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CompaDis™ - CDI0
Diana Joint Stock Corporation, PF U1085/07
Operating and Maintenance Instructions

Machine: CompaDis™ CDI0
Machine No.: C-14-802813-011-2050
Year built: 2007
Order code: Diana Joint Stock Corporation
Order no.: PF U1085/07
Issued: PF Wang Sufang, 2008.06

Checked: PF Jiang Lijie, 2008.06
Rev. 0, 2008.06.04 Chapter. , Page1 of 2

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The operating manual is protected by copyright. All usual rights reserved. It must not
be wholly or partly reproduced without authorization by Andritz AG. Contraventions
shall entail damage claims and may have penal consequences. All rights shall also be
reserved for any patents granted, registration of trade marks and technical
modifications without prior notification.
© 2008 Andritz AG

GRZ-2771275-v1-Title_page.FM
CompaDis™ - CDI0
TABLE OF CONTENTS
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Standards and guidelines . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 How to use the manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Warranty and guarantee . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Manufacturer's name and address . . . . . . . . . . . . . . . . . 4
1.6 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . 1
2.1 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3.1 General safety regulations . . . . . . . . . . . . . . . . . . . . . . . 1

3.2 Danger and warning signs . . . . . . . . . . . . . . . . . . . . . . . . 2
3.3 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.4 General remarks on machine/plant safety . . . . . . . . . . . 3
3.5 Hazardous applications . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.6 User's obligations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.7 General obligations of personnel . . . . . . . . . . . . . . . . . . 6
3.8 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.9 Personal protective apparel . . . . . . . . . . . . . . . . . . . . . . 10
3.10 Safety at the machine installation site . . . . . . . . . . . . . 11
3.11 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.12 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.13 Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.14 Hydraulics and pneumatics . . . . . . . . . . . . . . . . . . . . . . 13
3.15 Welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.16 Fluids, (liquids, gases, vapour or smoke). . . . . . . . . . . 14
3.17 Oils and greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
4.1 Field of Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4.2 Main plant components . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.3 Technological description . . . . . . . . . . . . . . . . . . . . . . . 13
4.4 Machine monitoring equipment . . . . . . . . . . . . . . . . . . . 15

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5 ERECTION WORK and TRANSPORT . . . . . . 1
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5.2 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5.3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5.4 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5.5 Erection work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5.6 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.7 Inspections and remaining work. . . . . . . . . . . . . . . . . . 10
5.8 Cold test (preparation for initial start-up) . . . . . . . . . . 11
6 START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6.3 Prerequisites for start-up. . . . . . . . . . . . . . . . . . . . . . . . . 2
6.4 Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6.5 Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7.3 Control via DCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
7.4 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.5 Normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.6 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7.7 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7.8 Emergency cut-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7.9 Re-start after emergency stop . . . . . . . . . . . . . . . . . . . . 5
7.10 Operating malfunctions and troubleshooting . . . . . . . . 6

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8 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 1
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8.3 Regular maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
8.4 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
8.5 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8.6 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8.7 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8.8 Lubrication schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8.9 Removing the rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8.10 Changing the disperser fillings . . . . . . . . . . . . . . . . . . . 13
8.11 Changing the stuffing box packings . . . . . . . . . . . . . . . 15
8.12 Changing the shaft protection sleeve at the rotor . . . . 18
8.13 Bearing change, adjusting device . . . . . . . . . . . . . . . . 19
8.14 Bearing change at rotor . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.15 Setting the position transducer . . . . . . . . . . . . . . . . . . 25
8.16 Changing the V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8.17 Checking the V-belt tension . . . . . . . . . . . . . . . . . . . . . 27
8.18 Installation and removal of belt pulley . . . . . . . . . . . . . 27
8.19 Bearing change at screw . . . . . . . . . . . . . . . . . . . . . . . . 29
8.20 Changing the shaft protection sleeve at the screw . . 30
8.21 Removing the screw shaft . . . . . . . . . . . . . . . . . . . . . . . 31
9 SUPPLIER DOCUMENTATION . . . . . . . . . . . . 1
9.1 453 10 - Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9.1.1 Ball valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9.1.2 Level switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9.2 453 50 - Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9.2.1 Curved tooth gear coupling . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9.2.2 Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9.2.2 Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9.3 453 51 - Drive - Inlet screw . . . . . . . . . . . . . . . . . . . . . . . . 2
9.3.1 3-phase asynchronous motor . . . . . . . . . . . . . . . . . . . . . . . . 2
9.4 453 65 - Adjusting device . . . . . . . . . . . . . . . . . . . . . . . . 2
9.4.1 Gear motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
9.5 453 70 - Oil recirculating and cooling filter unit . . . . . . 2
9.5.1 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
9.5.2 Ball valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
9.6 453 80 - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9.6.1 Hudraulic nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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9.7 720 42-Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . 3

9.7.1 Displacement transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9.7.2 Resistance thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9.7.3 Level switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9.7.4 Proximity switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
9.7.5 Speed monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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CompaDis™ - CDI0
1 INTRODUCTION
This manual is part of the Andritz AG technical documentation for the
plant. It is intended as a supplement to the training provided, to supply the
basic knowledge required for proper, safe and economical use of the
equipment delivered by Andritz AG. Observing these instructions helps
avoid hazards and reduce repair and downtime costs, as well as
increasing the reliability and useful life of machines.
1.1 Use
Target group This operating manual is intended for users with a knowledge of
mechanical engineering and is for the exclusive use of the operator and
his personnel.
Personnel entrusted with work on the machine must have read and
understood these operating instructions and comply with them. This refers
in particular to the following tasks:
• Handling, starting and stopping
• Troubleshooting
• Maintenance and upkeep
• Transportation
• Maintenance and disposal of process materials, cleaning of machine
and area around the machine.
The following sections are especially important:
• the Chapter on SAFETY,
• the safety instructions contained in various other chapters
Supplementary The mill operator shall complete this manual by adding national
instructions regulations on safety at work, health protection and environmental
protection.
Instructions on any special operational conditions concerning work
organization, sequence of work/operations and the personnel assigned to
the job shall also be added. This includes instructions on supervising and
reporting obligations.
Storage Keep the entire operating manual near the place where the machine is
installed and within easy reach.
1.2 Standards and guidelines

The machine/plant has been built in accordance with state-of-the-art
standards and the recognized safety rules. The equipment conforms to
the equivalent European standards.
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1.3 How to use the manual
Presentation • Chapter and paragraph headings are printed in capitals in the

continuous text.
Chapter on SAFETY
• Designations of indicating and handling elements are written in
inverted commas in the continuous text.
Operate switch ”xxx”
• Lists without numbering do not require operations to be carried out in a
certain order.
Pictograms The following pictograms are used in the manual:
Warning signs
Warning signs are shown with an explanation of the

type of hazard.
The meanings of the different graduations of hazards

are described in the Chapter on SAFETY.
Marks an instruction on handling of the machine or

system.
Marks a useful piece of information
Marks a cross-reference to another Chapter with

absolute path indication.
e.g. /MACHINE/SAFETY

CompaDis™ - CDI0
Work steps Work steps are presented in tables. Work steps are numbered and must
(operations) be carried out in the order specified.
Numbering of
pages, tables and
figures Pages Consecutive numbering of Chapters 2-1
Tables Tab.+ Consecutive numbering of Chapters Tab. 2-1
Figures Fig. + Consecutive numbering of Chapters Fig. 2-1
Abbreviations
Tab. Table
Fig. Figure
Illustrations and The illustrations and graphic charts show the basic design of the machine.
graphic charts This may not necessarily correspond exactly to the design supplied.
Detailed information on the equipment supplied
.../PARTS BOOK
.../SUPPLIER DOCUMENTATION
1.4 Warranty and guarantee

Andritz AG's general terms of delivery and sale shall apply.
Guarantee and liability claims towards Andritz AG shall become void if
personal injury or material damage is caused by one or several of the
following:
• Use of the machine/system for any purpose other than its designated
use.
• Non-conformity of erection work, start-up and handling of the
machine/system.
• Non-observance of the safety instructions in the manual.
• Non-authorized structural changes to the machine/system.
• Non-observance of the maintenance and upkeep instructions.
In the event of a claim for repair under guarantee, ANDRITZ AG reserves
the right to assess the damage to the machine/system.

CompaDis™ - CDI0
1.5 Manufacturer's name and address

Andritz AG
Stattegger Strasse 18
A-8045 Graz
Our Service Department will be pleased to help you and can be contacted
at:
Andritz AG
Stattegger Strasse 18
A-8045 Graz
Pulp Technology Service Department
Tel.: +43/316-6902-2759
Fax: +43/316-6902-424
e-mail: Karl.Eickhoff@andritz.com
In case of emergency outside working hours:

Tel.: +43 316 6902-0
1.6 Copyright
The operating manual is protected by copyright. All usual rights reserved.
It must not be wholly or partly reproduced without authorization by Andritz
AG. Contraventions shall entail damage claims and may have penal
consequences. All rights shall also be reserved for any patents granted,
registration of trade marks and technical modifications without prior
notification.
© 2007 Andritz AG

CompaDis™ - CDI0
2 SAFETY
2.1 General safety regulations
The chapter on safety contains general safety regulations which must be
observed when working on the machine/plant.
In addition to the present safety regulations, the various chapters of the
operating manual contain further safety regulations relating to individual
tasks. DANGER and WARNING SIGNS highlight these additional safety
regulations in the operating instructions.
Safety instructions on components not supplied by Andritz AG are
contained in the descriptions of the components provided by
sub-suppliers.
/COMPADIS™ CDI0/SUPPLIER DOCUMENTATION
The safety instructions supplement ANDRITZ AG's operating instructions.
All safety instructions must be observed. Disregarding the safety
instructions may cause a risk to life and limb, environmental pollution
hazards and/or damage to property.
Andritz requires the operator to provide the following:
• The operator must compile a comprehensive general safety program.
Anyone working at or in the vicinity of the machine must have received
training for working on plants of this type and on the process running
there, including where to mount barriers and markings.
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2.2 Danger and warning signs

The entire SAFETY chapter is of extreme importance and relevant to
safety. Thus, the information in this chapter is not marked with special
danger and warning symbols.
In the Chapters on ERECTION WORK, START-UP, OPERATION, and
MAINTENANCE in this Manual, warnings are marked by a pictogram. The
following warning signs are used:
This symbol indicates there may be a risk to life and limb.

