FP SPOMAX S.A.

Kaliska 61/63, 63-400 Ostrów Wielkopolski, POLAND

tel.+48 625921717, fax +48 627361136
www.spomax.pl ; e-mail: info@spomax.pl

ROLLER MILL

Type FMO7A

OPERATING INSTRUCTIONS
Serial No. 162

Year of manufacture: 2019

Release 2

1 Operating Instructions – Roller mill FMO7A

 Prior to acceptance, installation and start-up, all employees and engineering supervision
performing service work on the device, as well as transportation and warehouse
personnel should be thoroughly familiarized with the contents of these Operating
Instructions. Observing the guidelines included in these Instructions will allow
uninterrupted and trouble-free operation of the device.
These Operating Instructions should be available to service personnel at all times.
When contacting the manufacturer regarding the device, please refer to information on
the data plate located on the device.
All comments, remarks and suggestions regarding the device should be directed at
manufacturer’s address:

FP SPOMAX S.A.
Kaliska 61/63, 63-400 Ostrów Wielkopolski, POLAND
tel.+48 625921717, fax +48 627361136
www.spomax.pl ; e-mail: info@spomax.pl

2 Operating Instructions – Roller Mill FMO7A

 Table of Contents
Page:
1. Health and safety principles .................................................................................... 4
1.1 General .......................................................................................................................................................... 4
1.2 Detailed health and safety principles regarding the use of roller mills ......................................................... 4
2. Intended use ........................................................................................................... 5
3. Technical characteristics ......................................................................................... 6
4. Structure ................................................................................................................. 8
5. Operation .............................................................................................................. 11
6. Transporting, packaging, storing ........................................................................... 11
7. Acceptance ........................................................................................................... 12
8. Installation ............................................................................................................. 12
8.1. Setting .............................................................................................................................................................. 12
8.2. Product feeding and conducting ....................................................................................................................... 12
8.3. Roller mil drive ................................................................................................................................................ 13
8.4. Roller mill aspiration........................................................................................................................................ 13
8.5. Pneumatic system ............................................................................................................................................. 15
8.6. Electrical system .............................................................................................................................................. 17
9. Preparing to operation ........................................................................................... 18
10. Start-up ................................................................................................................. 19
11. Control .................................................................................................................. 19
12. Daily operation and regulation............................................................................... 19
12.1 Daily operation ............................................................................................................................................ 19
12.2 Lubrication .................................................................................................................................................. 20
12.3 Belt tension regulation ................................................................................................................................ 21
12.4 Insert regulation .......................................................................................................................................... 22
12.5 Supply slot regulation ................................................................................................................................. 23
12.6 Milling slot regulation ................................................................................................................................. 23
12.7 Batch basket cleaning .................................................................................................................................. 24
13. Technical operation, part regeneration and replacement ...................................... 26
13.1 Brush replacement ....................................................................................................................................... 26
13.2 Dismounting pulleys ................................................................................................................................... 27
13.3 Dismounting the belt gear ........................................................................................................................... 28
13.4 Replacing milling rolls ................................................................................................................................ 29
14. Defects and troubleshooting.................................................................................. 33
15. Reliability ............................................................................................................... 35
15.1 Operational readiness .................................................................................................................................. 35
15.2 Durability periods........................................................................................................................................ 35
16. Equipment ............................................................................................................. 36
16.1 Standard equipment ..................................................................................................................................... 36
16.2 Special equipment ....................................................................................................................................... 36
17. Spare parts............................................................................................................ 36
18. Shipping list ........................................................................................................... 38
19. Warranty ............................................................................................................... 38
Appendix:
1. Control system operating instruction
2. Communication with superior system
3. Declaration of Conformity

Operating Instructions – Roller Mill FMO7A 3

1. Health and safety principles

1.1 General

Roller mill is a self-contained device safe both mechanically and electrically that meets the
requirements of EC Machine Directive. Doors, windows and guards are equipped with locks.
Regulatory elements are led outside and rotating parts have been shielded.
Electric motors and other elements of the electrical system comply with IP54 protection standard.
All works like: positioning, operation, maintenance, troubleshooting and lubrication can be
performed only by personnel thoroughly familiarized with these Operating Instructions and
trained in this respect.

1.2 Detailed health and safety principles regarding the use of roller mills

To ensure safe operation, the user of the roller mill should observe the following
recommendations:
 Works is only allowed if the machine is fully operational and all the guards are on place,
 During operation, the window should be lowered, doors and guards closed,
 Manipulating inside the roller mill during device operation is forbidden;
 Worn out brushes should be replaced in advance, in order not to allow rubbing brush
housings and rollers,
 Milling roll driving motors can only be stopped when corn flow is completely cut off
and all residues are crumbled,
 Corn can be supplied when the milling rollers achieve their nominal revolutions,
 Roller mill should be connected to the ground network to lead away electrostatic
charges,
 Electrical system should be protected from electric shock (continuity of the protective
wire should be strictly maintained),
 Electrical power system should protect the device in case of short-circuits or overloads,
 All repair works on electrical system can be performed by a qualified electrician only,
 Activities related to inspections, technical operation and repairs can be performed with
power supply cut off,
 Driving belts should be properly tensed, which prevents slipping and dangerous
temperature increase which may result in ignition,

Observe general health and safety as well as fire prevention regulations when operating the
device.

