PPD 0600-00 2DRT 2018-En

Original operational documentation No.
0600/2DRT/00/05-2018
Confidential
ORIGINAL OPERATIONAL DOCUMENTATION

DOUBLE DISC REFINER
DOUBLE INLET
FAMILY
2DRT
Name: Post: Tel.: E-mail:

Elaborated: Ing. Zdeněk Popelka Designer SPL 00420 585 152 189 popelka@papcel.cz
Head of design
Approved: Ing. Ondřej Vlk 00420 585 152 149 vlk@papcel.cz
department SPL
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Original operational documentation No. 0600/2DRT/00/05-2018
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CONTENTS
INTRODUCTION ............................................................................................................................................................... 5
TECHNICAL DESCRIPTION ............................................................................................................................................ 6
1.1 MACHINE USE ................................................................................................................................................. 6
1.1.1 MACHINE DESIGN ADVANTAGES ................................................................................................... 6
1.1.2 MACHINE PROCESS ADVANTAGES ............................................................................................... 6
1.1.3 MACHINE STANDARD DESIGN AND MARKING .............................................................................. 7
1.2 MACHINE BLOCK DIAGRAM .......................................................................................................................... 8
1.3 MACHINE OPERATION PRINCIPLES ............................................................................................................. 9
1.4 PROCESS PARAMETERS ............................................................................................................................... 9
1.4.1 OPTIMISATION OF OPERATION CONDITIONS/PROCESS PARAMETERS ................................. 10
1.5 MACHINE DESIGN PARAMETERS ............................................................................................................... 10
1.5.1 GENERAL PARAMETERS ............................................................................................................... 10
1.5.2 MACHINE DIMENSIONS .................................................................................................................. 11
1.6 2DRT MACHINE UNIT PARTICULAR PARTS .............................................................................................. 12
1.6.1 MACHINE BODY .............................................................................................................................. 12
1.6.2 WORK CHAMBER ............................................................................................................................ 13
1.6.3 SEALING .......................................................................................................................................... 13
1.6.4 SHAFT BEARING HOUSING ........................................................................................................... 13
1.6.5 FUNCTIONAL ELEMENTS ............................................................................................................... 14
1.6.6 REFINER PLATES FEED DEVICE ................................................................................................... 14
1.6.7 LUBRICATION .................................................................................................................................. 15
1.6.8 COUPLING ....................................................................................................................................... 15
1.6.9 DRIVE ............................................................................................................................................... 16
1.6.10 INFLOW SOCKET, OUTFLOW SOCKET ......................................................................................... 16
1.6.11 PARTICULAR PARTS ...................................................................................................................... 16
1.7 STANDARD MACHINE ACCESSORIES ....................................................................................................... 16
1.8 COMMONLY USED MEASURING AND CONTROL ELEMENTS ................................................................. 16
1.9 MACHINE CONTROL ..................................................................................................................................... 17
1.10 ELECTRIC MOTOR ................................................................................................................................... 17
1.11 MATERIAL DESIGN .................................................................................................................................. 17
2 SAFETY RECOMMENDATIONS........................................................................................................................... 18
2.1 GENERAL INFORMATION ............................................................................................................................ 18
2.2 MAIN HAZARDS ............................................................................................................................................. 19
2.3 GENERAL HAZARDS .................................................................................................................................... 19
2.4 SAFETY SIGNS .............................................................................................................................................. 21
2.5 GENERAL RECOMMENDED SIGNS IN THE WORKSHOP.......................................................................... 23
2.6 BASIC SAFETY INSTRUCTIONS .................................................................................................................. 24
2.6.1 GENERAL RECOMMENDATIONS ................................................................................................... 24
2.6.2 ORGANIZATION ............................................................................................................................... 24
2.6.3 APPROPRIATE PERSONNEL AND THEIR DUTIES ....................................................................... 25
2.6.4 SAFETY INSTRUCTIONS FOR OPERATION.................................................................................. 25
2.6.5 WARNING AGAINST SPECIAL TYPES OF RISKS ......................................................................... 27
2.6.6 WARNING AGAINST GAS, DUST, VAPOUR AND SMOKE ............................................................ 27
2.6.7 NOISE ............................................................................................................................................... 28
2.6.8 OILS, GREASES AND CHEMICAL SUBSTANCES ......................................................................... 28
2.7 BASIC SAFETY INSTRUCTIONS FOR THE MACHINE ................................................................................ 28
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2.7.1 WARNING ......................................................................................................................................... 28
2.7.2 EMERGENCY ................................................................................................................................... 29
2.7.3 FREQUENT CAUSES OF ACCIDENTS ........................................................................................... 30
2.7.4 ELECTRICAL EQUIPMENT HAZARD .............................................................................................. 30
2.7.5 OPERATOR WORKSTATION .......................................................................................................... 31
2.7.6 EQUIPMENT FOR WORKERS WHEN THE MACHINE IS IN OPERATION .................................... 31
2.8 SAFETY MEASURES TO BE TAKEN BY THE OPERATOR ........................................................................ 31
2.8.1 SAFETY PROGRAMME ................................................................................................................... 32
2.8.2 SAFETY TRAINING .......................................................................................................................... 32
2.9 SAFETY PRECAUTIONS TO BE TAKEN BY THE PERSON OPERATING THE MACHINE ....................... 33
2.9.1 READINESS FOR START ................................................................................................................ 33
2.9.2 PROTECTIVE AND SAFETY DEVICES ........................................................................................... 33
2.10 RESIDUAL RISKS ..................................................................................................................................... 34
2.10.1 RISK OF A HUMAN ERROR DURING INSTALLATION AND REMOVAL........................................ 34
2.10.2 RISK OF A HUMAN ERROR DURING THE TRANSPORT OF THE EQUIPMENT.......................... 34
2.10.3 RISK OF BEING DRAWN IN OR CAUGHT WHEN THE MACHINE IS IN OPERATION ................. 35
2.10.4 RISK OF SLIPPING AND TRIPPING WHEN THE MACHINE IS IN OPERATION ........................... 35
2.10.5 RISK OF POWER FAILURE ............................................................................................................. 35
2.11 ENVIRONMENT ......................................................................................................................................... 36
2.12 DISPOSAL OF THE MACHINE ................................................................................................................. 36
3 ASSEMBLY ........................................................................................................................................................... 37
3.1 SHIPPING, HANDLING .................................................................................................................................. 37
3.2 DELIVERY INSPECTION AND TAKING ........................................................................................................ 37
3.3 MACHINE STORAGE ..................................................................................................................................... 37
3.4 INSTALLATION AND ASSEMBLY ................................................................................................................ 38
3.5 PROTECTION OF OPENINGS ....................................................................................................................... 38
3.6 PIPING ............................................................................................................................................................ 38
3.7 CHECKING MOTOR ROTATION DIRECTION .............................................................................................. 38
3.8 LUBRICATION FILLINGS CHECK-UP .......................................................................................................... 38
3.9 REFINING PLATES POSITION DETECTION ADJUSTMENT ....................................................................... 38
4 MACHINE OPERATION ........................................................................................................................................ 41
4.1 MACHINE OPERATION CONDITIONS .......................................................................................................... 41
4.2 PUTTING THE MACHINE INTO OPERATION ............................................................................................... 42
4.2.1 MACHINE CHECK-UP AND ADJUSTMENT BEFORE PUTTING INTO OPERATION .................... 42
4.2.2 START-UP, ADJUSTMENT, REFINER PLATES RUN-IN ................................................................ 42
4.2.3 IN-LINE MACHINE SHUTDOWN PROCEDURE .............................................................................. 42
4.3 REGULAR MACHINE OPERATION............................................................................................................... 43
4.3.1 MACHINE FAILURE STATE ............................................................................................................. 43
5 MACHINE OPERATION, MAINTENANCE AND REPAIRS .................................................................................. 44
5.1 MAINTENANCE PERIODS ............................................................................................................................. 44
5.2 RECOMMENDED SERVICE INSPECTIONS ................................................................................................. 44
5.3 ADJUSTMENT ................................................................................................................................................ 45
5.4 MAINTENANCE OF THE MACHINE PARTS ................................................................................................. 45
5.4.1 REFINER PLATES CHECK-UP AND REPLACEMENT ................................................................... 45
5.4.2 SEALING OPERATION AND CONDITION CHECK-UP ................................................................... 47
5.4.3 STUFFING BOX CHECK-UP ............................................................................................................ 50
5.4.4 PACKING CORDS REPLACEMENT, SEAL ADJUSTMENT ............................................................ 51
5.4.5 BEARING SUPPORT OPERATION CHECK .................................................................................... 51
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5.4.6 BEARING REPLACEMENT .............................................................................................................. 52
5.4.7 DISMANTLING BEARING BODY ..................................................................................................... 52
5.4.8 BEARING SUPPORT CONDITION CHECK ..................................................................................... 53
5.4.9 MOUNTING BEARING SUPPORT ................................................................................................... 54
5.5 POSSIBLE FAILURE STATUSES AND THEIR SOLUTIONS ....................................................................... 54
5.5.1 SHAFT SUPPORT ............................................................................................................................ 54
5.5.2 SEALING NODE ............................................................................................................................... 54
5.6 IMPLICATIONS OF NON-OBSERVING RECOMMENDED SERVICE INSPECTIONS AND GENERAL
MACHINE OPERATION INSTRUCTIONS........................................................................................................................ 55
5.7 MACHINE LUBRICATION .............................................................................................................................. 55
5.7.1 LUBRICATION OF MAIN SHAFT BEARING SUPPORT .................................................................. 56
5.7.2 LUBRICATION OF TRAVERSE DEVICE AND SWIVELS ................................................................ 56
5.7.3 ELECTRIC GEARBOX LUBRICATION ............................................................................................ 57
5.7.4 LIFTING GEARBOX LUBRICATION ................................................................................................ 57
5.7.5 DRIVE GEARBOX LUBRICATION ................................................................................................... 57
5.7.6 LABYRINTH LID LUBRICATION ...................................................................................................... 57
5.7.7 LUBRICANT MISCIBILITY ................................................................................................................ 57
6 DELIVERY SCOPE ................................................................................................................................................ 58
6.1 BASIC ACCESSORIES .................................................................................................................................. 58
6.2 ANCHORING AND ASSEMBLY MATERIAL ................................................................................................. 58
6.3 HANDLING MEANS ....................................................................................................................................... 58
7 SPARE PARTS ...................................................................................................................................................... 59
7.1 RECOMMENDED SPARE PARTS FOR TWO YEARS OPERATION AND FOR STAND-BY STOCK ......... 59
7.2 ORDERING DATA .......................................................................................................................................... 60
8 DOCUMENTATION DELIVERED WITH THE MACHINE ...................................................................................... 61
EC DECLARATION OF CONFORMITY ......................................................................................................................... 62
EU DECLARATION OF CONFORMITY ......................................................................................................................... 62
SYMBOLS USED IN THE DOCUMENTATION TEXT
Information, notice
Warning - possible danger (noise, slipping, stumble, cutting, bump, impaling…)