Non-compliance with the warning signs may lead to serious health
DANGER problems or even fatal injuries, and can cause extensive damage to
property.
This symbol indicates that there is an imminent health risk, as well

as a risk of environmental pollution and of damage to property.
WARNING Non-compliance with the warning signs may cause moderate health
problems and/or extensive environmental pollution and damage to
property.
This symbol points to a dangerous situation.

Non-observance of these signs may cause environmental pollution and
CAUTION damage to property.
Further symbols and pictograms used are described in the

INTRODUCTION.
2.3 Designated use

The CompaDis™ should only be used according to the specifications
forming part of the purchase order.
Use of the machine/plant for any other purpose is considered contrary to
its designated use.
Any modifications to the scope of supply made without the agreement of
Andritz AG are considered contrary to the designated use.
The term designated use also covers adherence to the operating
instructions, compliance with the operating, inspection and maintenance
conditions and with the regulations on cleaning and upkeep.

CompaDis™ - CDI0
2.4 General remarks on machine/plant safety

The machine/plant has been built in accordance with state-of-the-art
standards and the recognized safety rules. Nevertheless, its use may
constitute a risk to life and limb of the user or of third parties, or cause
damage to the machine/plant and to other material property.
The disperser is designed such that Zone 2 according to EN 746-2 can
prevail inside without creating any risk before the equipment is started up,
provided that the control system is designed according to the Andritz AG
guidelines.
During operation, sparks - which are a potential source of ignition - can be
passed on to the subsequent units. The personnel must be informed on
what to do in case of fire.
The machine/plant may only be operated when in perfect condition and
with due consideration to safety and the risks involved. All protective
devices and the emergency cut-out devices must be in place and fully
functional.
Malfunctions and unforeseen changes to the machine/plant must be
remedied immediately.
2.5 Hazardous applications

The machine was developed specially for the process specified in the
sales contract. All changes to this process must be checked and
approved because Andritz does not know in detail the chemical and
biological properties of the numerous materials that can be processed in
this machine. The machine as-sold is not suitable for safe processing of
hazardous materials unless additional precautions are taken.
Before processing materials that are already combustible, explosive,
toxic, or hazardous in other ways or which can become hazardous in a
reaction, the operator must conduct a thorough hazard analysis and risk
evaluation of the entire process. This includes drawing up of contingency
plans for handling process errors and faults.
In particular, the following must be observed:
1. If combustible or potentially explosive materials are to be processed,
all electric motors, cabling and operating elements MUST be
explosion-proof. Furthermore, maintenance work on the plant MUST
be performed using non-sparking tools. Smoking is forbidden.
2. If the material processed is toxic, appropriate safety measures MUST
be implemented.

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2.6 User's obligations
Designated use The user of the machine is responsible for its designated use.
Work instructions In addition to the operating instructions, the applicable legal regulations in
the user countries and other rules governing safety at work, health and
environmental protection must be observed and personnel instructed in
these matters.
Qualification of The machine/plant may only be operated, maintained and serviced by

personnel authorized, skilled personnel with hands-on training.
assigned
Personnel must be of the legal minimum age.
Any person undergoing training or in apprenticeship or under instruction
may only work on the machine/plant after receiving instruction on the
theory and only under the supervision of an experienced person.
Instructions The customer's operating and maintenance personnel is to be instructed

by qualified persons after completion of the installation work.
The user undertakes to have new, additional operating and maintenance
personnel instructed in machine/plant operation and maintenance to the
same extent and applying the same care, and with due consideration to
the safety instructions.
Workers entrusted with the transportation, erection work, start-up,
operation, and maintenance of the machine/plant must have read and
understood the operating instructions, especially the chapter on SAFETY,
the safety instructions concerning a certain activity, as well as the safety
instructions issued by sub-suppliers.
Definition of fields The user shall be responsible for:

of responsibility
• definition of the machine operator's responsibility and his right to give
instructions
• definition of the contents and responsibility for keeping the records on
functioning and any failure of the monitoring equipment (log book)
• personnel areas of responsibility in terms of operating, tooling,
maintenance and upkeep.

CompaDis™ - CDI0
Inspections The operator undertakes

• to check at regular intervals whether the safety instructions and
regulations governing work on the machine are observed.
• to carry out regular training to confirm the level of knowledge of the
operating and maintenance personnel.
Attaching safety The operator shall ensure that all regulations relevant to security are
devices observed and that all symbols and signs are mounted in the production
area in accordance with local regulations.
• Safety devices and regulations (see Chapter 2.8)
In addition, Andritz recommends mounting the following devices, symbols
and signs, in as far as these are not already included in the local
regulations.
• Markings on the floor for vehicle routes, protective fencing and danger
areas (yellow)
• Fencings and covers
• Railings (foot, centre and chest height)
• Emergency lighting
• Shut-off device for drive motor
• Signs on fire-fighting equipment
• Signs for emergency calls
• Direction arrows to exits
• Direction arrows to escape routes
• Signs to first-aid post
• Emergency switch
The national fire protection regulations must be observed.

CompaDis™ - CDI0
2.7 General obligations of personnel

To avoid personal injury and material damage, all persons working on the
machine shall observe the following safety instructions:
• Observe the safety regulations in the operating instructions and on the
machine.
• In the event of a safety-relevant functional disorder, stop and secure
the part of the plant affected. Report disorders and have them repaired
immediately.
• Do not perform any work in a manner disregarding safety
considerations.
• Use only the machine accesses, paths and passages foreseen for this
purpose.
• Do not touch moving and rotating parts and/or reach out beyond them.
• Keep the machine and the workplace clean. Do not place tools and
other objects on the machine/plant.
• Do not wear any garments/jewellery that might get caught on moving
machine/plant parts. This includes ties, scarves, rings and necklaces.
• Do not wear long hair hanging down.
• Familiarize yourself with the function and any failure of machine
monitoring equipment (log book) before starting work.
• No smoking in the vicinity of the machine/plant.
• Wear personal protective apparel when working on the machine/plant
(see section 2.8).

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2.8 Safety devices

The machine/plant must not be operated without effective safety
equipment.
Safety equipment must not be circumvented, dismantled or made
unserviceable during operations. The safety equipment is there to protect
operating personnel.
Safety equipment and access thereto must be kept clear.
Safety covers Abb. 2-1 shows the safety covers at the CompaDis™.
The CompaDis™ must not be operated without the safety covers
mounted.
2 3 1
Abb. 2-1 Safety covers at CompaDis
Item Component
1 Coupling guard
2 V-belt cover
3 Cover for screw shaft

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Emergency-off The machine/plant has emergency-off buttons to stop it in case of an

switch, emergency emergency.
cut-out
The following emergency-off switches are provided on the machine:
• EMERGENCY-OFF button is located at the side on the operating
panel of the CompaDis™:
Emergency switch
Abb. 2-2 EMERGENCY-OFF button at operating panel
The user shall provide the following emergency-off switches:

• EMERGENCY-OFF button near the CompaDis™
The emergency-off button must comply with the process and control
description.

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Indicative, warning Indicative, warning and prohibiting signs must be observed. They must be
and prohibiting checked regularly for legibility and completeness and they must not be
signs removed or obstructed.
The following indicative, warning and prohibiting signs are attached to the
machine.
Warning: Danger of Hot surface warning! Do not reach into the Only authorized
hand injuries! machine! personnel are permitted
to climb onto the
machine!
Caustic substances may

be present!

CompaDis™ - CDI0
2.9 Personal protective apparel
General protective Operating personnel must use and carry personal protective equipment
apparel along with them in accordance with the national regulations or as
specified by the plant operator.
It should be compulsory to wear hard-toed boots throughout the entire mill
premises.
In addition to the regulations applying, we recommend using the following
safety equipment for certain work:
Activity Safety equipment

Time spent in the immediate
vicinity of the machine when
running
Taking pulp samples
Field installation and

maintenance work for which
parts of the machine have to be
removed
Tab. 2-1 Recommended safety equipment for certain work
Key to symbols
Protective clothing to prevent the Safety shoes as protection

pulp from coming into contact against foot injuries.
with the skin.
Gloves to prevent hand injuries. Ear protection to prevent damage

to hearing.
Goggles to prevent eye injuries. Standard hard hat as protection

against head injuries.
Tab. 2-2 Purpose of the safety equipment

CompaDis™ - CDI0
2.10 Safety at the machine installation site

A suitably large, clear, and unconfined working area must be created on
all sides of the machine. Pipework, ducting, etc. must be laid such as not
to impede access to the machine.
All operating and maintenance areas of the machine must have adequate
lighting and ventilation. (industrial lighting)
The foundations must be sized to withstand the loads caused by the
machine.
Area around machine and marked escapes to be kept clear. Area around
machine must be marked as danger zone. It must be possible to enter
and leave the operating area unimpeded.
Make sure machine and surrounding area are kept clean. In particular, oil
and grease on the floor and on machine elements may cause slipping.
This is therefore a considerable source of injuries, as are tools that have
not been put down in a safe place. The operating area must be clear of
waste materials, tools and other extraneous objects.
The floor around the machine must be provided with a non-slip finish.
In order to prevent any falls from or damage to the machine, it is forbidden
to climb onto machine elements or on the machine (except for the
treading areas provided). Use ladders or similar equipment in accordance
with recognized standards.
Ramps, platforms and lifts must be used to avoid injury or excessive
physical effort.
2.11 Temperature
The CompaDis™ is designed for a stock temperature of up to 130°C.
During work on the machine, the operator shall be responsible for taking
the necessary safety measures (e.g. protective gloves, training, etc.).
2.12 Noise
The total noise emissions from all machines in the production room can
restrict spoken communication and impair hearing.
The machine is designed such that no operator is required in the
immediate vicinity of the machine during normal operation. Appropriate
hearing protection should be worn throughout maintenance and adjusting
work while the machine is running.
2.13 Electrical equipment

All work on the electrical equipment, without exception, must be carried
out by skilled electricians.
Any form of contact with electrical equipment may cause fatal injuries.

