Buhler SZLH-400b User manual

Operating Instructions
Pellet Mill
SZLH - 400b
-420b
-420E
-508b
-508E
-520
SZLH-1-en-1605

Original Operating instructions
Copyright by BCHA

BCHA
Pellet Mill SZLH-1-en1605
Table of contents
3
Table of contents
1Important information.............................................................................................1
1.1 Scope of validity.........................................................................................................1
1.2 Contact.......................................................................................................................1
1.3 Personnel qualification...............................................................................................1
1.3.1 Mechanics ....................................................................................................1
1.3.2 Electricians ...................................................................................................1
1.3.3 Welders ........................................................................................................1
1.4 Typographical conventions........................................................................................2
1.4.1 Explanation of the warning instructions........................................................2
2Safety ...................................................................................................................3
2.1 Designated use..........................................................................................................3
2.2 Technical condition ....................................................................................................3
2.3 ATEX ID.....................................................................................................................3
2.4 Personnel qualification...............................................................................................3
2.5 Protection against unexpected start-up.....................................................................4
2.6 Protective devices......................................................................................................4
2.7 Safety signs ...............................................................................................................4
2.8 Safe work environment ..............................................................................................4
2.8.1 Slipping and stumbling hazard .....................................................................4
2.9 Residual risk ..............................................................................................................4
2.9.1 Safety rules...................................................................................................4
3Technical data.......................................................................................................6
3.1 Environments condition .............................................................................................6
3.2 Technical Parameters................................................................................................6
3.3 Power date................................................................................................................7
3.4 Dimensions ................................................................................................................7
3.4.1 SZLH400b ....................................................................................................7
3.4.2 SZLH420b ....................................................................................................8
3.4.3 SZLH420E....................................................................................................9
3.4.4 SZLH508b ..................................................................................................10
3.4.5 SZLH508E..................................................................................................11
3.4.6SZLH520 ....................................................................................................11
4Description ..........................................................................................................13
4.1 Identification.............................................................................................................13
4.1.1 Specification key ........................................................................................13
4.1.2 ATEX ID for use in Ex zone 22...................................................................13
4.1.3 ATEX ID without approval for potentially explosive zone...........................14
4.2 Overview..................................................................................................................15
4.3 Function ...................................................................................................................15
4.4 Subassembly ...........................................................................................................15

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BCHA
Pellet Mill SZLH-1-en-1605
Table of contents
4.4.1 Feeder ........................................................................................................15
4.4.2 Conditioner .................................................................................................16
4.4.3 Die hoist (optional) .....................................................................................17
4.4.4 Feed chute..................................................................................................17
4.4.5 Pellet chamber door ...................................................................................17
4.4.6 Pellet chamber ...........................................................................................17
4.4.7 Gearbox......................................................................................................18
4.5 Safety system ..........................................................................................................20
4.5.1 Overload protection device.........................................................................20
4.5.2 Pellet chamber door protective switch .......................................................20
4.5.3 External discharging...................................................................................20
4.6 Safety sign ...............................................................................................................20
5Transport ............................................................................................................22
5.1 Packaging symbols..................................................................................................22
5.2 Checking the delivery ..............................................................................................22
5.3 Intermediate storage................................................................................................22
5.4 Lifting instructions ....................................................................................................22
6Installation...........................................................................................................24
6.1 Pellet mill installation ...............................................................................................24
6.2 Foundation for pellet mill..........................................................................................24
6.3 Discharge opening...................................................................................................25
6.4 Hopper .....................................................................................................................25
6.5 Steam.......................................................................................................................25
6.6 Oil and molasses adding system.............................................................................26
6.7 Electric control system.............................................................................................27
7Commissioning....................................................................................................29
7.1 Putting the subassembly into operation...................................................................29
7.1.1 Die-roller clearance adjustment..................................................................29
7.1.2 Knife adjustment.........................................................................................30
7.1.3 Adjustment and calibration of rotational speed of feeder...........................30
7.1.4 Adjustment of angle of conditioner paddles ...............................................31
7.2 Checks before commissioning.................................................................................31
7.3 Checking protective devices....................................................................................31
7.4 Conformity ...............................................................................................................31
7.5 Test run see 8.1.......................................................................................................31
7.6 Check and Accept....................................................................................................31
8Operation ............................................................................................................32
8.1 Test run....................................................................................................................32
8.2 Operation .................................................................................................................33
8.2.1 Starting steps .............................................................................................33
8.2.2 Cautions for operation ................................................................................33
8.2.3 Shut-down steps.........................................................................................33
8.3 Use conditions ........................................................................................................34
9Troubleshooting ..................................................................................................35
10 Maintenance .......................................................................................................37
10.1 Everyday maintenance ............................................................................................37
10.2 Regular check and maintenance .............................................................................37