– health damage risk
Warning – attention, voltage (electric power injury danger, electric power supply outage)
– health damage risk
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INTRODUCTION
This is an operational documentation to the delivered machine. The documentation contains the machine use and
utilisation possibilities data; the machine technical and operation parameters; the instructions for the machine shipping,
erection and correct putting into operation; the instructions for the machine operation, safe work, adjustment and
maintenance; the data for ordering spare parts or the entire machine.
Before putting the machine into operation it is necessary to get acquainted in detail with all the machine parts, their
maintenance and the notes enabling a full machine utilisation in the manufacturing process.
This documentation is intended above all for technicians, supervisors, operators and maintenance staff. Observing all
the instructions in this documentation prevents losses and the machine operation should fully meet all of your requirements.
In the event of failure to comply with the operation documentation instructions the company reserves the right to:
- refuse complaints referring to equipment damages or failures caused due to non-observing the operation
instructions or due to a wrong machine maintenance or a machine operation incompatible with the operation documentation
principles;
- invalidate a provided guarantee if equipment damages or failures are caused due to non-observing the operation
instructions or due to a wrong machine maintenance or a machine operation incompatible with the operation documentation
principles.
All the recommendations comply with the manufacturer's Certificate of conformity and lose their validity if the
machine is modified without a manufacturer's agreement.
Without a manufacturer's agreement it is forbidden to deviate from limit operation values and data stated in the
operation instructions. The manufacturer does not assume any guarantee or complaint for damages caused due to
breaching the operation instructions.
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TECHNICAL DESCRIPTION
All the maximum values stated in this operation documentation referring to capacities, loads, pressures,
underpressures etc. are the limit values. The values are the basis for the design and strength calculations of machine
components but they are not guaranteed values in legal terms.
Exceeding or non-observing the given limit values during the machine operation endangers operators and machine
components and exclude any liability of PAPCEL, a. s., for any damage caused this way.
1.1 MACHINE USE
Refiners of the „2DRT„ family are designed for a wide range of manufacturing operations:
• deflaking of longfibre and shortfibre celluloses,
• deflaking recycled paper and groundwood;,
• fiberizing and refining chips, knotter pulp, semichemical pulps and uncommon papermaking raw materials like rag
pulp and others.
They are not assigned to refine stock containing sand, metal impurities and other hard abrasive materials able to cause
a machine damage.
1.1.1 MACHINE DESIGN ADVANTAGES
• stainless make enabling long lifespan period and resilience;
• easy replaceability of the most exposed parts - low service demand;
• inflow and work box shape functional design enabling a stock optimal flow.
1.1.2 MACHINE PROCESS ADVANTAGES
• a wide range of various refiner plates enable to choose a suitable refining or deflaking process by furnish sorts and
requirements on finished stock;
• several plate sizes enable to ensure optimum capacities by the stock preparation line (SPL) needs;
• a seal composed of packing cord, SpiralTrac bushing and sealing water.
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1.1.3 MACHINE STANDARD DESIGN AND MARKING
Double disc refiners type marking is „2DRT“ and they are marked as explained below.
Type marking:
Machine revolutions: 0 ……….. 590 rpm Refiner plate diameter: 18“ …….…… 457 mm
1 ……….. 740 rpm 20“ …………. 513 mm
2 …..…… 980 rpm 24“……………609 mm
26“……………660 mm
Sort of refiner plates:
The sort of used refiner plates depends on type of treated material and on type of process operation (shortening, fibrillation).
The machine nameplate data:

The type marking together with the manufacture year, the machine factory number and the machine unit number are
stated on the nameplate. This dataset is used for an easy machine identification when ordering spare parts.
The machine nameplate view:
Fig. 1 – PAPCEL machine nameplates
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1.2 MACHINE BLOCK DIAGRAM
The machine unit (pos. 1) is driven by an electric motor (pos. 7). The gearbox (pos. 10) max be used to reduce the
motor revolutions. The machinery is connected with couplings (pos. 6). Couplings are equipped with covers (pos. 8). The
machine unit with the drive are put on rails (pos. 9), standardly anchored to the concrete foundation by means of threated
rods and chemical mortar. The stock enters to the machine through two input sockets (poz. 2). The outlet of the stock is
through the socket (pos. 3). Inside the machine unit is the work chamber with refiner plates (pos. 5). The refiner is
loaded/unloaded by the plates traverse device (pos. 4).
Fig. 2 – Machine assembly
1 – machine unit 5 – refiner plates 9 – rails

2 – input socket 6 – coupling 10 – gearbox
3 – output socket 7 – electric motor
4 – plates traverse device 8 – coupling cover
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1.3 MACHINE OPERATION PRINCIPLES
Stock proceeds through the machine in the way called „TWIN FLOW“. From the two sockets the stock axially enters to
the work chamber. One part gets through the front refining zone and the other one proceeds through the back refining zone.
The balanced pressure in both zones is ensured by the slots in rotor. Having passed the refining zones, both flows are joint
and leave the chamber through the radial outflow socket.
The refining (beating) process carries out when stock passes the gap between the refining plates.
Fig. 3 – Machine function principle
1 – inlet 3 – gap between refiner plates 5 – refiner plates traverse device

2 – work chamber 4 – output
1.4 PROCESS PARAMETERS

Double disc refiner 2DRT covers the range of 20 to 120 t/24 hours.
Process parameters ** 2DRT2-18 2DRT2-20 2DRT3-24 2DRT3-26

Throughput l/min 400 ÷ 1000 600 ÷ 1400 800 ÷ 1600 1200 ÷ 2200
Work consistency % 3÷6 3÷6 3÷6 3÷6
Capacity t/24 h 20 ÷ 50 25 ÷ 60 40 ÷ 80 60 ÷ 120
Electric motor kW 160 140 350/400 400/450
Revolutions rpm 1000 1000 1000 750
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** The values are informative and for particular raw materials and processes they may vary.
Table 1 – Process parameters
1.4.1 OPTIMISATION OF OPERATION CONDITIONS/PROCESS PARAMETERS

The efficiency (intensity) of refining is set directly depending on the machine load. Broadly speaking, a constant specific
power consumption is considered for each raw material and the machine load is set according to the machine performance.
In practice the procedure is as follows:

a) the required throughput is roughly adjusted throttling the input and output clack valves;
b) the pumping power feed is measured;
c) the optimum load of the electric motor is set;
d) the machine throughput is finely adjusted;
e) the machine load is kept at the optimum value by means of the automatics.
In any case the running machine must be protected from penetrating hard objects able to cause a machine
damage or a quick refiner plate wear.
1.5 MACHINE DESIGN PARAMETERS

1.5.1 GENERAL PARAMETERS
Machine unit size

Parameters
2DRT2 2DRT3
Drive unit weight (w/o motor and base rails) 2520 kg 3850 kg
Highest work pressure 350 kPa 350 kPa
Dynamic coefficient 4 4
Inlet socket 2x DN80 2x DN100
Outlet socket 1x DN 125 1x DN 150
Flushing (seal) water connection Hosepipe adapter ø10 Hosepipe adapter ø10
Flushing (seal) water throughput (Q) 1 ÷ 3 l/min 1 ÷ 3 l/min
Refining plate diameter 457 / 513 mm 609 / 660 mm
Table 2 – General design parameters
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1.5.2 MACHINE DIMENSIONS
Fig. 4 – Machine main dimensions
Machine unit A B C D1 D2 E F G H J L
2DRT2 2210 890 320 DN80 DN125 630 575 550 1050 1100 *
2DRT3 2480 990 350 DN100 DN150 700 630 620 1210 1280 *
* acc. to electric motor and gearbox

Table 3 – Machine main dimensions
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1.6 2DRT MACHINE UNIT PARTICULAR PARTS
A basic part of each machine unit is a machine body (pos. 1). To the machine body flange is attached a work chamber
(pos. 2) with flange of outlet socket. The work chamber function space is packed by a special cord sealing (pos. 3). Sealing
chamber is attached to the work chamber. The part of sealing is flange of fixed inlet (pos. 4). A floating shaft (pos. 5) is
mounted in roller bearings inside the machine body. On the shaft is slipped on and attached the rotor (pos. 6). The housing
of the machine enable the movement of shaft with the rotor during the loading and unloading of the refiner. The work
chamber is closed by rotating cover (pos. 7). The traversing stator (pos. 8) is mounted to the machine body. The part of the
stator is is flange of the traversing inlet (pos. 9). The movement of the stator is ensured by the floating gearbox (pos. 10)
attached on the cover facing. Functional elements – refining plates (pos. 11) are attached on the rotor, work chamber and
traversing stator.
Fig. 5 – Machine unit particular parts
1 – machine body 5 – shaft 9 – traversing inlet

2 – work chamber 6 – rotor 10 – floating gearbox
3 – sealing 7 – rotating cover 11 – refiner plates
4 – fixed inlet 8 – traversing stator
1.6.1 MACHINE BODY

The cast carbon steel machine body is a basic part of the machine unit. The main shaft is mounted in the machine
body in roller bearings. The bearing body work space is packed with a shaft gufero ring and labyrinth sealing. The machine
body forms up the oil vat for bearings lubrication.
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1.6.2 WORK CHAMBER
The work chamber is a weldment made of stainless steel. The part od the chamber is flange for attachment to the
machine body. There is also the flange for sealing and swiveling cover attachment. On the shell, there is an outlet socket,
flange of control hole and flange of inlet for chamber drainage.
1.6.3 SEALING
The sealing body is a weldment made of stainless steel. By means of flange the sealing is attached to the work
chamber. The part of the sealing is flange of the fixed inlet. The sealing seals the shaft input to the work space of the
machine. The stuffing ensures the special ring SpiralTrac and packing cord. The flow of cooling water by the sealing is
controlled by SafeUnit.
1.6.4 SHAFT BEARING HOUSING
The shaft bearing housing is mounted in two roller bearings with extended inner ring (pos. 3) in the unit body (pos. 1).
The bearings enable the longitudinal movement of shaft (pos. 2). The sealing of bearing housing consists of labyrinth outer
glands (pos. 4, 5) and inner glands (pos. 6). To the inner labyrinth gland is pressed the sealing case (pos. 9) for sealing
(pos. 10). Sealing prevents the oil filling leaking out of the housing and entry of the impurities from labyrinth to the bearing
space. The labyrinth inner rings are longitudinally fastened by means of KM nut (pos. 7) and MB washer (pos. 8). The
sealing of inner labyrinth gland is by means of „O“ ring (pos. 12). The sealing of outer labyrinth gland is by means of „O“ ring
(pos. 11).
Fig. 6 – Shaft bearing housing
1 – body 7 – KM nut
2 – shaft 8 – MB washer
3 – roller bearing NUB 9 – sealing case
4 – labyrinth gland outer rear 10 – sealing
5 – labyrinth gland outer frontal 11 – „O“ ring
6 – labyrinth gland inner 12 – „O“ ring
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1.6.5 FUNCTIONAL ELEMENTS
The double refiner functional elements are equipped with refining composed of plate segments. The refining segments
are put on the rotor from both sides. The PAPCEL rotor plate segments are dynamically balanced. Due to two refining zones
and a single rotation direction the segments must be used in sets differing according to the right and left blade inclination.
The right-inclined stator + rotor plate set is mounted on the fixed stator amd on the rotor rear side. The left-inclined stator +
rotor plate set is mounted on the traversing stator and on the rotor front side.
The refiner plates are made of special abrasion resistant alloy ensuring their long lifespan. The refiner plates must be
always replaced in complete sets, i.e. the rotor and stator ones together. At the same time the segment order within the
plate set must be observed.
The segments are marked with disc manufacture numbers and segment assembly numbers. Particular discs can be
assembled only from segments of the same manufactue numbers. The traversing stator set and the refiner loading device
are put in the stator casing.
The machine can only be operated with the same type of refiner plates as it was delivered from the producer.
Replacement for another type of refiner plates is not possible. The layout of stator, rotor and floating shaft is jointed to the
fixed type of refiner plates.
Fig. 7 – Marking PAPCEL refiner plate segments
1.6.6 REFINER PLATES FEED DEVICE

