Machine manual

en-22466.001-E

Drive unit of the roller mill QUADROPOL®

Code Word

Order Number

POLYSIUS Order Code (POC)

Machine manual Contents
Drive unit of the roller mill QUADROPOL®

Contents

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

2 Safety...................................................................................................... 2-1
3 Components and mode of functioning.................................................3-1
3.1 Components............................................................................................. 3-2
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
6.2 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.......................................................................................7-5
7.5 Repair....................................................................................................... 7-6
8 Spare parts............................................................................................. 8-1
9 Appendix.................................................................................................9-1
9.1 Technical drawings...................................................................................9-1
9.2 Subsuppliers' documentation...................................................................9-1

en-22466.001-E
Machine manual Technical data
Drive unit of the roller mill QUADROPOL® 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 roller mill QUADROPOL®..................No.

Main drive unit

Year of construction............................................................................
Main gear unit
Type.....................................................................................................
Weight..............................................................................................kg
Continuous power output..............................................................kW
Driving speed...............................................................................min-1
Speed reduction..................................................................................
Water inlet temperature................................................................. °C
Coupling
Type.....................................................................................................
Size......................................................................................................
Main motor
Type.....................................................................................................
Rated capacity...............................................................................kW
Voltage..............................................................................................V
Nominal speed.............................................................................min-1
Overrunning clutch
Type.....................................................................................................
Size......................................................................................................
Actuation.............................................................................................
Vibration monitoring system
Type.....................................VIBROCONTROL 1000 / CV 110 / VS -
Setting value: alarm at.............................2.5 mm/s after 3 seconds
2

Setting value: shutdown at......................3.5 mm/s after 3 seconds

...............or 5 mm/s after the 2nd peak occurring within 5 seconds
Machine manual Technical data
Drive unit of the roller mill QUADROPOL® 3

Auxiliary drive unit

Geared motor
Type.....................................................................................................
Motor rating....................................................................................kW
Voltage..............................................................................................V
Output speed...............................................................................min-1

Auxiliary gear unit

Type.....................................................................................................
Driving power.................................................................................kW
Output speed...............................................................................min-1
Speed reduction..................................................................................

Coupling
Type.....................................................................................................
Size......................................................................................................

Auxiliary motor
Type.....................................................................................................
Rated capacity...............................................................................kW
Voltage..............................................................................................V
Nominal speed.............................................................................min-1
Machine manual Safety
Drive unit of the roller mill QUADROPOL® 1

2 Safety

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

Use
 The drive unit is part of the roller mill QUADROPOL®.
 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 the specified use is
forbidden. POLYSIUS AG is not responsible for any damage
resulting from any other than the specified use of the machine.
All other use is at the operator’s own risk.
 The observance of these and the maintenance instructions is
part of the specified use.

Transport and assembly

 All transport instructions in this manual refer exclusively to the
transport of the machinery in the plant area.
 Use only suitable hoisting and lifting equipment, which is in
serviceable order and has a sufficient load bearing capacity.
 Gearboxes equipped with oil pumps and pipes must be
transported with extra care. Before such gearboxes are
transported, the pipes should be disassembled and all sockets
and openings closed and securely weather-proofed to prevent
the ingress of foreign matter.
 Never work under a suspended load.

Operation
 Any safety checks before or during operation depend on the
relevant national regulations. The operator is responsible for
the performance and recording of such checks.
 If changes in the machine or its operating behaviour relevant to
safety occur, the machine must be immediately stopped.
 In the mill building of the roller mill hearing protectors have to
be worn.
Safety Machine manual
2 Drive unit of the roller mill QUADROPOL®

Maintenance

 Be sure to also comply with the safety instructions in the

operating manual and 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.
 You have to obtain the written permission of the plant manager
before you start with work inside the machine, 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.
 Make absolutely sure 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 absolutely
sure that there is no danger of suffering burns when touching
the machine, and before opening any inspection and service
covers, make absolutely sure that there is no longer any hot
material inside the machines.
 Make absolutely sure that all piping is depressurised.
 Make absolutely sure that no hot gas can enter the interior.
 Remove all incrustations, 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.
 Directly after the machine has been shut down, you are only
allowed to enter the interior wearing a breathing apparatus
with independent ventilation.
Machine manual Safety
Drive unit of the roller mill QUADROPOL® 3