4 Operating Instructions – Roller Mill FMO7A

2. Intended use

Roller mills are intended for milling of wheat, rye and corn in order to produce flour.
They can also be used to crush the cleansed corn in rye milling lines and crushing into
ground grain of the cleansed corn of wheat, rye, soya-bean, etc. with humidity up to 18%.
Using roller mills to crush other products requires special provisions.

Fig. 1

Operating Instructions – Roller Mill FMO7A 5

3. Technical characteristics
Table 1
Roller length
No. Parameters
800 1000 1250 800 1000 1250
1. Roller diameter [mm] 250 300
2. Ambient temperature [K] 263-323 ( -10 + 50 °C )
3. Air relative humidity [%] max 95
4. Relative humidity of the crumbled raw
max 18
materials [%]
5. High-speed (fixed) roller revolutions
[rpm] 320-820
6. Milling slot load [kg/m/24h] max 10000-15000
7. Installed power (for one section) [kW] max 45
8. 1:1,25; 1:1,5; 1:1,8;
Inter-roll gear ratio
1:1,2; 1:2,5;
Vibration amplitude carried on the 300 Hz 5
9.
floor and the building for dominant 50 Hz 11
frequencies [mm] 10 Hz 5,5
10. Noise intensity dB ( A) max 85
Aspiration 0,16÷ 0,20÷ 0,25÷ 0,16÷ 0,20÷ 0,25÷
Air flow volume [m3/s] 0,175 0,23 0,30 0,175 0,23 0,30
11. (for one
section)
Flow resistance [Pa] max 200
Roller mill Air flow volume [m3/h] 1
12. pneumatic
Air pressure [MPa] 0,6 (6 atm)
power supply
13. Overall dimensions [mm] According to Fig. 2
14. Weight [kg] 3040 3280 3630 3430 3730 4150
15. Weight with package [kg] 3380 3660 4050 3770 4100 4580
16. Capacity with package [m3] 7,2 8,3 9,3 7,2 8,3 9,3
17. Area occupied by package [m2] 3,4 3,8 4,2 3,4 3,8 4,2

6 Operating Instructions – Roller Mill FMO7A

 Fig. 2

Table 2
Dimension L L1 L2 L3 L4 L5 n1 n2
Roller length [mm] [piece]

800 1645 805 762 185 740 756 4 12

1000 1845 1005 862 188 940 956 5 14

1250 2095 1255 987 170 1190 1206 7 18

Operating Instructions – Roller Mill FMO7A 7

4. Structure
Roller mill basic assemblies include:
 Steel housing (1) Fig. 4), welded, enclosed as double-block with massive lower part being a
base on which milling rolls assemblies are placed, and lighter upper part including systems
that do not transfer loads, connected mainly to batch-dosing system and its control; in the
housing there is a system created with channels and guards that forces specific air and
material flow to the milling zone, that additionally causes the following:
- sucking of air and dusts from the batch basket that facilitates material flow,
- sucking of air and dusts from the milling zone that allows efficiency increase
- cooling of rolls by flowing air,
 Supply rolls assembly (2) (Fig.4) with lower roll drive due to inverter & gear-motor
assembly (3) (Fig.4). Upper roll is driven from the lower roll through belt gear with one-
side toothed belt. Supply roll speed varies automatically depending on the product level in
the inlet drum (4) (Fig.4). This causes the change of quantity of the supplied product to the
milling slot. The quantity of the supplied product can also be set by changing the supply slot
size through the arch segment (5) (Fig.4).
 Milling rolls assemblies (6) (Fig.4) with precise regulation of the milling slot performed
through watch knobs (7) (Fig.4) and (2) (Fig.3). Horizontal roll position allows optimum
supply of the material to the milling slot. The rolls have roller-bearings placed in
housings, embedded directly on conical plugs. Mobile and fixed housings are mounted to
the common bar, clutched together in the upper part. In connection with rolls they form an
assembly with closed force system, which with simultaneous isolation from the body
prevents vibration transmission and allows maintaining precise and stable milling slot.
Pressing and protection in case of overload is realized through disk spring assembly.
 Inter-roll belt gears (8) (Fig.4) with double-side multi-groove belt; drive wheels are
installed on expansion sleeves that facilitate mounting and dismounting.
 Door (9) (Fig. 4) and (3) (Fig.3).
 Window (10) (Fig. 3) and (4) Fig. ).
 Side guards (5) Fig. 3).
 Roll cleaning elements (11) (Fig. 4). Cleaning elements include:
- scrapers for self-rasping rolls,
- brushes for grooved rolls.
Cleaning elements are automatically moved away in the moment of roll pulling due to
using pneumatic actuators (15) (Fig.4)
 Control assembly. Capacitive probe was used in the control system (3) (Fig.4) and PLC
(14) (Fig.4) which controls all roller mill functions. It allows remote control of the roller
mill and is adapted to connect superior computer to control mill operation. It also allows
the start of milling rolls and their pushing or pulling due to pneumatic actuators (12)
(Fig.4). If necessary, it is possible to quickly disengage the roller mill using STOP button
located under operator panel (6) (Fig.3). Operator panel allows reading of the current
motor load and lower supply roll revolutions. Automatic switching of the roller mill
(pushing of the rotating rolls) is done in the moment of exceeding the threshold of filling
the drum with material. The level is recognized by the probe which transmits this
information, through controller and inverter to the gear motor that drives the supply rolls.
In case of lowering the material level in the drum below the lower threshold, the roller
mill is automatically switched off (rollers pulled). Changes of material level in the drum
cause continuous automatic change of supply rolls rotary speed which stabilizes the

