200 4000

OPERATION MANUAL

200-4000

Rustibus速 2000 LOW Electric

3 Phase 220/380/440 V - 50/50/60 Hz 3 x 380/440 V - 50/60 Hz 3 x 220 V - 50 Hz

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DECLARATION OF CONFORMITY

Manufacturer: Dalseide Shipping Services AS Bekkjarviksundet 1 N-5397 BEKKJARVIK NORWAY The authorised representative In the EEA: Rustibus N.V. Noordersingel 7 B-2140 ANTWERP BELGIUM

Hereby declares that the Products specified: Rustibus® de-scaling machine: 200-4000

Are produced in accordance to the requirements in and regulations on machinery Best. No. 522, which transpose the community legislation on machinery amended by Directive 98/37/EEC of the European parliament and of the council of 22nd June1998.

The following standards or standardized documents apply to this machine: 89/392/1/EEC, 91/368/EEC, 93/44/EEC, 93/68/EEC, EN 60 240 “Electrical equipment of industrial machines”

Year of CE marking: 1998

Place Signed by: Title:

Date Tore Dalseide Director

……………………………………………..

Genuine Rustibus® parts only!

Machine may vary from pictures

How to recognise Genuine Spares!

* fig.1

* fig.1

* fig.1 GENUINE SPARE PARTS are marked with either RUSTIBUS® PATENTED (* fig.1) Genuine spares parts are marked with a genuine RUSTIBUS® logo, so look for the logo or GENUINE RUSTIBUS PARTS (* fig.2) either on the item or on the label.

* fig.2

If they are not there, they’re not GENUINE PARTS. Use only the best, don’t settle for less. RUSTIBUS® If they are not there, they´re not genuine spares. Use only the best, don´t settle for less.

Machine may vary from pictures

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HELPFUL IDENTIFIERS In addition to information on installation and operation, this instruction manual may contain WARNINGS and CAUTIONS pertaining to user safety, and NOTES on important, useful operating guidelines.

A WARNING indicates a potentially hazardous situation, which if not avoided, could result in death or

serious injury.

A CAUTION indicates a potentially hazardous situation, which, if not avoided may result in minor or

major injury.

A NOTE is to alert the operator to important operating information.

ANSI Z535.5-1997 Definitions

IMPORTANT The safeguards and instructions in this manual cannot cover all possible conditions and situations, which may occur. As we cannot control the correct mounting, usage and utilization of this product, we can not be responsible or liable for any injuries, damages, losses or costs, which result from using our products in any way.

Do not attempt to operate this tool until you have read and understood all safety precautions and instructions listed in this manual.

Incorrect operation of this unit can cause serious injury.

Maintain your company’s fire and safety procedures while operating this tool.

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WARNING

Rotating equipment may cause serious injury – protect hands, feet, eyes and hearing.

The Chain drum is rotating at high RPM, show outmost care when connecting cable and when operating machine. ALWAYS THINK SAFETY FIRST!

Debris from scraping action may be scattered.

Respiratory protection should be considered depending on material being removed.

Rustibus® de-scaling machine may produce low energy sparks.

Before starting Rustibus® de-scaling machine, ensure that all fixing screws, bolts, fittings and chain drum are locking devices are in safe usable condition, fitted correctly and

correctly tensioned.

Never attempt to de-scale an area when its mechanical integrity is in doubt, according to ASME/API specifications or other applicable codes and standards.

CAUTION

Never install, remove or perform any maintenance on the Rustibus® de-scaling machine when the power supply is connected.

ALWAYS lift up machine(push down the handle) in order for the chain drum to rotate freely when starting the machine.



Always keep both hands on handles when operating the Rustibus® de-scaling machine.

Never operate the Rustibus® de-scaling tool while wearing loose hanging chains, hanging ID/security badges or garments that may be caught in the rotating parts.

Never start the Rustibus® de-scaling machine before it´s cables or hoses are properly secured and safely located.



Rustibus® de-scaling Tool should be properly maintained and stored when not in use to avoid damage to parts.