CompaDis™ - CDI0
Before beginning any maintenance or repair work, the operator must

disconnect the energy supply to all drives securely. This can be achieved
with a maintenance switch, lockable racks in the MCC, or with other
suitable measures that comply with the safety regulations.
Employees performing work on live parts should be accompanied by an
assistant who can operate the emergency switch if necessary.
Users of medical electronic equipment, such as pacemakers, must not
enter the electric danger zone.
Machine must be earthed to avoid electrostatic loading. Machine, gears
and motors must be connected to the earthing system.
Before beginning any maintenance or repair work with devices that are a
potential source of ignition, always ensure that the atmosphere inside the
disperser is not explosive.

CompaDis™ - CDI0
2.14 Hydraulic and pneumatic equipment

Hydraulic and pneumatic systems operate at high pressure. Malfunctions
in the hydraulic system may cause hazards to operating personnel,
damage to property and environmental pollution.
The specified operating data and the prescribed revision and
maintenance intervals must be observed at all times.
Systems must be depressurised before carrying out maintenance work.
Work on hydraulic and pneumatic equipment must not be carried out
other than by skilled erection personnel with special training and
experience in handling hydraulic and pneumatic equipment.
In order to avoid injuries (e.g. caused by whiplash), all pressurised flexible
hoses and pipes must be tied or held together.
2.15 Welding work

In general, welding work is only permitted after consulting Andritz AG. Any
welding work that is described in detail in the maintenance instructions is
excluded from this ruling.
When performing welding work, always observe the relevant safety
regulations, as well as the appropriate safety regulations for work
performed in enclosed and confined spaces.
HOT WORK PERMIT REQUIRED!

Danger of fire or explosion!
There is a considerable risk of fire or explosion during welding work.
DANGER
Always take the appropriate fire precautions before beginning work,
e.g. keep fire extinguishers at the ready.
All motors should be disconnected before carrying out electric welding

work.
During arc welding work, the earthing should never be allowed to run over
the rolling bearings. An earthing cable is to be connected up in the
immediate vicinity of the welding area.
Before beginning any welding work, always ensure that the atmosphere
inside the disperser is not explosive.

CompaDis™ - CDI0
2.16 Fluids, (liquids, gases, vapour or smoke)

Unintended chemical reactions may take place in fibre pulps during a
prolonged standstill and hazardous fumes may be produced.
The machine must be thoroughly cleaned after prolonged stoppages.
The area must be adequately ventilated.
Before beginning work on the machine, ensure that no liquids, gases,
vapours or smoke can enter the working area from feed pipes, discharge
pipes or shafts.
If it is not possible to reliably exclude the risk of liquids, gases, vapours or
smoke flowing in, all persons working in the danger zone must be
equipped with a safety harness and a safety rope. Each worker must be
monitored by a second person outside the danger zone.
It must always be possible to evacuate a worker from the danger zone
without delay.
2.17 Oils and greases

The safety instructions for the products concerned must be observed
when handling oil, grease and other chemical substances.
Suitable skin protection is required when handling aggressive media. See
manufacturers' information for the type of skin protection required.
Also observe relevant requirements for disposal.

CompaDis™ - CDI0
3 TECHNICAL DATA
3.1 Data
Operating data CompaDis™ CDI0

Max. permitted motor power rating. . . . . . . . . . . . . . . . . . . . . .315 kW
Nominal speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 rpm
Nominal throughput . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 t/d
Minimum flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 t/d
Maximum flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 t/d
Maximum operating temperature . . . . . . . . . . . . . . . . . . . . . . . 125 °C
Maximum operating pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . .3 bar
Sealing water Flow rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 - 5 l/min

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 bar above inlet pressure
Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < 20 °C
Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 microns (fresh water)
Weights Complete machine, without main drive . . . . . . . . . . . approx. 2000 kg

CompaFeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000kg
Actuating drive Nominal rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 kW

Nominal speed at 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 rpm
Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IP 55
Drive f. inlet screw Nominal rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 kW

Speed at 50 Hz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 rpm
Rotational speed of screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 667
Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IP 55
Main drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . see project data sheet and/or supplier documentation
Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . see project data sheet and/or supplier documentation
Disperser filling Disperser plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .see Parts Book
Rev. 0, 2008.06.04 TECHNICAL DATA Chapter.3 , Page1 of 2

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CompaDis™ - CDI0
Rev. 0, 2008.06.04 TECHNICAL DATA Chapter.3 , Page2 of 2

GRZ-2771278-v1-Technical_data.FM
CompaDis™ - CDI0
4 DESCRIPTION
4.1 Field of Application

The CompaDis™CDI0 is used to break up fibre bundles and to mix in
bleaching chemicals. The CompaDis™CDI0 detaches impurities, such as
dirt specks, stickies, wax and resin, from the fibres and reduces their size.
Abb. 4-1 CompaDis™ CDI0
Rev. 0, 2008.06.04 DESCRIPTION Chapter.4 , Page1 of 10

GRZ-2771279-v1-Description.FM
4.2 Main plant components
Rev. 0, 2008.06.04

CompaDis™ - CDI0
12
13 2 6 5 3
DESCRIPTION
9 10 8 4 7 1 11
Chapter.4 , Page2 von 10
Item Component Item Component Item Component

1 Housing 6 Disperser filling 11 Main drive
2 Inlet casing 7 Adjusting device f. rotor 12 Drive for feed screw
3 Bearing assembly and rotor shaft 8 Feed screw CompaSlice™ 13 Safety devices (not illustrated in full)
4 Rotor seal 9 Bearing assembly for feed screw
5 Rotor 10 Seal for feed screw
CompaDis™ - CDI0
Housing (Item 1) Function: The housing forms the process area in which the fiber bundles
are pulped and screened. It holds the seal and the bearing housing of the
rotor and forms the oil tank. The face end of the inlet casing (Item 2)
closes off the process area. The bi-partite design guarantees easy access
for maintenance work.
Design: Welded structure made of steel. All parts coming into contact with
the medium are made of acid-proof stainless steel. The inlet casing
(Item 2) can be swung out to the side after detaching the flange screws.
Steam feed Inlet casing Housing
Condensate drainage
Abb. 4-3 Housing and inlet casing
Inlet casing Function: In the inlet casing the fibre stock is heated using steam and
(Item 2) brought from the feed screw to the rotor (Item 6). The inlet casing holds
the seal and also the bearing housing for the feed screw. The face end of
the inlet casing closes off the process area of the housing (Item 1).
Design: Welded structure made of steel. All parts coming into contact with
the medium are made of acid-proof stainless steel. A set of disperser
fillings is screwed onto the face end, facing the housing (Item 1). Two
connections for steam feed are welded onto the top side of the inlet
casing. The stock temperature is monitored by a resistance thermometer.
Connections for adding the chemicals are provided at the side of the
housing.

CompaDis™ - CDI0
Bearing assembly Function: The shaft transmits the torque from the motor to the rotor. The
with rotor shaft bearing housing for the rotor has a movable mounting which can be
(Item 3) adjusted in axial direction in the housing (Item 1)
Design: The rotor shaft is made of tempering steel. One shaft end has a
conical shape for holding the rotor. The rotor shaft is supported in three
anti-friction bearings running in an oil bath.
Antifriction bearing
Abb. 4-4 Bearing assembly with rotor shaft
Rotor seal (Item 4) Function: The seal prevents the pulp from escaping from the housing. The
seal must have a continuous supply of sealing water. The connecting
dimension and water requirement are indicated in the arrangement
drawing.
Design: Stuffing box with five packing rings and one lantern ring.

CompaDis™ - CDI0
Rotor (Item 5) Function: The disperser filling (Item 6) is mounted on the rotor. The rotor
and bearing can slide back and forth in axial direction in order to set the
disperser gap.
Design: The rotor sits on the cone of the drive shaft. Four scrapers are
screwed on round the circumference of the rotor.
Abb. 4-5 Rotor
Disperser filling Function: The fibre bundles are broken up between the stationary and the
(Item 6) rotating disperser fillings. Since the disperser fillings have profiles, the
pulp is conveyed outwards radially.
Design: One disperger filling comprises eight segments. One disperser
filling each is screwed to the rotor and to the stator.
Scraper
Abb. 4-6 Disperser filling

CompaDis™ - CDI0
Adjusting device Function: The rotor with bearing assembly is moved back and forth in
for rotor (Item 7) axial direction by means of an electro-mechanical adjusting drive in order
to set the gap between rotor and stator. The position of the rotor is
measured by a displacement transducer. If there is no supply of pulp or
one of the safety devices is triggered, the adjusting drive disengages and
returns to the starting position.
Design: The gear motor drives the worm gear, which is connected to the
rotor bearing, via a screw shaft.
Worm gear
Screw shaft
Abb. 4-7 Adjusting device f. rotor

CompaDis™ - CDI0
Feed screw Function: The feed screw tears fibre flocs from the plug coming from the
CompaSlice™ plug screw and conveys the fibre pulp to the rotor. Here the pulp is heated
(Item 8) with steam, then chemicals are added to it and mixed in thoroughly.
Design: The feed screw is made of acid-proof stainless steel. The screw
flighting is welded to the shaft.
Abb. 4-8 Feed screw
Bearing assembly Function: Holding and supporting the feed screw.

for feed screw
(Item 9) Design: The feed screw runs in two self-aligning roller bearings. The
pedestal bearing housings are mounted on a bracket at the inlet casing.
Seal for feed Function: The seal prevents the pulp from escaping from the inlet casing.
screw (Item 10) The seal must have a continuous supply of sealing water. The connecting
dimension and water requirement are indicated in the arrangement
drawing.
Design: Stuffing box with five packing rings and one lantern ring.

CompaDis™ - CDI0
Main drive Function: The drive turns the rotor of the CompaDis™.
(Item 11)
Design: The three-phase motor is connected to the rotor via a curved
teeth coupling.
Drive for feed Function: The drive turns the feed screw of the CompaDis™.
screw (Item 12)
Design: Three-phase motor with V-belt drive.
Safety guards Function: Protects the rotating parts of the CompaDis™ outside the
(Item 13) housing against foreign objects and against contact.
Design: The covers are made of brass.
2 3 1
Abb. 4-9 Safety covers at CompaDis
Item Component
1 Coupling guard
2 V-belt cover
3 Cover for screw shaft

CompaDis™ - CDI0
4.3 Technological description
Steam feed
Condensate drainage
Pulp feed with plug
screw Adjusting device
Flushing connection
NaOH SILICATE
H2O2
Pulp with a consistency of 30% is fed from the plug screw to the feed
screw. In the CompaSlice™ the pulp is heated by steam to approximately
95°C and treated with bleaching chemicals. The pulp is reduced to flocs
by the feed screw and then fed to the disperger unit. The pulp flows
through the disperser fillings from the inside to the outside. During this
process the fibre bundles are broken down by the force of the friction
without being chopped up. Thanks to the considerable shearing forces,
impurities such as dirt specks, stickies, wax and resins are detached from
the fiber and dispersed. The dispersed pulp leaves the housing through
the discharge branch.
The pulp quality after dispersing is determined by the input of specific
energy to the pulp. The energy input is largely determined by means of
the gap between rotor and stator.

