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Machine Manual

en-22455.202-F

Mechanical drive of the separator


SEPOL® for roller mill

Code word

Order number

POLYSIUS Order Code (POC)


Machine Manual Contents
Mechanical drive of the separator SEPOL® for roller mill

Contents

1 Technical data......................................................................................... 1-1


2 Safety...................................................................................................... 2-1
3 Components and mode of functioning.................................................3-1
3.1 Components............................................................................................. 3-1
4 Transport and assembly........................................................................4-1
4.1 Transport and storage requirements........................................................4-1
4.2 Assembly.................................................................................................. 4-1
5 Lubrication..............................................................................................5-1
6 Preparation for the test run...................................................................6-1
6.1 Checks prior to the test run......................................................................6-1
7 Maintenance...........................................................................................7-1
7.1 Safety instructions....................................................................................7-1
7.2 Inspection.................................................................................................7-3
7.3 Servicing.................................................................................................. 7-4
7.4 Trouble shooting.......................................................................................7-4
7.5 Repair....................................................................................................... 7-5
8 Spare parts............................................................................................. 8-1
9 Appendix.................................................................................................9-1
9.1 Technical drawings...................................................................................9-1
9.2 Subsuppliers’ documentation...................................................................9-1

en-22455.202-F
Machine Manual Technical data
Mechanical drive of the separator SEPOL® for roller mill 1

1 Technical data

NOTE
Information concerning the electrical equipment is contained in
the separate electrical documentation or in the subsuppliers’
documentation.

Information on the intended use


See machine manual of the Separator.........................................No.

Drive unit
Type..............................................................................................A / B

Gear unit (3)


Type.....................................................................................................
Drive power.........................................................................................
Output speed.......................................................................................

Electric motor (1)


Type.....................................................................................................
Power...................................................................................................
Speed range........................................................................................

Coupling (2)
Type.....................................................................................................

Connecting element (6) for the separator cardan


shaft/coupling
Type.....................................................................................................

Figure 1
2

Type A Type B
Machine Manual Safety
Mechanical drive of the separator SEPOL® for roller mill 1

2 Safety

NOTE
Be sure to comply with the general safety instructions in the
supplement Important notes on the documentation

Use
 The machine is exclusively intended for driving the separator
SEPOL for roller mills.
Be sure to comply with the information concerning the
intended use of the machine in the section Technical data.
 Any use of the machine other than for the intended use is
forbidden. POLYSIUS AG is not responsible for any damage
resulting from any other than the intended use of the machine.
All other use is at the user’s own risk.
 The intended use also includes observance of the instructions
in the machine manual and the conditions for maintenance.

Transport and assembly


 All transport instructions in this manual refer exclusively to
transportation of the machine at the plant site.
 Only use suitable hoisting and lifting equipment which is in
serviceable order and has a sufficient load bearing capacity.
 Make sure that gearboxes equipped with oil pumps and pipes
are transported with extra care. Before transporting the
gearbox, disassemble the pipes, and close all sockets and
openings in a weather-proof and impact proof manner to
prevent the ingress of foreign bodies.
 Never work under a suspended load.
Operation
 Any safety checks before or during operation depend on the
relevant national regulations. The plant management is
responsible for the performance and recording of such checks.
 If changes in the machine or its operating behaviour relevant
to safety occur, shut the machine down immediately.
 Access to the roller mill is not allowed during starting up and
shutting down the roller mill.
Safety Machine Manual
2 Mechanical drive of the separator SEPOL® for roller mill

 Hearing protectors have to be worn in the mill building of the


roller mill.
Machine Manual Safety
Mechanical drive of the separator SEPOL® for roller mill 3

Maintenance
● Be sure to also comply with the safety instructions in the machine manual for
the roller mill and in the subsupplier's documentation.
● Keep the machine free of oily and combustible substances and materials.
Never use gasoline or other easily inflammable substances to clean the
machine.
● Before you start with work inside the machine, you have to obtain the written
permission of the plant manager, and you must shut down the plant section in
which the machine is installed.
● Make absolutely sure that all machines, motors and the material flow whose
operation might endanger persons or equipment are switched off and
safeguarded against restarting for the entire duration of the maintenance
work.
● Switch off the power supply to the electrical components before beginning any
maintenance work.
● Ensure that all parts of the machine have come to a complete standstill before
you remove any protection devices or open any covers.
● After shutting down the grinding table drive wait until it has come to a
complete standstill. Reverse rotation of the grinding table up to ¼ of a full
rotation is possible.
● The plant management must ensure that all moving parts are protected
against accidental contact.
● Before performing any work on the machine, make sure that there is no
danger of suffering burns when touching the machine and before opening any
inspection and service covers make certain that there is no longer any hot
material inside the machines.
● Make absolutely sure that all piping is relieved of pressure.
● Make absolutely sure that no hot gas can enter the interior.
● Remove all incrustations, possibly loose wear protection lining and other
materials that could fall down or slide down.
● Only use 24 volt lamps to illuminate the interior of the machine.
Safety Machine Manual
4 Mechanical drive of the separator SEPOL® for roller mill