Never use non Ex/Atex certified machines in potentially explosive atmospheres.

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SAFETY CONSIDERATIONS The machine is intended to be operated by qualified personnel who are familiar with relevant safety requirements. Safety equipment necessary for the prevention of accidents at the mounting and operation of machine shall be applied at all times.

It is the duty of the safety officers in charge to make sure that all personnel operating the machine meet these demands.

The machine operates using power supply. The transmission of these powers to the mechanical drum represents a certain danger and must be maintained continuously.

• It is advised to wear ear protection when operating machine.

• Always make sure the equipment on machine is in good condition.

• Always disconnect the power supply when maintaining or working on the machine.

• Use only original Rustibus® spare parts on the machine.

• Always think safety first when operating machine.

BEFORE STARTING THE OPERATION Congratulations on your new Rustibus® de-scaling machine. In order to ensure your full benefit and safety of operation we recommend you to read this operation manual carefully before starting.

Always lift up machine in order for chain drum to rotate freely when starting the machine. (i) Make sure all safety measurements are being considered. (ii) Confirm correct voltage before connecting cable to supply. (iii) Start and stop the machine and check that rotation is correct according to marking on machine. (iv) Make sure the cable is properly connected and safely located for your operation. (v) Scaling can start. Run machine forward and backward to achieve the best result. (vi) Do not run machine over sharp edges, but along these. The chain drum will last longer by working the machine with care. (vii) If the operations of the machine tend to be too rough, the el. Motor may be overloaded and the thermal protection will disconnect power supply. If this occurs, wait for three minutes and push “0” button and the “1” button to start again. This will reset the thermal relay. (viii) Use the Disposable Chain Drum until it is completely destroyed and then replace

the entire drum with a new one.

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INSTALLATION AND SETUP Rustibus® 2000 LOW ELECTRIC Before you begin.

Step 1: VERIFY THE COMPLETENESS OF YOUR RUSTIBUS® MACHINE. • Check that all components are attached properly and in a proper / safe working order.

(Check that there are no loose wires, guards or parts on the machine) Step 2: ASSOCIATED EQUIPMENT. • Ensure that you have the correct cable and plugs to correspond with the voltage of the machine and the power source you are using.

• We recommend the use of an Earth Breaker device to ensure full safety for the operators.

Step 3: BEFORE COMMENCING THE OPERATION. • Locate the section to be cleaned / de-scaled and determine if the area needs to be cleaned.

Excessive grease, dirt and other hazardous material should be cleaned from the surface area before operation of the Rustibus® machine.

• The Chain drum is rotating at high RPM, show outmost care when connecting cable and when operating machine. ALWAYS THINK SAFETY FIRST! • Connect your machine to its power source.

• Make sure the cable is properly connected and safely located for your operation.

• ALWAYS lift up machine (push down the handle) in order for the chain drum to rotate freely when starting the machine.

• Start and Stop the machine and check that rotation is correct according to marking on machine.

Step 4: OPERATION OF RUSTIBUS® MACHINE. • For the best results from your Rustibus® machine you should run the machine forward and backward over the area until appropriate result is achieved • Do not run the machine over sharp edges, but along them. Your machine will last longer if operated with care.

Step 5: MAINTENANCE OF RUSTIBUS ® MACHINE. • ALWAYS stop the machine and disconnect it from its power source before carrying out any maintenance on the machine.

• Use the Disposable Chain Drum until it is completely destroyed and then replace the entire drum with a new one.

Genuine Rustibus速 parts only!

Machine may vary from pictures

Rustibus速 disposable Chain drum

Rustibus速 2000 unit uses

Disposable Chain Drums.

The Chain Drums is designed for one-time-use only and does not require any spares replacement.

Simply use the Chain Drums until they are completely

destroyed and then replace them with new ones.

This makes the Rustibus速 2000 fast and efficient!

x

x

If one of the pins on the Disposable Chain Drums

should brake, it might create an unbalance in the rotation. To calibrate/repair the balance, the pin

opposite to the broken one should be removed.