The feed device controlling the functional elements - traversing stator movement - consists of an electric gearbox and a
lifting gearbox with a sliding trapezial screw. The screw end is equipped with a flange fixed-mounted to the traversing stator.
Sliding the screw out or in shifts the refiner plates in our out of the mesh. The work feed is approx. 0,1 mm/sec.
After shifting the traversing stator towards the rotor first the front refining zone segments get closer. Further stator
shifting causes an axial shift of the floating rotor and finally the rear refining zone segments get closer.
Then the refiner can be loaded further pressing the traversing stator. The unloading process is reverse. The stator
casing is turning on a swivel relative to the work chamber. Opening the casing enables replacing refining plates.
The lifting gearbox is delivered from the factory with a filing of long-life grease. The grease lubricates the worm wheel
mechanism and all the gearbox inner parts. The trapezial screw must be lubricated on a regular basis depending on the
machine workload and operation conditions.
The gearbox must be checked on a regular basis. A length of the check period depends on the machine workload and
operation conditions. A possible grease leakage from the bushing should be checked. If the grease leakage is revealed its
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reason must be found and removed and then grease must be refilled up to the required level. Also the trapezial screw
greasing must be regularly checked and refilled if necessary. Unsufficient greasing may cause overheating and a
subsequent extensive wear. Thus the gearbox lifetime is shortened. For greasing see 5.7 Machine lubrication.
A visual check of refiner plates wear during the operation is enabled with a position indicator It consists of two parts - a
rod and a sleeve with a scale. The indicator is mounted to the stator work box.
Fig. 8 – Refiner plates feed device
1 – displaceable stator part 4 – trapezial screw

2 – lifting gearbox 5 – position indicator
3 – electric gearbox
1.6.7 LUBRICATION
The refiner main bearings, the drive gearbox and and the plates feed electric gearbox are lubricated with oil. The
functional elements feed lifting gearbox is lubricated with a plastic grease according to gearbox producer. The other
machine parts are lubricated with plastic grease.
1.6.8 COUPLING
The clutch transfers torque moment from the main electric motor to the gearbox (if is mounted) to the machine. Gear
couplings are used to allow axial movement of the shaft during loading/ unloading. If a speed reduction gearbox is used, a
flexible coupling is used between the motor and gearbox. Coupling documentation is a part of the operational
documentation.
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1.6.9 DRIVE
The double disc refiners are driven by electric motors as per the following review.
Machine Power feed Frequency
Motor rpm Gearbox output rpm
type (kW) Hz
160 1000 50 -
2DRT2
250 1000 50 -
350 1000 50 -
400 1000 50 -
2DRT3 400 1500 50 750
450 750 50 -
450 1500 50 750
* The electric motor to be chosen as per the local power grid and starting conditions.
Table 4 – Machine drive

1.6.10 INFLOW SOCKET, OUTFLOW SOCKET
An outflow socket is a part of the work chamber and it is ended by edge ring and slip-on flange (delivery limits). Fixed
and moveable socket are stainless steel weldments. They are end by edge ring and slip-on flange (delivery limits). The
moveable socket is connected with the hose, which enables the axial movement of socket. The inflow piping is divided into
two arms closely to the machine and its shape is symmetrical for arm of fixed and moveable socket. On the inflow and
outflow piping must be well deposits for pressure sensors installation.
1.6.11 PARTICULAR PARTS
Wear and tear of particular parts depends on a sort of processed stock and on proper machine operation.
All the machine parts are designed not to be destructed during operation. Furthermore there was met a requirement to
remove sharp edges and rough surfaces able to cause any operators' injuries. Moving machinery parts are protected by firm
covers. Designing particular parts overall machine solidity was considered to maximally avoid vibrations and to maintain a
noise level below the allowed limit.
The used materials ensure a long parts' lifespan, they are harmful and do not threaten personnel health and safety
when running and cleaning the machine. The mentioned materials incl. work media comply with the European
environmental protection standards.
1.7 STANDARD MACHINE ACCESSORIES
In scope of the machine delivery there is delivered a set of tools including jigs for dismantling the rotor, the stuffing box
and shaft locking device for transport. If more refiners delivered the toolset is common for al the machines. Using the
tools and jigs see the Chapter 5 Machine operation, maintenance and repairs.
1.8 COMMONLY USED MEASURING AND CONTROL ELEMENTS
To adjust the required process parameters and to ensure operation we recommend to mount to the double disc refiner
the following accessories:
• pressure sensor with pressure controller for a work range of 0 to 500 kPa - mount on the outflow piping
• pressure sensor for a work range of 0 to 500 kPa - mount on the inflow piping
• manual control fittings on the machine inflow and ouflow - for flow setting
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Neither the pressure sensors nor the fittings are not delivered with the machine.
Stator position sensors and emergency sensor of stator unloading are installed and adjusted on the machine from
producer.
WHEN INSTALLING THE MACHINE THE POSITION SENSORS MUST BE ADJUSTED AS PER THE
CHAPTER 3.9 ADJUSTING DETECTION OF REFINING PLATES POSITION.
GIVEN THE POSITION SENSORS ADJUSTED WRONGLY THE LIFTING GEARBOX, MECHANISM OF
MOVEABLE STATOR AND REFINING PLATES MAY BE DAMAGED!
1.9 MACHINE CONTROL
The machine can be controlled either by a microcontroller or by a central control system. The machine operation is
automatic without a need of an operator's intervention.
The automatics enables the following functions:

• It allows to load the machine unit only if the pressure in the outflow stock pipe is sufficient. If the pressure
decreases below the allowed minimal set value the work members are automatically unloaded.
• If the rated motor current is exceeded by 10 % the work members automatically stop approaching and they are
drawn apart.
• If the electric motor is switched off the work members are drawn apart.
• It automatically keeps the required adjustable load according to the electric motor power input. The device is
adjustable on the value at least by 5 % higher than the pumping input.
• Refining cyclically, the required load is switched over in 3 grades in an adjustable time
• If the continuous freeness measuring is used the automatics adjusts the required load value according to the stock
freeness.
• It measures the total time of the motor run.
• It controls the stock pump before the refiner and the flushing water valve when starting and stopping the line.
• It enables the automatic start and stop of the refining line.
1.10 ELECTRIC MOTOR
A size of the used motor depends on a stock sort, on a refining process type (depending on a sort of the used refining
plates) and operation conditions. The motor must be able to bear a short-time (at least 60 sec.) overload up to 115 – 120 %
and an overcurrent protection must be set in a corresponding way.
The electric motor is put on sole plates included in the delivery. Usually footed motors are delivered with the IP 55
protection, complying with international IEC/EN standards enabling to be run in humid and dusty surroundings at
temperatures of up to 40 °C and in altitudes of up to 1000 m above sea level. For connection dimensions see DIN 42 677.
The motor shaft transfers the rotation move by means of the coupling. Delivered motor has got a separate operation
documentation being a part of the machine documentation. The motors must be stored in dry and dustless surroundings.
1.11 MATERIAL DESIGN
The machine parts coming to a contact with stock are made of stainless steel or stainless cast steel. The refining plates
are made of special abrasion resistant stainless cast steel. The stuffing box is made of stainless steel and treated with a
ceramic coating to extend its lifespan. The other machine parts re made of carbon steel or of cast iron.
Unless otherwise stated the machine parts made of structure steel and cast iron are protected against corrosion by a
zincum coating or a paint.
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2 SAFETY RECOMMENDATIONS
2.1 GENERAL INFORMATION
This chapter describes the safety recommendations and specifies various hazards. Also the labelling of the machine
is specified herein.
Please always bear the content of this chapter in mind. It is intended for your safety and for the safety of your
colleagues.
This also includes the observance of the safety precautions contained in this documentation, including the health and
hygiene procedures when working with the machine.
Hazard signs in the documentation:
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2.2 MAIN HAZARDS
Rotary parts – drives
2.3 GENERAL HAZARDS
Unpacking the machine
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Floors, bridges and staircases
Electrical equipment
Noise
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Towed loads
Fire hazards
2.4 SAFETY SIGNS
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The following safety labels must be attached to the machine.
SIGN PURPOSE LOCATION
Warns against rotary parts. Drive
Warns against an electrical accident. Live equipment
Orders the operator to consult the servicing manual if

in doubt.
Drive cover
Orders that all protective covers must be in place
before starting the machine.
Space next to the stuffing

Warns against another hazard
box
Table 5 – Safety signs for the stock preparation machine
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2.5 GENERAL RECOMMENDED SIGNS IN THE WORKSHOP

SIGN PURPOSE
Orders to wear hearing protection.
Orders to wear protective clothing.

(For common work – overall; for work
with chemicals – special body
protection must be worn).
Orders to wear safety shoes.
Warns against movable loads.
Orders to wear a hard hat when

working, especially when working
with cranes or equipment intended for
work with a load.
Forbids from smoking and handling

an open flame.
Orders to wear safety goggles when

working.
Table 6 – Signs in the workshop
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2.6 BASIC SAFETY INSTRUCTIONS
2.6.1 General recommendations
The machine is manufactured in accordance with the latest technologies and generally accepted safety engineering
guidelines. Despite this, the health and life of the user or third persons or equipment or other property may be endangered
when this equipment is used.
Make sure that the machine is only used by a professionally qualified (trained) person, when in an absolutely perfect
technical condition, in accordance with the purpose of its use, in accordance with the operating instructions, when knowing
the existing risks and when wearing and using the prescribed PPE. Have any failures, defects and faults which can affect
safety removed by a professionally qualified person.
2.6.2 Organization
- Store the operating instructions visibly in the place where the machine is installed in such a way that they are
continuously available.
- The operator must respect the instructions in the operating instructions and must also observe the general legal and
other applicable accident prevention and environmental regulations.
- The operator is obligated to use and wear protective devices and equipment to prevent injuries.
- Before starting to work, maintain or repair, all workers authorized to work on, maintain and repair the machine must be
trained in the operating instructions and the safety precautions contained therein first.
- Carrying out random checks on the workers’ work concerning the observance of occupational safety rules and
regulations and the observance of the working procedure in accordance with the instructions is recommended.
- The operators must not have long hair uncovered and must not wear loose clothing or jewellery, including rings. This
results in the hazard of being drawn in or caught in the machine and the operator is put in the danger of an injury.
Where this risk occurs, the “wear a headwear and do not wear loose-fitting clothing when working” regulation must be
observed.
- If regulations require, wear personal protective equipment.
- Observe all safety and warning instructions on the machine.
- Keep all signs – warning or safety – properly clean and legible.
- If any failures important to the safety of work on the machine or any changes in the behaviour of the machine when in
operation occur, the machine must be immediately turned off, the main switch must be tagged as “out of service” or
“Do not turn on. Machinery being worked on.”, and the failure must be reported to the appropriate persons.
- Making any changes, extensions or reconstructions of the machine which could affect the operation of the machine or
safety at work without the authorization of the supplier is forbidden! This also applies to the installation and setting of
the safety devices.
- Spare parts used must meet the technical requirements of the manufacturer, which is always guaranteed when original
parts are used.
- Making any adjustments in the programmes (software) of the programmable control system is forbidden.
- Observe the prescribed examination, inspection, and maintenance intervals.
- To keep the equipment in operation, it is essential to equip the workshop appropriately (e.g. non-sparking tools etc).
- Fire extinguishers must be available in the workplace!
- Observe the fire safety regulations!
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2.6.3 Appropriate personnel and their duties
- The machine may only be operated by persons authorized and properly trained in the operating instructions for this
machine and over the age of 18. When working with electricity, pressure equipment, or lifting equipment, these are
“persons professionally qualified and fit in terms of health”.
- Define clearly the personnel’s responsibility for operating the machine and for equipping, maintaining, adjusting and
repairing the equipment.
- “Unauthorized persons keep out” applies to the workplace/machine.
- An employee has the right and duty to refuse such work that could endanger his/her health or life or endanger other
persons or cause damage to property.
- Persons in training and adolescents may only work on the machine when under the supervision of a professionally
qualified or trained person
- Only professionally qualified persons – electricians – are allowed to work with the electrical equipment.
- Only professionally qualified persons are allowed to work on the hydraulic and pneumatic equipment.
2.6.4 Safety instructions for operation
2.6.4.1 Normal operation