8 Operating Instructions – Roller Mill FMO7A

milling process in the mill. To protect the personnel, doors, windows and guards are
equipped with locks.

Fig. 3

Operating Instructions – Roller Mill FMO7A 9

 Fig. 4

10 Operating Instructions – Roller Mill FMO7A

5. Operation

The crumbled material, falling into the batch drum is spread on the whole width of the supply
slot. Supply rolls select the material and supply it to the milling slot. The quantity of the
supplied material depends on supply roll speed and supply slot size. Crumbling depends on
the pre-set milling slot size, depending on the specific material needs. After crumbling the
material falls down gravitationally to the batch basket.

6. Transporting, packaging, storing

Roller mill can be transported with any means of transport with observance of general
transportation and work health & safety requirements. During transport, the roller mill should
be packed in the chest or placed on the wooden platform and covered with foil. Packing and
transporting method depends on agreements with the consignee.
During loading and unloading, the roller mill should be held by suspension elements (1)
(Fig.5) included in standard equipment. For this purpose:
 Install special rods driving them through the holes in the upper part of the roller mill
and screwing in suitable holes in the base.
 Install the element with screwed eye-bolt on protruded rod ends.
Roller mill can be lifted only by rigid crane device.
It is also permitted to horizontally move the roller mill placed on the rolls.

Fig. 5

Operating Instructions – Roller Mill FMO7A 11

Attention: During transportation, use only specified suspension points.
Do not enter under the lifted weight.
During storage, the roller mill should be placed in a dry room under roof, protected against
damages and maintained.

7. Acceptance

Check completion and compatibility with shipping list immediately upon receiving the
package as well as any mechanical damages, if any. In case of damages or missing parts,
inform the carrier and supplier immediately

8. Installation

8.1. Setting

Roller mill should be set on suitably durable ground. In order to decrease the impact of
vibrations and noise it is recommended to locate the roller mill on anti vibration frame, e.g. ca.
75mm thick and 150mm wide wooden frame. Frame corners should be cut on the depth about
15mm by deepening 4 rubber washers in them (it is recommended to use ca. 55º hardness
rubber (according to Shore) or from ca. 20mm thick cork. Roller mill should lay on slightly
protruded washers.
Roller mill body does not require to be screwed to the floor.

Attention: Roller mill should be connected to the grounding line in order to lead away
electrostatic charges that accumulate during operation.

8.2. Product feeding and conducting

Product feeding is performed through the batch drum (1) (Fig.6). Drum installation should be
performed in the following way:

 Insert drum on the roller mill body in such a way that the pegs (2) located in drum base
(diagonally) match the holes prepared in roller mill body.

 Screw drum to the roller mill body from below using screws (3) (drum diagonal)

 Make connection (4) (probe – controller), by putting plug into socket.

Product conducting may be performed using pneumatic or mechanical conveyance. Remember

that the fall pipe should not deviate from perpendicular more than 45º.

12 Operating Instructions – Roller Mill FMO7A

 Fig. 6

8.3. Roller mil drive

Check that drive wheels are in one surface with drive wheels of the roller mills and that driving belts
are properly tensed (see section 12.3). Belt tension should be checked periodically. First tensioning
should be performed after several operating hours.