BCHA
Pellet Mill SZLH-1-en-1605
Table of contents
5
10.3 Lubrication ...............................................................................................................38
11 Repair .................................................................................................................39
11.1 Die replacement.......................................................................................................39
11.2 Roller assembly replacement ..................................................................................39
11.3 Cleaning of feeder ...................................................................................................40
11.4 Disassembling and assembling of conditioner ........................................................40
11.5 Disassembling and assembling of die driving key...................................................40
11.6 Die repair .................................................................................................................41
12 Decommissioning................................................................................................42
12.1 Shutting down ..........................................................................................................42
13 Spare parts .........................................................................................................43
13.1 Inventory of spare parts ...........................................................................................43
13.2 Spare parts identification .........................................................................................43
13.3 Order instructions ....................................................................................................43
13.4 Spare parts lists .......................................................................................................44
13.4.1 Common wearing parts for SZLH400、SZLH420......................................44
13.4.2 Common wearing parts for SZLH508.........................................................45
14 Attachment..........................................................................................................47
14.1 Shear Pin .................................................................................................................47
14.1.1 SZLH400b ..................................................................................................47
14.1.2 SZLH420b ..................................................................................................48
14.1.3 SZLH508/520 .............................................................................................49

BCHA
Pellet Mill SZLH-1-en-1605
Chapter 1 Important information
1
1Important information
1.1 Scope of validity
Type
Die ID，Unit：mm
SZLH 400b
400
SZLH 420b
420
SZLH 420E
420
SZLH 508b
508
SZLH508E
508
SZLH520
520
1.2 Contact
►In case of inquiries, please contact the after-sales service department of man-
ufacturer.
►Have the Operation Manual at hand.
►Address
Buhler (Changzhou) Machinery Co., Ltd.
Address: Tianmu Lake Industrial Park, Liyang City, Jiangsu Province, China
Tel: [phone]
Fax: [phone]
1.3 Personnel qualification
1.3.1 Mechanics
Personnel that work on mechanical devices must be technically trained or have
completed training provided by the manufacturer.
1.3.2 Electricians
Personnel that work on electrical devices must be technically trained or have com-
pleted training provided by the manufacturer.
1.3.3 Welders
Personnel that carry out welding work on equipment must be technically trained.

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BCHA
Pellet Mill SZLH-1-en-1605
Chapter 1 Important information
1.4 Typographical conventions
1.4.1 Explanation of the warning instructions
DANGER
Type and source of danger
Danger will result in death or serious injury.
Actions for protecting against danger.
WARNING
Type and source of danger
Danger can result in death or serious injury.
Actions for protecting against danger.
CAUTION
Type and source of danger
Danger can result in injury.
Actions for protecting against danger.
NOTICE
Type and source of danger
Danger can result in property damage.
Actions for protecting against property damage.

BCHA
Pellet Mill SZLH-1-en-1605
Chapter 2 Safety
3
2Safety
2.1 Designated use
►SZLH series high-grade pellet mill is the main item of equipment for producing
feed pellets with application to large and medium scale breeding farm and
feed mill.
►The machine can be fitted with dies of Ø2~Ø10 hole diameter, which can be
chosen by user according to requirements
►The machine features compact structure, fine appearance, low noise, high
output with low power consumption, it is convenient in operation and reliable
in performance.
►The machine adopts (electromagnetic) frequency conversion speed-adjusting
motor for feeder and LLL large door conditioner access, with axial steam addi-
tion. Feeder is fitted with strong magnetic safety device, press overload pro-
tection device and external discharging mechanism.
►Always use the machine in compliance with its intended use.
►Always operate the machine in accordance with these Operating instructions.
2.2 Technical condition
If the machine is operated in defective condition, the safety, function and availabil-
ity are impaired.
►Never operate the machine unless it is in proper technical condition.
►Always comply with the maintenance plan.
►Always use the original spare parts as listed in the Spare parts catalog.
►If the operating behaviour of the machine changes, check the machine for
faults.
►Remedy all faults immediately.
►Never carry out unauthorised conversions or modifications to the machine.
2.3 ATEX ID
The ATEX ID indicates the conditions required for integrating the machine into an
Ex zone or connecting the machine to an Ex zone.
►Observe the identification plate.
2.4 Personnel qualification
Unqualified personnel cannot identify risks and thus are subject to greater dangers.
►Always assign the activities listed in these Operating instructions to technically
qualified personnel.