- Using work procedures and steps that are not safe is forbidden.
- Such measures must be taken that ensure that the machine is operated in a serviceable condition.
- Operate the machine in case that all safety and protective devices are installed and functional! It is forbidden to disable
the safety and protective devices.
- Checking the machine at least once a shift for obvious damage, failures, faults, or other errors and defects is required.
Report immediately any changes occurred to appropriate persons and immediately turn the machine off according to
the severity.
- In the event of a machine failure, turn the machine off immediately and have the failure removed.
- Follow the procedures for turning on/off the machine.
- Before turning on the machine / putting the machine into operation, make sure that nobody is endangered by the
machine when starting up.
- The operating mode switch must be in the “normal operation” position.
- Do not turn off and do not remove the exhaust or ventilation equipment when the machine is running.
2.6.4.2 Maintenance, failures and repairs
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- Observe the procedures for and intervals of adjusting, maintaining, and repairing prescribed in the operating
instructions, including the instructions in the lubrication chart and also the instructions for replacing spare and
consumable parts. These activities may only be carried out by trained, professionally qualified and authorized persons
designated to do so.
- Before starting repairs and maintenance, the operators must be informed that the machine is to be stopped and repairs
and maintenance are to be carried out. A supervisor must be appointed.
- Any work that relates to operation, the adjustment of production, or the change of equipment or adjustment of the
machine, inspections, maintenance, etc. require observing the regulations and the specified procedures for working for
individual activities.
- If the machine is turned off for the time of repairs or maintenance, it must be locked out against turning on throughout
this period to prevent an injury.
- Equipment on which maintenance and repairs are carried out must be disconnected from the power supply.
- When replacing individual parts and larger assemblies, fasten them carefully to the lifting device and ensure safe
handling. Make sure that only such lifting equipment is used that is appropriate and technically fit and has a sufficient
lifting capacity! Do not stay and do not work under lifted loads.
- Only a trained and professionally qualified person is allowed to lift loads and give instructions to the crane operators.
The persons giving instructions must be within the sight or an ear-shot of the operator.
- When working at heights, use safety equipment such as platforms, ladders, etc. When working at heights, secure
yourself against falling!
- Keep all handrails, platforms, ladders, floors, landings, etc. properly clean.
- At the start of maintenance work and during repairs such as changing oil, cleaning connections or fittings, etc. Using
aggressive cleaning agents is forbidden! Use non-fibrous cleaning cloths!
- After cleaning all places, check all fuel and oil pipes for leakage, loosen bolt joints, and damaged areas. Immediately
report any defects and failures and arrange for professional repair!
- Always retighten firmly the bolted joints that have been loosened during maintenance.
- If safety elements must be removed when carrying out repairs, replacement or maintenance, they must be immediately
installed to their original positions after the completion of the work and before putting the machine into operation.
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2.6.5 Warning against special types of risks
- Make sure to use original fuses with the prescribed amperage. If there is a power failure, turn the machine off
immediately!
- Only persons professionally qualified in the electric field are allowed to carry out work on electrical equipment or
operational equipment.
- The parts of the machine and equipment which require repair or maintenance must be disconnected from the power
supply. The parts turned off must be checked first whether they really are not live and then grounded, short circuited
and insulated from the other consumers and parts that are live.
- Make sure that all electrical equipment is regularly checked and tested. Have any defects removed immediately!
- Work on live parts and equipment requires the presence of another person who pushes / turns off the emergency
switch or the main switch if necessary. Secure the work area with a red and white chain with a warning sign. Use
electrically insulated tools!!
- When working on assemblies with high voltage, after disconnecting the voltage connect the supply cable to the
machine frame and short circuit the constructional components (e.g. capacitors) using a ground rod.
2.6.6 Warning against gas, dust, vapour and smoke
- Carrying out welding, flame cutting and grinding on the machine is allowed only if fire prevention and a sufficient
number of fire extinguishers are ensured. Otherwise, a fire or explosion may occur.
- Before the start of welding, cutting, grinding, and the like, the surroundings must be free of dust and combustible
matters and sufficient ventilation must be ensured to avoid ignition or an explosion.
- When working in confined spaces, observe the general safety regulations.
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2.6.7 Noise
- The noise protection devices installed on the machine must be in their working position when the machine is in
operation.
- The operator is obligated to use the prescribed personal hearing protection!
2.6.8 Oils, greases and chemical substances
- When handling oils, greases and other chemical substances, the applicable safety regulations for the product must be
unconditionally observed, including the protective equipment for work with these substances.
- Be careful when handling hot operating and auxiliary devices and means – the hazard of burns or scalds.
2.7 BASIC SAFETY INSTRUCTIONS FOR THE MACHINE
2.7.1 Warning
- These operating instructions also warn of the hazards resulting from the structural components, equipment and
accessories of the machine that are not or are partially included in the supply.
- The operator and maintenance workers’ responsibilities when replacing rolls, for example, must be clearly defined to
avoid any doubts as to competences when there is any uncertainty in connection with a problem, especially with
safety.
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- When carrying out work that involves repairs, modifications, adjustment, maintenance, etc., all procedures for turning
on and off specified in the operating instructions must be observed.
- Any inaccessible places near and inside the machine (e.g. dirty water tanks, drip pans, etc.) may only be entered after
locking the dangerous motions of any kind of all parts of the machine and after stopping and locking out the
corresponding pressure and energy sources (e.g. the pneumatic system, hydraulics, steam, water, etc.) and when the
safety measures are observed.
- When turning off the pressure and energy sources, the switches must be visibly labelled with “Attention. Machine is
being worked on – Do not turn on” and at the same time the switches must be mechanically secured against
unexpected starting.
- Any method of work which would endanger or reduce safety must be avoided!
2.7.2 Emergency
- In the event of an emergency or imminent danger immediately turn the machine off by pressing an emergency STOP
button.
- The emergency STOP buttons are placed on each control panel. They are clearly marked (a red button in
a yellow box). In severe cases, anybody who is near the machine must use them.
- Every worker working on the machine must be familiarised with the locations of the emergency buttons.
- The emergency STOP buttons must regularly undergo a test of their functioning.
- Do not use the STOP buttons to turn off quickly within normal operation.
- Reacting quickly by turning the machine off can sometimes save a life. Therefore, pay special attention!
- It is important to ensure that the escape routes are passable and kept clean. If necessary, walkways, bridges etc. can
be used as an alternative to an escape route and the same rules apply to them as those applying to the escape routes.
- In case of a fire in the machine area there is a danger of serious damage not only to the machine, but also to the area
in which the machine is placed. Depending on your abilities and knowledge, try to extinguish the incipient fire using
appropriate fire-fighting equipment as soon as possible. In case of a larger fire, call the fire brigade and evacuate the
area of the machine and the adjacent surroundings.
- The operators must be trained in reporting and controlling a fire and in the location of the escape routes and fire
extinguishers.
- When a fire is extinguished, remove all traces of the fire.
- If fire alarm systems are installed, they must be regularly inspected.
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2.7.3 Frequent causes of accidents
Dangerous points on the machine are marked accordingly.

Accidents can often be assigned to the following circumstances:
- Slippery working surfaces and floors.
- Handling tools near a machine part when in operation.
- Climbing over walkways and bridges and overcoming or bypassing safety devices in a place with no hatch.
- Walking over the machine on unsuitable parts – such as rollers or pipes.
- Touching the paper web, coating, or ropes.
- Insufficient or missing protection at the rotating part entries/exits.
- Work on pipes, hoses and shower equipment that are pressurized.
- Entering machine channels, passages, drip tanks, etc.
- Tripping over machine parts that are set aside, shower hoses, tools, and equipment.
- Incomplete protective equipment.
- Rashness and stress caused by lack of time.
- Acid and alkaline cleaning agents.
2.7.4 Electrical equipment hazard
- Due to permanent humidity in the machine area, the electrically operated machine parts are potential sources of
hazard.
- It is necessary to exercise extreme caution when working and to comply with the safety regulations for electrical
consumers for work in humid spaces.
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2.7.5 Operator workstation
- The operator workstation is located near the control panels in front of the machine.
- The foot bridges, platforms and ladders on the guide and driving side are used for accessing to the machine when
carrying out checks.
2.7.6 Equipment for workers when the machine is in operation
- The personnel must be trained in the correct use of the safety equipment.
- To avoid the possibility of an injury, it is necessary to have, use and wear the protective and safety equipment.
o Tight-fitting work clothing.
o Hearing protection.
o Safety shoes secured against slipping.
o If there is the danger of a head injury when working, a helmet must be worn;
o If there is the danger of an injury to the eyes or skin when working, safety goggles, work gloves, work clothing,
and safety shoes must be worn.
o If there is the danger of cuts when working, cut-resistant gloves (made of Kevlar fibres) must be worn.
o When working with hazardous chemicals, protective clothing must be worn.
o When corrosive acids, lye, etc. are used, safety showers must be installed. Pay special attention to the material
safety data sheet information.
- As the duty to wear and use protective clothing or other equipment is given due to the safety regulations and
precautions, the workers must be trained in wearing and using them.
- When selecting personal work aids and equipment, attention must be paid to ergonomics and the workers’ comfort.
2.8 SAFETY MEASURES TO BE TAKEN BY THE OPERATOR
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2.8.1 Safety programme
- An effective safety programme should be developed by the top management of the machine operator.
- The programme should include:
o Planning and managing workshops, workplaces and working procedures in accordance with the safety
requirements.
o Training the personnel in the occupational safety rules and regulations issued in accordance with the legislative
and internal regulations.
o Occupational safety drills for the personnel to ensure safe and disciplined behaviour.
o Checking the safety procedures at work during production.
o Identifying and removing dangerous points.
o Instructions for developing safety programmes and training for the paper manufacturer.
2.8.2 Safety training
The persons working with the machine must be properly trained before the start of work. Retraining in the hazards
arising from their work and in the measures to prevent them must be given at least once a year.
o Operating, cleaning and troubleshooting.

