserve the right to change de-

scribed features and specifications.

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1.2 Intended purpose

Drum chippers are utilised for the production of chips from wood / veneer / plywood

in a wide variety of applications, such as for sawmill wasted, pulpwood, fuel chips,

board industry and many others.

The described drum chipper is designed and built for a specific purpose; if the chip-

per is to be used for a different purpose or to produce a different product, you are

urged to discuss this with BRUKS-KLÖCKNER GmbH.

1.3 Copyright

The copyright of this operation manual remains property of BRUKS-KLÖCKNER

GmbH.

It is intended for those persons who are concerned with installation, start-up, mainte-

nance and repair of the BRUKS-KLÖCKNER-Drum chipper.

It contains instructions and technical drawings which shall not be copied - neither

fully nor partly - and shall not be notified or transmitted to other persons.

BRUKS-KLÖCKNER GmbH

Grabenstraße 1

D-57647 Hirtscheid-Nistertal

Telefon: +49-(0)2661-28-0

Fax : +49-(02661) 28-180

www.bruks-klockner.com

[email protected]

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2 SAFETY INSTRUCTIONS

2.1 The BRUKS-KLÖCKNER-Drum chipper is technically sound and safe to operate.

However, any machine can cause dangers if operated in an unsafe manner or by

personnel unfamiliar with the machine.

2.2 Every person concerned with installation, start-up, operation and maintenance

of the chipper must have read and understood the complete manual, in particu-

lar the section "safety instructions". The user is advised to have this confirmed

by signature of the appropriate personnel.

2.3 The drum chipper is designed exclusively for the production of chips from wood. Any

other use is improper and no responsibility can be accepted by the manufacturer.

2.4 The user is responsible to protect the machine from foreign metal or rocks etc. with

appropriate devices, such as metal detectors, magnets, cleaning rolls etc.

2.5 The user must also ensure that the area surrounding the chipper is within the allow-

able limits for dust concentrations.

2.6 The inferred area and the movable fedoras must be guarded by fencing or barriers.

2.7 Noise control is to be provided as per local regulations.

2.8 Emergency stop buttons must be located in the immediate vicinity of the machine.

2.9 Near the chipper earplugs must be worn.

2.10 Unauthorised changes and modifications to the machine must not be done for rea-

sons of safety.

2.11 The user is responsible that the machine is only operated in good condition.

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2.12 The operating personnel is required to inspect the chipper at least once daily and

report any defects or changes in operation immediately.

2.13 Regular inspection, maintenance and repair checks must only be performed with ma-

chine at a standstill.

If for this purpose protecting devices, coverings or similar have to be opened or re-

moved, the drum chipper must be prevented from accidental starting. This is normally

done by locking out the main switch.

2.14 Any work must only be performed with machine at a standstill.

2.15 No protective or safety devices may be removed.

If it is necessary to remove guards for maintenance, they must be re-installed imme-

diately upon completion of the work.

2.16 The hydraulic unit is equipped with an accumulator. This may have to be inspected

and approved by the local authorities. The user is responsible to observe the local

regulations in full and obtain such approval if necessary as well as later re-

inspections.

2.17 The accumulator was sealed through TÜV, the appropriate authority in Germany and

the seal may not be removed.

2.18 All work on the hydraulic unit, except as listed here-in, must only be performed by

qualified tradesmen.

2.19 Prior to any work on any part of the hydraulics, all machine parts must be lowered.

2.20 Those units in connection with the accumulator will remain pressurised after lowering

of machine parts and motors are stopped. For this reason, the oilside of the accumu-

lator must be drained prior to commencing work on the hydraulics. (see chapter „in-

spection and maintenance“).

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2.21 When working underneath the hood, it must be secured with the holding pin.

2.22 When working underneath the cradle, it must be secured with the cradle support

.

2.23 When working on the rotor it must be secured with the holding pin.

2.24 When working with the knives, cut resistant safety gloves must be worn.

2.25 Besides these safety instructions, all appropriate local rules and regulations must be

observed.

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3 MACHINE DESCRIPTION

3.1 Constructional design

3.1.1 Rotor bearings

The rotor is running on oversized spherical roller bearings. The steel housings are

flanged and spigotted into the chipper housing side plates. Seals are lip type.

