Roller Mills Maintenance

Page 1
Page 2
Page 3
Roller mill RM 54/27– Songifa
+ High drying capacity

+ Grinding, drying and
separating in only one unit
+ Compact arrangement
+ Low energy requirement
+ Proven wear protection
+ Does not necessarily need
a proper mill building
Page 4
Raw Mill Assemblies
- Feed chute
- Mill housing
- Grinding roller pair
- Confining air
- Grinding table
- Tie rods & hydraulic system
- Mill main drive & auxiliary drive
- SEPOL Separator
- Water injection
- Roller pair Dismounting device
Page 5
SEPOL
Hoist carrier
Upper housing
Hoist
Roller pair
Drive
Lower housing
Nozzle ring
Grinding path
Tie rods
Page 6
Feed Chute
Page 7

Feed Chute
with chute optimised

Page 8

Coarse Feed Valve
Material Hot gas Hot gas outlet Hot gas inlet
Page 9

Coarse Feed Valve
Basic data
Maximum moisture content 5.7 %
Construction size ¬ 1600 x 1600
Diameter of the housing (internal) 1600 mm
Length of the valve (internal) 1600 mm
Overall height with base frame 2400 mm
Rotational speed of the vane rotor 6.5 min--1
Total weight 9000 kg
Heating with hot air requires the following indications

Minimum velocity of the hot air in the valve vmin 18 m/s
Minimum hot air volume at V. min 17625 m³/h
Nominal width of the supply pipe 400 mm
Minimum temperature of the hot air at the valve 200 °C
Maximum permissible temperature of the hot air 350 °C
Page 10

Coarse Feed Valve
Overload coupling
Type Syntex 50 TD1 Rotex GS48/50
Overload torque set when being

delivered 180 Nm
Page 11

Coarse Feed Valve
Scraper jammed
Wear on top of the

sealing strips
Wear inside the housing

Page 12

Material Feed Chute
Heated feed chute
Hot gas
Page 13

Feed Chute
Material flow
Feed chute
Hot gas
20°C
max. 350°C
259°C
261°C
Page 14
Feed Chute
Mill housing
Page 15

Mill housing
Mill doors
Page 16

Mill housing
Rubber seal
Mill doors
Page 17

Mill housing
Page 18

POSITIONS FOR THE NOZZLE RING Mill housing
6.1 Cover box
6.2 Nozzle ring segment
6.3 Cover plate
6.4 Carrier
Nozzle ring
6.5 Nozzle ring segment
6.6 Adjusting segment
6.7 Adjusting device
6.8 Adjusting guide
6.9 Fixing plate
6.10 Sealing rope
6.11 Sealing
6.12 Adjustment lever
6.13 lever shaft
6.14 Safety pin
Page 19
Roller pair Feed Chute
Mill housing
Page 20

Roller Pair
Page 21

Roller Pair
Page 22

Roller Pair
Basic data
Outside diameter of grinding rollers 2650
mm
Material of roller tyres wear resistant
cast iron
Weight of one roller tyre 10,3 t
Weight of one complete roller pair unit
80,3 t
Setting values for oil temperature
Alarm 115 °C Shutdown 125 °C
Maximum wear, measured value „S2“
150 mm
Data for repair work
Dimension „Z“ for pre--tensioning of the grinding
roller bearings 0.1 mm .
(Difference between the dimension „X” and the
height of the intermediate ring, see 7.4 Repair)
Page 23

Roller Pair
Components
• Roller carrier
• Shaft
• Bearing tension cover
• Roller bearing
• Roller body
• Clamping ring
• Roller tyre
Page 24

Roller Pair
Item No. relating to the roller pair unit
1 Roller carrier 13 Outer bearing cover
2 Axle 14 Bearing cover plate
2.3 Spring--type straight pin 25 Roller tyre
3 Slide ring 26 Stud
4 Bearing, inner 28 Washer
5 Intermediate ring 29 Retaining ring
6 Bearing, outer 35 Oil drain plug
7 Bearing tension cover 36 Cover for oil probe
8 Roller body 36.1 Cover
9 Inner bearing cover
10 Air chamber cover
11 Radial shaft seal
12.1 Hose pipe for radial shaft seal
Page 25

