Buhler SDW 800/1000 User manual

Bühler AG
CH-9240 Uzwil/Switzerland
Phone [phone]
Fax [phone]
www.buhlergroup.com
Operating Instructions
Three-roll Mill
SDW 800/1000
SDW 800/1000-Ex
Spare Parts Catalogue, see 80394 SDW_80357-1-en-0703

2Three-roll Mill
SDW 800/1000 (-Ex), 80357-1-en-0703 © Copyright 2007 Bühler AG

Three-roll Mill Introduction 3
Introduction
These operating instructions (translation) include basic information on the design,
the installation, start-up, operation and maintenance of the machine.
The following separate documentation is integral part of the operating instructions:
– Spare Parts Catalogue, see 80394
For comprehension of these operating instructions
Important notes are distinguished as follows:
DANGER!
Hazards which can result in physical injuries or in death.
CAUTION!
Hazards which can result in operation failures or machine damage.
Note:
Important information or instructions.
•Procedural instructions are marked by point of eyecatcher.
If the machine is certified on the Nameplate with the appropriate ATEX
designation for operation in the explosion-dangerous area, the information
and instructions marked by are condition for the perpetuation of the
ignition protection. Therefore they must be absolutely kept.
© Copyright 2007 Bühler AG SDW 800/1000 (-Ex), 80357-1-en-0703

4 Introduction Three-roll Mill
SDW 800/1000 (-Ex), 80357-1-en-0703 © Copyright 2007 Bühler AG

Three-roll Mill Table of contents 5
Table of contents
1Safety ............................................................................................................ 9
1.1 General .......................................................................................................................... 9
1.2 In the explosion-dangerous area ................................................................................. 10
During maintenance works.............................................................................. 10
2Description ................................................................................................. 11
2.1 Identification................................................................................................................. 11
2.1.1 Nameplate....................................................................................................... 11
2.1.2 Type code........................................................................................................ 11
2.2 Use in accordance with intended purpose................................................................... 12
2.3 Design and function ..................................................................................................... 13
2.3.1 Three-roll Mill .................................................................................................. 13
2.3.2 Roll positions................................................................................................... 14
2.3.3 Cambered chilled-iron rolls ............................................................................. 16
2.3.4 Hydraulic system............................................................................................. 17
Pump unit ........................................................................................................ 18
Hydraulics (standard) ...................................................................................... 18
Options............................................................................................................ 19
2.3.5 Roll drive ......................................................................................................... 20
2.3.6 Roll cooling...................................................................................................... 21
Open flow-through cooling .............................................................................. 21
Open flow-through cooling with cooling water tank ........................................ 23
2.3.7 Hydraulic oil cooling ........................................................................................ 25
2.3.8 Product trough................................................................................................. 26
Hopper plates.................................................................................................. 26
2.3.9 Scraper............................................................................................................ 27
2.3.10 Safety bar........................................................................................................ 28
2.3.11 Level monitoring (option)................................................................................. 29
Design without certification for explosion-dangerous areas ........................... 29
Models certified for the explosion-dangerous area......................................... 29
2.3.12 Filling hydraulic system (option)...................................................................... 30
2.3.13 Roll nip setting (option) ................................................................................... 30
2.3.14 Bucket tilting device (option) ........................................................................... 31
Loading capacity ............................................................................................. 32
2.3.15 Protective cover (option) ................................................................................. 32
2.4 Technical data.............................................................................................................. 33
2.4.1 Weight ............................................................................................................. 33
2.4.2 Dimensions...................................................................................................... 33
Machine........................................................................................................... 33
Control cabinet ................................................................................................ 33
2.4.3 Power rating .................................................................................................... 33
Ratings ............................................................................................................ 33
Motor power .................................................................................................... 34
2.4.4 Roll cooling...................................................................................................... 34
2.4.5 Hydraulic system............................................................................................. 34
2.4.6 Noise data ....................................................................................................... 34
© Copyright 2007 Bühler AG SDW 800/1000 (-Ex), 80357-1-en-0703