 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 absolutely 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 of
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 work to be carried out inside the plant sections 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.
 Make absolutely sure that the hydraulic piping is depressurised
before disconnecting it.
 Never use the pumps of the hydraulic system to empty or fill
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.
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.
Safety Machine manual
4 Drive unit of the roller mill QUADROPOL®

● In particular, never carry out any electrical or autogenous welding and flame-
cutting work on the grinding table, the grinding track and the roller tyres, as
these points may become starting points of cracks. Never connect earthing
cables to these components either.
Machine manual Safety
Drive unit of the roller mill QUADROPOL® 5

Conclusion of maintenance work

● After having finished all maintenance work, check all joints and connections
for leaks.
● Remount all protection devices when 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
Drive unit of the roller mill QUADROPOL® 1

3 Components and mode of functioning

The drive unit for the QUADROPOL® roller mill is of different

designs depending upon the mill size, gear unit manufacturer and
space available at the installation location.
A bevel planetary gear unit is used as the main gear unit in order
to reduce the speed. The grinding table is mounted directly on
the horizontal driving flange of the main gear unit.
The auxiliary drive unit is installed with an overrunning clutch to
enable slow rotation of the grinding table for maintenance work.
In the case of smaller roller mills, the overrunning clutch is
manually meshed before starting the auxiliary drive unit. For
larger roller mills, the overrunning clutch is pneumatically
connected.
In the case of roller mills from the size 20/10, the auxiliary drive
unit is also used to start the roller mill. The auxiliary drive unit is
first started, the main motor is then switched on after
approximately 2 to 4 minutes.
A vibration monitor is installed on the casing of the main gear
unit to check the running behaviour of the roller mill. If the
vibration frequency on the drive unit is exceeded then an alarm is
triggered and the main motor is switched off.

NOTE
If the roller mill is shut down for longer periods of time, the main
gear unit should be rotated once a week for a short time in order
to prevent damage to the gear unit.
Please observe the corresponding notes in the manufacturer’s
documentation.
Components and mode of functioning Machine manual
2 Drive unit of the roller mill QUADROPOL®

3.1 Components

NOTE
Some details of the drawings in this manual may not be identical
with the drawings supplied under the contract.

Item nos relating to the drive unit

1.0 Main gear unit

2.0 Coupling
3.0 Main motor
4.0 Overrunning clutch
5.0 Auxiliary gear unit
6.0 Auxiliary motor
7.0 Safeguard
8.0 Oil supply system
9.0 Vibration monitor
10.0 Gear unit bed plate
11.0 Base frame for the main motor
Machine manual Components and mode of functioning
Drive unit of the roller mill QUADROPOL® 3

Figure 1
Machine manual Transport and assembly
Drive unit of the roller mill QUADROPOL® 1

4 Transport and assembly

4.1 Transport and storage requirements

The drive unit is transported in single parts or in subassemblies.
It must be ensured 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. The parts must not 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.
Special care is required for the transport of gear units already
equipped with oil pumps and pipes. Prior to any transport, the
pipes should be disassembled and all sockets and openings
should be closed and weather-proofed to protect the gear unit
against the ingress of foreign matter. Ensure that all protective
covers can be easily removed when necessary.

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.

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 the used tools and appliances and the
personnel is important for the correct execution of the assembly
work.
Transport and assembly Machine manual
2 Drive unit of the roller mill QUADROPOL®

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 track and the
roller tyres, as these points may become starting points of
cracks.
Never connect earthing cables to these components either..

Mounting sequence

 Check the mill foundation for dimensional accuracy according

to the layout drawing and the construction drawing,
respectively.
 Mark the longitudinal and transverse axes on the mill
foundations and the steel structure of the building.
 Align the gear unit bed plate (10.0) and the base frame (11.0) to
the main motor.
 The gear unit bedplate must be aligned with the help of the
setscrews and a precision spirit level or a levelling instrument
and secured against displacement. (Maximum difference in
height: 0.1 mm per meter bedplate).
 The measurements must be recorded in a dimensional protocol!
 Grout the gear unit bedplate.
 Position the main gear unit (1.0). Check for proper contact
(arrow) on the gear unit bed plate (10.0) by means of a
thickness gauge. If a gap exceeding 0.05 mm is found, consult
POLYSIUS AG.
Machine manual Transport and assembly
Drive unit of the roller mill QUADROPOL® 3