Item : 200-0156 Disposable Chain Drum - Set Weight: 19 kg / 42 lbs IMPA: 59.12.09

Item: 200-0151 Disposable Chain Drum Assembly Incl.: - Disposable Chain Drum Set (200-0156) - 17mm Bearing (200-0170) - 20mm Bearing (200-0180) - Shaft for Head (200-2300) Weight: 22,5 kg / 50 lbs

Genuine Rustibus速 parts only!

Machine may vary from pictures

SPARE PARTS FOR CHAIN DRUM SYSTEM

Item : 200-2300 Shaft to Chain Drum and Wire Brush Weight: 1,1 Kg /2,4 lbs ISSA: 55.306.14

Item : 200-0170 Bearing 17mm (Incl. Casing) Weight: 0,235 Kg / 0,51 lbs ISSA: 55.306.03

Item : 200-2220 Pulley - w/Bush Weight: 2 kg / 5 lbs ISSA: 55.306.12 For use on shaft to chain drum and wire brush.

There are a series of select Pulleys / Bushes available to fit each type of power unit.

Item : 200-0180 Bearing 20mm (Incl. casing) Weight: 0,615 Kg / 1,35 lbs ISSA: 55.306.04

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BUILDING A DISPOSABLE CHAIN DRUM FROM SCRATCH Disposable Chain Drum for Rustibus® 2000 Information guide for use and installation of the system.

The rotation unit to the Rustibus® 2000 is now more efficient with the new Disposable Chain Drum system.

This new one-piece unit is delivered complete and therefore does not require further replacement of spare parts.

Simply use it until it is totally destroyed and then replace it with a new one.

The Rustibus® 2000 should only be used on a flat horizontal surfaces. All sorts of obstacles should be avoided at all times such as sockets,edges etc. De-scaling should be done along side weldings NOT across. If one of the chain links / pins should brake and create an unbalance in the machine, simply cut the chain links on the opposite side of the broken one.

1.

2.

3.

C. C.

B.

A. Part Numbers: 200- 0156 - Disposable Chain Drum Set 200- 2300 - Shaft for Head (Incl.Washer & Nuts)

4.

Firstly place one of the Chain Cassettes on the shaft until it contacts with the shaft base (A)

5.

The next step is to place the other Disposable Chain Cassettes on the shaft, making sure the rivet heads (B) are facing in the same direction towards the base and that the Cleft sections (C) line up with each other accordingly.

6.

D.

When mounting the Chain cassettes on the shaft make sure that the rivets of each cassette are in contact with those of the next, this ensures that ALL the chain links are free and not caught between the Chain Cassette sections.

You are then able to fasten it all in place with the TWO nuts and washer. First place the washer (D).

We recommend that you use Loctite.

- The order of assembly is clearly shown in pictures 1 – 6.

Genuine Rustibus速 parts only!

Machine may vary from pictures

Removing the chain drum removing the disposable Chain Drum

Information guide on how to remove the Chain Drum.

1.Removing the Chain Drum from Rustibus速 2000 Series is the same for all types : low, standard, electric, pneumatic and our Atex/Ex Certified machines.

2.Remove belt cover

3. Lay down machine like the picture so the chain drum is free to rotate.

(On the LOW machine you have to put the machine in a upright position (on the power weight/flat front) so the chain drum is free to rotate).

4. With use of a screw driver and rotating the chain drum with your hand you 5. Put the machine on a support can remove both belts. Do not put your fingers in between! that stops the chain drum rotating.

Remove pulley (see explanation on the next page how to) Watch your fingers!

Genuine Rustibus® parts only!

Machine may vary from pictures

Removing the chain drum removing the PULLEY

Information guide on how remove the Pulley.

Take off the pulley: loosen the ‘umbrako-bolts’ (* fig.2) in the Bush. (See picture below) Place one of these bolts in the ‘Third hole’ (* fig.1)and tighten up the bolt until the Pulley is loose. Pull off the pulley by hand or use light tools.