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BCHA
Pellet Mill SZLH-1-en-1605
Chapter 2 Safety
►The owner/operator must ensure that the personnel comply with the locally
valid regulations and laws pertaining to safety and safety-conscious work.
►The owner/operator must assign responsibilities and tasks and inform person-
nel of these assignments. Give keys and passwords to authorised personnel
only.
2.5 Protection against unexpected start-up
If the machine starts unexpectedly, people who are working at the machine can be
seriously injured.
►Set the safety switch to "0" and lock it.
►Remove the key and keep it with you.
2.6 Protective devices
If protective devices are ineffective, this poses a danger to people.
►Before operating the machine, always verify that all protective devices are ef-
fective.
2.7 Safety signs
If safety signs are not visible or legible, this poses a danger to people.
►Replace safety signs that are not visible or legible.
►Do not remove or cover up safety signs.
2.8 Safe work environment
2.8.1 Slipping and stumbling hazard
Slippery surfaces and stumbling hazards can result in serious accidents.
►Always keep walkways, grips, steps, railings, platforms and ladders free of
grease, oil, and other dirt.
►Never climb or walk on the machine and do not use it for storage. Use the
provided steps and platforms only.
►Wear non-skid safety shoes.
2.9 Residual risk
2.9.1 Safety rules
►There should not be foreign materials such as stone, iron impurity and flaxen
thread in the mash feed.
►Turn on the main motor first when starting the machine; whereas turn off the
feeder motor first when stopping the machine.
►Feed die with oily feed before turning off the main motor, because pellets of
oily feed is loose and will not easy to block the die holes. This should be done
even more especially so when the particular die will be left unused for a long
time.
►Clear away the accumulated feed in the pellet chamber after die has stopped
rotating.

BCHA
Pellet Mill SZLH-1-en-1605
Chapter 2 Safety
5
►Operate strictly in accordance with the operation steps and points for attention.
Overload operation is not allowed thus preventing the failure caused by the
such operation.
►During operation, to avoid injury, opening the pellet chamber door is not al-
lowed.
►Don’t place your hands into the inspection door for taking feed sample or other
action. To take sample, the self-made special-purpose tool should be used.
►When adjusting the knife, make sure that distance between knife and outer di-
ameter of die is not less than 3mm.
►When any abnormal condition is found or machine failure appears, the normal
Shut-down steps should be followed. After stopping the machine, check and
remove the cause for shutdown. Only after all is normal should production op-
erations continue.
►To obtain good quality pellets and high output, every driving part of the ma-
chine should run normally and there should be a good feed formulation. The
most important thing is to adjust the rotational speed of feeder and steam
amount correctly to ensure that the main motor operates under the maximum
rated current load and also ensure the proper temperature and humidity for
the conditioned material. Different formulations have different requirements on
the steam addition requirements, thus the operator should try best to establish,
record and accumulate experience and control flexibly by feel testing and eye-
sight. In addition, basically stable steam pressure should be ensured and
generally pressure fluctuation cannot be larger than 0.05Mpa.

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BCHA
Pellet Mill SZLH-1-en-1605
Chapter 3 Technical data
3Technical data
3.1 Environments condition
SZLH
400b
SZLH
420b
SZLH
420E
SZLH
508b
SZLH
508E
SZLH
520
Displacement noise
[dB(A)]
≤85
≤85
≤85
≤85
≤85
≤85
Die working temperature
[℃]
≤90
≤90
≤90
≤85
≤85
≤85
Steam working pressure
[Mpa]
0.2-0.4
0.2-0.4
0.2-0.4
0.2-0.4
0.2-0.4
0.2-0.4
Steam consumption
[t/h]
≥0.5
≥0.5
≥0.5
≥1
≥1
≥1
Steam temperature
[℃]
130-150
130-150
130-150
130-150
130-150
130-150
Steam bag pressure
[Mpa]
0.6～0.8
0.6～0.8
0.6～0.8
0.6～0.8
0.6～0.8
0.6～0.8
3.2 Technical Parameters
SZLH
400b
SZLH
420b
SZLH
420E
SZLH
508b
SZLH
508E
SZLH
520
Output (t)
3-12
3-14
3-16
4-20
4.8-24
4.8-28
Die ID [mm]
Φ400
Φ420
Φ420
Φ508
Φ508
Φ520
Effective Width of Die
[mm]
120
120
140
155
185
185
Pellet Specification [mm]
Φ2-Φ10
Φ2-Φ10
Φ2-Φ10
Φ2-Φ10
Φ2-Φ10
Φ2-Φ10
Roller Number
2
2
2
2
2
2
Roller OD [mm]
Φ 190
Φ206
Φ206
Φ222
Φ222
Φ255
Pellet Shaping Rate
[%]
≥95
≥95
≥95
≥95
≥95
≥95
Pellet Powdering Rate
[%]
≤10
≤10
≤10
≤10
≤10
≤10