Figure 2

 Bolt together the main gear unit and the gear unit bed plate.
 Tightening torques as per drawing in section Technical
Drawings
 Drill and ream the fitting holes between the gear unit and the
gear unit bed plate and fit the bolts.
 Mount the remaining components of the drive unit of the roller
mill including all accessories.
 Set up the oil supply system (8.0) and lay the oil pipework.
 Absolute cleanliness must be ensured when laying the
pipework between the oil supply system and the main gear unit.
 (Also refer to the manufacturer’s instructions)
Machine manual Lubrication
Drive unit of the roller mill QUADROPOL® 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

Lubrication points

Designation Remark

Main gear unit/oil supply system

Auxiliary gear unit

see manufacturer’s instructions
Main motor

Auxiliary motor
Machine manual Preparation for the test run
Drive unit of the roller mill QUADROPOL® 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 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 the foundation bolts been tightened?
 Have the transport safety devices been removed?
 Have the screwed connections of the gear unit bedplate (10.0)
with the foot of the main gear unit (1.0) been tightened with the
specified tightenting torque?
 Have the couplings been mounted and checked in accordance
with the manufacturer’s instructions?
 Has the main motor been mounted and checked in accordance
with the manufacturer’s instructions?
 Has the main motor been correctly mounted and aligned (has
the sense of rotation been checked)?
 Have the main gear unit and the auxiliary drive been mounted
and checked in accordance with the manufacturer’s
instructions?
 Has the oil supply system been been properly connected and is
it ready for operation? (see also manufacturer’s
documentation)
 Have the oil pipes been checked for leaks?
 Has the monitoring equipment been properly installed and set?
 Have all protective devices and warning signs been properly
fitted?
Preparation for the test run Machine manual
2 Drive unit of the roller mill QUADROPOL®

6.2 Test run

Only when perfect functioning of the machinery interlocks has
been verified may the roller mill be operated in no-load operation;
no-load operation of the roller mill is to be understood as the
mere rotation of the grinding table by the auxiliary drive.
It is advisable to subject the drive unit to a test run. While doing
so, check the machinery interlocks, observing the special
instructions issued by the suppliers.
Machine manual Maintenance
Drive unit of the roller mill QUADROPOL® 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.
Do not enter the areas cordoned off during operation of the
machine.

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.
Stay at an adequate distance.

DANGER
There are hot inert gases in the grinding compartment.
You could be seriously injured or killed.
I. Make absolutely sure that there are no remaining hot gases in
the roller mill and that any hot gases can 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 Drive unit of the roller mill QUADROPOL®

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 having completed the maintenance work, you must check the
machine/plant again in accordance with the section Checks prior to the
test run.
Machine manual Maintenance
Drive unit of the roller mill QUADROPOL® 3

7.2 Inspection

No. Work to be performed Frequency Remarks

1 Make general visual inspection for daily

 Leaks
 Damage
2 Check for abnormal noises from daily
 Main motor (3.0)
 Main gear unit (1.0)
3 Check the temperatures of daily
 Main gear unit (1.0)
 Main motor (3.0)
4 Inspection work
 on main gear unit
 on main motor acc. to
manufacturer’s
 on overrunning clutch (4.0)
instructions
 on oil cooler
 on auxiliary drive and check for function
5 Check oil filter of gear oil supply acc. to
system manufacturer’s
instructions
6 Take oil sample from the oil supply every 6  Check the oil for
system months lubrication
properties and
soiling
 If there is foam in
the oil then the oil
must be replaced
Maintenance Machine manual
4 Drive unit of the roller mill QUADROPOL®

7.3 Servicing

CAUTION
When the mill has been stopped and there is danger of frost, the
water must be drained from the oil cooler.

No. Work to be performed Frequency Remarks

1 Clean main motor (3.0) every 4 weeks

2 Maintenance work acc. to
manufacturer’s
 on main gear unit
instructions
 on main motor
 on overrunning clutch (4.0)
 on oil supply system (8.0)
 on oil cooler
 on auxiliary drive unit
3 Cleaning of the breathing filter on as required
the main gear unit (1.0)

4 Cleaning or replacement of the oil as required

filter in the oil supply system (8.0)
Machine manual Maintenance
Drive unit of the roller mill QUADROPOL® 5

7.4 Trouble shooting

The most important functions of the roller mill will be monitored
during operation. Any trouble occurring in these functions will
trigger an alarm and/or stop the roller mill.