6 Table of contents Three-roll Mill
2.5 Operating materials...................................................................................................... 35
2.5.1 Cooling water................................................................................................... 35
2.5.2 Hydraulic oil ..................................................................................................... 35
2.5.3 Gear oil ............................................................................................................ 35
2.5.4 For maintenance work..................................................................................... 35
2.6 Specific line pressure ................................................................................................... 36
2.7 Dimension drawings..................................................................................................... 37
3Transport..................................................................................................... 38
3.1 General......................................................................................................................... 38
3.2 Storage......................................................................................................................... 38
3.3 Suspension on the crane ............................................................................................. 39
4Installation................................................................................................... 40
4.1 General......................................................................................................................... 40
4.2 Local conditions............................................................................................................ 40
Ambient conditions .......................................................................................... 40
4.3 Erection ........................................................................................................................ 40
4.3.1 Installation procedure ...................................................................................... 41
4.4 Electrical installation..................................................................................................... 42
4.4.1 Connecting to the power supply...................................................................... 42
Connecting the control cabinet........................................................................ 42
4.4.2 Earthing ........................................................................................................... 43
4.5 Installation of supply lines ............................................................................................ 43
4.5.1 Product lines.................................................................................................... 43
4.5.2 Cooling water lines .......................................................................................... 43
5Start-up........................................................................................................ 44
5.1 General......................................................................................................................... 44
5.2 Pre-operational inspections.......................................................................................... 45
5.3 Settings ........................................................................................................................ 46
5.3.1 Roll cooling setting .......................................................................................... 46
5.3.2 Filling in hydraulic oil and adjusting operating pressure.................................. 47
5.3.3 Aligning the rolls .............................................................................................. 48
5.3.4 Setting counter-pressure, hopper plate and scraper knife contact pressure .. 50
5.3.5 Inserting and fixing the scraper and setting it.................................................. 51
5.3.6 Level monitoring (option)................................................................................. 53
Without certification for the explosion-dangerous area................................... 53
Certified for the explosion-dangerous area ..................................................... 54
5.3.7 Calibrating the position indicator (option)........................................................ 57
5.3.8 Filling hydraulic system (option) ...................................................................... 58
5.3.9 Tightening the V-belts ..................................................................................... 59
5.3.10 Bucket tilting device (Option)........................................................................... 59
5.3.11 Adjusting of minimum roll nip (option) ............................................................. 60
5.4 Inspection of functions.................................................................................................. 61
5.4.1 Inspection of machine functions...................................................................... 62
Direction of rotation of the hydraulic pump motor ........................................... 62
Direction of rotation of the rolls........................................................................ 62
SDW 800/1000 (-Ex), 80357-1-en-0703 © Copyright 2007 Bühler AG

Three-roll Mill Table of contents 7
5.4.2 Checking the safety functions ......................................................................... 62
Emergency stop .............................................................................................. 62
Safety bar........................................................................................................ 63
5.5 Checking EU conformity .............................................................................................. 64
Check list for establishing EU conformity........................................................ 64
6Operation .................................................................................................... 66
6.1 General ........................................................................................................................ 66
6.2 Control panel................................................................................................................ 68
Functions......................................................................................................... 69
6.3 Operation ..................................................................................................................... 70
6.3.1 Prepare the start ............................................................................................. 70
6.3.2 Starting the machine ....................................................................................... 70
6.3.3 Machine turning off.......................................................................................... 71
6.3.4 Emergency stop .............................................................................................. 71
Emergency stop button ................................................................................... 71
Restart after emergency stop.......................................................................... 71
6.4 Roll nip setting (option) ................................................................................................ 72
6.5 Instructions for operation ............................................................................................. 73
6.5.1 “Sifting”............................................................................................................ 73
6.5.2 Process parameters ........................................................................................ 74
Influence of roll contact pressure and roll temperature................................... 74
6.6 Cleaning ....................................................................................................................... 75
6.6.1 Cleaning the machine ..................................................................................... 75
6.6.2 Cleaning of the rolls ........................................................................................ 75
Cleaning the first roll ....................................................................................... 77
Cleaning the second and third roll .................................................................. 78
6.7 Faults and troubleshooting........................................................................................... 79
7Maintenance ............................................................................................... 81
7.1 General ........................................................................................................................ 81
7.2 Maintenance and lubrication chart............................................................................... 83
7.3 Maintenance work........................................................................................................ 86
7.3.1 Hopper plate maintenance .............................................................................. 86
7.3.2 Cleaning water filter ........................................................................................ 86
7.4 Spare and wear parts................................................................................................... 87
7.5 Disposal ....................................................................................................................... 87
8After-sales service ..................................................................................... 88
Address for the after-sales service and the spare parts sale.......................... 88
© Copyright 2007 Bühler AG SDW 800/1000 (-Ex), 80357-1-en-0703