● Directly after the machine has been shut down, you are only allowed to enter
the interior wearing breathing apparatus with independent ventilation.
● Cold shock due to excessive temperature differences must be avoided, as it
could cause stress cracks in the roller tyres.
● You are not allowed to enter the interior without breathing apparatus until you
have sufficiently purged it with fresh air. Make sure that there is sufficient
oxygen inside the machine.
● When work is being performed inside the machine, make absolutely sure that
fresh air is supplied continuously (by injection or suction), so that the inhaled
air remains free from noxious constituents. Aeration with pure oxygen is
forbidden.
● When work is carried out in the roller mill, a large amount of dust has to be
expected, so make sure that dust protection masks are worn.
● For repair/maintenance work to be carried out inside the plant components,
you have to install auxiliary platforms if necessary. These auxiliary platforms
must be of stable design.
● The hydraulic system has been specially designed for the supplied machine
and must, therefore, not be used for any other machine without the express
consent of POLYSIUS AG.
● Only use hydraulic oil that complies with the requirements in section
Lubrication.
● Make absolutely sure that the hydraulic piping is depressurised before
disconnecting it.
● Never use the pumps of the hydraulic system for emptying or filling the oil
tank.
 If you drain hydraulic oil at operating temperature, you risk scalding yourself.
 Only use pure nitrogen and never oxygen for filling the piston accumulators.
Machine Manual Safety
Mechanical drive of the separator SEPOL® for roller mill 5

Flame cutting, grinding or welding work


● Strictly observe the welding instructions when performing any welding work.
● When electric arc welding or cutting are being performed, you must ensure
that personnel cannot come into contact with electrically conductive
components. Use insulating underlays for this purpose.
● Never situate the source of the welding current in a confined space where
walls have conductive properties.
● If you carry out electric welding on any part of the machine, never conduct the
welding current through plain or antifriction bearings, other moving connecting
elements or measuring devices. Always directly connect the welding current
return lead to the part being welded.
● In particular, never carry out any electrical or autogenous welding and flame-
cutting work on the grinding table, the grinding surface, the roller tyres and the
tie rods as these points may become starting points of cracks. Never connect
earthing cables to these components either.
Conclusion of maintenance work
● After all maintenance work, check that there are no leaks in joints and
connections.
● Remount all protection devices when the maintenance work has been
finished. Make absolutely sure that no persons are inside the plant component
before you properly close the inspection and service covers.
 Check that all signs are complete and distinctly legible. Mount
new signs if necessary.
Machine Manual Components and mode of functioning
Mechanical drive of the separator SEPOL® for roller mill 1

3 Components and mode of functioning

The mechanical drive for the separator SEPOL is equipped with


a speed-controlled electric motor. This makes it possible to
infinitely adjust the speed of the rotor.

During production, the drive unit operates automatically. The


functional sequences are electronically controlled and monitored.

For commissioning and corrective maintenance all functions can


also be performed manually.

3.1 Components

NOTE
Some details of the drawings in this manual may not be identical
with the drawings supplied under the contract as listed in the
section 9.1 Technical drawings.

The mechanical drive for the separator SEPOL comprises the


following

sub-assemblies
 electric motor
 coupling
 gear unit
 drive bracket
 protection device
Components and mode of functioning Machine Manual
2 Mechanical drive of the separator SEPOL® for roller mill

Items of the drive unit type A


1 Electric motor
2 Coupling
3 Gear unit
4 Drive bracket
5 Protection device
6 Connecting element

Figure 2
Machine Manual Components and mode of functioning
Mechanical drive of the separator SEPOL® for roller mill 3

Items of the drive unit type B


1 Electric motor
3 Gear unit
6 Connecting element

Figure 3
Machine Manual Transport and assembly
Mechanical drive of the separator SEPOL® for roller mill 1

4 Transport and assembly

4.1 Transport and storage requirements

The machine is transported in single parts or in sub-assemblies.