Do not use an Adjustable Bearing Puller to do this!

*fig.2 *fig.2

NOTES ON BELT REMOVAL.

*fig.1

Taking off and reinstalling the Belts can be done by turning the chain drum and using a screwdriver to lever off the belts.

Genuine Rustibus® parts only!

Machine may vary from pictures

Removing the chain drum removing the disposable Chain Drum

Information guide on how to remove the Chain Drum.

6. Remove bolts and take out the “key” .

*fig.1

7. Remove bolts on the other side of the chassis and loosen the allen screw (*fig.1) like picture above.

8. Remove Chain drum.

Genuine RustibusÂŽ parts only!

Machine may vary from pictures

Replacing the chain drum replacing the disposable Chain Drum Information guide on how to replace the Chain Drum.

*fig.1

*fig.1

1.Replacing the Chain Drum on RustibusÂŽ 2000 Series is the same for all types : low, standard, electric, pneumatic and our Atex/Ex Certified machines.

2. Make sure that the grease nipple (*fig.1) is poiting down when you are putting the chain drum inside the chassis.

3. Make sure that the square bearing is on the inside and the round bearing is on the outside.

4. Put on the bolts but don´t fasten them more then necessary.

5. Go on the other side of the chassis and make sure the round bearing is on the correct spot.

Genuine RustibusÂŽ parts only!

Machine may vary from pictures

Replacing the chain drum replacing the disposable Chain Drum Information guide on how to replace the Chain Drum.

*fig.2

6. Put on the bolts, but don´t fasten them more then necessary aswell.

7. Now fasten the bolts on the square 8. Go back and fasten the round beraing tight. bearing completely. Also the allen screw (*fig.2).

*fig.1

* 9.Position the *key*(*fig.1) on the shaft with the square bearing.

*

10.Put on the Pulley and make sure its level. Cross thight the pulley in the 2 *umbrako-holes.

11. Lay down machine like the picture so the chain drum is free to rotate.

(On the LOW machine you have to put the machine in a upright position (on the power weight/flat front) so the chain drum is free to rotate).

Genuine Rustibus速 parts only!

Machine may vary from pictures

Replacing the chain drum replacing the disposable Chain Drum Information guide on how to replace the Chain Drum.

12.Put on the first belt .To get it in the track closest to the chassis use a screwdriver while you rotate the chain drum. Put then on the second belt using your hands. Do not put your fingers in between!

Watch your fingers!

13. Then put the belt cover back on.

Ready for use.

Machine may vary from pictures

Genuine Rustibus速 parts only!

RUSTIBUS速 2000 LOW THREE PHASE MACHINE The Rustibus速 2000 LOW can be delivered with the following voltages:

Connection El - Motor: 3 x 220 / 380 / 440V -on Connection EL- Motor: 380-440V - 50/60Hz

S

R

T

U1

V1

W1

W2

U2

V2

Yellow / Green

R

S

T

U1

V1

W1

W2

U2

V2

Yellow / Green

220V - 50/60Hz

Do not change the motor connection without adjusting the circuit breaker.

The setting should correspond with the setting indicated on the ID plate on the motor.Also the Voltage trip needs replacement in order to correspond to the correct voltage/Hz. Repairs and/or adjustments to the electric settings should always be done by a qualified electrician.

Cable & plugs used for three phase machines

200-0130

200-0141

200-0140

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Genuine Rustibus® parts only!

1L -001 200

1 -115 200

200

-001

0L

Spare part list – Rustibus® 2000 LOW

200-0012 200-0100/ 200-0101/ 200-01002

200-4020

200-4001

200-0090 200-0110L

Item:200-0158 Replacement Wire Brush (Brush Only) Weight: 16 kg / 35 lbs ISSA: 55.315.04

Item : 200-0155 Wire Brush Assembly Incl.: - Replacement Wire Brush(200-0158) - 17mm Bearing (200-0170) - 20mm Bearing (200-0180) - Shaft for Head ( 200-2300) - Weight: 20,0 kg / 44,0 lbs - ISSA: 55.315.02

Genuine Rustibus® parts only!

