Professional Documents
Culture Documents
Roll Frosting
Roll Frosting
Operating instructions
66452-1-en
0007
Preface
These operating instructions refer to the roll frosting system MDMB.
They shall be handed over to the persons responsible for the operation and
the supervision of these devices.
These operating instructions contain the information required for the user regarding
installation, operation, and maintenance.
Descriptions of activities which do not require any special knowledge have been
omitted.
Repair instructions exceeding the normal maintenance work are not provided.
The machine meets all acknowledged safety regulations. However, improper
use can involve physical danger for the user.
Highest priority, therefore, has been given to safety.
The symbols below are used to highlight specific information regarding safety:
Important information
• Procedures upon receipt
Inspect the equipment visually in accordance with the delivery contract as
soon as it has been received.
• Storage
Equipment that is not installed immediately must be stored somewhere where
it is protected against weather and other influences.
• Installation
The assembly and installation of the machine and machine equipment must
only be carried out by observing all installation instructions supplied.
• Design versions
If different designs are described in the documentation provided, only the
information concerning the version supplied will apply. We reserve the right
to make modifications due to technical progress up to the time of delivery.
• Duty of instruction
Commissioning and maintenance must only be carried out by trained special-
ists.
Prior to initial start-up, the operating personnel must familiarise themselves with
the documentation provided.
Table of contents
1 Safety .......................................................................................................... 1-1
1.1 Safety of persons ......................................................................................................... 1-1
1.2 Safety concept for the control units .............................................................................. 1-1
1.2.1 Connecting to the electrical mains .................................................................... 1-1
1.3 Safety concept ............................................................................................................. 1-1
1.4 Designated use ............................................................................................................. 1-1
2 Description ................................................................................................. 2-1
2.1 Structure ....................................................................................................................... 2-1
2.2 Function ....................................................................................................................... 2-2
2.3 Dimensioned sketches .................................................................................................. 2-3
2.4 Machine data ................................................................................................................ 2-4
2.4.1 Compressed air data ......................................................................................... 2-4
2.4.2 Aspiration ......................................................................................................... 2-4
2.4.3 Connected electrical load .................................................................................. 2-4
2.4.4 Set values for blasting ...................................................................................... 2-4
2.5 Noise data .................................................................................................................... 2-5
2.6 Operating equipment ..................................................................................................... 2-5
2.7 Planning notes .............................................................................................................. 2-6
3 Transportation ............................................................................................ 3-1
3.1 Attaching to a crane ...................................................................................................... 3-1
3.2 Transportation weights .................................................................................................. 3-2
4 Assembly .................................................................................................... 4-1
4.1 On-site requirements .................................................................................................... 4-1
4.2 Set-up ........................................................................................................................... 4-1
4.3 Electrical connections ................................................................................................... 4-1
4.4 Compressed air and aspiration connections .................................................................. 4-1
5 Operation .................................................................................................... 5-1
5.1 Operating elements ....................................................................................................... 5-1
5.2 Set-up ........................................................................................................................... 5-1
5.3 Operating sequence ...................................................................................................... 5-2
5.4 Electrical interlocking .................................................................................................... 5-2
5.5 Adjustments ................................................................................................................. 5-2
6 Maintenance ............................................................................................... 6-1
6.1 General information ....................................................................................................... 6-1
6.2 Blasting guns ................................................................................................................ 6-1
7 After-sales service ..................................................................................... 7-1
7.1 Stockkeeping of spare parts ......................................................................................... 7-1
7.2 Address ........................................................................................................................ 7-1
7.3 Recommended spare parts ........................................................................................... 7-3
7.3.1 Roll frosting system .......................................................................................... 7-3
1 Safety
1.1 Safety of persons
• Safety covers must always be installed and locked. Open or removed safety
covers are danger spots for crushing and cutting injuries.
• Always keep safety devices in good working condition. Safety devices must
not be bridged over or put out of operation.
• Maintenance work at the machine or parts thereof must only take place with
the installation at a standstill. It is absolutely imperative and without exception
that the installation is switched off and that the switch is locked!
2 Description
The roll frosting system is used for roughening or frosting chilled-iron rolls.
2.1 Structure
6 7 8 9 10 11 12
1 16 15 14 13
Fig. 2.1
2.2 Function
Frosting is a processing procedure in which abrasive (17) is blasted on the surface
to be processed in order to attain a certain roughness and structure of the surface.
This procedure is based on the injector principle. In order to attain a regular,
controlled roughness and structure of the roll surface, the roll must rotate and be
blasted by two injector blow guns (7) which move on a carriage (18) parallel to the
roll axis and in proportion to the roll rotation (2).
The injector works by compressed air that is blown into a sand nozzle via an air
nozzle, the bore of which is approximately half as large as that of the sand nozzle.
The expansion of the compressed air resulting thereof produces a vacuum that is
used to take in the abrasive.
The abrasive is mixed with the carrier air in the discharging mug (15) (see Fig. 2.2,
Pos. 15) which is installed at the deepest point of the abrasive bin (1). The abrasive
is added to the compressed air stream in the injector gun (7) and is accelerated in
the blasting nozzle (see Fig. 2.2, Pos. 7).
The used-up abrasive (fines content) is exhausted via the aspiration wall (9), filtered
in the attached small filter (12) which is equipped with a fan (11), and is then collect-
ed in the dust container (13).