8.4. Roller mill aspiration

Roller mills should be strictly aspirated with fresh air in quantity according to table 1. Air flows
in through the slot under the window. For pneumatic conveyance, a separate aspiration network is
not necessary, because air used for conveyance also serves as aspiration.
When using mechanical conveyance, roller aspiration system must be installed. If the fall is
sufficient, suction connection should be performed according to Fig.7, but if the fall angle from
the bucket conveyor is too small and auger needs to be built-in, in such case suction connection
should be performed according to Fig.8, minding to raise the auger channel about 150mm in
order to allow unobstructed air flow.

Operating Instructions – Roller Mill FMO7A 13

 `

Fig. 7

Fig. 8

14 Operating Instructions – Roller Mill FMO7A

8.5. Pneumatic system

Compressed air system is intended for supplying the roller mill pneumatic system. Installation
should be performed according to comments below and suitable diagrams presented on Fig. 9, 10a
and 10b.

Air requirement is calculated taking ca. 1 m3/h on one roller mill. For correct operation of the
system, compressor should be selected in such a way that its efficiency was at least 3 times greater
than total air requirement for a specific number of roller mills. Air compression in the network
required for roller mill correct operation equals 0,6 MPa. In pneumatic system it is recommended to
use fitting set according to the drawing below. Air filter should have filtering insert that ensures
compressed air cleaning (related to solid particles) to the size of 40 µm.

Fittings set

Grease gun

Reduction valve

Filter with
dehydrator

Supply source
Supply block Plastic hose Øz8/ Øw6
-pipe ½” for up to 12
Dehydrator roller mills
Inclination 1% -pipe ¾” for up to 13
roller mills

Fig. 9
Example of connecting compressors for a site up to 12 roller mills is presented on Fig. 10a. Roller
mill manufacturer, based on separate order delivers two compressor units, compressed air tank and
five cut-off valves. Pressure regulator located on the compressor unit should be connected to motor
start contactor coil. With such connection, the regulator causes switching compressor motor on or

Operating Instructions – Roller Mill FMO7A 15

 off maintaining the required pressure. Compressor connection example diagram for a site with more
than 12 roller mills is presented on Fig. 10b.
In both connection systems, compressors are selected in such a way that only one compressor is
sufficient for standard operation. The second one is auxiliary and is switched on only for the period
of inspections and repairs of the operating compressor.

Pipe G1/2 to fitting

set filter
Compressed
air tank of Ball valve G1/2
Angular sleeve cut-
capacity 2,5m3 off valve Dn65

Pipe G3/4

Ball valve G3/4

Compressor unit

Fig. 10a

Pipe G3/4 to fitting

set filter

Compressed
air tank of Angular sleeve cut-off Threaded ball
capacity 4m3 valve Dn100 valve G3/4

Pipe G11/4

Ball valve G11/4

Compressor unit

Fig. 10b

Steel pipes leading to the fitting set should be placed under the rows of roller mills with 1% fall
towards dehydrator. Air supply from steel pipes to roller mills should be performed using plastic
hose with diameters z8/w6 supplied by the roller mill manufacturer. For that purpose, before
connecting to roller mills, in the steel pipe perform holes 7,5÷ 8 mm and weld in special flanges
(supplied). Then, on the ends of properly cut hose, put special nuts (supplied), put the hose on

16 Operating Instructions – Roller Mill FMO7A

special flange end and on power supply block flange end and tighten with nuts. Connection method
is presented on Fig.9.

When performing pneumatic system, consider the following guidelines:

 Install compressors in dry and dust-free room, equipped with devices generating natural
air moves;
 Compressed air tank should be installed in the open space;
 Compressed air tank and compressors with tanks should be installed in places not exposed
to raised temperature, the most suitable boundary temperature is 288÷293 K (15°÷20°C).
 When installing compressor and tanks observe requirements listed in engineering
specification;
 Fitting set including the filter, reduction valve and grease-gun should be installed in the
place with easy access for observation and regulation by the personnel.
 For installation use only steel pipes with clean interior

8.6. Electrical system

When installing the roller mill, pay attention to proper connection of driving motors that
allows correct operation of the installed device. Overload and shock protection as well as
other protections should be selected by the user and be compliant with currently biding
standard. Protective cable continuity should be strictly maintained and care taken that the
cable does not contact sharp edges. Installation and service of electric system should be
performed by qualified electrician. In addition, recommendations for motor operation included
in motor manufacturer operating instructions should be observed.
Electrical connection diagrams – see Enclosure 1 “Control system operating instructions”.

Operating Instructions – Roller Mill FMO7A 17

9. Preparing to operation
Roller mill is delivered in maintained condition, unless agreed otherwise with the consignee.
Directly before start-up, remove the protective film from the milling rollers. All roller and self-
lubricating bearings have red-painted grease-guns intended for bearing lubrication. Bearings are
filled with solid grease by the manufacturer – according to section 12.2.