CompaDis™ - CDI0
4.4 Machine monitoring equipment

The CompaDis™ has the following monitoring equipment:
• Proximity switch for monitoring the final positions in rotor adjustment
• Temperature probe in the inlet casing
• Temperature probe in the oil tank
• Vibration monitoring unit to monitor the anti-friction bearings at the
rotor shaft
• Gap measuring

CompaDis™ - CDI0
5 ERECTION WORK and TRANSPORT

5.1 General
This chapter describes certain steps for transport, storage and installation
of the CompaDis™ CDI0, which may be the responsibility of the operator.
Activities which are carried out by ANDRITZ AG, including works
assembly, are not the subject of this description.
5.2 Safety regulations
Disregarding the safety regulations may cause a risk to life and limb.
If the safety regulations are disregarded, this may cause a risk to life
and limb and damage to the machine or its components.
DANGER
All safety instructions in this section must be strictly observed.
If the CompaDis™ is not secured to the foundation, it must always

be supported by appropriate means under the feed screw when put
down!
CAUTION
The CompaDis™ tilts forward due to the uneven distribution of
weight.
General safety All applicable accident prevention rules must be observed.

instructions
Do not exceed permissible crane loads and weights on lifting gear and
ropes/shackles. Loads must be secured against falling down.
Do not step or walk below suspended loads. Standing below suspended
loads is dangerous and thus, strictly forbidden.
Jolts must be avoided. This applies especially to pre-assembled
machines and fillings.
Qualification of Transport and unloading to be carried out by personnel specially familiar

personnel with such work.
assigned
Workers entrusted with lifting and conveying equipment must have the
required national qualification.
Start-up may only be carried out by trained, skilled workers.
Rev. 0, 2008.06.04 ERECTION WORK and TRANSPORT Chapter.5 , Page1 of 12

GRZ-2771280-v1-Erection.FM
CompaDis™ - CDI0
Personal The following protective equipment must be worn when carrying out field
protective apparel installation and transport work:
• Hard hat
• Protective clothing
• Protective gloves
• Protective shoes
• Goggles
5.3 Transportation
During transport or loading/unloading there is a risk to life and limb

from falling machine components and also a danger that machine
components may be damaged.
DANGER
Do not lift machine and transport crates except at the points marked
for lifting by crane or forklift.
If the entire machine is lifted and there are several different types of
lifting lug available, personnel should only use suitable lugs
(according to the transport sketch) for the work in hand.
Do not step or walk below suspended loads.
Delivery The CompaDis™ is supplied pre-assembled. Machine components and

auxiliary materials are packed in crates.
Transport sizes and weights are stated in the shipping documents.
Largest supply weights:
/COMPADIS™ CDI0/ TECHNICAL DATA

CompaDis™ - CDI0
Abb. 5-1 Attaching the CompaDis™ (symbolic illustration)
Acceptance • Check whether supply is complete (against shipping documents and

packing lists) and in perfect condition.
• In the event of transport damage or short supply, do not accept goods
but notify forwarder and ANDRITZ AG's shipping department.
• If there is a hidden defect or any damage, notify forwarder and
ANDRITZ AG's shipping department within two weeks.
5.4 Storage
The following instructions must be observed if the system is not to be
installed immediately.
• Please inform ANDRITZ AG's shipping department.
• Provide weather protection for stored machine components. In
particular, avoid wide variations in temperature and ensure that the
equipment is kept clean.
• Incidentals should be protected against damage and unauthorized
withdrawal by storing in a lockable room.
• Packing should not be removed until field installation work begins.

CompaDis™ - CDI0
5.5 Installation
General
Disregarding the sequence plan and the installation instructions

may result in hazardous situations causing a danger to life and limb,
as well as machine damage.
WARNING
The sequence of erection work is important and must be strictly
observed.
Completion of the various steps must be documented in the certificate of

completion of erection work.
The sequence of erection work is shown in step-by-step tables. Individual

activities are numbered in their order of precedence.
Required The following supplementary documentation must be available at the

documentation at beginning of field installation work:
installation site
• Foundation and arrangement drawing
• Pipe connection diagram
• Documentation on electrical, measuring and control equipment
• Packing lists for each individual consignment
Preparations Foundation
Foundation prepared according to ANDRITZ AG's foundation plan.
The following preparations have to be made prior to placing the
CompaDis™ on the foundation:
• Mark axes and elevations on the foundation.
• Check the workmanship of the foundation before beginning erection
work.
Preservation
Corrodible machine parts are protected with "Cortec VCI 369"
preservative grease.
The preservative grease need not be removed.

CompaDis™ - CDI0
The CompaDis™ should not be detached from the crane until it has
been anchored to the foundation or is supported under the feed
screw!
CAUTION
The CompaDis™ tilts forward due to the uneven distribution of
weight.
Machines or machine components may fall during transport at

installation site.
Do not lift machine and transport crates except at the points marked
DANGER
for lifting by crane or forklift.
Do not step or walk below suspended loads.
Parts of the body may be caught or crushed during installation work.

Do not insert your hand below suspended loads.
DANGER Wear your personal protective apparel.
Machine Set up, align and prepare the foundation for the CompaDis™ as follows:
installation
Step Activity
1 Secure the foundation blocks (1) to the machine (3) in a
central position using hexagon head bolts (2).
2 Position shims (4) on the foundation.
3 Lift CompaDis™ and place on the shims (4). When doing so,
support the CompaDis™ at the face end using the crane.
4 Align CompaDis™ according to the foundation drawing.
5 Align CompaDis™ horizontally.
6 Grout in the foundation blocks (1) with non-shrink grouting
compound (5) only and tighten the screws (2) a little.
7 Set up shuttering.
8 Check machine alignment after the grouting compound at the
foundation blocks has hardened. Then complete the base
casting layer with non-shrink grouting compound (6).
9 When the grouting compound has hardened completely,
tighten the fastening screws (2) according to the torque table
provided in the Chapter on "Maintenance".
10 Pull the coupling half onto the rotor shaft according to the
manufacturer's instructions ( /COMPADIS™
CDI0/SUPPLIER DOCUMENTATION).
Tab. 5-1 Foundations for the CompaDis™

CompaDis™ - CDI0
6 2 3
Abb. 5-2 Foundations for the CompaDis™

CompaDis™ - CDI0
Mounting the Prepare the foundation, position and adjust the motor as follows:
motor
Step Activity
1 Pull the coupling half onto the shaft stub of the motor.
2 Insert a 5 mm thick shim between the foundation blocks and
each motor leg.
The shims are inserted to compensate for the height tolerance
during motor change!
3 Secure the foundation blocks (1) at the motor (3) in a central
position using hexagon head bolts (2).
4 Position shims (4) on the foundation.
5 Raise motor and place on the shims (4).
6 Align motor according to the foundation drawing.
7 Set the correct spacing between motor shaft and rotor shaft
(see Abb. 5-4), while taking account of the spacing between
the fillings.
The setting dimensions in Abb. 5-4 can be found in the
arrangement drawing.
8 Align the motor horizontally.
9 Grout in the foundation blocks (1) with non-shrink grouting
compound (5) only and tighten the screws (2) a little.
10 Set up shuttering.
11 Check machine alignment after the grouting compound at the
foundation blocks has hardened. Then complete the base
casting layer with non-shrink grouting compound (6).
12 When the grouting compound has hardened completely,
tighten the fastening screws (2) according to the torque table
provided in the Chapter on "Maintenance".
13 Check the alignment of the coupling once again and note this
down in the erection work record for the coupling.
Tab. 5-2 Mounting the motor

CompaDis™ - CDI0
6 2 3
Abb. 5-3 Foundation for the motor
CompaDis™CDI0 Motor
Abb. 5-4 Shaft spacing, CompaDis™ - motor
Permitted angle deviation Permitted radial deviation
Abb. 5-5 Permitted deviations

CompaDis™ - CDI0
5.6 Connections
Pipework All connections and connecting dimensions at the CompaDis™ are shown
in the arrangement drawing.
Errors in the installation of pipework and hoses may result in risks

to life and limb and in damage to the machine.
Mount all pipes stress-free and free of vibration.
CAUTION
The pipework must be mounted such that it does not stress the
machine during operation (e.g. by heat expansion of the pipes).
Sampling ports
Sampling fittings are to be provided in the pipes carrying the pulp.
Instruments The instrumentation (instruments, actuators and control devices) of the

CompaDis™ is to be installed according to the flow sheet.
For information on installation and connections, see:
/COMPADIS™ CDI0/SUPPLIER DOCUMENTATION/
Vibration The vibration measuring probes are to be installed according to the

measurements control loop.
Electrical Complete electrical installations according to electrical documentation

equipment provided by Andritz AG.

CompaDis™ - CDI0
5.7 Inspections and remaining work
Sense of rotation Prerequisites

of motor
• Motor is connected to power supply.
• Coupling is open
Checking sense of rotation:

The sense of rotation of the motor should be checked according to the
following table:
Step Activity
1 Switch motor on briefly.
2 The sense of rotation of the motor shaft must match up with
the direction arrow.
3 Switch motor off again.
Tab. 5-3 Checking the sense of rotation of the motor
Sense of rotation Prerequisites

of the actuator
Actuating drive is connected to power supply.
Checking sense of rotation:
The sense of rotation of the motor should be checked according to the

following table:
Step Activity
1 Switch motor on briefly.
2 The sense of rotation of the motor shaft must match up with
the direction arrow when under load.
3 Switch motor off again.
Tab. 5-4 Checking the sense of rotation of the actuating drive
Coupling Mount coupling according to data provided by coupling manufacturer.

The tolerances observed when aligning the coupling are to be recorded in
the erection work report on the coupling.
Setting the Setting the position transducer and the limit switch, see
position
transducer /COMPADIS™ CDI0/MAINTENANCE.
Other work Other work to be completed:

• Clean the machine.
• Mount safety covers (coupling guard, etc.).