18 9 11
12
7
17
13
15 1
Fig. 2.3
520
695
30
270
800
1610
~ 2250
Compressed air supply
1994
1781 0°
12
(customer)
30°
676.5
301
1350
1660
DN 120
2505
Platform
2100
~ 800
90
665 390
~ 800
1875
2027
Fig. 2.4
2.4.2 Aspiration
• Per blasting system: 18 m3/h
Measuring procedure:
1 2
) according to ISO 6081 ) enveloping surface method according to DIN
45635
ø 120 mm
1 6
2
Compressor
min. 140 Nm³/h
operating pressure 5...6 bars
Accumulator
min. 750 l G 1” G 1/8”
G 1”
Maintenance unit 4a
4 3 5
Fig. 2.5
Standard supply:
(1) Frosting system including machine control system, without wiring
(2) Dust filter MVRN-4/12, equipped with a fan and a dust collection bin
(3) Platform
Options:
(4) Compressor system and compressed air maintenance-unit
(5) Compressed air line
(6) Aspiration line
3 Transportation
Note:
The transport must only be handled by persons who are familiar with and trained for
this task.
max. 60°
Fig. 3.1
Note:
For stability reasons, screw the eyebolts in completely.
The angle of traction of the suspension ropes must not exceed 60°.
Danger!
Do not pass beneath suspended loads!
Caution!
The lifting gear has to be checked for the required design and the permissible load
capacity.
Note:
Generally the transport weights in the shipping papers apply and have to be ob-
served!
4 Assembly
4.1 On-site requirements
The operating side (front of machine) must be freely accessible, min. 2 m.
The other sides, approx. 0.5 ... 0.8 m.
The admissible floor loading must be 1.5 times higher than the weight of the
machine, including the roll.
Through holes are provided in the base plate for fastening the frosting system.
4.2 Set-up
(See dimensioned sketch, chapter 2.3, and planning notes, chapter 2.7)
5 Operation
5.1 Operating elements
1 2 3 4
11 12 13 14
Fig. 5.1
5.2 Set-up
The operating sequence can be checked without blasting with the door either
opened or closed:
• Main switch «ON» (13).
• Press the «Rotation» button (10).
• Press the button «Blasting nozzle carriage left (8)» or «Left» (9).
• Potentiometer (6) «Roll rotation»
• Potentiometer (7) «Carriage travel»
Caution!
Release button at end position.
The blasting nozzle carriage does not stop automatically.
5.5 Adjustments
1. Set the operational air pressure against the frosting system to 5 bars by
means of a pressure reduction valve (to be supplied by customer).
2. Set the two blasting nozzles vertically to an angle «X» of 55 ... 65° in a
distance of 70 ... 100 mm (see Fig. 5.2) from the surface of the roll.
Blasting nozzle
00
0-1
7
X
Roll
ce
Distan mm
00
70 –1
Roll
Fig. 5.2
3. Adjust the change-over limitation for the horizontal blasting nozzle carriage by
means of set collars. The blasting nozzles must move beyond the full length of
the roll shell before the change-over can take place.
Set collar
Fig. 5.3
7. The desired number of blasting cycles can be selected with the preselection
counter at the right side of the blasting cabinet.
8. An aluminous abrasive (Abrasit) with grain 20 (0.8...1.2 mm) shall be used for
blasting. Fill 50 kg of abrasive into the abrasive bin. Refill 2 kg of aluminous
abrasive after 3...4 rolls. The abrasive must be exchanged completely after
15...20 rolls.
Note:
The desired roll surface roughness depends on the duration of blasting, the blasting
pressure and the abrasive product used.
A good surface roughness is Ra = 2.5...3.5 ± 0,5 µm.
Caution!
The cabinet door must remain closed during the blasting process. The door is locked
with a safety switch. If the door is opened, the blasting operation is interrupted.
Danger!
It is absolutely necessary to wear eye protection while operating the roll
frosting system!
9. The dust sleeve is rinsed automatically. The used abrasive product in the dust
collection drawer must be emptied regularly. (See BV MRVN-4/12).
6 Maintenance
Danger!
Perform all maintenance, cleaning and inspection work with the machine at
a standstill only (all machine movements have to be stopped).
The service or the local switch must be set to «0» and locked.
1 2
Air
Sand
Caution!
Defective air nozzles, i.e. ones with a hole on the side caused by wear, destroy the
gun body within a few minutes.
When exchanging the air nozzle and installing the new nozzle, make sure the noz-
zle opening is flush with the rubber seal in the gun body.
7 After-sales service
7.1 Stockkeeping of spare parts
Please use the following pages with the appropriate illustrations when ordering
spare parts.
Please note that special manufacturing and delivery specifications are frequently
applied to Buhler and non-Buhler parts and that the spare parts supplied by
Buhler will always conform to the latest technical state of development.
Ordering instructions
An order for spare parts must include the following information:
(Table with examples)
(see nameplate)
.................... MDMB UNW-76001-017 Air nozzle ............
Note:
These order details are required in order to prevent incorrect deliveries.
In case of uncertainties, please enclose dimensioned sketch with description.
Motors or gears units:
Indicate the motor or gear unit number when making any inquiries or placing
orders for spare parts.
When placing an order for spare parts and wear parts without part numbers,
state subassembly number and instead of the part number the item number
on the parts list.
7.2 Address
Bühler AG
Customer Service Grain Processing
CH-9240 Uzwil, Switzerland
Phone +41 71 955 30 40
Fax +41 71 955 33 05
service.gp@buhlergroup.com
Fig. 7.1
4.1 6 7 8 9
10 12
5 16
Fig. 7.2
13
14
Fig. 7.3 15
11
Fig. 7.4