Before first start-up, after longer standstill or repair, check technical condition by the following
activities:

 Check if all screws and nuts have been properly fixed,

 Check if rotating elements are properly guarded, and that they do not rub fixed
elements, like baffles, body, guards, inserts, etc.,
 Check that there are no foreign objects over the supply rolls,
 Check position of the plastic inserts located directly over the rolls – according to
section 12.4,
 Regulate the pressure of brushes or scrapers (if installed) – according to section 13.1,
 Check lubrication correctness – according to section 12.1,

Fig. 11

18 Operating Instructions – Roller Mill FMO7A

  Rotate the rolls by pulling the drive wheels in direction of operation in order to check if
there are no foreign objects between rolls,
 Check if the arch segment (1) (Fig.11) is parallel to the supply roll – loosen the grip if
necessary (2) (Fig.11) and perform regulation by rotating the eccentric pin (3) (Fig.11)
 Close the window, door and close the side guards.

10. Start-up
Roller mill prepared to operation should be started-up without corn supply. Check correct
operation on idle run. The roller mill should run evenly, without vibrations and shocks.
If roller mill operation is without objections, corn intended for crushing can be supplied.
In that case, the following adjustments should be performed:
 supply slot size – according to section 12.5
 milling slot size - according to section 12.6.
Adjustment depends on the kind of the supplied corn and expected milling effects and the
required efficiency.

There may be the need for calibration (sensitivity setting) of capacitive probes regarding variable
relative permittivity (dielectric constant) of the crumbled products and due to their humidity.
Perform calibration according to appendix 1 - “Control system operating instructions”.

In normal operation and for short breaks - roller mill should not be disconnected.
During mill operation breaks, switching off the roller mill should be performed in reverse
order than for switching on. Prior to that, cut off corn supply to the roller mill.

Attention: Electric control system should provide immediate disconnection on emergency.

11. Control
Controller input and output description and control panel operation - see appendix 1
“Control system operating instructions”.
“Communication with superior system” - see appendix 2.

12. Daily operation and regulation

12.1 Daily operation

Activities related to roller mill operation are limited to the checking of:
-correct operation of supply system,
-quality of the product after crumbling and correcting crumbling slot, if necessary,
-operation of milling roll bearings – excessive noise, heating or play indicate damage or
bad lubrication,
-pulley gear operation - audibly.
Additionally, the window should be cleaned daily.

Operating Instructions – Roller Mill FMO7A 19

12.2 Lubrication

In the roller mill, all heavily loaded elements that swing or rotate are lubricated with solid
grease. Lubrication is performed through grease guns painted red. In such places, lubrication
should be periodically performed every 500 hours, not less frequently however than every 3
months.

Fig. 12

Supply roll roller bearings are enclosed bearings and are lubricated by the manufacturer,
which lasts for the whole period of their life
Milling roll roller bearings should be fully filled with grease , and spaces around them, from
about half the volume.
Every 3 months the bearings should be lubricated by forcing into each of them about 50 grams
of grease. Replace the worn grease during every roll dismounting.
Recommended greases are listed in the table below.

20 Operating Instructions – Roller Mill FMO7A

 Table 5
Roller bearings and other points
Supplier lubricated with solid grease

Brand

CPN ŁT-4S2
Retinax A
Shell
Alvania R3
Mobil Mobilux 2 or Mobilux EP2
BEACON EP3
ESSO
UNIPEX N3
BP BP ENERGREASE LS3
TEXACO MULTIFAK EP2
GRMU EP2
Agip
GRLP 2
Duralith
Chevron
Grease EP2
Fina Marson EPL2
Total Multis EP2

Attention: It is a principle to not mix different brands of greases. Roller mills have only these
lubrication points filled by the manufacturer, which are lubricated with ŁT-4S2
grease.

12.3 Belt tension regulation

Belts should be tensed before start-up. Belt tension correctness are measured by belt
deflection between the wheels by charging the belt with force depending on belt type
(according to Fig.13).
Table 6
Trial load Smaller gear wheel Deflection depth per 100
Belt profile f (kg) diameter mm axis spacing – E’
dk (mm) (mm)
≥112÷160 3,00
>160÷224 2,55
SPB 7,5
>224÷355 2,22
>355 2,10

Operating Instructions – Roller Mill FMO7A 21

 e – axis spacing (mm)
dk – small wheel diameter (mm)
E – deflection depth (mm)
E’ – deflection depth per 100 mm
axis spacing (table above)
f – trial load (weight in kg –
table above)

Fig. 13
Example: Belt type SPB;
Axis spacing e = 800 mm;
Trial load f = 7,5 kg;
Small wheel diameter dk = 160 mm;
From the table E’ = 3,00 mm;

– deflection depth should equal to: E = e

100
x E’ = 800
100
x 3,00 = 24,0 mm

First tension correction should be performed after several hours of operation, next ones as
necessary.
Ensure that pulleys are on one surface.

