Operating Manual Version 04/10

Operating Manual
(Translation of the original German operating manual)

Ballistic Separator STT 1500, STT 2000 or PPK

Version 04/10

Manufacturer:

STADLER Anlagenbau GmbH

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
Tel.: (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69

STADLER Anlagenbau GmbH 1

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

1 Introduction ............................................................................................................ 3
2 Warranty and Liability ............................................................................................ 4
2.1 Additional Warranty Conditions ............................................................................. 4
2.2 Invalidation of the Warranty ................................................................................... 5
2.3 Liability Exclusion .................................................................................................. 5
3 Safety Information.................................................................................................. 7
3.1 Identification of Safety Information ........................................................................ 7
3.2 Use for Intended Purpose...................................................................................... 7
3.3 Organisational Safety Measures............................................................................ 8
3.4 Selection and Qualification of Operating Personnel ............................................ 10
3.5 Safety Instructions for Machine Operation........................................................... 11
3.6 Safety Instructions for Assembly and Maintenance ............................................. 13
3.7 Information on Special Hazards........................................................................... 16
3.8 Special Rules....................................................................................................... 18
3.9 Residual Hazards ................................................................................................ 18
4 Operating and Use of the Ballistic Separator....................................................... 23
5 Maintenance Work on the STADLER Ballistic Separator .................................... 25
5.1 General ................................................................................................................ 25
5.2 Lubricating bearings and gears ........................................................................... 25
5.3 Maintenance Work After the First Running.......................................................... 25
5.4 Maintenance Work After Each Work Shift (every 8 hr.) ....................................... 26
5.5 Weekly Maintenance Work .................................................................................. 26
5.6 Monthly Maintenance Work ................................................................................. 28
5.7 Annual Maintenance Work................................................................................... 28
5.8 Maintenance Work After X Operating Hours ...................................................... 28
5.9 Replacement of Wearing Parts ............................................................................ 29
5.10 Other Maintenance Work..................................................................................... 29
5.11 Use of Personal Protective Equipment Against Falling ....................................... 30
5.12 Moving the Paddles and Venting the Motor Brake .............................................. 31
5.13 Lubrication Table ................................................................................................. 32
6 Troubleshooting and remedy ............................................................................... 33
7 Technical Data..................................................................................................... 34
8 Airborne Noise ..................................................................................................... 35
9 Spare Part Ordering and Service Address .......................................................... 36

STADLER Anlagenbau GmbH 2

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

1 Introduction

Dear customer;

You have chosen a STADLER Ballistic Separator the correct choice for a solid design that
guarantees a long service life with a low maintenance cost.

The information that you need to be aware for the installation, operation and
maintenance of a STADLER Ballistic Separator is provided in this operating
manual.

Even if you only acquire a STADLER Ballistic Separator as partly completed machinery in
accordance with the Machinery Directive 2006/42/EC, we would like you to have this infor-
mation. For assembly, partially assembled machines are provided with a separate assembly
manual.

Please read this operating manual prior to using the Ballistic Separator and observe the in-
formation provided.

This will ensure that you achieve a high operational safety, a long service life and thus the
desired success through the use of the STADLER Ballistic Separator.

This operating manual is part of the machine equipment. It must be stored safely and be
available to operating personnel at all times.

It is a supplement to the documentation for the complete system of which your STADLER
Ballistic Separator is a component. It is considered to be an operating manual in accordance
with Appendix I No. 1.7.4 of the Machinery Directive 2006/42/EC.

If the STADLER Ballistic Separator is sold, the operating manual must be transferred to the
new owner.

Copyright

The copyright for this operating manual remains with STADLER. This operating manual is
entrusted to the owner or operator of the STADLER Ballistic Separator for personal use and
may not be duplicated in whole or in part, distributed or used for commercial purposes, or
provided to others.

Manufacturer: STADLER Anlagenbau GmbH

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
Tel.: (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69

STADLER Anlagenbau GmbH 3

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

2 Warranty and Liability

2.1 Additional Warranty Conditions

STADLER gives a warranty in accordance with our Conditions of Supply and Payment.
The following additional conditions apply:

1. We give a 12-month warranty on the goods supplied by us in accordance with

the following provisions:

The warranty period begins upon delivery. An extension of the warranty period
due to out-of-service times during duration of repair is excluded.

Our warranty (repair or replacement) covers all provable material or manufac-

turing defects that occur within the warranty period and are notified to us within
this period. The warranty conditions of the corresponding manufacturer apply in
the case of defects in, or damage to, electrical components, incandescent/glow
lamps, motors, plastic parts, glass/paintwork/enamel damage, thermostats,
fans, pressostats, hermetic expansion valves, low-temperature or climatic
valves, control devices, solenoid valves and time switches.

Defects or damage caused by natural wear or incorrect operating or mainte-

nance, excessive stressing, improper use (see section 3.2), climatic, electric or
chemical influences are excluded from the warranty.

2. Consignment packages must be inspected for damage or theft prior to ac-

ceptance. Damaged consignments must only be accepted from the carrier
after written acknowledgment of the damage. In the case of obvious de-
fects, the complaint of defect must be received by us no later than one
week after receipt of the goods.

3. The return of goods, regardless of whether they are still under warranty or have
an expired warranty, requires our prior consent. Goods returned without our
consent will not be accepted by us.

4. We are entitled to demand with due consideration to item 3 that goods un-
der warranty are returned to us for the purpose of checking the warranty claim.

5. If the repair cannot be effected on-site, the device must be sent to our following
address (together with an exact description of the defect or complaint):
STADLER Anlagenbau GmbH
Robert-Bosch-Strae 4
D-88361 Altshausen
Germany

6. The on-site noise-reduction and vibration-reduction work to be performed by the

user or by his contractor, e. g. in respect of the foundation is a component of
the corresponding contract of sale.

STADLER Anlagenbau GmbH 4

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

2.2 Invalidation of the Warranty

Any warranty entitlement becomes invalid in the following cases unless regulated otherwise
in a separate contract:

1. if a STADLER Ballistic Separator is installed, assembled or disassembled by a

anyone other than by the specially trained STADLER personnel or a specialized
company approved by the STADLER Company ;

2. if changes, interventions, repairs, or installation of third-party components are

not performed by STADLER or a specialized company approved by us but
rather by a third party;

3. if accessories or spare parts are used which are not approved by STADLER or
which are not STADLER original spare parts;

4. if repairs or interventions are undertaken by personnel who are not authorised

or trained;

5. damage resulting from incorrect operating or improper use.