o Starting and stopping the machine.
o Replacing the scraper blades.
o Replacing the rolls.
o Replacing the coverings.
o Removing waste and broke when the rolls, ropes and screens are running.
o Using tools and equipment when the machine is running.
o Handling of water and pressure hoses.
o Checking, monitoring and maintaining.
o Wearing and using personal protective equipment.
o Behaviour in case of emergency.
o Working with chemical substances.
o Safety when working with electrical equipment.
o Working when there is the danger of a fire and explosion.
- Safety training, which should develop their leadership in the area of evaluating independently and objectively the
hazard and taking appropriate actions.
- Instructing and training are the best for accident prevention.
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2.9 SAFETY PRECAUTIONS TO BE TAKEN BY THE PERSON OPERATING THE MACHINE
The operator must ensure that only authorized persons work on the machine. The operator is responsible for the
work of third parties in his/her work section.
2.9.1 Readiness for start
- Put the machine into operation only when all the safety devices are installed and effective.
- The passages and traffic routes must always be free and unobstructed. Keep these routes and passages, including
foot bridges, clean so that an injury caused by tripping or slipping is avoided. Always coil the hoses. Put tools and
materials away or mark them visibly. Also remove all remains of paper, oil, etc.
- Before starting the machine or a drive, unauthorized persons must leave the area of the machine.
- Before putting the machine into operation, the appropriate signal must be given. This signal must sound for
5 seconds and the machine must begin to be started only after the elapse of 15 seconds.
2.9.2 Protective and safety devices
- The safety and protective devices are marked with a warning yellow colour.
- The safety and protective devices and covers must not be removed during the operation of the machine.
- The safety and protective devices must not be removed or changed; they must be checked regularly to ensure that
they permanently perform their function.
- Remove failures of these devices without delay to avoid an injury.
- All safety devices which are removed during maintenance work must be unconditionally installed in their original
positions immediately after the end.
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2.10 RESIDUAL RISKS
This chapter describes the residual risks which we have not managed to remove or which cannot be removed using
available means of protection.
2.10.1 Risk of a human error during installation and removal
The machine may only be installed and removed by workers familiarized with the problems of the machine and under
the guidance of the main chief fitter who is responsible for the proper installation and removal of the machine. The workers
must observe the applicable safety regulations and wear and use protective equipment. Special care must be taken when
handling individual parts using a crane.
2.10.2 Risk of a human error during the transport of the equipment
During the transport of the equipment to the customer, individual parts or units of the equipment must be properly
secured to prevent them from tipping over or shifting and their subsequent damage. The carrier must take special care on
roads, observe the traffic rules of the appropriate countries, and make sure to take a regular rest to reduce the risk of
damage to the equipment due to a traffic accident.
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2.10.3 Risk of being drawn in or caught when the machine is in operation
This risk is eliminated by protective covers when the machine is in operation. To minimize this risk, the machine
operator must take extra care and check whether his/her work clothing is properly done up (whether there is no loose piece
on him/her which could be caught by or drawn in the machine).
2.10.4 Risk of slipping and tripping when the machine is in operation
To minimize this risk, increased demands should be placed on cleanliness and tidiness around the machine. The
building design must consider the fact that no obstacles must protrude from the floor around the machine. If necessary,
mark the dangerous points with a warning colour or sign.
2.10.5 Risk of power failure
As regards a power failure, we do not assume any residual risks. In the event of a power failure the machine will be
shut down. It is however necessary to exercise caution.
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2.11 ENVIRONMENT
If the machine is operated improperly, there is a danger of a negative environmental impact in the form of oil spills.
The points of possible dripping must be checked regularly. Any emissions of (hydraulic or gearbox) oil are solved using an
absorbing material and the subsequent disposal of the agent used; this agent becomes hazardous waste.
When the equipment is properly installed and operated according to the manufacturer’s instructions, its operation
fully complies with the environmental protection regulations and standards.
2.12 DISPOSAL OF THE MACHINE
Clean the metallic parts, remove non-metallic components (rubber and oil) from them and submit them to an
authorized person for recycling. The electrical waste and oils (hydraulic, gearbox and other) are catalogued as hazardous
waste according to Act No. 185/2001 Coll. According to the above Act and Government Decree No. 383/2001 Coll., these
may only be disposed of by a person authorized to handle hazardous waste. Lubricants and other additives must be
disposed of according to the related material safety data sheets.
The rubber and other materials not mentioned above are to be managed by the company according to the permit to
handle waste in the Others category, which is issued by the Environmental Department having local competence according
to Act No. 185/2001 Coll.
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3 ASSEMBLY
3.1 SHIPPING, HANDLING
The machine is shipped assembled. On a carrier it must be properly fixed against shift, turning over or fall. The
machine handling during loading to the vehicle or during installation to the site is by means of rope and hooks attached to
the refiner body according to the sketch. The shaft must be attached by the device to prevent the axial shaft shift during the
shipping. Separately loaded parts are shipped in boxes.
ATTENTION!
For shipping and handling the
machine before final putting on
the sole plates, the drainage
valve in the work box bottom
part is dismantled!
Shaft is axially fixed. The

device must be disassembled
after the adjusting of the
machine toward the motor (or
gearbox). The device gives the
specific shaft position for
adjusting of gear coupling.
Fig. 9 – Machine handling

3.2 DELIVERY INSPECTION AND TAKING
Check carefuly whether the delivery refers to your order, the delivery note and packing list. Inform immediately the
supplier about all the found failures and damages. If stored for a longer time the machine must be conserved against
corrosion.
3.3 MACHINE STORAGE
Storing the machine keep the allowed range of surrounding influences.
STORAGE CONDITIONS
min. 5 °C
Temperature
max. 50 °C
Humidity max. 80 %
Table 5 – Storage conditions
The stored machine must be covered and placed to avoid a contact with water.
The shift must be turned by 90° once in two months.
The machine must not be stored in dusty surroundings.
Before storing drain work medium out of the machine.
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3.4 INSTALLATION AND ASSEMBLY
The machine unit with the electric motor (and possible with gearbox) is put on a concrete foundation to which sole
plates are anchored by means of threaded rods and chemical mortar. The sole plates with the adjusted machine are levelled
by means of thrust screws. Once overall adjusted, the machine is finally grounded and thus the entire machine assembly is
perfectly fixed.
The mounting works may be carried out only by the personnel sufficiently trained for the works. The works are carried
out under the technical supervision (e.g. of an erection supervisor, a commissioning team or a technician, a mechanical
designer) keeping the given rules (included in the technical, design and operation documentations). The machinery parts are
lubricated and adjusted. The overall machine adjustment is done after its erection.
Around the machine there must be left a free space enough to carry out the maintenance.
The machine start/stop control boards must be distinctly visible and well lighted to enable a safe and quick control, i.e.
the machine start and stop. They must be properly protected from humidity. The machines work in the wet surroundings MI
30°C at the air relative humidity of up to 95% /25°C. The work media temperature is 10 to 40°C. The workshop wiring must
be equipped with an emergency stop device enabling averting a real or threatening danger. Switching this controller off must
not restart the machine, it may only enable its new start. A power failure must not cause any dangerous situation.
An electric wiring material is not included in the deliveries of refining and deflaking machines. The electric wiring must be
carried out as per the standard ČSN EN 60204-1:2000 and the subsequent standards.
When mounting, adjusting, maintaining and cleaning the machine it is esentially necessary:
• to ensure the start controller to disable the machine start in the time when the operators work inside the vessel;
• mounting the rotor, to check its correct rotation direction marked visibly by the informative arrow on the machine unit
body.
3.5 PROTECTION OF OPENINGS
There are no openings requiring more than a usual attention paid to the machine protection.
3.6 PIPING
The machine connection parts are no basic support of the entire pipeline. Therefore the piping anchoring must be
designed separately or within the project. Possible shape of inlet piping, which is divided to the fixed and moveable entrance
arm and is drawn on the foundation plan of the machine. The piping of moveable socket must be equipped with hose
enables the shift of the socket. Specification of the hose is given on the foundation plan of the machine.
3.7 CHECKING MOTOR ROTATION DIRECTION
Before starting the refiner always check the correct motor rotation direction. The motor as well as the rotor must rotate
clockwise in view from the drive side. The correct direction of the motor rotation is marked by an arrow cast on the refiner
body. When using the gearbox for control of motor revolutions the direction of motor and machine revolutions could be
different. Refiner being loaded, the electric gearbox motor of the plate traverse is turning counterclockwise in view from the
fan side.
3.8 LUBRICATION FILLINGS CHECK-UP
Before starting the refiner up check the levels of the lubricant fillings to avoid a risk of ungreased machine run. The
ungreased machine is worn extremely quickly which causes damage of the entire machine or its parts. The lubricated
places, sorts and amounts of the lubricant fillings are explained in the Chapter 5.7 Lubricating machine. Therefore it is
suitable to check the lubricant fillings levels as per the same chapter.
3.9 REFINING PLATES POSITION DETECTION ADJUSTMENT
The machine is usually equipped with absolute encoder (pos. 1) for stator position sensing and with inductive sensor
(pos. 2) which is used to protect of stator during the unloading. Absolute encoder and emergency sensor are set up from
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producer. During the refiner plates changing is necessary to enter a „refining plates changing“ command in the control
system – this will cause the encoder will be reseted – this is important for measuring the refining plates wear.
The encoder serves to unload the refiner, which always (irrespective of the refiner plates wear) relieves the refiner
plates by 3 mm per zone (6 mm of total unloading). Furthermore, the encoder displays the refiner plates wear in the system.
The emergency sensor serves as a safety lock during the unloading, when it prevents the unloading over the possible
limit of moveable stator and possibly crashing the refiner. This sensor also serves to unload the refiner when it is put into
service position.
Fig. 10 – Position detection
1 – encoder 2 – inductive sensor

(emergency)
If you need to change or reset the encoder, it is necessary to set the operating range of the sensor. This is set when
the machines cover is opened to avoid the collision of the refiner plates when adjusting the maximum load position. The
stator out of the cover position is measured (X value).
The setting up process is as follows:
- open the stator cover, switch the control to manual mode
- unlock the emergency sensor of maximal movement
- unload the refiner and at the same time measure the value of X-maximal unload
- after reaching a given distance enter the 4mA encoder limit position into the system
- unlock the emergency sensor
- loading the refiner and simultaneously measure the value X-maximal load
- when the given distance is reached, enter the 20 mA limit encoder position into the system
This sets the scope of the encoder. When changing the refiner plates, the system prompts for a „refiner plates
changing“ command, which determines the scratching position of new refiner plates and starts the measuring of wear.
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In the case of changing or over setting up of inductive sensor the face of the sensor will round up with face of silon nut.
If the sensor bracket moves, then the procedure is as follows:
- the sensor round up with face of silon nut

- release the sensor bracket, move the bracket as far as possible from the moveable stator
- in the manual mode unload the refiner and simultaneously measure the value X-emergency sensor
- shift the bracket to the moveable stator until it switch on
- tighten the bracket, secure the bolts with adhesive against the release
-
Fig.11 – Inductive sensor - detail
Fig. 12 – X-value measuring
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Machine X-maximal unloading X-maximal load X-emergency sensor

2DRT2 9 mm 59 mm 11 mm
2DRT3 4 mm 54 mm 6 mm
Table 4 – X value setting up
4 MACHINE OPERATION
For the correct and reliable machine operation keep the following requirements and recommendations.
4.1 MACHINE OPERATION CONDITIONS
• The refiner may be operated only by the trained and sufficiently instructed personnel. The operators must observe the
instructions as per the respective operational documentation. Any unskilled intervention may cause a serious machine
damage.
• The machine must be permanently run in the automatic mode. Do not let the machine run in the manual – service
mode (even though unloaded!) more than 3 to 5 minutes - the seal suffers!
• The machine requires to be regularly checked the following:
o switchbox function;
o stock pressure controller function;
o seal condition;
o work members wear; the excessive wear is indicated by stock throughput decline when the input pressure grows
while the output pressure drops. The functional elements wear can be read off on a scale located on the machine
cover. Refiner plates wear also detects the encoder on the motor of loading the refiner. The wear rate is shown in
the refiner control system.
• The following operation termperatures must be observed (see the Table 7 below):
OPERATION TEMPERATURES
min. 5°C
Machine surroundings
max. 50°C
min. 10°C
Stock
max. 50°C
Sealing water min. 1°C
Table 5 – Operation temperatures
If the sealing water temperature drops below 1°C it must be heated.
• The machine surroundings air humidity may be up to 80 %.