3.1.2 Feedroll carrier pivot

The feedroll carrier pivot connects the pivot/cradle with the machine housing and it is

formed by heavy spherical roller bearings in flanged steel housings.

3.1.3 Lower feedrolls and bearings

The feedrolls with special tooth profile are running in heavy spherical roller bearings

in flanged steel housings, spigotted in the housing sidewalls. Seals are lip type.

The teeth of the feedrolls are hard tipped to prevent wear.

The feedrolls are driven by a gear motor driving the first feedroll behind the rotor with

roller chain drives from roll to roll. These chain drives are protected by an oilbath type

chain case, completely enclosed, ensuring proper lubrication while keeping out dust

and dirt.

3.1.4 Upper feedrolls and bearings

These feedrolls are similar to the lower feedrolls with the exception that they are

mounted in a carrier, which pivots up and down to adjust for different sizes of pieces

to be chipped.

Drive is by gear motor to the first feedroll at the inlet.

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3.1.5 Counter knife carrier

The anvil carrier is positioned on top of the anvil carrier support, welded into the ma-

chine. The anvil carrier is held by plates and pressure bolts on each side of the hous-

ing. To change anvils, the carrier can be moved laterally by hydraulics. Anvil carrier

and support are provided with replaceable wear plates.

3.1.6 Rotor

Description of bearings see 3.1.1.

The rotor consists of the welded steel rotor, the knives and knife mounting device.

The standard knife mounting is by clamping plates with bolts, tapered wedge type

knife clamping is also available. The rotor is provided with replaceable wearplates

underneath the knives.

The rotor is mounted onto the shaft utilising tapered ring locking elements.

3.1.7 Hood

The hood covers the housing over the rotor and provides access for knife changes.

The hood pivot is a bushing type.

3.1.8 Screen

The screen is of welded steel construction, heavily re-inforced and mounted in guides

in the housing sideplates.

3.1.9 Feedroll carrier

The feedroll carrier is a solid welded steel fabrication, and carries the upper feedrolls.

The carrier is pivoting from the inlet of the machine, see 3.1.2.

3.1.10 Machine housing

The machine housing is a heavy welded steel construction and carries all

aforementioned components.

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3.1.11 Hydraulic plant

The hydraulic plant includes the hydraulic power pack, the cylinders and piping on

the machine.

The power pack consists of motor, pump, accumulator, tank and all control valves.

The connection from the ping to the power pack and to the cylinders is by high pres-

sure hoses.

3.1.12 Motor plant

On smaller machines with lower drive power the pulley will be normally mounted di-

rectly onto the motor shaft. The motor itself will be placed on slide rails and the whole

belt drive is secured by a protection cap.

High drive power and great belt tension powers (particularly when using flat belts)

require a separate bearing of the motor pulley. In those cases the motor and the pul-

ley are to be mounted separately on a console. Depending on the power transmis-

sion, connection is to be effected by means of a jaw clutch or bolt coupling. The pul-

ley is fastened by means of cone clamping devices on the shaft. The bearing is per-

formed by heavy roller bearings in plummer blocks. The whole console is born on

slide rails and can be moved on same by adjusting spindles for tensioning, respec-

tively loosening of the belt.

Also refer to the spare part drawings, chapter "Spare part drawings and piece lists"

mentioned in above groups.

3.1.13 Cradle support

BRUKS-KLÖCKNER Drum Chippers are fitted by standard with hydraulically driven

support rods used for supporting the swing when open for cleaning and repair works.

Support rods fastened on left and right side on extended cylinder supports with

knuckle eyes. Provide upper end with ball head. During machine operation placed

slanting to rear. With the swing completely open the rods are hydraulically moved

forward until reaching position under the ball socket in the swing-cylinder support,

then the swing is lowered by some centimetres until the swing is resting on the rods.

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3.1.14 Run-up device (if requested)

The run-up device is a hydraulic donkey drive that with reduced electrical power in

combination with hydraulic power transmission shall overcome the existing inertia of

masses of the system of chipping rotor ? pulley ? electric driving motor.

The reason is to reduce or prevent the starting currents that would generate with di-

rect start by the main motors.