Even after the guarantee period, we recommend the continued use of STADLER original
spare parts. Only STADLER original spare parts and (spare) parts approved by the
STADLER Company have the precise dimensions and material quality to fulfil the demands
they will be subjected to.

2.3 Liability Exclusion

1. A liability by STADLER is excluded if the warranty and liability provisions

are not complied with upon receipt of a damaged consignment (see sec-
tion 2.1, item 2).

2. STADLER has no liability for injury, loss, damage or danger resulting from an
improper use (see section 3.2).

3. STADLER assumes no liability for damage and hazards that arise due to failure
to comply with applicable accident prevention guidelines, other generally recog-
nized safety-related and occupational health rules, as well as internal company
rules and regulations (see Chapter 3.3).

4. STADLER has no liability for injury, loss, damage or danger resulting from un-
authorised modifications on a STADLER Ballistic Separator or the use of spare
parts, accessories, add-on devices, etc. not tested and approved by STADLER
(see section 3.2).

5. STADLER has no liability for injury, loss, damage or danger resulting from the
installation, assembly or disassembly of a STADLER Ballistic Separator by per-
sons other than the specially-trained technical employees of STADLER or of a
specialist company authorised by STADLER (see section 2.2).

STADLER Anlagenbau GmbH 5

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

6. STADLER assumes no liability for injuries, property damage or other damage

and hazards that arise due to a failure to comply with the safety instructions,
with the operating manual or through violation of the duty of care during han-
dling and operation and maintenance, including the care, servicing and repair of
STADLER Ballistic Separators, even if these requirements are not specifically
referred to in the safety instructions, operating and maintenance manuals.

7. STADLER has no liability in respect of the compliance with the noise/vibration

specification of a STADLER Ballistic Separator if the contractually agreed work
by the user/operator for the reduction of noise/vibration is not performed.

STADLER Anlagenbau GmbH 6

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

3 Safety Information

3.1 Identification of Safety Information

Read this operating manual before commissioning, maintaining, or repairing the STADLER
Ballistic Separator. Comply with all safety instructions.

As an additional aid, the operating manual has prominent notes with regard to particular haz-
ard points. These notes are identified with the following symbols:

Caution
Danger for persons. Observe the information in order to avoid accidents and
injuries.

Important information that must be observed for the operation and maintenance
i of the machine.

3.2 Use for Intended Purpose

The STADLER Ballistic Separator is designed for the separation of material as described in
the data sheets delivered with the machine. Any other use is an improper use.

STADLER Ballistic Separators are not intended for use in areas at risk of explosion in accor-
dance with ATEX Directive 94/9/EC.

For the intended use of a STADLER Ballistic Separator, the technical data specified by the
manufacturer i. e. specified by us or by our suppliers must be complied with.

Intended use expressly includes compliance with the instructions in this operating manual
and in the documentation of the system in which the STADLER Ballistic Separator is inte-
grated, as well as compliance with the service and maintenance requirements.

Unauthorised modifications on a STADLER Ballistic Separator or the use of spare parts,

accessories, add-on devices, etc. not tested and approved by STADLER can negatively in-
fluence the safety of the STADLER Ballistic Separator.

Caution
Implement the safety measures described in the following sections in or-
der to avoid accidents and injuries.

STADLER Anlagenbau GmbH 7

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

3.3 Organisational Safety Measures

1. The STADLER Ballistic Separator was manufactured in accordance with the

state of the art and the recognised safety rules and is safe in operation. Despite
this, a danger of injury or death for the operators or others or adverse effects on
the STADLER Ballistic Separator or other property can exist during its use, es-
pecially in the case of
- incorrect use
- Improper use.

2. Use the STADLER Ballistic Separator only for its intended purpose, in a techni-
cally perfect condition and in a safety-conscious and hazard-conscious way and
with due observance of the contents of this operating manual! Malfunc-
tions/defects, especially those which can impair the safety, must be corrected
immediately!

Golden Rule:
Dont assume, check!
Before each putting into operation, check the STADLER Ballistic Separator for
its safeness in operation! Cautious and careful working is the best protection
against accidents!

3. The operating manual must always be available where the STADLER Ballistic
Separator is in use and must therefore be kept in a clean, dry location. An in-
complete or illegible operating manual must be immediately made complete or
replaced!

4. The operating instructions and other documents and regulations concerning the
system, of which the STADLER Ballistic Separator is a part, must be observed!

5. Supplementing this operating manual are the legal, generally applicable and
other binding accident prevention and environmental protection regulations of
the respective country in which the STADLER Ballistic Separator is used, which
must be complied with and impressed upon those involved. This includes in par-
ticular the applicable accident prevention guidelines and the other generally
recognized rules governing safety and occupational health, as well as your
company's internal rules and regulations. If necessary special instructions (op-
erating instructions, or similar instructions) must be issued.

Such obligations can also for example deal with the handling of hazardous sub-
stances and the provision and wearing of personal protective equipment.

6. For consideration of operational peculiarities, e. g. relative to work organization,

work procedures, or assigned personnel, the operating manual must be sup-
plemented with appropriate instructions, (work procedures, or similar items), in-
cluding regulation of the supervisory and reporting obligations.

STADLER Anlagenbau GmbH 8

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

7. Personnel assigned to work on the machine must have read and understood
the operating manual and in particular the safety instructions before starting
work. This applies in particular to persons who work only occasionally on the
machine.

8. Through occasional checks at a minimum, the user/customer must monitor. op-

erating and maintenance personnel for safety-conscious and hazard conscious
work in compliance with the operating manual.

9. The user/operator is obliged to operate the machine only when in perfect condi-
tion and, insofar as necessary or required by regulations, require the operat-
ing/maintenance personnel to use personal protective equipment, etc.

10.The golden rule in the case of safety-relevant changes on the machine or

changes in its operating behaviour is: stop the machine immediately and correct
malfunctions/faults (or have them corrected)!

11.Do not make modifications, add-ons or conversions on the machine which im-
pair the safety, respectively do not make modifications without the approval of
STADLER.

This also applies to the incorporation and adjustment of safety devices and the
welding of load-bearing components.

12.Spare parts must conform to the technical requirements specified by

STADLER. This is always ensured in the case of original spare parts.

13.The danger always exists of getting injured, e. g. by becoming entangled or

caught!

Remove jewellery, like rings, wristwatches, bracelets, etc., before working on

the machine!

Never wear long hair loose!

Wear tight-fitting clothes! No loose clothing, e. g. open jacket, tie or scarf!

14.Keep the machine clean including the safety, warning and information labels
on it (do not use solvent for such cleaning).