Roller Pair
Confining air
system
P
Page 26

Roller Pair
Confining air system
Page 27

Roller Pair
view
Page 28

Roller Pair
Confining air
Page 29

Roller Pair
Rotating part Static part
Positive air pressure to avoid dust penetration

Page 30

Roller Pair
Oil circulation system

Page 31

Roller Pair
Oil circulation system
Filter contamination checked by

Delta Pressure
Metal detector to separate particles

of the oil
Page 32

Roller Pair
Recording of the wear

on the roller tyres
Page 33

Roller Pair
Page 34

Roller Pair
Maximum wear on roller tyres

To prevent breakage of the roller tyres, the specified maximum limit values „S2” = 150 mm
must not be exceeded (see Section Technical data).
Page 35

Roller Pair
Recording of the wear on the roller tyres
Page 36

Roller Pair
Force application to the roller pair units

Force application to the roller pair is determined by the position of the hooks relative to the roller unit
axis. Experience has shown that shifting the hooks influences the wear pattern on the roller path. For
this reason, the roller pair units are equipped with adjustable hooks.
A wear-measuring inspection of the grinding elements forms the basis for the decision in which
direction to shift the hooks. A shift towards the outside (+Y) is necessary when the inner roller path
shows more advanced wear. A shift towards the centre of the grinding table (--Y) is necessary when
the outer roller path shows more advanced wear.
The roller pair units are delivered with the hook mounted in „zero position (A)”.
When turning around the roller pair units to spread the wear uniformly over the roller tyres, definitely
make sure that the hooks are in the same position relative to the roller unit axis (both in magnitude
and direction) as before turning.
NOTE
The tie rods are always suspended from the outer hooks (20).
Page 37

Roller Pair
Force application to the roller pair units
• Roller Pairs are delivered with

hooks in the zero position
• Wear inspection of the table
may indicate a need to reverse
roller pair 180 degrees
• Hooks MUST remain in SAME
position relative to the roller
unit axis.
Permissible shifting of hooks

in +Y direction 80 mm
in --Y direction 80 mm
Page 38

Roller Pair
Turning roller pair units around
Remove the roller pair units, turn them around through 180°
outside of the roller mill and re-install them into the roller mill.
When the roller pair units have been turned around,

definitely make sure that the hooks are in the same
position relative to the roller unit axis (both in magnitude
and direction) as before turning.
After installation of the roller pair units, the oil probes must be
re-calibrated and checked for proper functioning.
Page 39

Roller Pair
Replacement of the roller tire
Lay the roller pair unit horizontally on its side. Remove the nuts
from studs (26) and force off the clamping ring (27) by means of
the forcing screws. The roller tire can now be lifted off. If the
roller tire (25) has got stuck on the roller body (8) and cannot be
pulled off by means of customary fitting tools, the roller tire may
also be sprung off.
In this case proceed as follows:
Locally heat up the roller tire (25) by means of a welding
torch,
Then cool the heated areas with water (quenching).
25
Polysius personnel must be present at the first time.

Page 40

Roller Pair
Sequence of Roller bearing exchange
Prior to the assembly all parts must be checked and cleaned.
To guarantee the pre tensioning of the grinding roller bearings,

the distance of the inner rings of the bearings (dimension „X”) must
be checked with the auxiliary device (40).
For this purpose the bearing must be put into a condition

without bearing clearance.
Page 41

Roller Pair
Sequence of Roller bearing exchange
Page 42

Maintenance - roller pair
Inspection
No. Work to be performed Frequency Remarks
1 Check oil level in the oil reservoirs for weekly
lubrication of the radial shaft seals
2 Check oil level in the oil circulation weekly

system
3 Check oil level in the grinding rollers every 3 months weekly

during commissioning
Page 43

Inspection
4 Take an oil sample of the grinding every 6 months check the oil for lubrication
roller lubrication system properties and soiling
5 Check the wear on the roller tyres (25) every 6 months during commissioning
every 3 months; see Item
Recording of the wear
6 Check the wear on the guide pins (21) every 3 months the permissible wear is
10 mm
Page 44