CompaDis™ - CDI0
5.8 Cold test (preparation for initial start-up)
Prerequisites The following utilities must be available:

• Electric power
• Sealing water (the pipes must be flushed out and connected up).
Cleaning • Open machine and remove any heavy parts that may have been
stored inside, as well as any fastening devices for transport purposes.
Lubrication • Initial filling of lubricant according to lubricating schedule (bearings,

etc.).
Damage to machine due to use of wrong lubricant.

Only use lubricants with the properties listed in the lubrication
CAUTION schedules.
Cold test The checks to be performed must be carried out according to the cold test
report and ticked off after completion.

CompaDis™ - CDI0

CompaDis™ - CDI0
6 START-UP
6.1 General
This Chapter describes the preparations and steps required for initial
start-up of the CompaDis™ CDI0.
If safety regulations are disregarded, this may cause a risk to life
DANGER

instructions
Qualification of Start-up may only be carried out by skilled workers with the appropriate
personnel training.
assigned
Personal The following protective equipment must be worn when carrying out
protective apparel start-up and erection work:
• Hard hat
• Goggles
Rev. 0, 2008.06.04 START-UP Chapter.6 , Page1 of 4

GRZ-2771281-v1-Startup.FM
CompaDis™ - CDI0
6.3 Prerequisites for start-up

The following must be checked before start-up:
• Erection work completed.
• Cold test completed.
• Installation site has been cleared and cleaned.
• Power and water supply are available.
• Check supply of sealing water to seals.
• All safety guards mounted.
• First filling of lubricants (gearing, bearings, etc.) provided.
• The sense of rotation of the drives has been checked.
• Function and shift point of the limit switch for rotor adjustment have
been checked.
• All electric interlocks are functional and checked.
• All control circuits have been installed and tested.
• Process control system (DCS) installed and tested.
• The CompaDis™ and all pipes have been flushed out thoroughly.
• Shut-off elements are open in the steam feed pipe.
• Shut-off elements are open in the chemicals feed pipe.
• Shut-off elements are closed in the flushing water pipe.
• Shut-off elements are open in the dilution water pipe.
• Shut-off elements are open in the cooling water pipe.
• Pulp feed is open.

CompaDis™ - CDI0
6.4 Start-Up
Machine may be damaged if incorrect start-up procedures are used.

All electric interlocks must be functional and checked.
CAUTION
Before start-up, the procedure must be defined together with Andritz AG's
start-up engineer.
Machine start-up according to the following documents:
• Start-up certificate
During start-up, practical training will also be provided on the machine.

Participants must receive instruction on the theory beforehand.
After start-up, the machine will be handed over to the mill operator in a
complete, reliable condition and ready for operation.
6.5 Certificates
The following certificates must be completed and signed after start-up:
• Start-up certificate
• Provisional acceptance certificate

CompaDis™ - CDI0

CompaDis™ - CDI0
7 OPERATION
7.1 General
This chapter describes the activities required for starting, operating and
stopping the CompaDis™. Possible malfunctions and troubleshooting
methods are also presented.
If safety regulations are disregarded, this may cause a risk to life
DANGER

instructions
It is forbidden to operate the CompaDis™ without all the required safety
devices.
Qualification of The equipment may only be operated by qualified personnel.

personnel
assigned Operating personnel must know where the emergency-off switches and
the escape routes are located.
Operating personnel must have been instructed in the function and

possible failure of machine monitoring equipment, and in carrying out
maintenance and inspection work (shift log book, maintenance inspection
records).
Personal The following personal protective equipment/apparel shall be used when

protective apparel performing work on the machine (e.g. troubleshooting):
• Hard hat
• Goggles
Rev. 0, 2008.06.04 OPERATION Chapter.7 , Page1 of 8

GRZ-2771282-v1-Operation.FM
CompaDis™ - CDI0
Safe operation The CompaDis™ is operated at high temperature. Thus it is important to

ensure that housing cover, manholes, windows, etc. have been closed
properly with fully functioning fixing elements.
Under no circumstances should the machine be operated at a higher
temperature than the maximum permitted inlet temperature.
/COMPADIS™ CDI0/ TECHNICAL DATA
7.3 Control via DCS

The CompaDis™ can be started up entirely from the DCS. The
CompaDis™ and all auxiliary units are started and stopped with the group
start and stop function.
Abb. 7-1 Monitor display (symbolic illustration)

CompaDis™ - CDI0
7.4 Start-up
Prerequisites Before starting the machine, complete the following preparation work:
• Check for residual pulp that has dried on.
Automatic starting When using the group start, all of the steps required are implemented
automatically by the DCS.
If the CompaDis™ does not start up, check that the interlockings comply
with the description of process control and instrumentation.
7.5 Normal operation
Do not operate without all safety devices ON!

DANGER
During operation, operating personnel must make sure that data are
recorded in the shift log book and data recording sheets, and also carry
out the following work.
Daily jobs and The following work has to be performed in normal operation:
checks
Component or process value Check and activity

Power input Compare the set value with the
actual value.
Steam feed Check steam pressure and
temperature.
Locking water consumption Optimum consumption
approx. 3 l/min.
Check flow meter for function and

cleanliness.
Bearing Check vibration monitoring unit.
Check oil temperature.
In case of a malfunction, proceed according to section 7.10 (Operating

faults and troubleshooting).

CompaDis™ - CDI0
7.6 Operating conditions
Substance will burn!

Power consumption as a percentage of the nominal
Operating range
Dispersion ineffective
Throughput as a percentage of the nominal
Abb. 7-2 Operating range
7.7 Shutdown
Automatic When using the group stop, all necessary steps are carried out
shutdown automatically by the DCS.

CompaDis™ - CDI0
7.8 Emergency cut-out

If there is a danger to personnel or any other operating faults (excessive
noise or vibrations), the emergency stop procedure should be
implemented according to the following table:
Step Activity
1 Push the emergency-off button at the CompaDis™.
This shuts down the CompaDis™ and the feed system

simultaneously. The rotor adjustment disengages
automatically.
2 Switch off main switch for CompaDis™ drives and interlock.
3 Detect and eliminate fault (see Chapter on Troubleshooting
7.10).
Tab. 7-1 Emergency cut-out
7.9 Re-start after emergency stop
Prerequisites for Before starting up again after an EMERGENCY STOP, the reason for the
starting stoppage must be found and eliminated.
Starting The machine should be started up according to section 7.4.
Pulp may dry on inside the CompaDis™ after a longer shutdown

period if it has not been flushed out.
CAUTION Empty the CompaDis™ manually before re-starting.

CompaDis™ - CDI0
7.10 Operating malfunctions and troubleshooting
Malfunction Cause Remedy

Poor dispersing The specific energy applied is Increase set value for power
too low. consumption.
Increase dry solids after
dewatering at the dewatering
machine.
Disperser fillings are worn. Replace disperser fillings (
/COMPADIS™ CDI0/
MAINTENANCE).
The power consumption is too The specific energy applied is Reduce set value for power
high. too high. consumption.
Reduce dry solids after
dewatering at the dewatering
machine.
Pulp temperature is too low. Check steam supply.
Increase set temperature
value.
Rotor bearing is worn. Replace rotor bearing (
/COMPADIS™ CDI0/
MAINTENANCE).
Substance will burn. Too little flow. Increase the flow rate.
The specific energy applied is Reduce set value for power
too high. consumption.
Too much wear on the Pulp is not cleaned Check that the cleaning stage
disperser fillings. adequately. is functioning properly.
The feed screw is clogged. The pulp consistency is too Reduce dry solids after
high. dewatering at the dewatering
machine.
Regulate the pulp consistency
by adding dilution water.
Stuffing box is overheating. Too little flow of sealing water. Set sealing water flow.
Sealing water supply is Switch CompaDis™ off.
clogged. Clean the locking water feed
pipe.
Stuffing box gland is too tight. Loosen the screw fitting at the
stuffing box gland.
Set sealing water flow.
Tab. 7-2 Operating malfunctions and troubleshooting

CompaDis™ - CDI0
Malfunction Cause Remedy

Pulp escaping at the stuffing Locking water pressure is too Increase locking water
box seal. low. pressure until it is 0.5 bar
above the pressure of the
pulp.
Stuffing box packing is worn. Replace stuffing box packing.
Shaft protection sleeve is Switch CompaDis™ off.
worn. Replace the shaft protection
sleeve.
Tab. 7-2 Operating malfunctions and troubleshooting

CompaDis™ - CDI0

CompaDis™ - CDI0
8 MAINTENANCE
8.1 General
This chapter describes the maintenance and upkeep of the CompaDis™,
which is the responsibility of the machine operator.
All activities mentioned in this chapter must be performed at the correct
time.
The ANDRITZ AG service department is at your disposal for
troubleshooting, as well as for extensive maintenance and repair work.
/COMPADIS™ CDI0/INTRODUCTION)
Repair work on the plant components must be carried out at the
manufacturer's works.
Workers trained and authorized by Andritz AG may carry out repairs on
site after obtaining consent from AAG.
If the safety regulations are disregarded, this may cause a risk to life
DANGER

instructions
Sufficient space for maintenance work must be included right away in the
arrangement drawing.
Maintenance and service work is not permitted while the machine is in
operation.
Do not exceed permissible crane loads and weights on lifting gear and
ropes/shackles. Secure loads against falling down.
Do not step or walk below suspended loads. Standing below suspended
loads is dangerous and thus, strictly forbidden.
Machine must be thoroughly cleaned before carrying out any
maintenance work.
Use only original spare parts.
Rev. 0, 2008.06.04 MAINTENANCE Chapter.8 , Page1 of 32

GRZ-2771283-v1-Maintenance.FM
CompaDis™ - CDI0
Safety guards After completion of maintenance work, all required safety guards must be
mounted again.
Energy supply Before beginning any maintenance or repair work the operator must
disconnect the energy supply to all drives securely. This can be achieved
with a maintenance switch, lockable racks in the MCC, or with other
suitable measures that comply with the safety regulations.
Lighting The operator shall ensure that adequate lighting is provided (with
extra-low voltage bulbs) during service and repair work.
Qualification of Maintenance and upkeep must be carried out by specially trained, skilled
personnel personnel only.
assigned
All work on the electrical equipment, without exception, must be carried
out by skilled electricians.
Personal The following protective equipment must be worn when carrying out
protective apparel cleaning and maintenance work:
• Hard hat
• Goggles

CompaDis™ - CDI0
Welding work In general, welding work is only permitted after consulting Andritz AG.
When performing welding work, always observe the relevant safety
regulations and the appropriate safety regulations for work performed in
enclosed and confined spaces.
HOT WORK PERMIT REQUIRED!