15.Observe all safety, warning and information labels on the machine. Replace
missing or unreadable labels immediately!

16.Comply with legally prescribed intervals for recurring tests/inspections or main-

tenance work, or those specified in the operating manual!

17.For the performance of maintenance measures inc. inspection, maintenance

and repair tasks, it is essential to use workshop equipment appropriate for the
task. All associated work equipment, machines, etc., must be in faultless, ready-
to-use condition.

STADLER Anlagenbau GmbH 9

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

18. All persons assigned with the operating, maintenance or repair of the machine
must be informed about the location of fire fighting/protection equipment and
know how to use it.

3.4 Selection and Qualification of Operating Personnel

Employment Restrictions:
Pursuant to applicable German Accident Prevention Regulations, the user may
employ, for work on/with technical equipment, only insured persons who are at
i least 18 years old and are familiar with the equipment and the process.
Only persons who are physically and mentally suitable, have been instructed in
the handling of the machine and its maintenance, have proven their capability
to the user and can be expected to reliably fulfil the tasks assigned to them may
be employed.

1. Do not allow unauthorized persons to work with the machine!

2. Only dependable personnel may work on or with the machine.

3. Observe the minimum age required by law (or otherwise)!

4. Use only trained or instructed personnel on the machine.

5. Allow untrained or uninstructed personnel or personnel undergoing a general

training to work on/with the machine only under continuous supervision of an
experienced person!

6. Persons under the influence of alcohol or drugs may not enter the plant, of
which the STADLER Ballistic Separator is a component.

7. Specify the responsibilities of personnel for operating, setting-up, servicing and

repairing, clearly and precisely.

8. Specify the responsibility of the machine operator/system operator.

9. Authorize the machine operator/system operator to reject third-party instructions

where these conflict with safe procedures.

10. Work on the electrical equipment may only be performed by qualified electri-
cians who:
- are capable of performing tasks on electrical equipment, e. g. in accor-
dance with DIN VDE 0105-100 or DIN EN 50110-1 or 2,
- have been instructed in the general accident prevention guidelines,
- know the contents of this operating manual and act in accordance with it;
this particularly applies to the safety instructions.

STADLER Anlagenbau GmbH 10

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

Note:
DIN EN 50110-1 contains the following, slightly modified, definition of an elec-
i trically skilled person based on the International Electro-Technical Vocabulary
(IEV 195-4-1): person with relevant education, skills and experience to enable
him or her to perceive risks and to avoid hazards which electricity can create.

11.All maintenance tasks involving the mechanical systems of the STADLER Bal-
listic Separator that extend beyond merely cleaning and checking the proper
fastening or attachment of protective devices may only be performed by special-
ized personnel, who:
- are qualified to do so due to proper vocational (preferably technical) spe-
cialized training, e. g. as machinist or mechanic,
- have been instructed in the general accident prevention guidelines,
- know the contents of this operating manual and act in accordance with it;
this particularly applies to the safety instructions.

12.As the employer you are legally obligated on a suitably regular basis, at least
once a year, to instruct your personnel of dangers which come up before they
start work, while performing their duties, and thereafter as well as on the meas-
ures to be taken avoid the dangers before work is begun.

3.5 Safety Instructions for Machine Operation

1. Do not work in a way that can be unsafe!

Danger Area:
The danger area is the area in which persons are endangered by the move-
ment of the machine or the conveyed material. This also includes the area
i reached by falling conveyed material.
We define the following danger zones during the operation of the Ballistic Sepa-
rator:
1. The internal zone due to moving parts.
2. Due to potential parts ejected, a distance of 4 m around the Ballistic
Separator, provided it is open at the top. Entrance is allowed only for
authorised and instructed staff wearing personal protective equipment
(helmet, safety gloves, tight safety goggles against mechanical injuries,
hearing protection).

2. If the safety clearance cannot be maintained, cordon off a danger zone.

3. It is forbidden to place yourself in a danger zone!

4. Stop work and switch off the Ballistic Separator (bring it to a standstill) if per-
sons do not leave the danger zone in spite of warning!

5. Make yourself familiar with the place of work before starting the work!

STADLER Anlagenbau GmbH 11

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

6. Take measures to ensure that the machine can only be operated in a safe and
functionally-correct condition!

7. Operate a STADLER Ballistic Separator only when all protective devices and
safety-necessary devices, e. g. removable protective devices, are in place and
in a working order!

8. Check the machine for externally-identifiable damage or defect at least once a

day/shift. Immediately report occurred changes (including that of the operating
behaviour) to the responsible person! If necessary, stop the machine immedi-
ately and prevent a subsequent starting!

9. Stop the machine immediately and prevent a subsequent starting in the case of
machine malfunction! Correct faults immediately (or have them corrected)!

Functional checking of protective devices:

Immediately after the first putting into operation of technical equipment, the op-
erating personnel must check the functionality of protective devices on a daily
i basis. Identified defects must be reported immediately to the supervising per-
son.
The supervising person must immediately have defective protective devices
replaced or repaired and, until such replacement work is completed, give work
instructions that ensure the safe operation.
The protection devices of the Ballistic Separator are:
1. Cover hoods of the couplings and motor shafts check if existing and
correctly mounted!
2. Cover hoods of the shaft ends protruding from the side walls check if
existing and correctly mounted!
3. Cover hoods of the motor fans check if existing and correctly
mounted!
4. Circular and arch segments to cover the recesses in the side walls to
set the paddle inclination check if existing and correctly mounted!
5. Plastic plugs to close the unused screw holes for clamp screws in the
side walls in the adjusting area check if existing and correctly
mounted!
6. EMERGENCY STOP buttons functional test!
7. Safety end switch at all doors and flaps functional test!

10.Start and operate the machine only from the intended place of work!

11.Carry out switch-on and switch-off procedures in accordance with the operating
manual or documentation for the system in which the STADLER Ballistic Sepa-
rator is installed and watch the control displays!

STADLER Anlagenbau GmbH 12

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

12.Before putting the machine into operation (switch-on/start-up), ensure that no-
one can be endangered by this.

Before each switch-on or start-up, the supervising person must check that the
switch-on or start-up of the machine cannot endanger anyone.

An audible alarm signal alone is not sufficient!

13.Persons and living animals must not enter the STADLER Ballistic Separator.

14.Ensure a sufficient work area illumination!

3.6 Safety Instructions for Assembly and Maintenance

The term maintenance in the following text covers maintenance, inspection, repair and
cleaning.