Servicing
1 Retighten the studs (26) with the every 6 months if the roller tyres are new,
specified tightening torque. after 30 to 50,after 250,
Damaged studs have to be replaced. after 500 operating hours
2 Retighten the following bolted connections every 6 months at the first start-up and
with the specified tightening torque as per subsequently to every
table in section Repair repair after 30 to 50
- of hook (20) operating hours
- of guide pin (21)
- of outer bearing cover (13)
- of bearing cover plate (14)
- of confining air connection (22) to the
roller carrier
3 Turn around roller pair units as required latest all 2 years see Repair
Page 45

Servicing
4 Shift hooks (20) as required see Repair
5 Replace roller tyres (25) as required see Repair
6 Replace guide pins (21)

or rehabilitate by build--up welding as required
Page 46

Fault Cause Rectification
Oil supply of the roller pair Exhaust gas temperature re--adjust exhaust gas
units too high temperature
Indicator 1
Temperature monitor Fault in confining air system repair the confining air system
responds
Indicator 2 Oil level is too low re--adjust exhaust gas

Oil level monitor of the temperature
oil probe responds Leakage in roller pair unit
repair the confining air system
top up oil
find and eliminate leakage
Alarm from the see separate

oil circulation system machine manual
Page 47
Mill housing
Grinding table
Page 48

Grinding Table
Page 49

Grinding Table
1. Technical Data:
• Outside Diameter 5770 mm
• Height 2140 mm
• Number of table liner segm. 6
• Weight of table liners 31570 kg
•Total weight of the Grinding table 110780 kg
Page 50

Grinding Table
5 5
9 4 9
8 3 3
1 2 8
6 6
11 7 7
10 10
1 Whole grinding track surface machined 6 Sleeve centred

2 Evenness of grinding track 7 Sleeve material
3 Contact surfaces of clamping plates machined 8 Clamping plate secured
4 Dimensional check using template 9 Clamping plate reinforced
5 Interstices filled 10 Expansion bolt with rolled thread
11 Expansion bolt heat-insulated
Page 51

Grinding Table
Wedge element
Grinding track
Nock
Dam ring
Table insulation
Page 52

Grinding Table
All bolts and nuts of the fastening System have to

fixed with a required torque
Please refer for the required torque always in the

Grinding table assembly drawing
Page 53

Grinding Table
Correct mounting is
very important!
Page 54

Grinding Table
Page 55

Grinding Table
Adjustable Table Seal
adjustable
Page 56

Grinding Table
Grinding Table
Insulation
Page 57

Grinding Table
- Dam Ring
- Discharge Ring
Page 58

Grinding Table
Discharge Ring
Scraper elements
Wear plates
Page 59

Grinding Table
Discharge Ring
Scraper elements
Page 60

Grinding Table
Recording of wear on the grinding track
Checking and recording of wear on the

grinding track every 6 months
During the commissioning phase: every 3 months
Page 61

Recording of wear on the grinding track
Grinding Table
S1 A B
3
Page 62

Grinding Table
• Dam ring adjustment
acc. to wear
measurement New
20...25% wear
40...50% wear
Page 63

Maintenance - grinding table
Inspection
1 Checking and recording of wear every 6 months During the
on the grinding track (2) commissioning phase:
every 3 months
Page 64

Servicing
1 Retighten the expansion bolts (8.1) every 6 months When the table liners
with the specified tightening torque. Are new, after 30 to 50,
Damaged expansion bolts have to be after 250, after 500
replaced. operating hours
2 Retighten the following bolted connections every6 months At the first start-up and
with the specified tightening torque acc. subsequently to every
to the drawing specification repair after 30 to 50
- of table body (1) with gear unit operating hours
. of dam ring heightener (4)
- of cover (5.1)
3 Check the seals in the joints between the every 6 months If necessary, stuff with
table liner segments, dam ring and grinding sealing cord and then
table cover strongly compress the
cord
Page 65

Servicing
4 Adapt the dam ring heightener (4) to match as required
the wear progress of the grinding track
5 Replace worn out table liners (2) as required