Danger of fire or explosion!
There is a considerable risk of fire or explosion during welding work.
DANGER
Always take the appropriate fire precautions before beginning work,
e.g. keep fire extinguishers at the ready.
All motors should be disconnected before carrying out arc welding work.
During arc welding work, the earthing should never be allowed to run over
the rolling bearings. An earthing cable is to be connected up in the
immediate vicinity of the welding area.
Before beginning any welding work, always ensure that the atmosphere
inside the disperser is not explosive.
Gases, steam or Before beginning any service work, ensure that no gas, vapour or smoke
smoke can enter the working area from feed pipes, discharge pipes or shafts.
If it is not possible to reliably exclude the risk of gas, steam or smoke
flowing in, all persons working in the danger zone must be equipped with
a safety harness and a safety rope. Each worker must be supervised by a
second person outside the danger zone.
It must always be possible to evacuate a worker from the danger zone
without delay.
Before beginning any maintenance or repair work with devices that are a
potential source of ignition, always ensure that the atmosphere inside the
disperser is not explosive.

CompaDis™ - CDI0
8.3 Regular maintenance

For machines operating continuously (24 hours/day, 7 days/week), a
prescheduled maintenance period every two weeks is recommended.
During these periods the machine should be shut down, thoroughly
cleaned, and checked for wear.
Machines operating less than 24 hours a day should undergo these
routine checks and be cleaned at each shutdown.
General machine The following checks should be made when the machine has been shut
checks down:
Component Checks
Sealing water supply Examine for leaks and check flow rate.
Gear unit Examine for leaks and check oil level.
Bearing Check oil level
Tab. 8-1 General machine checks
In the course of general machine checks, all additional units should also
be checked to guarantee that the entire plant functions satisfactorily. For
these checks, the attached maintenance and upkeep instructions
provided by the manufacturer must be observed.
Malfunctions and inadmissible changes found during these checks must
be rectified immediately.

CompaDis™ - CDI0
Cleaning Machine must be cleaned as follows before carrying out any maintenance
work:
• Shut down pulp feed, open locking water pipe and disengage
adjusting device at the same time.
• Shut down chemicals feed.
• Open discharge branch and shut off pulp discharge pipe.
• Flush out machine.
Contact with the pulp may cause skin damage and burning.
Persons working with the pulp should not suffer from any allergic
condition to such substances!
WARNING
Personal protective apparel must be worn.
Contact with the chemicals may cause skin damage and burning.
WARNING
Do not use caustic agents for cleaning.

Make sure no water, steam or other cleaning medium enters
CAUTION electrical plant components.

CompaDis™ - CDI0
8.4 Maintenance schedule

In addition to the work outlined below, maintenance has to be carried out
in accordance with section 8.3 and normal operation work.
/COMPADIS™ CDI0/OPERATION
Monthly The following maintenance work is to be carried out at monthly intervals.
Component Activity
Bearings • Check temperature and for noises.
Gear unit • Check oil level
• Check temperature
• Check for leaks
• Check for unusual noises
Seals • Check leaking water rate.
Tab. 8-2 Monthly
6-monthly The following maintenance work is to be carried out at 6-monthly

intervals.
Component Activity
V-belt • Check tension.
Coupling • Check for wear.
Tab. 8-3 6-monthly
Annually The following maintenance work is to be carried out at annual intervals.
Component Activity
V-belt • Check for wear.
Screws/bolts • Check that screws/bolts are firm and
tighten if necessary.
Seals • Check for function and wear.
Emergency-off switch • Check function.
Tab. 8-4 Annually

CompaDis™ - CDI0
8.5 Fasteners
Screw/bolt Bolts and screws are manufactured in several classes of material. The
material heads of these screws and bolts are marked to show the strength class.
Damaged or lost fasteners should only be replaced with fasteners of the
same material.
Check Unless they are suitably tightened, screws/bolts can work loose or fail
under operating conditions. This is why all connecting screws/bolts must
be checked in the course of maintenance work.
• During the first six months: every 2 to 2½ months
• After the first six months: 6-monthly
Tighten During checks and maintenance work it is imperative to tighten all

connecting screws/bolts to the torque specified for each one in the
drawings or in the table below.
Pre-stressing forces and tightening torques in the table apply to normal
screwed/bolted connections. Please contact Andritz AG if you have
special requirements.
Tab. 8-5 Tightening Torques and Pre-Loads for Set Screws (coarse thread)
The thread and screw head should be lubricated with an appropriate

lubricant (for example Molyslide Plus from Loctite).
Wrong torque tightening may cause machine damage and hazards

leading to personal injury.
The above pre-loads and tightening torques
CAUTION
must be observed.
8.6 Spare parts

A list of the spare parts required for the COMPADIS™ CDI0 can be found
in the parts book.

CompaDis™ - CDI0
/TEILEHANDBUCH
Details on spare parts from sub-suppliers are also included in
specifications from component suppliers.
8.7 Lubrication
The CompaDis™CDIxx is supplied ex works without oil fillings.

The CompaDis™CDIxx must be filled with oil before start-up.
CAUTION The correct oil level can be read off at the oil level window.
Before start-up, check whether all lubrication points, in particular the

bearings and gears, have been filled with the appropriate lubricants (see
separate lubrication schedule).
Details on lubrication are also included in specifications from component
suppliers.
Please also observe maintenance instructions on the maintenance signs
and rating plates attached to machine and components.
Improper disposal of waste oil is an environmental risk!

Do not add foreign matter such as solvents, brake fluid or cooling
liquid.
CAUTION
Collect leaking oil and dispose of properly without causing
environmental pollution.
Oil based on vegetable raw materials should always be collected
and disposed of separately.

CompaDis™ - CDI0
8.8 Lubrication schedule
1 2 5 3 4
Lubricating point Quantity Intervals /

[grammes, litres] Operating hours
Item Structural No. Designation Recommended First Refill Refill Oil/Grease

component lubricant filling change
1 Bearing for 1 Self-aligning roller NLGI Class 1 150 g 7,5 g 150 h 8000 h
screw shaft bearing DIN 51818
(Mobilux EP 1)
2 Bearing for 1 Self-aligning roller NLGI Class 1 150 g 7,5 g 150 h 8000 h
screw shaft bearing DIN 51818
(Mobilux EP 1)
3 Bearing for rotor 1 Oil tray Mobil SHC PM 55 l Oil level Oil 8000 h
220 gauge level
gauge
1) Open drain plug at the flange

CompaDis™ - CDI0
Lubricating point Quantity Intervals /

[grammes, litres] Operating hours
Item Structural No. Designation Recommended First Refill Refill Oil/Grease

component lubricant filling change
4 Coupling 2 Lubricating ISO-VG 460 640g 1) 3000 h

bore at the (Mobiltemp
flange SHC 460
Special)
5 Drive 1 Gear unit /COMPADIS™ CDI0/ SUPPLIER DOCUMENTATION
1) Open drain plug at the flange

CompaDis™ - CDI0
8.9 Dismounting the rotor
Removing the Proceed according to the following table when removing the rotor:
rotor
Step Procedure
1 Clean the machine (see section 8.3) and empty out flushing
water.
2 Shut down all drives at all poles and secure against
accidental start.
3 Detach pipes (Item 1-9).
Contact with the chemicals may cause skin damage and
burning.
4 1
2
5
7 8 9
4 Do not detach the screws (Item 10) and swivel the inlet
casing (Item 11) to the side until you have ensured that the
rotor has completely stopped rotating.
10
11
Tab. 8-6 Dismounting the rotor

CompaDis™ - CDI0
Step Procedure
5 Detach screws (Item 12) and remove the rotor cap (Item 13)
with the seal (Item 14).
6 Remove the top segment of the disperser filling (Item 21)
(see section 8.10).
7 Position the assembly device (Item 22) and screw down
tightly with the screws provided (Item 23).
8 Bend the safety guard (Item 15) upwards and detach the
shaft nuts (Item 16).
9 Screw the hose of the hydraulic pump into the bore (Item 20)
and push the rotor (Item 17) off.
10 Remove bearing (Item 19).
12 21
14
13
15 19
20
18
16
17
22
23
Tab. 8-6 Dismounting the rotor

CompaDis™ - CDI0
Installing the rotor The rotor is installed in reverse order to the above.
Always replace the seals when the unit is dismantled.
:
Step Procedure
1 Push the rotor onto the shaft until it is sitting securely.
2 Measure the gap. The gap must be at least 3,6 mm and not
more than 4,5 mm.
3 If the push-on distance is less than 3,6 mm because the rotor
has been mounted several times, the shaft protection sleeve
must be cut to the appropriate length to obtain 4,5 mm
push-on path again.
4 Press the rotor on hydraulically until the gap is 0 mm.

The tightening torques on the drawings and/or table (Tab. 8-5)
CAUTION
must be observed.
4,5 max. push-on path

3,6 min. push-on path
55
Abb. 8-2 Sliding the rotor on

CompaDis™ - CDI0
8.10 Changing the disperser fillings
Removing the Remove the disperser filling sets according to the following table:
disperser fillings
Step Procedure
1 Swivel the inlet casing to the side (see section 8.9).
2 Secure the segments (Item 1) in position and turn out the
screws (Item 2).
3 Remove the segments.
Tab. 8-7 Removing the disperser fillings
2
1
Stator Rotor
Abb. 8-3 Removing the disperser fillings


CompaDis™ - CDI0
Installing the Proceed according to the following table when installing the disperser
disperser fillings fillings:
Step Procedure
1 Clean the supporting surfaces on the rotor and stator and
check that they are even.
2 Check the tap holes for securing the refiner fillings. Repair
any damaged threads with Helicoil threaded inserts.
3 Coat the threads and the head supports of the screws with a
suitable lubricant. Mount the segments according to their
numbering system. Only tighten screws slightly (Item 2). The
segments must still be movable.
4 The numbers are shown on the front and on the reverse side
of the segments.
The type designation of the disperser filling is cast on the
operator side.
5 Align the stator segments to make the spacing between the
segments the same everywhere. Tighten screws (Item 2).
Tightening torques for screws according to section 8.5.