1. Do not work in a way that can be unsafe!

2. Comply with the inspection, adjustment and service schedules specified in the
operating manual, including specifications with regard to the replacement of
components! Only trained specialised personnel should execute these activities.

3. The machine may not be started-up for testing purposes or maintained by unau-
thorised persons.

4. Inform the operating personnel before the start of any special work or mainte-
nance work! Nominate a supervising person!

5. For all tasks that affect the operation, conversion or adjustment of the machine
and its safety-related devices, as well as for all maintenance tasks, the switch-
on/switch-off processes must be executed in accordance with the operating
manual or in accordance with instructions in the documentation of the system in
which the STADLER Ballistic Separator is integrated, and the information pro-
vided with regard to maintenance must be observed.

6. Insofar as necessary, prevent a general access to the maintenance work area

by other persons!

7. Switch off the controller for the STADLER Ballistic Separator and for the other
machines around it and bring them all properly to a standstill (de-energized
all-pole disconnect!) before carrying out maintenance. To do this throw over the
respective main switch, motor protection switch, contactor, etc. and lock it, keep
the key with you until the tasks have been completed! .

Affix a warning sign e. g. "Machine is being repaired do not switch on!" to

the switch or the switching cabinet.

STADLER Anlagenbau GmbH 13

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

Proceed in the same manner if an appropriate switch is not present e. g. by

unscrewing all of the fuses, carrying them away with you and affixing a warning
sign!

Merely activating a switch that affects only the system controller and not
the power supply, activating an EMERGENCY-STOP switch or opening a
door or flap secured with a safety limit switch is not an adequate safe-
guard against restart!

8. When approaching the Ballistic Separator in operation, always wear personal

protection equipment: helmet, safety shoes, tight safety goggles against me-
chanical damage to your eyes as well as hearing protection.

In case of maintenance works at a shut-down STADLER Ballistic Separator,

wear at least helmet and safety shoes as well as the respectively required per-
sonal protective equipment for the machines and devices you are using or for
specific work procedures. Before the maintenance works, find out which meas-
ures are required (e. g. from official provisions, accident prevention regulations,
operating instructions for the machines and devices you are using, operating in-
structions of your company, risk and safety datasheets or similar).

Do not wear gloves when working at rotating parts the injury resulting from
getting caught is more severe than, for example, a cut!

When carrying out maintenance works in the internal area, never forget per-
sonal protective equipment against falling from the paddles!

9. Entering the STADLER Ballistic Separator while the system controller is

switched on and the machine has not be correctly brought to standstill (not de-
energized and secured against restart) is categorically prohibited!

10.The following items apply if maintenance work with running machine parts is
unavoidable:
- Maintain a safe distance from all rotating and moving components!
- Do not work alone!
- All participating persons must be authorised to operate the overall machine
(plant) of which the STADLER Ballistic Separator is a component!
- All participating persons must be able to see each other!
- At least one person must always be able to stop the machine immediately
(such as a safety post at the next EMERGENCY STOP button)!

11.Before starting assembly work on a machine, make sure that all movable parts
cannot roll away or accidentally move!

12.Use only suitable and technically perfect lifting equipment and lifting tackle with
sufficient load capacity!

13.During replacement, carefully fasten individual components and larger compo-

nent groups to the lifting gear and secure them so that they cannot pose a haz-
ard.

STADLER Anlagenbau GmbH 14

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

14.When lifting and transporting system components, make sure that the compo-
nents are always set down on frame elements.

15.Employ only experienced persons for the slinging/fastening of loads and for in-
structing crane operators! The instructing person must be in the view of the op-
erator or give the operator verbal instructions.

16.Do not stay or work under suspended loads!

17.Use the incorporated or other safe climbing aids or work platforms when carry-
ing out maintenance/assembly work above head-height. Do not use machine
components as climbing aids!

18.In case of maintenance and assembly works in great height, preferably use
equipment providing collective protection (such as railings), but at least per-
sonal protection equipment against falling. When working in great height, al-
ways work in groups of at least two persons!

19.Keep all holding devices, steps, railings, platforms, ladders, etc., on which you
could slip free of dirt, oil, snow, ice, etc. !

20.Retighten screws slackened during the maintenance or assembly work!

21.If the disassembly of safety devices is necessary for conversion/maintenance

work, the reassembly and testing of the safety devices must occur immediately
after the completion of the work.

22.Stably obstruct/support the places of danger to life and limb (shearing points,
squashing points) on the machine before you start work at such danger places.

23.Do not carry out assembly and maintenance work below elevated STADLER
Ballistic Separators unless they have been propped up so that they are safe
and stable.

Hydraulic cylinders, jacks, etc. alone do not sufficiently support raised ma-
chines.

24.Forceful strikes on locking pins can cause them to fly out or splinter! Danger of
injury!

25.Carry out all the maintenance tasks specified in the operating manual and com-
ply with the guidelines with regard to the replacement of components. Only
trained, specialist personnel may perform the corresponding tasks.

26.Clean the machine after each shift and check it for loose screws, damage and
leaks. Correct defects immediately!

27.When handling oils, fats and other chemical substances, observe the applicable
safety regulations for your country as well as the regulations concerning the
handling of hazardous substance and the protection of the environment (includ-

STADLER Anlagenbau GmbH 15

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

ing the EC safety datasheets or any other safety data sheets of the respective
manufacturer applicable in your country)!

28.Ensure a proper, safe and environmentally-friendly disposal of replacement

parts and consumables (e. g. recycling container), especially in the case of oil,
grease and other chemical substances!

3.7 Information on Special Hazards

1. Before carrying out any maintenance, the system in which a STADLER Ballistic
Separator is installed must be de-energized and reliably safeguarded against
being switched on again without authorisation or unintentionally (brought to
standstill) there is danger to life if the system starts accidentally.

2. Maintenance work at electric components and other work at electric parts of the
machine may be carried out only by specially skilled and experienced persons
qualified staff that is skilled for such tasks, for instance in accordance with DIN
VDE 0105-100 or DIN EN 50110-1 or -2!

Maintenance works beyond the mere cleaning and inspection of the protection
devices for correct mounting and functional tests at mechanic parts may be car-
ried out only by persons with appropriate professional (preferably technical)
training, e. g. as engine fitter or mechanic.

3. The electrical equipment of the machine must be regularly checked for exter-
nally identifiable damage. Defects such as loose connections or burnt cables
must be corrected immediately!

4. Only perform welding work, burning work, and grinding work on the machine if it
has been expressly approved. (see example of a permit). Such work can cause a
fire hazard or risk of explosion!