12.4 Insert regulation

Plastic insert regulation located directly over upper rolls (1) (Fig. 14), is performed with each
roll replacement or regeneration. These elements are installed on “bean” shaped holes that
allow their moving and positioning.

Fig. 14

22 Operating Instructions – Roller Mill FMO7A

12.5 Supply slot regulation
Supply slot is set by screwing the bolt (1) (Fig.15) in or out after loosening the counter-nut (2)
(Fig.15). Screwing the bolt in increases the slot, screwing the bolt out decreases it.

Fig. 15

12.6 Milling slot regulation

Milling slot regulation is performed by turning the knob (1) (Fig.16) after releasing the lock
(3) (Fig.16) (releasing the lock is done on control panel – see Control panel operating
instructions). Decreasing the slot is done by turning the knob clockwise, increasing the slot is
done by turning the knob counter clockwise. The slot is regulated until demanded milling
efficiency is obtained.
With first setting, after the mill has been regulated, unlock the clock indicator by loosening
the knob (2) and with housing fixed set to any position, easy to remember, e.g. to 12:00, at
both sides of the roller mill (left and right). Then lock with the bolt (2).

Fig. 16

Operating Instructions – Roller Mill FMO7A 23

12.7 Batch basket cleaning

Sequence of activities:
 Open the door (1) Fig.17,
 Release the clasp (2) Fig.17,

Fig. 17

 Lift the hinged front door (3) Fig.17,

 Release the clasp (1) Fig.17a,
 Pull out the supply rolls assembly (1) Fig.17b.

24 Operating Instructions – Roller Mill FMO7A

 Fig. 17a

Fig.17b

Operating Instructions – Roller Mill FMO7A 25

13. Technical operation, part regeneration and replacement

13.1 Brush replacement

Brushes (1) (Fig.18) are subject to normal wearing during roller mill operation. Brushes
are freely suspended on pegs (3) (Fig.18) screwed into body side. The brush is pressed
to the roll by the counterweight (4) (Fig.18) in the form of a rod. The pressing can be
regulated as a result of moving the counterweight suspended on the bolts. With setting
the counterweight, secure its position by nuts and counter-nuts.

1
3

5
Fig. 18
In order to remove the brush from the roller mill dismount the chain (5) (Fig.18), hold it,
turn slightly and lift, pulling it out of the pegs (3) in which it is suspended. To replace
the brush, unscrew it from the steel channel in which it is placed.
During operation, when the brush is worn gradually, it can be pulled out of the housing
by turning the regulatory screw (2) (Fig. 18). Counter-hold the nut in desired position.
Check brush wearing at leas weekly.

Attention: Do not let the brush to be worn to such extent, that the channel or the
housings rub the roll. Such position is a serious risk to safety.

26 Operating Instructions – Roller Mill FMO7A

13.2 Dismounting pulleys

Fig. 19

In order to dismount, perform the following:

- Release locking set screws (1) Fig.19),
- Unscrew labelled bolts (2) Fig.19 (cadmium plated),
- Put M12x16 screws into the holes from unscrewed bolts with loosening the sleeve rings,
- Remove the wheels (3) Fig. 19.
Installation should be performed in reverse order, ensuring that the locking set is mounted
with inner surface covered slightly with oil.
Screws should be tightened using torque wrench with torque equal to 71 Nm. Tightening
should be gradual, inspecting wheel front and radial play. In case of the roller mill, wheel
setting and belt tension should be performed according to section 12.3.

Operating Instructions – Roller Mill FMO7A 27

13.3 Dismounting the belt gear

Dismounting the belt gear should be performed according to Fig.20 and 20a with the following
activities:
 Loosen screw (1) Fig.20,
 Slacken the stretcher (3) Fig.20a (by turning the tensioning wheel plug),
 Remove pulley (2) Fig.20a,
 Remove belt,
 Remove pulley (1) Fig.20a.

Dismount the wheels according to section 13.2.

Perform installation in reverse order.
With installation completed, check belt tension. Tension value should equal about 45 Hz. Then
tighten screw (1) Fig.20.

When operating the device, check belt tension at leas twice monthly.

Fig. 20

28 Operating Instructions – Roller Mill FMO7A

 Fig. 20a

13.4 Replacing milling rolls

Replace the milling rolls by performing the following activities:

 Open and remove the door (1) Fig. 21,
 Dismount side guards,
 Remove driving belts,
 Dismount pulley according to section 13.2,
 Lift the hinged front door (2) Fig.21 according to section 12.7,
 Dismount roll surface cleaning elements (3) Fig. 21 according to section13.1,
 Dismount sealing washers (4) Fig. 21 on roll ends,
 Dismount belt gear according to section 13.3,
 Dismount clutching system (1) Fig. 22, by loosening the counter-nut (2) Fig. 22,
nut (3) Fig. 22 and remove the system,
 Unscrew the two bolts that secure front roll bearing housings
 Remove the front roll together with housings and bearings