Machine may vary from pictures

Spare part list – Rustibus® 2000 LOW PARTS TO CHASSIS UNIT 200-0010L CHASSIS - LOW PCS 200-0011L HANDLE FOR LOW MACHINE PCS 200-0110L COVER FOR BELTS PCS 200-0012 PLASTIC GRIPS FOR HANDLE (2 PCS) SET 200-0062 WATER NOZZLE SYSTEM PCS 200-0080 MALE WALL MOUNTED SOCKET 3X 220/380/440V PCS 200-0081 FEMALE WALL MOUNTED SOCKET 3X 220/380/440V PCS 200-0090 WHEELS (2 PCS) SET 200-0100 STARTER COMPLETE 3X 220V/60HZ PCS 200-0101 STARTER COMPLETE 3X 220V/50HZ PCS 200-0102 STARTER COMPLETE 3X 380/440V - 50/60HZ PCS 200-0113 EXTRA CABLE INCL. PLUGS 3X2,5mm² + E PCS 200-0115 CIRCUIT BREAKER 3x380/440V-50/60Hz PCS 200-0116 VOLTAGE TRIP 3x220V - 60HZ PCS 200-0117 BELTS 1000 (2 PCS) Low Machines SET 200-0118 VOLTAGE TRIP 3x220V 50Hz PCS 200-0119 VOLTAGE TRIP 3x 380/ 440V 50/60 Hz PCS 200-0130 CABLE, 50M 3X2,5 mm2 + E PCS 200-0140 FEMALE PLUG 3X 220/380/440V PCS 200-0141 MALE PLUG 3X 220/380/440V PCS 200-0147 CIRCUIT BREAKER 3X220V-50/60Hz PCS 200-1100 STARTER BOX (EMPTY BOX) PCS 200-6135 EARTH BREAKER - SAFETY SWITCH W/MALE PLUG PCS PARTS TO HEAD (ROTATION PART) UNIT 200-0155 WIRE BRUSH – COMPLETE PCS 200-0156 DISPOSABLE CHAIN DRUM (4 PCS) SET 200-0157 DISPOSABLE CHAIN CASSETTE PCS 200-0158 REPLACEMENT WIRE BRUSH PCS 200-0170 BEARING 17MM INCL. CASING PCS 200-0180 BEARING 20MM INCL. CASING PCS 200-0211 WASHER FOR SHAFT PCS 200-2220 PULLEY SPZ 132-2 w/BUSH 20mm (On Rotation Head) PCS 200-2221 BUSH 20mm PCS 200-2300 SHAFT FOR HEAD PCS

Genuine Rustibus® parts only!

Machine may vary from pictures

Spare part list – Rustibus® 2000 LOW PARTS TO “RUSTIBUS 2000 - LOW” UNIT 200-1151 ADJUSTMENT SCREW - LOW PCS 200-4001 POWER WEIGHT-LOW 200-4020 ELECTRO MOTOR - LOW PCS 200-4021 FAN FOR MOTOR PCS 200-4022 COVER FOR FAN PCS 200-4034 PULLEY for shaft Electric Motor low (SPZ 95-2 w/ BUSH 28MM) PCS 200-4035 BUSH 28mm Electric Motor low PCS

starter box The starter system in the starter box on the Rustibus® 2000 is preinstalled for the specific voltage upon delivery.

If the voltage is to be changed on the machine, the starter system must be replaced accordingly.

Circuit breaker Circuit breaker When a new Rustibus® machine is delivered from Dalseide Shipping Services, it is clearly marked which power supply it is intended for.

For specific part numbers see parts list.

For specific part numbers see parts list.

Machine may vary from pictures

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Additional Features Water Nozzle System

In order to reduce potential dust, a Water Spraying System has been installed on the front of your machine, which sprays the surface wet before going over with the chain links. (Part number: 200-0062)

Earth breaker safety device This safety device is highly recommended to connect between power supply and Rustibus

machine in order to ensure full safety for the operators. (Part number: 200-6135)

Genuine Rustibus® parts only!