5. Clean the machine and the surrounding area to remove dust and combustible
material and ensure a sufficient ventilation before welding, burning and grinding
work danger of explosion! Always keep a sufficient number of fire extinguish-
ers ready at the STADLER Ballistic Separator, or provide a sufficient number of
fire hoses. Put them under water pressure before beginning the works and
check that water is really coming!

6. If combustible substances are processed in the STADLER Ballistic Separator,

they could ignite if unfavourable circumstances coincide. Therefore, provide fire
extinguishers at the STADLER Ballistic Separator!

7. Whenever dealing with electrical equipment in a STADLER Ballistic Separator

(electrical tools such as power tools, lamps etc. and in particular electric arc
welders) be aware that you are inside a confined and electrically conductive en-
vironment. Faulty electrical equipment represents a life threatening danger of
electric shock!

STADLER Anlagenbau GmbH 16

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

- Thus, adhere to the codes of conduct and operating requirements for elec-
trical equipment and their use under such conditions as per the applicable
technical regulations, standards etc. valid in your country (in Germany the
professional trade association information BGI 534 and 594 and also the
standard DIN VDE 0100-410; similar regulations in other countries, e. g.
standards IEC 60364-4-41 or HD 60304-4-41).
- Therefore, either drive all electrical equipment with a safety extra-low volt-
age protection type IP 2X min., protection class III.
- Or, protect by electrical separation protection class II connect only one
consumer at a time to the protective transformer and also adhere to further
requirements for electrical equipment and tools in a confined electrically
conductive environment.

Example for a permission document

STADLER Anlagenbau GmbH 17

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

3.8 Special Rules

1. Before each switch-on or start-up of the machine, the supervising person must
check that the switch-on or start-up cannot endanger anyone.

An audible alarm signal alone is not sufficient!

2. The leaving of walkways, working platforms, etc., when the controller is

switched on and the machine is not properly stopped is strictly forbidden. Do not
reach through barriers, do not lean over barriers!

3. Machinery components or equipment parts not forming a part of the scope of

supply of STADLER must not impair the safe operation of the STADLER Ballis-
tic Separator. They must conform to the expected use requirements.

4. EMERGENCY STOP devices must not be removed, altered or deactivated oth-

erwise.

5. The installed fire protection devices must not be displaced, damaged, removed
or otherwise made unusable. Replace/repair missing or defective fire protection
devices immediately.

6. Danger of fire Smoking or naked flame is strictly forbidden!

3.9 Residual Hazards

A STADLER Ballistic Separator is as a rule supplied as partly completed machinery in ac-

cordance with Machinery Directive 2006/42/EC; it cannot perform any particular function by
itself and is intended to be combined with other machines or partly completed machines to
form a complete functional entity or to be installed in another machine. The particular precise
installation conditions are not generally foreseeable and are moreover usually out of STAD-
LER's control. The Ballistic Separator therefore does not unconditionally fulfil all prerequi-
sites for a machine to be placed on the market in accordance with 3 (1) of the German 9th
GPSGV (Ninth Ordinance pertaining to the Equipment and Product Safety Act) and not all of
the basic health and safety requirements of Appendix I of the Machinery Directive
2006/42/EC. Residual dangers can remain (also see assembly instructions)..

It is the responsibility of the person who assembles the Ballistic Separator with other ma-
chines or partly completed machinery into an complete entity, or installs it in another ma-
chine, etc., to deal with these hazards in a reasonable fashion and to ensure and document
that the complete entity conforms with safety and health requirements. In this matter, there
should be consultation with STADLER, if necessary. Until that point, commissioning of the
STADLER Ballistic Separator is expressly prohibited.

Note the following with regard to residual dangers:

1. No possibility of stopping the machine under optimum conditions

EMERGENCY STOP device for switching off the STADLER Ballistic Separator

STADLER Anlagenbau GmbH 18

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

in an emergency not included in the scope of supply, unless supplied with own
switching cabinet.

Recommendation for protective measures:

Install an EMERGENCY STOP device near the STADLER Ballistic Separator
and integrate it into the EMERGENCY STOP circuit of the overall plant.

Note:

i EMERGENCY STOP devices are required for an operational machine (i. e. en-
tire plant with all its parts including the STADLER Ballistic Separator);
EMERGENCY STOP devices near the STADLER Ballistic Separator are re-
quired for unscheduled maintenance works while the machine is running (see
section 3.6).

2. No possibility to stop the machine under ideal conditions supplied safety end
switches for stopping the STADLER Ballistic Separator in case of an opening of
doors and flaps not integrated into the control of the overall plant.

Recommendation on protective measures:

Integrate safety end switches into the circuit of the overall plant, so that the
Ballistic Separator as well as all other plant parts from which a hazard may
emanate will stop if the doors or flaps are opened.

3. No possibility to stop the machine under ideal conditions main switch, motor
protection switch, repair switch and similar for stopping the STADLER Ballistic
Separator not included in the scope of delivery, unless supplied with own
switching cabinet.

Recommendation on protective measures:

Provide main switch, motor protection switch, repair switch and similar for the
Ballistic Separator and integrate them in the circuits of the overall plant.

Note:
Lockable main switches are indispensable for a three-pole isolation from the
i voltage source including protection against restart (regular shut-down) before
any maintenance work or similar. Motor protection switches or equivalent de-
vices are imperative to protect the motor from an overload during operation.
Lockable repair switches on site for a three-pole isolation from the voltage
source are strongly recommended unless the main switch is mounted near the
Ballistic Separator.

4. No possibility to stop the machine under ideal conditions missing data ex-
change between the control or circuit of the overall plant and those of the
STADLER Ballistic Separator if supplied with own switching cabinet.

STADLER Anlagenbau GmbH 19

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

Recommendation on protective measures:

Secure the data exchange via fixed wiring between the overall plant and the
Ballistic Separator. The actuation of EMERGENCY STOP devices of the over-
all plant must also actuate a stop command at the Ballistic Separator and vice
versa. The opening of doors and flaps with actuation of the supplied safety end
switches must actuate a stop command for other machines of the overall plant
if such machines may pose a risk when entering the Ballistic Separator.

Note:
The integration of the control of the Ballistic Separator into the control of the
overall plant can generally be implemented with the means of software (data
i bus or similar). However, this is not the case for safety-relevant functions,
where fixed wiring is to be preferred. Only if the respective software as well as
the transmission and processing elements have been tested in accordance
with the applicable technical regulations and standards and certified by an in-
dependent and officially recognised testing laboratory, and if there are no op-
posing official provisions in the country of use, can the integration by means of
software be acceptable for safety-relevant functions as well.