6 Place the rotor segments on the centring device and align
such that the spacing between the segments is the same at
all points. Tighten screws (Item 2).
Tightening torques for screws according to section 8.5.

Tab. 8-8 Installing the disperser fillings
Reset the position transducer again each time it has been removed (see
section 8.15).

CompaDis™ - CDI0
8.11 Changing the stuffing box packings
Removing the Proceed according to the following table when removing the packing:
stuffing box
packing
Step Procedure
1 Clean the machine (see section 8.3).
accidental start.
3 Detach the screws (Item 1) and remove the splash ring
(Item 2).
4 Detach the nuts (Item 3) and pull back the stuffing box gland
(Item 4).
5 Remove old stuffing box packings (Item 5).
6 Take off the lantern ring (Item 6).
7 Then remove the remaining stuffing box packings (Item 5).
8 Clean the stuffing box gland, lantern ring and packing area
thoroughly.
9 Check shaft protection sleeve (Item 7) and replace if worn.
Notches or grooves on the surface of the shaft protection

sleeve cause excessive wear on the stuffing box
packing!
Tab. 8-9 Removing the stuffing box packing
4
6
5
1
5
7
2
Abb. 8-4 Changing the stuffing box packing, rotor side

CompaDis™ - CDI0
Installing the Proceed according to the following table when installing the packing:
stuffing box
packing
Step Procedure
1 Mark packing (see Abb. 8-5) and cut to the appropriate
length.
Keep stuffing box clean, do not stretch or squash stuffing box

when measuring and cutting.
2 Wrap the packing round the shaft protection sleeve, then
push the first packing ring into the stuffing box, starting at the
butt joint.
The ends of the ring must form a butt joint with no gap.
3 Push the first packing ring right in using a suitable tool. Mount
the second packing ring with the butt joint offset by 120
degrees.
4 After inserting the second packing ring, mount the lantern
ring.
5 Mount the remaining packing rings with the butt joints offset
by 120 degrees.
6 When the stuffing box gland has been installed, tighten all
nuts evenly according to the setting guidelines provided
below.
Tab. 8-10 Installing the stuffing box packing
Packing cord
Flush joint, no gap
Packing marking
Abb. 8-5 Marking the stuffing box packing

CompaDis™ - CDI0
Setting the
stuffing box gland
New packings swell because they absorb water. This increases the
surface pressure on the shaft and the large amount of sealing water that
escapes at first is then reduced.
The stuffing box packing will be damaged if the stuffing box gland is
screwed too tight.
If the stuffing box gland is too tight, this will cause burning on the
CAUTION seal surfaces.
Set the stuffing box gland according to the following table:
Step Procedure
1 Tighten the screw fitting slightly at the stuffing box gland.
2 Turn on supply of sealing water.
3 Start up the machine.
4 Shut down the machine after a few minutes and check the
temperature of the stuffing box seal.
The temperature of the seal casing must not exceed 40°C.
5 Tighten the stuffing box gland further until there is less
sealing water escaping.
Tab. 8-11 Setting the stuffing box gland
• The stuffing box should be checked at short intervals during the first
few hours in operation.
• Set the stuffing box such that the shaft at the stuffing box gland is
always moist.
• Loosen the screw fitting at the stuffing box gland if the stuffing box
overheats.

CompaDis™ - CDI0
8.12 Changing the shaft protection sleeve at the rotor
Removing the Remove the shaft protection sleeve according to the following table:
shaft protection
sleeve
Step Procedure
accidental start.
3 Dismantle the stuffing box packing (see section 8.11).
4 Dismantle the rotor (see section 8.9).
5 Pull off the shaft protection sleeve (Item 1) with O-ring
(Item 2) forwards over the shaft.
Tab. 8-12 Removing the shaft protection sleeve
1
3
Mounting the shaft The shaft protection sleeve is installed in reverse order.
protection sleeve
The shaft protection sleeve as spare part is supplied with excess length
and must be cut to the appropriate length when installed (see Tab. 8-19.
INFORMATION
When the shaft protection sleeve is changed, the two seals (Item 2 and
item 3) have to be replaced.

CompaDis™ - CDI0
8.13 Bearing change, adjusting device
Removing the Proceed according to the following table when removing the bearings:
bearing
Step Procedure
accidental start.
3 Drain oil from housing.
4 Detach the screws (Item 1) and remove the covers (Item 2).
5 Dismantle the drive (Item 3) according to the manufacturer's
instructions and remove the feather key.

Tab. 8-14 Dismounting the bearing
1
2
Abb. 8-6 Dismounting the bearing
Step Procedure
6 Secure the shaft (Item 1) to prevent it from falling down.

CompaDis™ - CDI0
Step Procedure
7 Loosen and remove screws (Item 2).
8 Rotate the shaft until the screw is no longer engaged.
9 Pull out the shaft with the bearing housing (Item 3) and the
inner bearing race (Item 4), then place on the work surface.
10 Remove seal (Item 5).
11 Dismantle the bearing housing (Item 6) and remove the seals
(Item 7).
3 1 6
2 5 4 7
Dismantling direction of the shaft
Abb. 8-7 Removal of bearing


CompaDis™ - CDI0
Step Procedure
12 Remove the locking ring (Item 1) from the bearing housing
(Item 2).
13 Dismantle the outer race of the bearing (Item 3) with rolling
elements.
14 Undo the screws (Item 4) and pull back the inner bearing
cover (Item 5).
15 Detach the screws (Item 6) and remove the cover (Item 7).
16 Remove rotary shaft seal (Item 8).
17 Pull the shaft (Item 9) with the two bearings (Item 10) out of
the bearing housing (Item 11).
18 Remove the outer bearing race still in the bearing housing.
19 Detach the two lock nuts (Item 12) and pull both bearings
(Item 10) off the shaft.
20 Check shaft protection sleeve (Item 13) and replace if worn.
Notches or grooves on the surface of the shaft protection

sleeve cause excessive wear on the rotary shaft seal!
11 4
3
1 2
13 5
7
9
8 12 10
Fig. 8-8 Removal of bearing
Mounting the Installation of the bearing in reverse order.

bearings
Always replace the seals when the unit is dismantled.

CompaDis™ - CDI0
8.14 Bearing change at rotor
Preparations for Proceed according to the following table when removing the bearings:
changing the
bearing
Step Procedure
accidental start.
3 Dismantle the rotor (see section 8.9).
4 Remove the shaft of the adjusting device (see section 8.13).
5 Disconnect the coupling flanges to the motor.
6 Remove the shaft protection sleeve (see section 8.12).
7 Remove the sealing water connection to the stuffing box.
8 Remove the position transducer.
Tab. 8-17 Preparations for removing the bearing
2
17 12
4
11
16
9
3 10
6
13
5
14
1
15
7
Fig. 8-9 Removal of bearing

CompaDis™ - CDI0
bearing
Step Procedure
1 Remove gland housing (Item 1).
2 Unscrew retainer (Item 2) for bearing housing.
3 Pull rotor shaft (Item 3) out of the machine horizontally
complete with bearing housing (Item 4).
4 Remove the bearing cover (Item 5) with rotary shaft seal
(Item 6) and packing (Item 7).
5 Remove spacer ring (Item 8).
6 Undo the bolts (Item 9) and remove the bearing cover (Item
10).
7 Pull the sleeve (Item 13) off the shaft.
8 Bend the locking plate upwards, unscrew the shaft nut (Item
14), and remove the spacer ring (Item 15).
9 Pull the bearing housing (Item 4) off to the right (in relation to
Abb. 8-9).
10 Remove the parts of the bearing still on the shaft according to
the manufacturer's instructions.
( /ATTACHMENT / ANTI-FRICTION BEARINGS,
MAINTENANCE, INSTALLATION AND REMOVAL).
11 Remove the springs (Item 11) and the spacer ring (Item 12).
12 Press the spherical roller bearing (Item 16) off hydraulically.
Tab. 8-18 Removal of bearing
3 6 5 7 16 11 4 11 15 14 13
8 12 10 9

CompaDis™ - CDI0
Assembly Assemble the rotor bearings according to the following table:
Step Procedure
1 Reinstall in reverse order to Tab. 8-18
2 Check the guide bushes on the rotor side (Item. 2) and motor
side (Item 17) and replace if necessary.
3 Push the rotor onto the shaft until it is sitting securely.
4 Measure the gap. The gap must be at least 3,6 mm and not
more than 4,5 mm.
5 If the push-on distance is less than 3,6 mm because the rotor
has been mounted several times, the shaft protection sleeve
must be cut to the appropriate length to obtain 4,5 mm
push-on path again.
6 Press the rotor on hydraulically until the gap is 0 mm.
7 Maintain axial clearance between spherical roller bearing and
front cover
Axial clearance: 0,3 - 0.5 mm
8 Reset the position transducer again each time it has been
removed (see section 8.15).
Tab. 8-19 Assembling the rotor bearing

The tightening torques on the drawings and/or table (Tab. 8-5)
CAUTION
must be observed.
4,5 min. push-on path

3,6 max. push-on path
55
Abb. 8-11 Sliding the rotor on

CompaDis™ - CDI0
8.15 Setting the position transducer
Setting the Set the position transducer according to the following table:
position
transducer
Step Procedure
1 Move the disperser fillings together until they are touching.
2 Move the disperser fillings 0.5 mm apart and check whether
the rotor can be rotated freely.
3 Turn the adjusting screw (Item 1) until the display shows
zero.
4 Secure the adjusting screw in position using the top nut
(Item 2).
5 Position the two limit switches (Item 3) such that they are
triggered if the gap is less than 2 mm and greater than 14
mm.
Tab. 8-20 Position transducer
2 1
3
Tab. 8-21 Position transducer

CompaDis™ - CDI0
8.16 Changing the V-belts
When a V-belt becomes loose, the load transmission drops and

there is more wear (smell of rubber).
CAUTION!
Always replace the complete set of V-belts!
Changing the Change the V-belts according to the following table:

V-belts
Step Procedure
accidental start.
2 Remove safety covers.
3 Relieve tension on V-belts (Item 1). To do this, loosen the top
nuts (Item 2) and turn the adjusting nuts (Item 3) downwards
at the tensioning device.
4 Remove the V-belts from the pulleys.
5 Mount the new V-belts.
6 Tension the V-belts with the tensioning device. Both belt
pulleys (Item 4) must be aligned to one another. Approximate
values for tensioning, see Abb. 8-13.
7 Rotate the drive completely several times to distribute the
tension evenly.
8 Check the V-belt tension once again.
9 Mount safety cover.
Tab. 8-22 Changing the V-belts
Abb. 8-12 Changing the V-belts
Re-tension new V-belts after a few hours in operation.