• The refiner operation must be protected from penetration hard bodies able to cause a damage or a quick refiner plates
wear.
The refiner plates should be changed whenever the bar height reaches 1,5 to 2 mm or whenever the
stock flow through the refiner does not get to the required throughput.
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4.2 PUTTING THE MACHINE INTO OPERATION
Putting the machine into operation, one must carry out the sequence of the activities as described in the following
chapters.
4.2.1 MACHINE CHECK-UP AND ADJUSTMENT BEFORE PUTTING INTO OPERATION
The refiner is put into operation by a manufacturer's service center specialist. Check-up of mounting, electric motor
rotation, setting and adjustment of end-limit switches and adjusting the machine on the required process parameters must
be done.
If needed any intervention into the electric wiring system the machine main circuit breaker must be
switched off.
4.2.2 START-UP, ADJUSTMENT, REFINER PLATES RUN-IN

Starting the machine up, adjustng and running the refiner plates in one must carry out the sequence of the following steps:
1) Thoroughly clean the storage tank, clean all the pipelines, fittings and the machinery connected before the refiner
flushing with water at least three time. After each flush always drain all the possible impurities. Flush all the
machinery at rest.
2) Check-up and if needed refill the levels of lubricants.
3) Check-up adjustment and uniform tightening off all the stator and rotor refiner plate segments.
4) Secure position of the refiner plates - before starting-up the machine must be entirely unloaded (the plates
must be drawn apart so that a gap of approx. 3 mm occurs in each of both refining zones - see the Chapter 3.9
REFINING PLATES POSITION DEFLECTION ADJUSTMENT.
5) Switch the automatics over to the manual mode.
6) Turn sealing water on.
7) Switch on the refiner and then the stock pump.
8) Fluently load the refiner up to the so called "scratch" positon (meaning the first contact of the rotor and stator
segments).
9) Fluently load the refiner up to 70 to 75 % within approx. 2 hours.
New refiner plates always run in as per the items 3) to 7).
4.2.3 IN-LINE MACHINE SHUTDOWN PROCEDURE
Shutting the refiner down, one must proceed as follows:
1) Unload the machine.
2) Switch the stock pump off (before a longer outage fush the machine with water).
3) Switch the main electric motor off.
4) Turn off the sealing water input.
5) Switch off the automatics main switchboard.
For the standard operation use only the automatic mode.
For short-time as well as for long-time breakdowns ensure the surroundings temperature at least 5°C. If
the temperature falls lower drain work medium away from the entire line.
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4.3 REGULAR MACHINE OPERATION
Before starting the machine up turn on sealing water. Non-observance of this condition may cause fibres and impurities
deposition in the stuffing box with a possible result of its rubbing. When the machine runs check the oil level in the machine
body (see Chapter 5.7 MACHINE LUBRICATION), pressure and throughput conditions, the refining process, the sealing
condition.
Before switching the machine off flush it with water. Non-observance of this condition may cause blocking rotor with
dried stock.
Forbidden handling
The forbidden handling is stopping the rotor drive while the stock pump is working. If the pipelines and the machine
are not cleaned after a new restart troubles with a blocked rotor may occur.
4.3.1 MACHINE FAILURE STATE
If the electric power supply is interrupted or if another in-line machinery fails proceed as follows:
• switch the machine over to the manual mode;
• set the machine into the initial position (unload the refiner plates);
• flush the particular machines and pipelines with water (had stock dewatered during a longer outage dismantle and
locally clean the machine covers and particular pipelines);
• furthermore check up the lubricant level in the refiner, check up the work member positions - the machine must be
entirely unloaded (the rotor must be in a distance of 3 mm from the stator), check the machine sensors, the sealing
water condition, functions of the sealing water monitoring and control unit.
Restarting the machine:
• turn on sealing water, switch on the refiner and the pump;
• fluently load the refiner up to the work load;
• switch over to the automatic mode.
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5 MACHINE OPERATION, MAINTENANCE AND REPAIRS
The machine operation reliability and long lifespan require a regular maintenance, therefore it is necessary to observe
the prescribed maintenance activities and the maintenance schedule without fail.
Observe the following general principles of the machine treatment and maintenance:
• keep the machine properly clean;
• grease the machine moving parts in the periods as per the lubrication schedule (see Chapter 5.7 Machine
lubrication);
• clean the machine inside only switched off and ensure that it cannot be switched on while one works inside;
• carry out all the repairs on the machine switched off and observe safety instructions.
The machine is designed so that the operators' interventions are minimal and so that the access to the maintained places is
good.
5.1 MAINTENANCE PERIODS
Machine part Check period Check mode Part lifetime *) **)

once every 3
Machine unit body visual no limit
weeks
once every 3
Work chamber visual no limit
weeks
once every 3
Moveable stator visual no limit
weeks
once every 3
Cover visual no limit
weeks
Refiner plate monthly visual wear & tear part
Shaft bearing once every 10 visual, acoustic, by contactless
~5 years
support days thermometer
once every
Seal visual ~1 year
workshift
once every 3
Plate traverse device visual no limit
weeks
Table 6 – Machine maintenance
*) “no limit“ – if properly operated and all the operation conditions met
**) the bearing lifespan is valid if the lubrication schedule is observed (see Chapter 5.7), i.e. if they are lubricated on a
regular basis with recommended grease. The design has considered their maximum possible operation loads. The
lifetime is significantly reduced in the case of failure statuses like flushing by water or stock when the sealing is
maintained wrong.
5.2 RECOMMENDED SERVICE INSPECTIONS
The recommended sevice inspection period is 6 months.
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5.3 ADJUSTMENT
The changing of refiner plates is necessary at the closed cover adjust the gap between the refiner plates to the value 3
mm at one refining zone.
5.4 MAINTENANCE OF THE MACHINE PARTS
5.4.1 REFINER PLATES CHECK-UP AND REPLACEMENT
After releasing the bolts connecting the stator casing (pos. 1) with work chamber (pos. 2) is possible to turned the work
chamber around the journal (pos. 3). Thus the refiner work space is opened. After dismantling the shaft cap (pos. 4), release
the rotor keys and mount the device (pos. 5) to the rotor. The rotor is possible to shift from the shaft and turn it on the device
out of the machine work space. Use special bolt (pos. 6) for rotor dismantling.
Fig. 13 – Refiner work space
1 – stator casing 3 – swivel 5 – rotor device

2 – work chamber 4 – shaft cap 6 – special bolt
Whenever checking refiner plates, clean the functional elements and remove foreign bodies possibly wedged into the
segment grooves.
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Only entire refiner plate sets may be replaced keeping with the segment marking - see the Chapter 1.6.5
FUNCTIONAL ELEMENTS.
CAUTION!
Tightening the stator casing fastening screws the traversing stator must be put away (service position) and
the floating rotor must be pressed by the right rotor plate to the right stator plate to prevent damage of the
floating rotor and sliding stator.
The functional elements wear can be read off on a scale located on the machine cover. Refiner plates wear also
detects the encoder on the motor of loading the refiner. The wear rate is shown in the refiner control system. The minimum
remaining height of the refining plates blades is 1,5÷2 mm. The wear of the refining plates results in reduced flow through
the refiner.
Fig. 14 – Open machine assembly
1 – rotor refiner plates 3 – cover sealing

2 – stator refiner plates 4 – scale of refining plates wear
When changing the refiner plates, it is necessary to re-set the gauge of refiner plates wear. The adjustment is made so
that the refiner is gradually loaded in the service position until the total clearance between the refiner plates (right and left
refining zones) is 6 mm. This value is set on a scale - i. e. in the „scratch“ position of the refiner plates the scale will be 0 and
the overall wear of the refiner plates can be read from this position.
Mounting new refiner plates, pay attention not to mistake the rotor plate (pos. 1) for the stator plate (pos. 2) and also
the rotor and stator plates for particular zones one for another. With regards to their balancing the plates must be replaced
always in complete sets (rotor and stator plates together). Together with that also keep the segment order within each set as
per the marking. To avoid mistaking segments when replacing the refiner plates the segments are marked with set and
segment numbers. The particular discs (plates) may be composed only of segments of the same set number.
The orientation of the refiner plates in the machine as well as the disc image are shown below in the Fig. Fig. 15 –
Refiner plates assembly.
Before closing the machine work chamber check the condition of the sealing ring (pos. 3) on the work box body and
replace it if is necessary. Close the work chamber carefully to avoid the sealing ring damage.
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P – right refining zone (bars directed to the left), L – left refining zone (bars directed to the right), M – electric motor
Fig. 15 – Refiner plates assembly
5.4.2 SEALING OPERATION AND CONDITION CHECK-UP

The work box space is sealed with a special packing cord. The shaft reaches into the work box space and is equippped
with a replaceable packing box (pos. 3) with a sealing „O“ – ring (pos. 9). The box is secured against the twisting by a key
screwed to the shaft (pos. 4, 5). The sealing body (pos. 1) is screwed to the work chamber and equipped with hosepipe
adaptor (pos. 13) for sealing water inlet. The work space is divided from the sealing by a lid (pos. 2) screwed to the sealing
body. A special SpiralTrac ring (pos. 6) with 3 packing cords (pos. 7) are placed behind the lid. A minimum leakage through
the sealing cords is ensured by means of the packing gland (pos. 8) with screws (pos. 12) producing in the packing space a
needed pressure. The sealing body is sealed with a „O“-ring (pos. 11). To the sealing box is slide the rotor, which is also
sealed by „O“-ring (pos. 10).
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Fig. 16 – Machine sealing
1 – sealing body 6 – SpiralTrac ring 11 – „O“-ring

2 – lid 7 – packing cord 12 – adjustment of sealing pulling-out
3 – box 8 – packing gland 13 – sealing water inlet
4 – key 9 – „O“-ring
5 – screw 10 – „O“-ring
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Pure sealing water brought to the stuffing box helps to take stock out of the grooves especially at higher
consistencies. From the sealing description its design and manufacture simplicity as well as minimum maintenace
demands follow.
The main sealing work elements are the SpiralTrac ring and the packing cords. The spiral ring is almost maintenance-
free and does not rotate (as well as for example the flushing ring).
To the space of sealing chamber is brought pure sealing water and it helps to take stock out of the grooves.
Fig. 17 - SpiralTrac ring
The groove system of the SpiralTrac gland utilises the rotation flow in the separation chamber (1) to create the axial
flow component oriented to the larger diameter of the conical recess (2). A part of the flow is guided throуgh the outflow
groove (3). Flushing water (4) flows to the gland space through the holes (5) in the separation chamber space. The holes (5)
are drilled in the direction of the shaft rotation. The flow through the outflow groove is enabled even with a very little flush
quantity. Any impurity coming with the fush is immediately separated in the chamber and drained through the groove (6) of
the SpiralTrac ring. Particles having penetrated to the bushing space from the area behind the rotor are centrifugated to the
outflow groove (3) guiding them back to the rotor. The flow through the outflow groove pushes the impurities beyond the
neck at the end of the chamber (7).
For a correct function the SpiralTrac water inflow piping is equipped with solenoid valve (not included in the delivery), a
clack-valve and a flowmeter controlling the flow by means of an inductive switch.
A manufacturer of the sealing water monitoring and control unit is specified in a delivery contract (usually the
unit SAFEUNIT SFP-08-10 by JohnCrane Co. or a similar one is used).
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Sealing water monitoring and control unit description:

• Connect water (1) to the flowmeter.
• Disconnect water from the seal.
• By means of the control valve (A) set the throughput on a value required by the seal - approx. range of 1 to 3 lpm.
• Reconnect water piping to the seal.
• Set the seal tightness; the pressure gauge shows the water pressure
inside the seal.
• Set the red indicator (D) on the flowmeter and the red arrow (E) on the
pressure gauge on the required values. That enables to watch the flow
and pressure changes and check the seal
The unit inflow and outflow are placed on the instrument bottom side:
1. Water inflow to the instrument
2. Water outflow to the seal
Fig. 18 – Monitoring unit
If the gauge on the instrument is unreadable clean it as follows:

1. Press cleaning button (C) on the unit right side (this function influences neither water pressure nor flow).
2. The gauge surface is cleaned by a float.
3. Carry on until the gauge is well readable again.
4. If the alarm is on it is not activated by pushing the cleaning button.
For a trouble-free operation of the sealing water monitoring and control unit (usually SAFEUNIT SFP-08-10) the next
conditions for sealing water must be observed:
• solid particles contents up to 10 mg/l (water should not contain clay or similar fine-grained material);
• solid particles size up to 50 µm;
• silicate contents up to 10 mg/l;
• permanganate value up to 30;
• iron contents up to 1 mg/l;
• total water hardness <10°dH.
The seal water pressure must exceed the seal work pressure (in the stuffing box) at least by 60 kPa.
5.4.3 STUFFING BOX CHECK-UP

To check the stuffing box on the shaft dismantle the sealing divided lid from the drive side and lid of the sealing from
the chamber. This creates a space for pulling-out the Spiral Trac ring and packing cords. In the case of stuffing box wear we
use a jig for box dismantling.
3 screws that are part of the jig screws to the box. Now slide the jig to the shaft and lock the protruding screws into the
bayonet grooves of the jig. Using a pull-out screw we remove the box from the shaft.
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Fig. 19 – Jig for box dismantling
5.4.4 PACKING CORDS REPLACEMENT, SEAL ADJUSTMENT

Replacing the sealing cords proceed as follows:
• cut a proper length at the angle of 70 - 75°; ideally use a sealing cord cutter where an exact length and angle can
be set;
• wind the cord rings and place them so that the cut is always turned by 90°;
• tighten the lid until the seal is well compressed;
• loose the lid and start the machine - the water leakage occurs;
• in small steps tighten the lid screws untill a leakage of aprox. 20 to 30 drops per minute occurs;
• the run-in time of the higher leakage shoul be approx. 15 minutes;
• keep the seal clean - without stock leakage.
For the seal use packing as per the spare parts list.
To dismantle the entire stuffing box dismantle the shaft from the bearing support.
5.4.5 BEARING SUPPORT OPERATION CHECK
The bearing support should be checked on a regular basis. Thus bearing excessive heating, vibration and/or accoustic
signs of bearing wear should be checked.
The temperature is measured by means of a contactless thermometer on the machine body surface. The temperature
should not exceed a maximum of 80°C while at normal operation conditions the bearing temperature ranges between 45
and 60°C.
Other bearing wear signs are noise and excessive vibrations in the bearing area. Check them listening to the machine
run accoustic manifestations and putting hand on the machine unit body. Then ask a maintenance serviceman to check the
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bearing suport condition.
If suspected of wear or damage dismantle and thoroughly check the entire bearing support.
5.4.6 BEARING REPLACEMENT
If bearing wear found replace them. It is recommended to change both bearings together. In fact, even seemingly
sound bearing may have function surfaces damaged (e.g. microcorroded) which can cause a need of a new bearing
replacement within a quite short time period.
The work description below is only a hint how to proceed. If the repair is beyond your experience/skills you should
rather entrust it to the machine manufacturer.
5.4.7 DISMANTLING BEARING BODY
• dismantle the coupling cover, disconnect the coupling
• release the inlet and outlet piping on the machine flanges, empty the stock/water from the machine chamber
• let out the oil from bearing body
• before replacing bearing take away the hub with the rotor (see chap. 5.4.1), then remove the seal front part and the seal
packing parts – the SpiralTrac, packing cords, the lid
• pull-out the stuffing box (see chap. 5.4.3)
• to close the machine lid with moveable stator and attach with screws
• dismantle as unit the stator lid, chamber and stuffing box – follow an extra caution to the end of the shaft
• after that is possible to release the KM nut (pos. 7) of labyrinth sealing
• remove the inner labyrinth lid (pos. 6)
• remove the outer labyrinth lid (pos. 4,5)
• now the shaft can be pushed out of the bearing body – during the pushing out the bearings should not be tilted by tilting
the shaft centered on only one bearing
Fig. 20 – Forbidden shaft handling
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Fig. 21 – Chamber dismantling
Fig. 22 – Shaft housing
1 - body 7 – KM nut
2 – shaft 8 – MB washer
3 – roller bearing NUB 9 – sealing box
4 – outer rear labyrinth lid 10 – sealing
5 – outer front labyrinth lid 11 – „O“-ring
6 – inner labyrinth lid 12 – „O“-ring
5.4.8 BEARING SUPPORT CONDITION CHECK

Before a thorough bearing support check clean all the parts well, best of all wash them in gasoline. Then check the
body, the shaft and the bearings. After a bearing crush check the respective front contact surface. If damaged it must be
reground. It is also recommended to measure the shaft run-out. (Fig. 23 - Shaft).
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Fig. 23 - Shaft
5.4.9 MOUNTING BEARING SUPPORT

Mounting the bearing support, work very carefully to prevent a damage of the bearings and the shaft contact surfaces.
Bearings stored less than a year in their original intact packagings may be used directly. The self-evident requirement for
mounting the support is the utter cleanness of all the parts, cleannes of the workplace and using the jigs.
For mounting the bearing support we recommend the following procedure:

• onto the shaft (pos. 2) slide the heated inner rings of roller bearings (pos. 3)*
• into the body press-on the outer parts of roller bearings (pos. 3)*
• into the body (pos. 1) slide the shaft (pos. 2) with pressed-on bearings parts
• mount the outer labyrinth lids (pos. 4, 5) incl. packing (pos. 11) and sealing (pos. 10)
• slide the inner labyrinth lid (pos. 6) incl. box (pos. 9) and packing (pos. 12)
• labyrinth attach with MB washer and KM nut (pos. 7, 8)
• manually rotate the shaft to check right rotation of the shaft in housing – without stammering
• labyrinth sealing fill with grease by means of lubricators
• fill the oil up to centre of oil gauges
• mount the chamber with gland body and stator lid
• slip the box and all components of the gland
• slide and fix the rotor
• assembly the coupling, slip the coupling cover
• connect the inlet and outlet piping
• wash the machine and adjust the water sealing
• regularly check the oil level in the bearing body and the bearing housing impermeability during the machine running
* Heating is done by means of electro-induction heating in a special heating device for bearings or in a clean oil
bath at about 100° C.
5.5 POSSIBLE FAILURE STATUSES AND THEIR SOLUTIONS

5.5.1 SHAFT SUPPORT
If the bearings are heated up to more than 80 °C, the machine must be stopped and the reason of the failure status
must be found out. The bearings may be damaged due to non-observing the lubrication schedule (see the Chapter 5.7
MACHINE LUBRICATION), due to overloading machine by an improper refining process control or due to another forbidden
handling. The temperature of the machine body should be checked with a contactless thermometer and the body surface
temperature must not exceed 80 °C. In a regular operation the bearing temperature ranges from 45 to 60 °C and the
temperature of 80 °C is the highest permissible one.
5.5.2 SEALING NODE
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If the sealing water excessive leaks the seal must be adjusted, i.e. slowly tighten the gland screws until the leakage is
stabilised on a volume of approx. 30 to 40 drops per minute. If this procedure has no effect the seal must be dismantled, the
sealing cords and the SpiralTrac ring condition must be checked. If the sealing cord is damaged (clotted, compressed etc.),
it must be changed, the sealing water flow set (see Chapter 5.4.2 SEAL OPERATION AND CONDITION CHECK-UP), the
openings in the ring cleaned, the seal mounted and properly adjusted.
If the stuffing box is excessively rubbed it must be replaced. The box is put on the shaft and fixed with 3 screws against
shifting and turning. Dismantling the box, loosen the screws and put the box away from the shaft. Mounting the box proceed
in a reverse order. The seal contact surfaces must be cleaned and greased with a graphite jelly. Use the sealing elements
as per the spare parts list.
The procedure of replacing sealing cords is described in the Chapter. 5.4.4 PACKING CORDS REPLACEMENT, SEAL
ADJUSTMENT
5.6 IMPLICATIONS OF NON-OBSERVING RECOMMENDED SERVICE INSPECTIONS AND GENERAL MACHINE
OPERATION INSTRUCTIONS
Neglecting the recommended service inspections and the machine operation instructions may cause failure statuses or
accidents causing unscheduled machine outages and an unfourable impact on the entire line performance.
5.7 MACHINE LUBRICATION

Operation realiability and a long machine lifespan require a regular appllication of correct lubricant in correct amounts.
Therefore the prescribed lubricant sorts and quantities and the lubrication periods must be observed.
Before putting the machine into operation check the levels of lubricants to avoid an ungreased machine
run leading to its total or partial damage.
The machine unit lubrication points are marked in the picture. The sorts and quantities of the lubricants and greases are
stated in the table below.
Fig. 24 – Machine lubrication
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Lubric No. of
Lubricati Lubricant Lubricant
ation lubrica
Lubricated place on Lubricant sort quantity quantity
positio tion
period for 2DR2 for 2DR3
n points
Shaft support A 1 biannual Oil Esso NUTO H46 33 L 58 L
Grease Mogul LV2-
Stator traverse B 2 quarterly 30 g 35 g
EP
Grease Mogul LV2-
Swivel C 2 quarterly 25 g 30 g
EP
Lifting gearbox D 2 * * * *
Electric gearbox E 1 * * * *
Grease Mogul LV2-
Labyrinth sealing F 1 quarterly 30 g 40 g
EP
Gear coupling G 1 * * * *
Gearbox H 1 * * - *
Electric motor I 1 * * * *
Charging opening,
A1 1 - - - -
deaeration
Discharging opening A2 1 - - - -
*) As per the manufacturers operational documentation
Table 7 – Machine lubrication
5.7.1 LUBRICATION OF MAIN SHAFT BEARING SUPPORT
The 2DRT main shaft bearings are lubricated with a stationary oil filling inside the machine unit body. The ESSO
NUTO H46 oil (or its analogue) is recommended with the kinematic viscosity of 45 mm2/s at 40°C, the freezing point of -
33°C and the flash-point of 220°C.
Oil comparation:
ESSO SHELL CASTROL

NUTO H46 SHELL TELLUS 46 CASTROL MAGNAGLIDE D 32
Table 8 – Oil reference table
5.7.2 LUBRICATION OF TRAVERSE DEVICE AND SWIVELS
For the quarterly lubrication of traverse device sliding surfaces and the swivels the grease Mogul LV2-EP or its
analogue is recommended, i.e. a plastic lubricant based on lithium soaps with additives against oxidation and rusting and a
high-pressure additive. The grease must comply with specifications NLGI 2–3; ISO 6743/9 CCEA 2/3; DIN 51 502 k2/3k-30.
Plastic grease features:

• ensuring low wear and high operation reliability of lubricated bearings;
• suitable for lubricating heavily strained roller and friction bearings;
• long-term serviceable in wide range of operation conditions (temperature, revolutions);
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• very well resistant to water;
• excellently protecting greased bearings against corrosion;
• universal plastic lubricants for mechanical and similar plants.
Plastic grease comparation:
MOGUL SHELL CASTROL