5. Possibility of damage to the cable systems for drive motors by environmental in-
fluences (e. g. moisture, dust, impact or other mechanical influences) resulting
in not only an electric shock hazard for persons having contact with parts that
have become live due to the defect condition but also a hazard due to the fail-
ure of control circuits.

Recommendation for protective measures:

Prevent damage through protective devices for cables use of cable ducts,
protective pipes or laying under covers.

Note:
i Secure cable ducts properly and permanently to walls, frames, etc.; cable ducts
supported by cable no longer fulfil their protective function after a certain time.

6. Hazard from squashing at the crankshafts if they are accessible from below
through ejection shaft.

7. Hazard from falling in connection with machines danger of falling into shafts or
on belt conveyors, chutes, if the area under the STADLER Ballistic Separator is
accessible.

Recommendation for protective measures:

In both cases, install lateral, separating, protective devices that prevent an ac-
cess to the danger places under the STADLER Ballistic Separator.

STADLER Anlagenbau GmbH 20

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

Note:
i In both cases, comply with the safety distances preventing the reaching of a
danger point requirements of the applicable DIN EN standards.

8. Hazard through falling in connection with machinery danger of falling, for in-
stance into the chute, during cleaning, maintenance etc.

Recommendation on protective measures:

When entering the paddles, use personal protective equipment in accordance
with the applicable standards against falling (e. g. DIN EN standards). Use
lanyards (cord, belt straps, chain) or connecting elements at the appropriate
attachment point.

9. Hazard from impact in the head area

Recommendation for protective measures:

Install yellow/black impact protection at machine parts located at head height
(paint marking and padding)).

10.Danger due to falling or ejected objects (scrap) in the working area from above
and at the interfaces to other downstream conveyor belts, etc. or risk of injury
caused by sharp-edged scrap.

Recommendation for protective measures:

Corresponding appropriate cover of open areas, marking of the danger spots if
covering technically not possible; entering a danger zone of 4 m circumference
only for authorised and instructed staff wearing personal protective equipment
(helmet, safety shoes, tight safety goggles against mechanic injuries, hearing
protection.

11.Hazard from noise depending on the specific use conditions.

Recommendation for protective measures:

Carry out airborne noise measurements; implement suitable screening meas-
ures, sign noise area in which personal protective equipment (hearing protec-
tion) must be worn.

12.Hazards through the ignition of flammable processing material due to friction

between paddles and housing wall.

STADLER Anlagenbau GmbH 21

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

Recommendation on protective measures:

Keep the side walls clean and remove deposits of dust. Look out for discol-
oured varnishing due to increased temperatures and indentations in the side
walls. Rectify indentations immediately (otherwise the gap between the side
walls and the paddles may increase, which may lead to material getting
jammed in the gap).

13.Burns caused by hot motors or drives.

Note:

i Motors and drives can reach temperatures of 100 C. This is primarily a risk if
they are worn mechanically or the cooling fins, ventilation grills, etc. are espe-
cially dirty. Therefore watch for any unusual heat build-up and, if there is any,
replace the motor and drive for the first issue and clean them for the second.

Recommendation on protective measures:

Do not touch when in operation without appropriate personal protective equip-
ment (especially protective gloves) before it has cooled. Also take particular
care when changing oil.

STADLER Anlagenbau GmbH 22

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

4 Operating and Use of the Ballistic Separator

The starting, control and stopping of the STADLER Ballistic Separator is usually effected
from the control centre of the machine into which the Ballistic Separator is integrated.

Refer to the relevant machine control system documentation.

Caution
Observe the safety information/instructions in section 3 before, during and after
the use!

Note:

i A STADLER Ballistic Separator may only be loaded when it and the machine
into which is integrated are running. Failure to observe can cause damage to
the drive or the STADLER Ballistic Separator.

Note:

i The speed of the STADLER Ballistic Separators STT 1500, STT 2000 or PPK
cannot be changed and depends on the motor or the transmission selected!

STADLER Ballistic Separators may be supplied together with a switching cabinet which in-
cludes operating buttons etc. for automatic and manual operation.

Fig. 1 Operating panel of the switching cabinet

The elements in the top row of the operating panel include the following (from left to right):

STADLER Anlagenbau GmbH 23

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

1. White indicator lamp Control voltage is on when the main switch is on On

and the control voltage supply functions correctly. This means the Ballistic
Separator is operational.

2. Selector switch with three positions; Auto: Ballistic Separator is controlled by

the control of the overall plant and is switched on and off from there in auto-
matic operation; Off: a start command is possible neither from the control of
the overall plant nor from a position on site (Attention: only controlled stop
no regular three-pole shut-down!); Hand/Manual: Ballistic Separator can be
switched on and off on site with the corresponding buttons.

3. Red indicator lamp Centralised alarm is on if the EMERGENCY STOP but-

ton has been actuated, if a door or flap or the corresponding safety end switch
has been opened or is not closed correctly or if a motor protection switch has
been actuated.

4. Button Ballistic Separator on; if the selector switch is on Hand/Manual, the

Ballistic Separator will start if this button is pressed.

The elements in the second row of the operating panel mean or actuate the following (from
left to right):

1. EMERGENCY STOP button with engaging mechanism and unlocking by pull-

ing; for the quick stop of the Ballistic Separator (not for regular three-pole
shut-down; that is what the main switch is for!). If actuated, the red indicator
lamp Centralised alarm is on; unlock only after the source of the alarm has
been removed!

2. Indicator lamp Confirm EMERGENCY STOP; actuate this button after

unlocking the EMERGENCY STOP button, closing an open flap or door or re-
starting a switched off motor protection switch (also only after removing the
source of the failure!); re-activates the EMERGENCY STOP relay in the
switching cabinet, the Ballistic Separator can only be re-started in manual or
automatic operation after confirmation.

Circuit corresponds to category 4: Confirmation possible only after both lines

have been closed again.

3. Position reserved for possible special functions.

4. Button Drives off; if the selector switch is on Hand/Manual, the Ballistic

Separator will stop if this button is pressed (no regular three-pole shut-down).

The main switch is at the bottom of the operating panel. For the Ballistic Separator to run in
manual or automatic operation, it must be set from Off to On. For regular shut-down, it is
set to Off and secured with a padlock. This is required before any maintenance work and
also if the source of an alarm needs to be removed after actuating the EMERGENCY STOP,
the motor protection switch etc.