Operating Instructions – Roller Mill FMO7A 29

 Fig. 21

30 Operating Instructions – Roller Mill FMO7A

 Unscrew the two bolts and remove inter-roll inserts from the sides (4) (Fig.22)
 Unscrew the two bolts that secure rear roll bearing housings
 Remove the rear roll together with housings and bearings

Fig. 22

Install the rolls in reverse order. Due to the necessity of retaining the bearing spacing on
roll plugs it is recommended that the installed rolls have no clenched bearings and
external covers. When setting rolls ensure that the sealing ring tooth matched the proper
hole of the internal cover. When screwing the low-speed roll housing to the cradle and
high-speed roll housing to the supporting bar, tighten the bearing with the nut so that the
play in the upper part of the bearing between the inner surface of the external ring and
roll surface equals to 0,04 ÷ 0,05 mm.
Dismount the housings with bearings in the following order:
 Dismount external covers (1) Fig. 23,
 Bend back the tooth of the washer (2) Fig. 23,
 Loosen the bearing nut (3) Fig. 23 without removing it (move from the bearing
1 ÷ 2 mm),

Operating Instructions – Roller Mill FMO7A 31

  Using hydraulic pump (hose end (4) Fig. 23 screw into the prepared hole in the
plug) slide the bearing (5) Fig. 23 from the cone on the plug till the moment of
contact with bearing nut,
 Dismount bearing housing (6) Fig. 26,

Fig. 23
 Unscrew and remove the nut,
 Remove the bearing,
 Remove internal covers and sealing rings.

Install in reverse order.

During installation ensure that from the drive side, install the bearings with longitudinal
play – internal and external covers.
With each installation and dismounting of milling rolls, regulate the milling slot. It is
performed during roll installation:
 Set specific distance (155 mm) between brass pivots according to Fig. 22,
 Preliminarily set the milling slot by suitable regulation of the clutching system
(1) (Fig.22) by turning the nut (3) (Fig.22) and after setting, counter-hold with
counter-nut (2) (Fig.22).
 With slot set, reset (set to start position) the clock (regulatory) knobs according
to section 12.6.

32 Operating Instructions – Roller Mill FMO7A

14. Defects and troubleshooting

ATTENTION: The following defects can be removed by the user.

No. Defects Reason Removal method

p.
1 One- a The segment is not set Set segment parallel to the roll by turning
side parallel to the supply roll the eccentric pin
supply
2 Irregular a Humidity of the milled Maintain the humidity within limits
supply product too high
b Supply slot too large Decrease slot size
c Contaminations in supply Lift segment manually to max. slot
slot
3 Incorrect a Slot between milling Decrease the slot by turning both
milling rolls too large regulatory knobs

b Slot between rolls fluctuates 1) Check if the clutching system is locked

(1) Fig.27
2) Check if regulatory knob lock is
engaged
c Slot between rolls does Check element turning of the rear roll
not change despite housing suspension elements and
turning the knobs lubricate them
d Incorrect roll groove Select appropriate to milling
parameters technology
e Roll grooves worn out Groove anew
f Roll surface too smooth Matt roll surface

g incorrect ratio of the inter-roll Select appropriate to milling technology

gear
h Rye humidity incorrect Maintain humidity within limits
15,5-16%
4 Milling a Rye too humid Maintain humidity - section 3h
rollers stuck b Weed addition too large, e.g. Remove such seeds in cleaning process
garlic seeds and oily plants

c Milling slot set on one-side Set rolls parallel

d Rolls pushed too much Increase the slot slightly

e Dirty or worn out remove, clean brushes, regulate according to
brushes section 13.1 or replace
f Worn out scrapers regulate according to section 13.1 or replace

Operating Instructions – Roller Mill FMO7A 33

No. Defects Reason Removal method
p.
5 Roll proximity a Locked knobs Unlock the knobs according to
regulation knobs turn section 12.5
with resistance or not
b Thread surfaces significantly Clean and apply oil
turn at all
dusted
6 Noisy operation a Milling rolls stuck See section 4
b Rolls tightened too much Increase the slot between rolls

c Roll play excessive 1)check bearing condition and

replace if necessary
2)check roll play and polish or
groove, if necessary

7 Roll bearings heat up a Too much or too little grease Dismount the bearing,
in bearing housing replace and lubricate

b Roller bearings damaged Install new bearing

8 After switching on the a Roller mill switched on (rolls Disconnect roller mill and clean
drive, belts fall down or closed) and milling slot covered the slot by turning the wheel in
get damaged; main reverse direction, or increase the
motor protection can be milling slot
engaged

34 Operating Instructions – Roller Mill FMO7A

15. Reliability

15.1 Operational readiness

Roller mills type FM07A are built to allow continuous operation with observing
usability range and operation requirements. Operational readiness index equals to 0,98.