It must be observed that suitable lifting equipment is employed in
removing the parts from the transport vehicles and transferring
them to the storage area.
When they arrive at the site, all parts must be inspected for
transport damage and placed on wooden beams with the
provision of suitable protection against rain, contamination and
damage. Under no circumstances may the parts be stored
directly on the ground.
Motors, couplings, gear units, measurement and control
equipment must be stored in buildings which are well aerated and
must be protected against moisture.

Gear units
Transport ropes may only be fastened at the indicated points.
Make sure that gearboxes equipped with oil pumps and pipes are
transported with extra care. Before transporting the gearbox, it is
advisable to disassemble the pipes, and close all sockets and
openings in a weather-proof and impact proof manner to prevent
the ingress of foreign bodies. Make sure that all protective covers
can be easily removed.
If you intend to store the parts for more than 6 months, please
consult POLYSIUS AG to clarify whether special preservation
measures are required.

4.2 Assembly

General requirements
The following assembly instructions do not detail the individual
steps for assembling the unit, but rather give an overview of the
work to be performed.
Changes in the planning of the plant during the processing of the
contract may lead to deviations from these assembly
instructions.
Transport and assembly Machine Manual
2 Mechanical drive of the separator SEPOL® for roller mill

NOTE
Final assembly and assembly inspection by an assembly
specialist from POLYSIUS AG are preconditions for our warranty.

We recommend that the assembly work is supervised from start


to finish by specialists from POLYSIUS AG.
Careful selection of tools and appliances used and of the
personnel is important for the correct execution of the assembly
work.
Machine Manual Transport and assembly
Mechanical drive of the separator SEPOL® for roller mill 3

CAUTION
If you carry out electric welding on any part of the machine, never
conduct the welding current through plain or antifriction bearings,
other moving connecting elements or measuring devices, in order
to prevent damage to these parts.
Always directly connect the welding current return lead to the
part being welded.
Never carry out any electrical or autogenous welding and flame-
cutting work on the grinding table, the grinding surface, the roller
tyres and the tie rods as these points may become starting points
of cracks.
Never connect earthing cables to these components either.

Sequence of assembly
On account of the differing local conditions it is not possible to
establish uniformly applicable instructions for mounting. It
should, however, be possible to observe the most essential
aspects described in the following.

Mounting of the drive unit can only be performed as described in


the following once the separator has been pre-assembled:
 mount the drive bracket (4) on the separator,
 pre-assemble the connecting element (6),
 mount and align the gear unit (3) on the drive bracket in
accordance with the manufacturer’s instructions,
 mount the electric motor (1) in accordance with the
manufacturer’s instructions.

When all the drive elements have been aligned and mounted the
monitoring facilities and protection devices (5) may be installed.
Machine Manual Lubrication
Mechanical drive of the separator SEPOL® for roller mill 1

5 Lubrication

CAUTION
Ensure that the lubricants are stored, used and disposed of in an
environmentally-friendly manner and observe your national
environmental legislation when handling lubricants.

Lubrication chart

Figure 4

Lubrication points

No. Qty. Designation Remark

1 1 Gear unit According to manufacturer’s


instructions
2 1 Electric motor
Lubrication Machine Manual
2 Mechanical drive of the separator SEPOL® for roller mill

3 1 Connecting element (if


required)
Machine Manual Preparation for the test run
Mechanical drive of the separator SEPOL® for roller mill 1

6 Preparation for the test run

NOTE
It is a prerequisite of our warranty that the first test run is
carried out in the presence of and according to the instructions of
specialists from POLYSIUS AG.

6.1 Checks prior to the test run

After completion of the assembly work and prior to the first test
run, check all parts of the plant according to the list below. Take
particular care that all material remnants, tools and assembly
aids are removed.
 Have all the bolts been firmly tightened?
 Has the direction of rotation of the electric motor been
checked?
 Has the coupling (2) been properly mounted?
 Has the connecting element (6) been properly mounted?
 Has the axial parallelity and the axial gap been checked in
accordance with the tolerance data specified by the coupling
manufacturer?
 Has the gear unit (3) been mounted in accordance with the
manufacturer’s instructions?
 Have all lubrication points been filled with lubricant according
to specification?
 Has proper functioning of the interlock system been checked?
 Have all the protection devices been fitted?
Machine Manual Maintenance
Mechanical drive of the separator SEPOL® for roller mill 1

7 Maintenance

7.1 Safety instructions

CAUTION
The noise level In the machine building can exceed 90 dB(A).
Your hearing could be harmed.
Wear hearing protectors.

DANGER
The machine is hot.
You could be seriously injured or killed.
I. Wear the prescribed protective clothing.
II. Wait until the mill has cooled down before starting the
maintenance work.

WARNING
There are rotating components at the machine.
You could suffer severe injuries.
During operation of the machine, do not enter the area cordoned off
with the safety chain.