STADLER Anlagenbau GmbH 24

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

5 Maintenance Work on the STADLER Ballistic Separator

5.1 General

Read this section carefully before the start of maintenance work. Not all STADLER Ballistic
Separators have an identical appearance. They are modified to suit the customer wishes if
necessary. The following applies analogously in the case of design changes.

Caution
Unless otherwise specified, the machine must be switched-off (electrically iso-
lated) before the start of maintenance or repair work. Observe the safety infor-
mation /instructions in section 3!

5.2 Lubricating bearings and gears

The re-lubrication should be done with 5 to 10 grams of grease. To ensure the compatibility
of the greases, use only good universal grease with a lithium soap base. Mixtures of grease
with different thickening agents should be especially avoided because the resulting chemical
processes could then cause, among other things, a reduction or complete loss of the lubrica-
tion properties.

Note:
During the re-lubrication of the sealed bearings with a grease gun, the sealing
rings rolled into the outer ring can be pressed out of the anchoring by the
i grease pressure.
A re-lubrication should therefore be done carefully so that the grease under
pressure can distribute evenly.
Please refer to the operating instructions of your grease gun!

If start-up is sluggish, and particularly in cold weather and low temperatures, we recommend
replacing the gear oil of the gear unit with a lower-viscosity oil (e. g. a CLP HC synthetic oil).
Avoid mixing different oils, because the lubricating characteristics are reduced or completely
lost due to chemical processes among other things. Change oil as prescribed by the gear
unit manufacturer.

5.3 Maintenance Work After the First Running

Retighten the bolts on the shaft clamping devices

STADLER Anlagenbau GmbH 25

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

To do:
1. The bolts on the shaft clamping devices (Fig. 4 /3) must be retightened
i the first time after 20 and after 100 operating hours with a torque wrench
(tightening torque = 195 NM)
2. The same must be repeated every 500 operating hours (see 5.8)

5.4 Maintenance Work After Each Work Shift (every 8 hr.)

Check sidewalls for discolouration and distortion.

Check crankshafts and paddle bolts and remove deposits if necessary as

well as checking gaps between the paddles and the sidewalls for any
trapped material

To do:
1. Check all rotating parts and shafts for free running twice per shift.

i 2. Remove any wrapped-around material during the next operating pause.

3. Adhering parts must be removed in order to prevent bearing damage.
4. Remove any material jammed between the outer paddles and the hous-
ing.
5. Visually check dynamically-stressed parts for damage.

Fig. 2 Crankshaft Fig. 3 Paddle bolting

Clean out dust, debris, etc. from motor cooling fins, motor fan grate and
the switching cabinet fan grate, if a switching cabinet is present

5.5 Weekly Maintenance Work

As a general rule, all shift maintenance work should be carried out before
the shift starts

STADLER Anlagenbau GmbH 26

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

Clean and grease crankshafts (crankshaft pillow block bearing 8x and

crankpin bearing 12 x)

To do:
1. Screw out four bolts per pillow block bearing (Fig. 4 /1) and remove
bearing protection.
i 2. Manually clean open pillow block bearing from curlers and dirt do not
blow it off with compressed air or steam!
3. Grease pillow block bearing via grease nipples (Fig. 5/1).
4. Remount bearing cover. Make sure the crankshaft can move freely and
does not touch the bearing cover.Lubricate journal bearing (Fig. 4 /2).

Fig. 4 Lubricating nipple on pillow block Fig. 5 Lubricating nipple on pillow block
bearing and journal bearing bearing

Fig. 6 Grease line for pillow block bearing Fig. 7 Elastic coupling with dismounted
cover

STADLER Anlagenbau GmbH 27

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

Please note:
On some STADLER Ballistic Separators, the grease nipples of the pillow block
bearings are greased from the outside (Fig. 6). For this construction type, the
i bearing cover need not be removed for greasing or cleaning provided it is en-
sured that there is no soiling on the inside. However, that there is no soiling
under the bearing cover can be presumed only if the processing material con-
tains little fine materials.
Unless this is ensured, dismounting the bearing protection and weekly cleaning
below are indispensable!

5.6 Monthly Maintenance Work

First carry out all weekly maintenance work

In case of versions with grease lines, remove the bearing cover of the
crankshaft pillow block bearings, check the inside for soiling and remove it
as required

Check dynamically-stressed parts for damage and replace if necessary

(check for wear signs on the sides of the paddles and replace if necessary)

Check all moving parts for wear and tear, and replace if necessary. Above
all, check the elastic coupling star (Fig. 7) for wear and tear (to do this, re-
move the guard and put it back on afterwards)

Check that bolts are present and tight

Check that all safety devices are complete and are functioning correctly,
including safety limit switches

5.7 Annual Maintenance Work

Always first carry out all monthly maintenance work

The maintenance work to be carried out on the motors is described in the accompanying
maintenance manual from the motor manufacturer.

5.8 Maintenance Work After X Operating Hours

Tighten the bolts on the shaft clamping devices

To do:
i The bolts (Fig. 4/3) on the shaft clamping devices must be retightened every
500 operating hours with a torque wrench (tightening torque = 195 NM)

STADLER Anlagenbau GmbH 28

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

5.9 Replacement of Wearing Parts

In principle, the paddles, their coverings and the crankshafts are wearing parts.

A replacement of crankshafts and paddles may be necessary after approx. 5000 operating
hours depending on stressing during operation. This work is expressly reserved for the tech-
nical staff of STADLER. The crankshafts should be overhauled only by STADLER.

The coverings of the paddles may be replaced by instructed personnel of the user as de-
scribed below.

Replacement of paddle coverings

To do:
1. Undo the bolts (M 12) on the paddles preferably with a battery-
operated hammering spanner.
i 2. If the paddle position must be changed for replacement, manually fan
the brakes at the motor.
3. Replace the covering, retighten all bolts.

Fig. 8 Bolts on the paddle coverings

5.10 Other Maintenance Work

Adjustment of Paddle Tilt (only STT models, not PPK models)

To do:

i 1. Hook two suitable chain hoists (each 2 t loading capacity not included
in the scope of supply of STADLER) into the lifting eyes (Fig. 9/1) on the
right and left sides of the STADLER Ballistic Separator.
2. Slightly tension the chain hoists.

STADLER Anlagenbau GmbH 29

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

3. Remove the desired number of segments in the adjustment direction

(Fig. 9/2) and undo the clamping bolts (Fig. 10/1, 10/2).
4. Remove the four M 16 bolts on both sides (Fig. 9/3).
5. Raise or lower the chain hoists to obtain the desired paddle tilt; avoid
collision.
6. Tighten all bolts in reverse order. The removed cover segments can be
refitted when rotated by 180 o.
7. One hole change corresponds to 2.5 tilt.