LV2-EP SHELL ALVANIA EP CASTROL SHEEREOL EPL 2
Table 9 – Plastic grease reference table
5.7.3 ELECTRIC GEARBOX LUBRICATION
The sort and the quantity of the lubricant is stated in the manufacturer's electric gearbox operational
documentation.
5.7.4 LIFTING GEARBOX LUBRICATION
The sort and the quantity of the lubricant is stated in the manufacturer's lifting gearbox operational documentation.
5.7.5 DRIVE GEARBOX LUBRICATION
If the machine is supplied with an electric motor-gearbox-machine, the gearbox lubricant and its amount is stated in the
manufacturer’s gearbox operational documentation.
5.7.6 LABYRINTH LID LUBRICATION
As the labyrinth lid is a rotating part it is lubricated when the refiner is out of operation (when replacing refiner plates,
dismantling the machine unit etc.). The same lubricant is recommended like for the lubrication of the traverse stator and
swivel sliding parts, i.e. the plastic grease Mogul LV2-EP (for more specification and the reference see the Chapter and
table 5.7.2 LUBRICATION OF TRAVERSE DEVICE)
5.7.7 LUBRICANT MISCIBILITY
If the lubricant sort is to be changed the entire volume of the original lubricant should be replaced. The thing is that the
additives included in the lubricants might be incompatible even if the main lubricant components are miscible.
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6 DELIVERY SCOPE
The refiner is delivered completely assembled. The machine is tested and balanced. On the customer's request it can
be delivered with or without the electric motor. Electric wiring and connecting the electric motor are not included in the
delivery scope.
6.1 BASIC ACCESSORIES
See the Chapter 0 Wear and tear of particular parts depends on a sort of processed stock and on proper machine
operation.
All the machine parts are designed not to be destructed during operation. Furthermore there was met a requirement to
remove sharp edges and rough surfaces able to cause any operators' injuries. Moving machinery parts are protected by firm
covers. Designing particular parts overall machine solidity was considered to maximally avoid vibrations and to maintain a
noise level below the allowed limit.
The used materials ensure a long parts' lifespan, they are harmful and do not threaten personnel health and safety
when running and cleaning the machine. The mentioned materials incl. work media comply with the European
environmental protection standards.
STANDARD MACHINE ACCESSORIES.
6.2 ANCHORING AND ASSEMBLY MATERIAL
The refiner is anchored to the concrete foundation on the base rails by means of threaded rods and chemical mortar.
For positions of anchoring holes, anchor types and diameters of the pre-drilled holes see the Foundation plan. The base
rails and anchoring material are the part of the machine delivery. Delivery of chemical mortar is specified in the contract.
6.3 HANDLING MEANS
To handle the refiner parts use the standard handling means (e.g. bridge of truck cranes, forklifts, hand pallet trucks,
jacks etc.). The handling means are not included in the delivery scope.
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7 SPARE PARTS
None spare parts are delivered with the machine. They must be ordered separately as per one's consideration or need.
Any spare part to the machine can be ordered with PAPCEL.
For the spare parts list see the Spare parts list.
To these recommended spare parts for 2 years‘ operation (exactly to all quick wear & tear parts) the standard warranty
conditions are not applied. The lifetime period of these parts is depend on the type of processed material, operation
parameters of machine and its technological position.
7.1 RECOMMENDED SPARE PARTS FOR TWO YEARS OPERATION AND FOR STAND-BY STOCK
For a trouble-free operation the following spare parts are recommended:
For two-years operation:
Pcs for
Pcs in Specification for Specification for
Name 2years
machine 2DRT2 2DRT3
operation
Refiner plates * 1 set * * 2-6 sets
Stuffing box 1 2000.595.000.D3 2000.596.000.D3 1
O –ring of box 1 85x4 120x4 1
16x16-2020 Type
Packing cord 1 14x14-1530 Type 1730 1
1730
Rubber cord ø10-
Lid sealing ** 1 Rubber cord ø10-2150 1
2650
O – ring of rotor 1 104x4 140x4 1
O – ring of rotor lid 1 100x4 140x4 1
*) Depends on the required process

**) Glue with Permabond 791/Loctite 406 adhesive
Note: If more machines ordered a single set is sufficient.
Table 10 – Recommended spare parts for the two-years operation
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For stand-by stock:
Pcs for
Pcs in Specification for Specification for
Name 2years
machine 2DRT2 2DRT3
operation
Bearing 2 NU320 ECJ ATYP NU326 ECJ ATYP 2
Washer 2 MB20 MB26 2
Nut 2 KM20 KM26 2
Box 2 4370.022.003.D4 4370.018.003.D4 2
Packing 2 G130x160x12 G160x190x15 2
O – ring of labyrinth 2 100x4 130x4 2
O – ring of labyrinth 2 235x4 330x4 2
Packing of gland body ** 1 Rubber cord ø10-1200 Rubber cord ø10-1500 1
Stator packing ** 1 Rubber cord ø10-1730 Rubber cord ø10-2240 1
Scraper ring A38 1 200x220x10,2/18 210x230x10,2/18 1
**) Glue with Permabond 791/Loctite 406 adhesive

Table 11 - Recommended spare parts for the stand-by stock
7.2 ORDERING DATA

The recommended spare parts must be ordered separately as per one's consideration or need. Any spare part to the
machine can be ordered with PAPCEL company.
Ordering spare parts please state:

• machine size
• part name and mark
• number of pieces
• machine type
If needed please contact the sales department of PAPCEL company Litovel.
PAPCEL, a.s.
Uničovská 132
CZ - 784 10 Litovel
Tel.: 00420 585 152 111
Fax: 00420 585 343 001
papcel@papcel.cz
www.papcel.cz
60
Confidential
8 DOCUMENTATION DELIVERED WITH THE MACHINE
1. Foundation plan drawing

2. Lubrication schedule
3. Machine unit spare parts catalogue
4. Assembly drawing
5. Documentation of subdeliveries
61
Confidential
EC DECLARATION OF CONFORMITY
EU DECLARATION OF CONFORMITY
Manufacturer: PAPCEL, a.s.

IČO: 25 35 04 71
Address: Uničovská 132

Litovel 784 01
Czech Republic
Description and identification of the machinery:
Refiner 2DRT is used for refining of paper stock.
All the relevant provisions the machinery complies with:
According to the European Parliament and Council Directive 2006/42/EC (Government Regulation No. 176/2008 Coll.)
According to the European Parliament and Council Directive 2014/35/EU (Government Regulation No. 118/2016 Coll.)
According to the European Parliament and Council Directive 2014/30/EU (Government Regulation No. 117/2016 Coll.)
The list of harmonized standards used in assessing compliance:
ČSN EN ISO 12100 : 2011 – Safety of Machinery - General Principles for Design - Risk Assessment and Risk
Reduction (EC)
ČSN EN 1034-1+A1 : 2010 - Safety of Machinery - Safety Requirements for Design and Construction of Paper Making
Machinery and Equipment - Part 1: General Requirements (EC)
ČSN EN ISO 13857 : 2008 – Safety of Machinery. Safety Distances to Prevent the Upper Limbs to Reach Dangerous
Places (EC)
ČSN EN ISO 14120 : 2016 – Safety of Machinery. Guards. General Requirements for the Design and Manufacture of
Fixed and Movable Guards (EC)
ČSN EN 60204-1 ed.2: 2007 – Safety of Machinery. Interlocking Devices Associated with Guards. – Part 1: General
requirements. (EU)
ČSN EN 349 + A1 : 2008 – Safety of Machinery. Minimum Gaps to Avoid Crushing of Parts of the Human Body (EC)
EN 61000-6-2 : 2006 idt. to ČSN EN 61000-6-2:2005 EMC – Part 6-2: Common Standards - Resistance for Industrial
Environments (EU)
EN 61000-6-4 : 2007 idt. to IEC 61000-6-4:2006 EMC – Part 6-4: Common Standards – Emissions - Industrial
Environments. (EU)
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Confidential
The act 309/2006 on further Requirements with regard to Occupational Safety and Health (EC)
ČSN EN ISO 11202 : 2010. Acoustics - Noise Emitted by Machinery and Equipment - Determination of Emission
Sound Pressure Levels at Work Stations and Other Specified Positions Using Approximate Corrections to the Environment
(EC)
ČSN EN ISO 3746 : 2011. Acoustics - Determination of Sound Power Levels and Sound Energy Levels of Noise
Sources Using Sound Pressure - Operating Method of Measuring Envelope Surface over a Reflecting Plane (EC)
List of other technical standards and regulations:
The person responsible for assembling the technical documentation:
Ing. Zdeněk Popelka, PAPCEL, a.s., Uničovská 132, Litovel 784 01
The person responsible for producing the EC and EU Declaration of Conformity:
Ing. David Dostál, PAPCEL, a.s., Uničovská 132, Litovel 784 01
The manufacturer declares that the machinery complies with all relevant provisions of the European
Communities.
Litovel, on:
…….….……………………… …………………………………
Person in charge of producing Manufacturer/authorized representative
initial EC and EU Declaration of Conformity
63

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Original operational documentation No.

ORIGINAL OPERATIONAL DOCUMENTATION

Name: Post: Tel.: E-mail:

SYMBOLS USED IN THE DOCUMENTATION TEXT

Warning - possible danger (noise, slipping, stumble, cutting, bump, impaling…)

The machine nameplate data:

The machine nameplate view:

Fig. 1 – PAPCEL machine nameplates

Fig. 2 – Machine assembly

1 – machine unit 5 – refiner plates 9 – rails

Fig. 3 – Machine function principle

1 – inlet 3 – gap between refiner plates 5 – refiner plates traverse device

1.4 PROCESS PARAMETERS

Process parameters ** 2DRT2-18 2DRT2-20 2DRT3-24 2DRT3-26

1.4.1 OPTIMISATION OF OPERATION CONDITIONS/PROCESS PARAMETERS

In practice the procedure is as follows:

1.5 MACHINE DESIGN PARAMETERS

Machine unit size

Fig. 4 – Machine main dimensions

* acc. to electric motor and gearbox

Fig. 5 – Machine unit particular parts

1 – machine body 5 – shaft 9 – traversing inlet

1.6.1 MACHINE BODY

Fig. 6 – Shaft bearing housing

Fig. 7 – Marking PAPCEL refiner plate segments

1.6.6 REFINER PLATES FEED DEVICE

Fig. 8 – Refiner plates feed device

1 – displaceable stator part 4 – trapezial screw

Table 4 – Machine drive

The automatics enables the following functions:

Hazard signs in the documentation:

Rotary parts – drives

2.3 GENERAL HAZARDS

Unpacking the machine

Floors, bridges and staircases

2.4 SAFETY SIGNS

SIGN PURPOSE LOCATION

Warns against rotary parts. Drive

Warns against an electrical accident. Live equipment

Orders the operator to consult the servicing manual if

Space next to the stuffing

Table 5 – Safety signs for the stock preparation machine

2.5 GENERAL RECOMMENDED SIGNS IN THE WORKSHOP

Orders to wear hearing protection.

Orders to wear protective clothing.

Orders to wear safety shoes.

Warns against movable loads.

Orders to wear a hard hat when

Forbids from smoking and handling

Orders to wear safety goggles when

Table 6 – Signs in the workshop

2.6 BASIC SAFETY INSTRUCTIONS

2.6.1 General recommendations

2.6.3 Appropriate personnel and their duties

2.6.4 Safety instructions for operation

2.6.4.1 Normal operation

2.6.4.2 Maintenance, failures and repairs

2.6.5 Warning against special types of risks

2.6.6 Warning against gas, dust, vapour and smoke

2.6.8 Oils, greases and chemical substances

2.7 BASIC SAFETY INSTRUCTIONS FOR THE MACHINE

2.7.3 Frequent causes of accidents