Machine may vary from pictures

Rustibus® 2000 models available 200-1000 Rustibus® 2000, Complete 3X220/380/440V - 50/50/60 Hz – 5,5/5,5/6,4 kW

50 M Cable 3X2, 5 + E

200-2000

Rustibus® 2000 Diesel, Complete Dieselpower / 7,0 / 5,2 kW

200-X3000 Rustibus® X2000 Air (EX), Complete W/Air filter-Lubricator & Regulator

200-3000 Rustibus® 2000-Air, Complete W/Air filter-Lubricator & Regulator

200-4000 Rustibus® 2000 Low, Complete 3X220/380/440V - 50/50/60 Hz – 5,5/5,5/6,4 kW Incl. 50 M Cable 3X2, 5 + E

200-6000

Rustibus® 2000 Remote controlled 3X220/380/440V - 50/50/60 Hz – 5,5/5,5/6,4 kW 50 M Cable 3X2, 5 + E

200-9000 Rustibus® 2000 Low, Air driven Complete W/Air filter-Lubricator & Regulator

200-X9000 Rustibus® X2000 Low Air (EX), Complete W/Air filter-Lubricator & Regulator

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RUSTIBUS DE-SCALER WARRANTY/REPLACEMENT PLAN DALSEIDE SHIPPING SERVICES WILL REPLACE OR REPAIR ANY TOOL OR COMPONENT THAT FAILS DUE TO DEFECTS IN MATERIAL OR WORKMANSHIP FOR A PERIOD OF ONE (1) YEAR (12 MONTHS) FROM THE DATE OF SHIPMENT OF THIS PRODUCT FROM OUR FACILITY. A WARRANTY CLAIM WILL NOT BE HONOURED IF DEFECTS ARE NOT REPORTED WITHIN THE WARRANTY PERIOD, OR IF DALSEIDE SHIPPING SERVICES DETERMINES THAT DEFECTS OR DAMAGES ARE DUE TO NORMAL WEAR, MISAPPLICATION, LACK OF MAINTENANCE, ABUSE, IMPROPER INSTALLATION, ALTERATION, OR ABNORMAL CONDITIONS.

Dalseide Shipping Services is the original owner and manufacturer of Rustibus® We deliver GENUINE Rustibus® PARTS ONLY!

Dalseide Shipping Services cannot be held liable for any damages (to Rustibus® machines or personnel) as a result of use of non genuine parts. We reserve the right to refuse any claims on parts or Rustibus® machinery unless it can be proven that genuine parts only have been used on Rustibus® machines.

Dalseide Shipping Services will always seek to improve the Rustibus® machines design, specifications and production. Therefore, alterations may take place at any time. While every effort is made to produce up to date literature, the descriptions, specifications, illustrations and photographs in this manual should not be regarded as the definitive guide to current specifications; though all manuals are considered concise at the time of their production.

Machine may vary from pictures

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contact information

NORWAY: Dalseide Shipping Services AS Bekkjarviksundet 1

NO - 5397 Bekkjarvik Norway

Tel: + 47 5618 1200

Fax: + 47 5618 1201 E-mail: bergen@rustibus.com

ANTWERP: Rustibus N.V. Noordersingel 7 2140 Antwerpen Belgium

Tel: + 32 3227 2096

Fax: + 32 3227 2097 E-mail: antwerp@rustibus.com

SINGAPORE: Rustibus PTE LTD 18 Boon Lay Way #08-145 TradeHub 21 Singapore 609966

Phone: +65 62 62 52 26

Fax: +65 62 66 69 55 E-mail: singapore@rustibus.com

HOUSTON TX: Rustibus INC.

2901 West Sam Houston Pkwy North Suite E-325 Houston, TX 77043 USA

Tel: + 1 832 203 7170

Fax: + 1 832 203 7171 E-mail: houston@rustibus.com

sales@rustibus.com

w w w.rustibus.com