CompaDis™ - CDI0
8.17 Checking the V-belt tension
Abb. 8-13 V-belt tension
At a checking force of F= 50 N per V-belt, the depth of impression Ea is

approx. 15 mm.
8.18 Installation and removal of belt pulley
Removing the Remove the belt pulleys according to the following table:
V-belt pulleys
Step Procedure
1 Remove the V-belts according to Tab. 8-22.
2 Turn out the socket head cap screws in the taper sleeve.
3 Turn one of the screws into the push-off bore hole and push
the taper sleeve off (see Tab. 8-24).
4 Pull the unit off the shaft.
Tab. 8-23 Removing the belt pulleys

CompaDis™ - CDI0
V-belt pulley Taper sleeve Push-off bore hole
Tighten the taper sleeve Taper sleeve is tight Push off taper sleeve
Tab. 8-24 Taper-Lock taper sleeve
Installing the Install the V-belt pulleys according to the following table:
V-belt pulleys
Step Procedure
1 Clean shaft, hub bore hole and taper sleeve. Remove
protective varnish or oil.
2 Place the taper sleeve and the belt pulley inside one another
and match up the bore holes. Turn in screws loosely.
3 Push belt pulley and taper sleeve onto the shaft in one unit.
4 Tighten opposite screws evenly with the required torque.
/COMPADIS™ CDI0/ SUPPLIER

DOCUMENTATION/LUETGERT
5 Mount the V-belts and safety cover according to Tab. 8-22.
Tab. 8-25 Installing a belt pulley
Clamp the bushing onto the shaft first of all. Then align the hub by
moving it on the bushing.
Caution

CompaDis™ - CDI0
8.19 Bearing change at screw
bearing
Step Procedure
accidental start.
2 Dismantle the V-belts (see Chapter 8.17).
3 Take the belt pulleys off the drive shaft (see Section 8.18).
4 Ensure that the drive shaft is properly secured and cannot fall
down.
5 Open the pedestal bearing housing (Item 2) and remove the
top parts (Item 3).
6 Remove bearing grease.
7 Bend the safety guard (Item 5) upwards and unscrew the two
shaft nuts (Item 6).
8 Mark the position of the taper sleeves Item 4) on the shaft
before removing them.
9 Dismantle the taper sleeves (Item 4) according to the
manufacturer's instructions.
( /ATTACHMENT/ANTIFRICTION BEARINGS,
MAINTENANCE, INSTALLATION AND REMOVAL).
10 Detach the fastening screws (Item 1) at the pedestal bearing
housing.
11 Take the bearing (Item 8) off the shaft together with the
locating rings (Item 7), the intermediate ring (Item 9) and the
retaining ring (Item 10).
1
7
2
2
4 4
6 5 8 9 10 3 6 5 8

CompaDis™ - CDI0
Mounting the Installation of the bearing in reverse order.

bearings
• Clean all parts before assembling.
• Position the taper sleeves at the marking.
• Set the bearing play using a lock nut according to the manufacturer's
instructions ( /ATTACHMENT/ANTI-FRICTION BEARINGS,
MAINTENANCE, INSTALLATION AND REMOVALl).
• Replace the seals in the bearing housing each time the bearing is
removed.
• Fill the plummer blocks with grease (see 8.8 Lubricating schedule).
8.20 Changing the shaft protection sleeve at the screw
Removing the Remove the shaft protection sleeve according to the following table:
shaft protection
sleeve
Step Procedure
accidental start.
13 Dismantle the stuffing box packing (see section 8.11).
14 Dismantle the bearing (see section 8.19).
15 Pull shaft protection sleeve (Item 1) off the shaft.
Mounting the shaft The shaft protection sleeve is installed in reverse order.
protection sleeve

CompaDis™ - CDI0
8.21 Removing the screw shaft
Removing the Proceed according to the following table when removing the screw shaft:
screw shaft
Step Procedure
1 Swivel the inlet casing to the side (see section 8.9).
2 Remove the shaft protection sleeve (see section 8.20).
3 Pull the screw shaft (Item 1) out of the inlet casing (Item 2).
Tab. 8-29 Removing the screw shaft
Tab. 8-30 Removing the screw shaft


CompaDis™ - CDI0
9 SUPPLIER DOCUMENTATION
9.1 455 10 - Housing
9.1.1 Ball valve
Name of company VALZ
Technical data Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NKH-G 3.8

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NKH-G 1.1
9.1.2 Level switch
Name of company MUEHLER
Technical data Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63-K-VA-M3 NIVOTEMP
9.2 455 50 - Drive
9.2.1 Crowned tooth gear coupling
Name of company JAURE
Technical data Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HAC-35
9.2.2 Gear
Name of company FLENDER
Technical data Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1SH-SIZE 05 IN=1,4
9.2.3 Coupling
Name of company FLENDER
Technical data Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-EUPEX A-280
Rev. 0, 2008.06.04 SUPPLIER DOCUMENTATION Chapter.9 , Page1 of 3

GRZ-2771284-v1-Supplier_list.FM
CompaDis™ - CDI0
9.3 455 51 - Drive - Inlet screw
9.3.1 3-phase asynchronous motor
Name of company SIEMENS
Technical data Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160M, IEC 72-1

Motor power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 kW
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400 V
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Hz
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 l/min
Motor type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IM 1001 (B3)
9.4 455 65 - Adjusting device
9.4.1 Gear motor
Name of company SEW
Technical data Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KA47TDV100L4

Output: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 KW
Transmission ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.81
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 V
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M1/B
9.5 455 70 - Oil recirculating and cooling filter unit
9.5.1 Filter unit
Name of company HYDAC
Technical data Type . . . . . . . . . . . . . . . . .UKF-1/2.0/P+V/5/0.37/415-20/MF180/10/D
9.5.2 Ball valve
Name of company VALZ
Technical data Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NKH-G 3.4

CompaDis™ - CDI0
9.6 455 80 – Special tools
9.6.1 Hydraulic nut
Name of company SKF
Technical data Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HMV34E

Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M170x3
9.7 720 42 - Instrumentation
9.7.1 Displacement transducer
Name of company TWK
Technical data Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IW 254

Measuring stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 mm
Measuring accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5%
9.7.2 Resistance thermometer
Name of company ABB
Technical data Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WXX-88239999
9.7.3 Level switch
Name of company BUEHLER
Technical data Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nivotemp 63-K-VA-M3
9.7.4 Proximity switch
Name of company PEPPERL + FUCHS
Technical data Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NJ5-18GM50-A2
9.7.5 Speed monitor
Name of company IFM
Technical data Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DI0002


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CompaDis™ - CDI0

Diana Joint Stock Corporation, PF U1085/07

Operating and Maintenance Instructions

Issued: PF Wang Sufang, 2008.06

Rev. 0, 2008.06.04 Chapter. , Page1 of 2

Rev. 0, 2008.06.04 Chapter. , Page2 of 2

3.1 General safety regulations . . . . . . . . . . . . . . . . . . . . . . . 1

4.1 Field of Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Rev. 0, 2008.06.04 Chapter. , Page1 of 4

5 ERECTION WORK and TRANSPORT . . . . . . 1

Rev. 0, 2008.06.04 Chapter. , Page2 of 4

9.1 453 10 - Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Rev. 0, 2008.06.04 Chapter. , Page3 of 4

9.7 720 42-Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Rev. 0, 2008.06.04 Chapter. , Page4 of 4

1.2 Standards and guidelines

Rev. 0, 2008.06.04 INTRODUCTION Chapter.1 , Page1 of 4

1.3 How to use the manual

Presentation • Chapter and paragraph headings are printed in capitals in the

Pictograms The following pictograms are used in the manual:

Warning signs are shown with an explanation of the

The meanings of the different graduations of hazards

Marks an instruction on handling of the machine or

Marks a useful piece of information

Marks a cross-reference to another Chapter with

Rev. 0, 2008.06.04 INTRODUCTION Chapter.1 , Page2 of 4

1.4 Warranty and guarantee

Rev. 0, 2008.06.04 INTRODUCTION Chapter.1 , Page3 of 4

1.5 Manufacturer's name and address

In case of emergency outside working hours:

Rev. 0, 2008.06.04 INTRODUCTION Chapter.1 , Page4 of 4

Rev. 0, 2008.06.04 SAFETY Chapter.2 , Page1 of 14

2.2 Danger and warning signs

This symbol indicates there may be a risk to life and limb.

This symbol indicates that there is an imminent health risk, as well

This symbol points to a dangerous situation.

Further symbols and pictograms used are described in the

2.3 Designated use

Rev. 0, 2008.06.04 SAFETY Chapter.2 , Page2 of 14

2.4 General remarks on machine/plant safety

2.5 Hazardous applications

Rev. 0, 2008.06.04 SAFETY Chapter.2 , Page3 of 14

2.6 User's obligations

Qualification of The machine/plant may only be operated, maintained and serviced by

Instructions The customer's operating and maintenance personnel is to be instructed

Definition of fields The user shall be responsible for:

Rev. 0, 2008.06.04 SAFETY Chapter.2 , Page4 of 14

Inspections The operator undertakes

The national fire protection regulations must be observed.

Rev. 0, 2008.06.04 SAFETY Chapter.2 , Page5 of 14

2.7 General obligations of personnel

Rev. 0, 2008.06.04 SAFETY Chapter.2 , Page6 of 14

2.8 Safety devices

Abb. 2-1 Safety covers at CompaDis

Rev. 0, 2008.06.04 SAFETY Chapter.2 , Page7 of 14

Emergency-off The machine/plant has emergency-off buttons to stop it in case of an

The user shall provide the following emergency-off switches:

Rev. 0, 2008.06.04 SAFETY Chapter.2 , Page8 of 14

Caustic substances may

Rev. 0, 2008.06.04 SAFETY Chapter.2 , Page9 of 14

2.9 Personal protective apparel

Activity Safety equipment

Taking pulp samples