8 Table of contents Three-roll Mill
SDW 800/1000 (-Ex), 80357-1-en-0703 © Copyright 2007 Bühler AG

Three-roll Mill Safety 9
1 Safety
1.1 General
The machine is fitted with protection and safety devices in compliance with the
recognized safety engineering principles. Improper use of the machine may entail
dangers to the health and life of persons, or may cause damage to property.
These operating instructions must be kept close to the machine and be visible
anytime.
The machine must only be operated in compliance with all instructions and
prescriptions of these operating instructions.
•Pay special attention to the following danger areas:
– Danger of getting caught in nip:
Never reach into the nip or insert any object (such as spatula).
Do not wear thick protective gloves, which impede the capacity of tactile
sensation of your fingers.
Do not wear long, wide sleeves. The sleeves may get caught between
the rolls.
– If the machine is equipped with a protective cover (option), it must be
operated only with installed protective cover.
– For cleaning the rolls, insert the safety bar and fasten it, see
sect. 2.3.10.
– When cleaning, replacing the scraper knife or unfolding the apron,
always put on the scraper knife disassembly device, see sect. 5.3.5,
Fig. 5.10.
– When working in any of the machine’s danger areas, turn the all-pole
disconnecting lockable safety switch to “0” and secure against turning
on.
– When working on the electrical controller or on electrical components,
set the main switch on the control cabinet to “0” and lock it (key with
personnel).
•
•
•
•
•
•
•
•
•
In case of a danger of explosion, follow all the decisive safety instructions.
See sect. 2.2 “Use in accordance with intended purpose”.
Keep clean and do not remove or cover any warning and instruction signs.
Replace any damaged warning and instruction signs with new ones.
Do not remove or cover any designation numbers on electric wires.
Only lift the machine at the indicated suspension points, see chap. 3.
Do not walk or wait under suspended loads.
Only start-up and operate the machine when the protection devices are
intact and the safety equipment is operational, see sect. 5.1 and sect. 5.5.
Maintenance and cleaning work must be carried out only when the machine
is out of operation (no motion of the machine), see chap. 7.
Turn the all-pole disconnecting lockable safety switch to “0” and secure
against turning on.
Before operation of the machine make sure about function and operation of
the emergency stop switch, see sect. 6.3.4 “Emergency stop”.
Upon actuation of the emergency stop button, the main motor gets switched
off immediately.
The hydraulic pump remains in operation and must be switched off with the
push button “Hydraulic pump OFF”.
Always wear protective glasses during operation and maintenance of the
machine.
© Copyright 2007 Bühler AG SDW 800/1000 (-Ex), 80357-1-en-0703

10 Safety Three-roll Mill
1.2 In the explosion-dangerous area
•
•
In the explosion-dangerous area the machine must only be operated
according to its permission. The certification can be seen from the ATEX
designation on the Nameplate, see sect. 2.1 “Identification”.
The information and instructions marked with in these operating
instructions are indispensable for maintaining the ignition protection and thus
the certification for the indicated area. Therefore they must be observed
without fail.
During operation, the machine must be monitored in a way that the operating
personnel can react to operating failures.
Immediately stop the machine in the event of unusual running noise.
The installation and the product container must be in compliance with the
ATEX 95 directive.
Only operate the roll mill with the approved products, see sect. 2.2 “Use in
accordance with intended purpose”.
Only operate the roll mill with product.
When running the machine empty, observe the product inflow closely.
If there are foreign objects present, immediately switch off the machine.
Only use cleaning agents up to temperature class T3 in conformity with the
permission of the machine for the explosion-dangerous area, see sect. 2.1
“Identification”.
During maintenance works
•Only personnel who are authorised by the operator in accordance with their
safety instructions, must carry out maintenance work.
In the explosion-dangerous area, correct maintenance is the prerequisite for
maintaining the ignition protection.
Only use cleaning agents up to temperature class T3 in conformity with the
permission of the machine for the explosion-dangerous area, see sect. 2.1
“Identification”.
During all maintenance and cleaning work, avoid the build-up of ignitable
solvent fumes.
Do not stir up dust. Avoid dust settling.
In the proximity of combustible materials, do not carry out any welding or
emery works.
To maintain the ignition protection only use original spare parts, see
separate spare parts catalogue (80394).
Ensure that the machine is correctly earthed again after maintenance works.
(The equipotential bonding must not be broken through the removal of earth
conductors, through painting on contact surfaces or pipe joints), see
sect. 4.4.2 “Earthing”.)
SDW 800/1000 (-Ex), 80357-1-en-0703 © Copyright 2007 Bühler AG