For this purpose, the system chipping rotor ? pulley ? electric driving motor is

dragged up to the rated speed of the main motors by an installed hydraulic motor.

When reaching the rated speed the main motors are hooked up into the electric net-

work with the result that high power withdrawal of the electric network is prevented.

Subsequent to reaching the rated speed and join-up of the main motors into the elec-

tric network, the hydraulic motor respectively the hydraulic power transmission is un-

coupled via a specifically previewed coupling.

3.1.15 Rotor hood locking device (if requested)

The hood locking is a hydraulically operated safety device ensuring the automated

operation of the drum chipper. The hood can only be opened e.g. for replacing the

blades at the chipping rotor, with the chipping unit stopped or out of operation. For

this there is an electric link to the hood locking allowing opening of the hood only if

the a.m. conditions are met.

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3.1.16 Rotor turning device (if requested)

For positioning the blades in blade replacement position

With a hydraulically operated unit the chipping rotor of the drum chipper can be

automatically turned into the maintenance position (blade replacement position). This

is carried out with a specific ratchet construction driven by a hydraulic cylinder. Dur-

ing the work clearance stroke this ratchet engages into a toothed disc mounted onto

the rotor shaft, and turns it. By repeating this process the rotor is turned until the re-

spective position is reached.

Inductive proximity switches control the limits of travel of the hydraulic cylinder. With

standstill of the cylinder, a hydraulic shut-off valve blocks the cylinder is in the

reached position.

Because of the special shape of the ratchet and the blocking of the cylinder in main-

tenance position there is no need for a locking pin for blocking the rotor.

This also prevents overtravelling the maintenance position because of the rotor iner-

tia.

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3.1.17 Screen basket

The chipper is provided with a screen changing device. The rear side of the chipper

and the screen changing device are forming a unit.

To unlock the rear side of the chipper release the swivelling screw fittings. Through

the hydraulic the screen changing device can be driven out. Before changing the

screen, the fastening screws have to be released.

swivelling

screw-fitting

hydraulic cylin-

der

fastening screw

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3.2 Functional description

3.2.1 Stock feed

The material to be chipped is fed to the chipper by a belt or vibratory feeder. The up-

per and lower feedrolls positively grab the material and push it to the rotor at a con-

trolled rate. The upper feedrolls adjust for height of the material to be chipped.

The pressure of the upper feedrolls on the material is generated by the weight of the

feedroll carrier and the hydraulic cylinders are used to reduce this pressure to the

minimum required for proper feeding. This will extend life of the feedroll teeth and re-

duce damage to the wood.

3.2.2 Chipping operation

The knives chip the material by cutting the length of the chip with the thickness re-

sulting from the knife angle and specific characteristics of the wood being chipped.

The chips are collected in the pocket below the knife and carried past the anvil. The

chips are now thrown out by centrifugal force, with the oversize pieces held back by

the screen and chipped again.

3.2.3 Material distribution

The funnel under the chipper embraces the whole scuttle of the machine. Also fine

material under the feedrolls would be taken and lead in the following conveyor.

3.2.4 Overload protection

For preventing overload of the main motor, the drum chipper is fitted with a load-

depending feed control. With the power consumption of the main motor reaching

rated current, the feed motors are disconnected (time-delayed). They are automati-

cally reconnected if the power consumption of the main motor drops to 70% of the

rated value

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3.2.5 Start and run up

The machine is started with a hydraulic system up to rated speed to avoid high start-

ing currents. During run-up, the rotor speed is continuously monitored and adjusted

to rated speed. Only after remaining steady at rated speed, the hydraulic system is

switched off, and the main motors are switched on. The overriding clutch, which con-

nects hydraulic motor and electric motor, during run-up works in lock-in operation and

with switch-off of the hydraulic system in free-wheeling operation. This clutch works

wear resisting because of the hydro-dynamic clamping piece lift-off.

3.2.6 Hydraulic functions

• Reducing the swing contact pressure

The cylinders with the knuckle eyes on the swing are connected with the ac

cumulator on the hydraulic unit and are continuously pressurized. The function

is continuously active. The initial pressure is set with a manually operated

three-way cock.

• Hood locking open/closed