WARNING
Open doors can move suddenly and without warning.
You might be crushed.
Secure open doors against unintentional closing.

WARNING
Material can fall out.
You could be seriously injured or killed.
Keep adequate distance.

DANGER
The grinding compartment contains hot inert gases.
You could be seriously injured or killed.
I. Make absolutely sure that no hot gas is left in the roller mill and
that further hot gas cannot enter the interior.
II. Wear the prescribed protective clothing.
III. Wait until the mill has cooled down before starting the
maintenance work.
Maintenance Machine Manual
2 Mechanical drive of the separator SEPOL® for roller mill

DANGER
The mill feed material in the mill can fall down or give way.
You could be buried alive or sink into the material.
I. Make absolutely sure that there are no coatings of mill feed
material in the mill and in the inlet.
II. Make absolutely sure that the material has an adequate bearing
capacity or suitably cover the material.

WARNING
Suspended loads
You could be seriously injured or killed.
Never work under a suspended load.

Note
After you have completed the maintenance work, you must check the
machine/plant again in accordance with section Checks prior to the test
run.
Machine Manual Maintenance
Mechanical drive of the separator SEPOL® for roller mill 3

7.2 Inspection

No. Work to be performed Frequency Remarks

1 General visual check for every 4 weeks


 cracks
 leaks
 damage

2 Check for abnormal noises at the daily


 electric motor (1)
 gear unit (3)

3 Check of the temperatures at the daily


 electric motor (1)
 gear unit (3)

4 Inspection work on According to


manufacturer’s
 electric motor (1)
instructions
 gear unit (3)

5 Check of oil level in gear unit (3) every 4 weeks

6 Check of According to
manufacturer’s
 the coupling (2)
instructions
 the connecting element (6)
Maintenance Machine Manual
4 Mechanical drive of the separator SEPOL® for roller mill

7.3 Servicing

No. Work to be performed Frequency Remarks


1 Servicing work on gear unit (3) According to
manufacturer’s
instructions
2 Servicing work on electric motor (1) According to
manufacturer’s
instructions
3 If the torsional clearance at the as required According to
coupling (2) is too large, the coupling manufacturer’s
packs have to be replaced instructions
4 Servicing work on connecting According to
element (6) manufacturer’s
instructions

7.4 Trouble shooting

The drive unit for the SEPOL is interlocked with the roller mill.
The essential functions are monitored during operation. Any
faults occurring in these functions will trigger an alarm and/or
disconnect the drive unit.

Fault Cause Elimination

Gear unit (3) gets too Not enough oil in gear Top up oil or change oil
hot unit

Speed of electric motor Speed control defective Repair speed control in


(1) cannot be adjusted accordance with
manufacturer’s
instructions

Electric motor (1) gets Electric motor See machine manual of


too hot overloaded SEPOL separator

Dust and dirt particles Clean cooling system of


in cooling system electric motor
Machine Manual Maintenance
Mechanical drive of the separator SEPOL® for roller mill 5

If faults occur that are not described above, additional


information regarding cause and elemination of faults can be
found in the subsuppliers’ documentation.

7.5 Repair

Before performing any repair work, switch off the power supply to
all electrical components.
Ensure absolute cleanliness at all times during repair work in
order to prevent dirt from entering the bearings, the drive units or
other sensitive parts of the machine or plant.
Do not remove or open any flaps or protection devices before all
rotating parts have stopped.
If you ascertain any damage during the inspections and
maintenance, repair the damaged parts or replace them with new
ones.

For repair work on


 the gear unit (3)
 the couplings (2)
 the connecting element (6)
 the electric motor (1)
observe the respective instructions in the manufacturers’
documentation.

Note
After you have completed the maintenance work, you must check the
machine/plant again in accordance with section Checks prior to the test
run.

Tools and auxiliary devices


No special tools are required for repair work on the machine.
However, you may need torque wrenches of a bigger size than
normal.
The need for auxiliary equipment, such as scaffolds or hoists
depends on the conditions in your plant.
Machine Manual Spare parts
Mechanical drive of the separator SEPOL® for roller mill 1

8 Spare parts

NOTE
For spare parts for the following component groups please refer
to the manufacturers’ documentation.

 Electric motor (1)


 Coupling (2)
 Gear unit (3)
 Connecting element (6)
Machine Manual Appendix
Mechanical drive of the separator SEPOL® for roller mill 1

9 Appendix

9.1 Technical drawings

Designation Drawing no.

Assembly drawing

9.2 Subsuppliers’ documentation

Gear unit

Coupling