Fault Cause Elimination

Temperature on the Dust and dirt deposits in Clean cooling system of
main motor (3.0) too the cooling system the cooling system
high
the main motor is see machine manual
overloaded roller mill QUADROPOL®
Main motor (3.0) cannot Oil pressure for the gear  Check oil supply
be started unit  for leaks
 Check pressure switch
is too low; p < pmin
Gear unit oil too little oil in main gear Top up oil
temperature unit (1.0)
too high Oil cooler defective Check and repair the oil
cooler
Oil pump defective Repair oil pump
Oil filter contaminated Replace filter cartridge
Temperature switch Replace temperature
defective switch
Oil supply to main gear Failure of the heating Check and repair the
unit (1.0) system in the oil supply heating system
system
Display Oil cooling is either Check and repair the oil
insufficient or has failed cooling system
Alarm devices of the
main gear unit activated Oil filter contaminated Clean or replace oil filter
Piping to the main gear Clean the pipes on the
unit is clogged inside. Check the
measuring devices
Considerable vibrations Fault in the roller mill Check the control
control system system
Display
Power consumption of see machine manual
Vibration monitor
main motor (3.0) too roller mill QUADROPOL®
high
Maintenance Machine manual
6 Drive unit of the roller mill QUADROPOL®

If faults occur that are not described above, additional

information regarding cause and elimination of faults can be
found in the sub-suppliers’ documentation.
Machine manual Maintenance
Drive unit of the roller mill QUADROPOL® 7

7.5 Repair

Before performing any repair work, make sure all electrical

components are disconnected.
Ensure the utmost cleanliness at all times during the repair work
in order to guarantee that the bearings, the drive system, the
hydraulic system or other sensitive parts of the machine are kept
free of contamination.
Do not remove or open any flaps or protective equipment before
all rotating parts have stopped.

For repair work on the

 main gear unit (1.0)
 coupling (2.0)
 main motor (3.0)
 overrunning clutch (4.0)
 auxiliary gear unit (5.0)
 auxiliary motor (6.0)
 oil supply system (8.0)
 Vibration monitor (9.0)
always observe the machine manuals and operating instructions
of the manufacturers!

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

Tools and auxiliary equipment

No special tools are required for repair work on the machine.
However, torque wrenches of a bigger size than normal may be
necessary.
To facilitate the removal of the antifriction bearings, a high-
pressure oil pump is needed.
Whether you will need auxiliary equipment, such as scaffolding or
hoists, depends on the situation at your plant.
Machine manual Spare parts
Drive unit of the roller mill QUADROPOL® 1

8 Spare parts

Suggestions for enquiries and orders of spare parts

Dear Customer,
POLYSIUS AG want to make spare part enquiries and spare part
order placement as easy and efficient as possible. For this
purpose we have prepared a table containing all data required by
our spare parts department to ensure optimum processing in the
most speedy and trouble-free manner.
Please copy the title page and the page with the table. Fill in the
columns Quantity and Unit. Please mark those parts which you
require with a cross in the column Order or Enquiry. Send the title
page together with the table to the Spare Parts Department of
POLYSIUS AG.
If the table relates to more than one machine, please also inform
us of the POLYSIUS Order Code (POC) of the machine for which
you require the spare parts.
Spare parts Machine manual
2 Drive unit of the roller mill QUADROPOL®

Figure 3
Machine manual Spare parts
Drive unit of the roller mill QUADROPOL® 3

Code word: Order no.: POC:

Item Designation Qty. Unit Order Enquiry

1.0 Main gear unit 1 piece

2.0 Coupling 1 piece

3.0 Main motor 1 piece

4.0 Overrunning clutch 1 piece

5.0 Auxiliary gear unit 1 piece

6.0 Auxiliary motor 1 piece

8.0 Oil supply system 1 piece

9.0 Vibration monitor 1 piece

NOTE
You will find detailed spare parts lists in the subsupplier’s
documentation
Machine manual Appendix
Drive unit of the roller mill QUADROPOL® 1

9 Appendix

9.1 Technical drawings

NOTE
For drawing numbers, please refer to the table of contents of this
folder.

Designation Drawing no.

Assembly

9.2 Subsuppliers' documentation

Main gear unit

Coupling

Main motor

Overrunning clutch

Auxiliary gear unit

Auxiliary motor

Oil supply system

Vibration monitor