Note:
i The STADLER Ballistic Separators STT and PPK are differentiated by the fact
that with the PPK models, the paddle inclination cannot be adjusted.

1
2

Fig. 9 Chain hoists and bolts Fig. 10 Clamping bolts

5.11 Use of Personal Protective Equipment Against Falling

When entering the STADLER Ballistic Separator for maintenance works and going to the
edge on the paddles:

1. Use personal protective equipment against falling!

2. Adjust the length of the corresponding rope and its devices attenuating the
impact according to the dimensions of your Ballistic Separator as well as of its
chutes etc! A rope that catches you only after a 3 m fall is useless if you hit the
ground after 2 m!

STADLER Anlagenbau GmbH 30

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

3. Use two ropes if required (Fig. 11). In the Ballistic Separator, fasten yourself
on both sides to the fastening eyes provided for this purpose (Fig. 12 and 13).

Fig. 11 Fastening with two ropes Fig. 12 Fastening eye

Fig. 13 Rope, shackle and fastening eye

5.12 Moving the Paddles and Venting the Motor Brake

If you have to change the position of the paddles for maintenance, climb inside the
STADLER Ballistic Separator (do not forget to secure yourself against falling with personal
protective equipment! see Fig. 11), step to the end of one paddle and use your weight to
push down one paddle group against the other. If you step onto a paddle of the other group,
the group you just lowered will lift up again (make sure you do not get caught between the
paddles during these movements!). However, moving the paddles also requires that a col-
league vents (releases) the motor brake at the same time.

To do:

i 1. To vent the motor brake, take the brake lever from the motor (Fig. 14). It
is clamped onto the motor with springs.

STADLER Anlagenbau GmbH 31

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

2. Insert brake lever into the thread of the motor break and screw it in (Fig.
15 and 16).
3. To vent the brake, pull the lever toward the cover of the motor cooling
fan (Fig. 17). The brake is released and the paddles can be moved.
4. To retighten the brake, bring the level into the vertical position (Fig. 16).
5. After completing the works clamp brake lever to the motor again.

Fig. 14 Taking the brake lever from the motor Fig. 15 Inserting the brake lever

Fig. 16 Brake lever screwed in, vertical position Fig. 17 Brake lever tightened, brake re-
leased

5.13 Lubrication Table

Ballistic Separator Lubrication Point Lubrication Interval Lubrication

(Fig. 4/2), (Fig. 5/1),

Bearing Weekly Grease
(Fig. 6)

Oil drain as per gear- Oil as per data sheet

Gearbox on drive Yearly
box manufacturer info from manufacturer

STADLER Anlagenbau GmbH 32

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

6 Troubleshooting and remedy

Problem Remedy
Does not run The motor does not turn and/or Check freedom of motion for paddles and the shaft.
the motor circuit breaker is
thrown Clean and cut free
Material jams between bearing housing and frame

Remove material
Blockage caused by paddle; check if paddle is broken

Paddle must be replaced

Check current supply
Check motor
Check brake connection, if the brake does not open, it can if
necessary be opened manually
Motor turns Check coupling for secure seating

Tighten
Check shaft for breakage

Shaft must be replaced

Noises other than normal operating noise Check freedom of motion for paddles and the shaft

Clean and cut free

Check coupling for wear of the spacer ring

Replace
Check all bolts on the outer walls and on the frames and shafts
for firm seating

Tighten
Check sheet metal used to convey material for secure seating

Tighten bolts
Check that paddle alignment is straight, to do this check gap size
between paddles

Align or replace twisted paddles

Check paddle screens for firm seating

Tighten
Infeed material is not sifted Check paddle screens for blockage

Clean
If clogging and sticking is frequent, another paddle screen might
have to be used. In this case, contact STADLER, likewise if you
need spare parts.

STADLER Anlagenbau GmbH 33

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

7 Technical Data

See data sheets provided in the scope of delivery. A template follows.

STADLER Anlagenbau GmbH 34

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

8 Airborne Noise

The level of the airborne noise from the Stadler Ballistic Separator significantly depends on
the local use conditions and the type of material to be separated. The airborne noise level
increases with the hardness of the material. This is beyond the control of Stadler. The user
must therefore carry out airborne noise measurements under typical use conditions at the
installation site and according to the results, designate noise protection areas, implement
noise protection measures or require the use of personal protective equipment.

In idle mode without loaded material, the values below were measured under the condition
that no work locations on the Stadler Ballistic Separator have been specified. The measure-
ments were carried out under the following conditions:

Measuring point height above access platform: 1.60 m

Measuring point distance from machine body: 1.00 m

Measuring location: unenclosed site

Measuring device: CEL 269, (calibrated locally)

Measurements were carried out in accordance with the machine noise information regula-
tions of the German 3rd GPSGV (Third Ordinance pertaining to the Equipment and Product
Safety Act). The highest A-frequency-weighted noise levels with fast response correspond
the best with noise emission values within the scope of an orientating measurement.

The highest orientating measured noise level SPLA, F (A-frequency-weighted with fast re-
sponse) during operation without loaded material is 84.6 dB (A).

The highest measured SPLA, F (A-frequency-weighted with fast response) during operation
with transport material (commercial bulky waste) is 93.6 dB (A).

STADLER Anlagenbau GmbH 35

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69
Operating Manual Version 04/10

9 Spare Part Ordering and Service Address

Note:
We recommend the use of original parts during the entire operating life of the

i STADLER Ballistic Separator even after the elapse of the warranty period in
order to ensure a permanent efficiency and a long service life.

The original parts approved by us have been tested by us and therefore have
suitable properties. We also point out that warranty or guarantee claims can
only be made on STADLER original parts, respectively original spare parts.

Please refer to the spare parts lists delivered with the machine for the designation of spare
parts

Always give the following information when ordering spare parts:

1. machine type (see type plate)
2. serial number (see type plate)
3. part designation (see spare parts lists delivered with the machine)
4. desired quantity

State this information exactly in your written order or have the information available when
ordering by phone. This will make the work easier for you and us and prevent mistakes, in-
correct orders/deliveries.

Send your order to the following address. It is also the Service address.
STADLER Anlagenbau GmbH
Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
Tel.: (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69

STADLER Anlagenbau GmbH 36

Robert-Bosch-Strae 4
D-88361 Altshausen
Germany
 (+49 75 84) 92 26 60
Fax: (+49 75 84) 92 26 69