BCHA
Pellet Mill SZLH-1-en-1605
Chapter 3 Technical data
7
3.3 Power date
SZLH
400b
SZLH
420b
SZLH
420E
SZLH
508b
SZLH
508E
SZLH
520
Main Motor [KW]
75/90
90/110
90/110
110/132/
160
110/132/
160
110/132/1
60
Feeder [KW]
1.5
1.5
1.5
2.2
2.2
2.2
Conditioner [KW]
5.5(7.5)
5.5(7.5)
5.5(7.5)
7.5(11)
7.5(11)
7.5(11)
Die Rotational Speed
[rpm]
275
275
275
260
260
260
Feeder Rotational Speed
[rpm]
12-120
12-120
12-120
12-120
12-120
12-120
Conditioner Rotational
Speed [rpm]
270
275
275
270
270
270
3.4 Dimensions
3.4.1 SZLH400b
Φ12
280 200
350
270
1630
211 235 1410 830
315
1447
1802 430
1400
2380
774 451
1020
PP向K向
K
185x4=740
780
485
220x2=440
400
700
Fig3.1 SZLH400b Dimension Drawing

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BCHA
Pellet Mill SZLH-1-en-1605
Chapter 3 Technical data
3.4.2 SZLH420b
Φ12
1630
211 235 1410 830
315
1447
1802 430
1400
2380
774 451
1020
P
K
280 200
350
270
P向K向
185x4=740
780
485
220x2=440
400
700
Fig3.2 SZLH420b Dimension Drawing

BCHA
Pellet Mill SZLH-1-en-1605
Chapter 3 Technical data
9
3.4.3 SZLH420E
Φ12
1630
251 235 1410 790
315
1447
1802 430
1400
2380
774 451
1020
P
K
280 200
350
270
P向K向
185x4=740
780
485
220x2=440
400
700
Fig3.3 SZLH420E Dimension Drawing

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BCHA
Pellet Mill SZLH-1-en-1605
Chapter 3 Technical data
3.4.4 SZLH508b
Φ12
320
240
440
360
1630
171 297 1610 620
270
1572
1965 430
K
2540
810 872
1050
PP向
K
K向
185x4=740
780
485
220x2=440
400
700
Fig3.4 SZLH508b Dimension Drawing

BCHA
Pellet Mill SZLH-1-en-1605
Chapter 3 Technical data
11
3.4.5 SZLH508E
Φ12
320
240
440
360
1630
171 297 1610 620
270
1572
1965 430
K
2540
810 872
1050
PP向
K
K向
185x4=740
780
485
220x2=440
400
700
Fig3.5 SZLH508E Dimension Drawing

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BCHA
Pellet Mill SZLH-1-en-1605
Chapter 3 Technical data
3.4.6 3.4.6 SZLH520
Fig3.6 SZLH520 Dimension Drawing

BCHA
Pellet Mill SZLH-1-en-1605
Chapter 4 Description
13
4Description
4.1 Identification
4.1.1 Specification key
SZLH 508b
SZLH
Code
508
Die ID
b
Index
4.1.2 ATEX ID for use in Ex zone 22
The ATEX ID indicates the conditions required for integrating the machine into an
Ex zone or connecting the machine to an Ex zone.
II */3D T=125 °C
Explanation of symbols:
—
ATEX symbol
II
—
Device group
-/
—
No approval for connection to an Ex zone
*/
—
Internal category: No inherent internal source of ignition
3/
—
Internal category 3
2/
—
Internal category 2
(A3)/
—
Integrated Category 3 ignition-protected working materials
(A2)/
—
Integrated Category 2 ignition-protected working materials
(A1)/
—
Integrated Category 1 ignition-protected working materials
/-
—
No approval for use within an Ex zone
/*
—
External category: No inherent external source of ignition
/3
—
External category 3
D
—
Dust atmosphere
G
—
Gas atmosphere
EEx
—
Ignition protection in accordance with European Ex standard
c
—
Design safety in accordance with EN 13463
T
—
Maximum expected surface temperature in °C in normal operation at
full load with an ambient temperature of 40 °C.

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BCHA
Pellet Mill SZLH-1-en-1605
Chapter 4 Description
T
—
Maximum expected surface temperature in °C in normal operation at
full load with an ambient temperature of TA.
TA
—
Increased ambient temperature in °C
T3
—
Temperature class: Maximum surface temperature 200 °C
X
—
Instructions in the Operating instructions for maintaining explosion
protection equipment are indicated with the Ex symbol.
4.1.3 ATEX ID without approval for potentially explosive zone
II */-D
Explanation of symbols:
—
ATEX symbol
II
—
Device group
-/
—
No approval for connection to an Ex zone
*/
—
Internal category: No inherent internal source of ignition
3/
—
Internal category 3
2/
—
Internal category 2
(A3)/
—
Integrated Category 3 ignition-protected working materials
(A2)/
—
Integrated Category 2 ignition-protected working materials
(A1)/
—
Integrated Category 1 ignition-protected working materials
/-
—
No approval for use within an Ex zone
/*
—
External category: No inherent external source of ignition
D
—
Dust atmosphere
G
—
Gas atmosphere