15.2 Durability periods

Durability period of the following elements exposed to wearing with retaining parameters
according to section 3 and use requirements equals to:

 Grooved rolls until obtaining - min. 35 000 h

min allowable diameter

 brushes - 3 600 - 10 000 h

depending on the number of grooves

on roll surface and roll peripheral
velocity speed
.

 roll bearings - 20 000 h

Milling rolls are subject to normal wear during operation. If needed, roll working surface
should be regenerated by polishing and appropriate grooving. Minimum diameter of the
roll after regeneration can equal to 230mm.

ATTENTION: Wearing of the roll in normal operation does not entitle

the client to complaint claims.

Operating Instructions – Roller Mill FMO7A 35

 16. Equipment

16.1 Standard equipment

a) Operating Instructions – 1 piece
b) Warranty Card – 1 piece
c) Universal grip – 1+1 piece (for mounting bearings and protecting roll plugs)

16.2 Special equipment

Based on special order, brushes or scrapers can be obtained (for cleaning rolls), standard to check
parallel rolls, hydraulic pump to dismount bearings and lifting jack to dismount milling rolls.

17. Spare parts

Major spare parts made by the manufacturer or commercial parts are listed in the table below.
Order parts by stating:
- Address of the ordering party,
- Product name, type, serial number, year of manufacturing,
- Part name,
- Part number,
- Number of pieces,
- Terms included in “Comments” section of the table below.

Number
of piece
No. Part name Part number Comments
on the
roller mill
1 Milling roll 30AYO-02.01.00.00.1 4 item 11 Fig. 23

2 Perpetual supply roll 30AYO-03.05.00.00.1 2 rear

3 Lower roll 30AYO-03.06.00.00.1 2 front

4 Enclosed brush 30AYO-07.01.02.00.1 4 item 1 Fig. 18

FMO4S-
5 Scraper sheet metal 4 Optionally with brush
15.01.00.00.01.0
mounted from the inter-roll
6 Outer cover ver.1 30AYO-02.00.00.03.1 4 belt gear side
(1) Fig. 23
Mounted from the drive
7 Outer cover ver.2 30AYO-02.00.00.03.1 2
wheel side. (1) Fig. 23
mounted from the roll
8 Outer cover ver.3 30AYO-02.00.00.03.1 2 revolution sensor
(1) Fig. 23

36 Operating Instructions – Roller Mill FMO7A


No. Part name
9 Inner cover ver.1
10 Inner cover ver.2
11 Sealing ring
12 Bearing housing ver.1
13 Bearing housing ver.2
14 Adjustment lever
15 Adjustment screw
16 Coupling screw (rolls ø250)
Coupling screw (rolls ø300)
Plate spring øz=70, øw=28,5,
17
S=3, H=5,6
18 Felt ring ø90x111x7
19 Felt ring ø70x89x7
20 Felt ring ø36x49x5
21 Ball bearing 6006 2RS
Selfaligning bearing
22
22315ESK.TVPB
23 Locking set ø70/ø110
Operating Instructions – Roller Mill FMO7A
Number
of piece
Part number Comments
on the
roller mill
Mounted from the inter-roll belt
30AYO-02.00.00.04.1 4 gear
(7) Fig. 23
Mounted from the pulley side
30AYO-02.00.00.04.1 4
(7) Fig. 23
30AYO-02.02.00.00.1 8 (8) Fig. 23
 Mounted from the pulley
side (gear roll)
30AYO-02.00.00.04.1 4  Mounted from the inter-
roll belt gear (rear roll)
(6) Fig. 23
 Mounted from the pulley
side (rear roll)
30AYO-02.00.00.04.1 4  Mounted from the inter-
roll belt gear (front roll)
(6) Fig. 23
30AYO-02.00.00.09.1 4 (5) Fig. 22
30AYO-02.00.00.11.1 4 (6) Fig. 22
30AYO-02.07.00.00.1 4 (7) Fig. 22
30AYO-02.09.00.00.1 (7) Fig. 22
10 in 4
(8) Fig. 22 (set)
sets
External cover
8
(9) Fig.23
8 External cover (10) Fig. 23
8 Supply roll
8 Supply roll
8 Milling rolls (5) Fig. 23
6 (1) Fig.19
37
18. Shipping list

Includes equipment elements according to section 16. Shipping list may also include the list of
other parts shipped with the roller mill, not specified in section 16.

19. Warranty

The manufacturer, according to resolutions included in warranty card is obliged to repair free
of charge, damages that result from faulty material or workmanship. Failure to observe
regulations and guidelines included in these Operating Instructions or operating roller mills
incompatibly with intended use, will exempt the manufacturer from warranty obligations

38 Operating Instructions – Roller Mill FMO7A