Page 66

Separator
Main drive
Mill housing
Grinding table Tie rods

Page 67

Tie Rods and Hydraulic
Page 68

• Function
• Working side
• Damping side
• Grinding bed measuring device
• Limit switches
Page 69

Basic data
Maximum working pressure 162 bar
Start--up pressure „p0“ 60 bar
The pressure valves (12.1 to 12.4) are set by the manufacturer to 180 bar
Setting values for the pressure valves (17.1 to 17.4)
Pressure 60 bar
Pump (7.1 and 7.2)
Type 855 IPV4/4--13/13--471
Delivery rate 18.8 litres/min
Maximum conveying pressure 250 bar
Electric motor (10.1 and 10.2)
Type 3GBP162102--BDA
Power 15 kW
Hydraulic cylinder (30.1 to 30.4)
Type RG 360/160--500 M6427
Effective piston area 781.3 cm2
Piston accumulator (32.1 to 32.4)
Type AK 75--220--25/0/S/3
Gas volume (N2) 76 litres
Nitrogen quality 99.99 Vol% N2
Nitrogen pressure (filling pressure) 50 bar
Page 70

Description of functioning
The force required for grinding the feed material is generated by a hydraulic system.
Two hydraulic cylinders per roller pair ensure that the grinding force is evenly applied
to the rollers, while maintaining the maximum freedom of roller movement.
The hydraulic System permits infinite adjustment of the pressure in order to adapt
the grinding force to actual operating conditions.
When the mill is started up, the hydraulic pressure is lowered in order to reduce the
force applied to the grinding rollers. This in turn reduces the starting torque.
Each hydraulic cylinder is connected to a piston accumulator which dampens the

shocks generated by the rollers running over the bed of material.
Page 71

Itemnos
Itemrelating tothe
relating to thehydraulic
hydraulic unitsystem:
30 Hydraulic
1 Reservoir cylinder (30.1 to 30.4)
31 Distributor pipe (31.1
2 Rubber--metal to 31.4)
vibration damper (2.1 to 2.4)
3 Filling
32 Piston and ventilation
accumulator filterto 32.4)
(32.1
4 Oil level indicator
33 Valve block (33.1 to 33.4)
5 Ball valve (drain cock)
The pressure valves in the valve blocks
6 Level switch
are leaded
7 Pumpby(7.1 TÜVand(TECHNICAL
7.2) CONTROL
BOARD)
8 Coupling (8.1 and 8.2)
34 Distributor pipe (34.1
9 Pump support (9.1 andto 9.2)
34.4)
10 valve
35 Ball Electric(35.1
motorto (10.1 and 10.2)
35.4)
11 Valvefilling
40 Nitrogen block (11.1 to 11.4)
unit (40.1 to 40.4) consisting of
12 Pressure valve (12.1 to 12.4)
min. measurement coupler, pressure gauge and
13 Non--return valve (13.1 to 13.4)
valve14 Ball valve (14.1 to 14.4)
41 Hose
16 Shut--off valve, electrically actuated (16.1 to 16.4)
49 N217filling connection
Pressure valve (17.1 with screw--type coupling
to 17.4)
18 Filter
50 Min. (18.1 to high--pressure
measuring 18.4) hose
19 Min. measuring coupler
60 Ultrasonic measuring device (60.1 (19.1 to 19.4)
to 60.4)
20 Pressure gauge connection (20.1 to 20.4)
61 Pressure monitor (61.1 to 61.4)
21 Pressure gauge (21.1 to 21.4)
65 High--pressure
23 Ball valve (23.1hose (65.1 and 65.2)
to 23.7)
66 High--pressure hose(24.1
24 Flow control valve (66.1toto 66.4)
24.4)
67 High--pressure
25 Filter (return hose (67.1 to 67.4)
flow filter)
28 Radiator
68 High--pressure hose (68.1 to 68.4)
29 Temperaturehose
69 High--pressure sensor(69.1 to 69.4)
45 Electrical switch cabinet
Page 72

Maintenance - hydraulic tie rods
Inspection
1 Check of the hydraulic system for leakage 1 x per shift
2 Check of the filter (25) for dirt 1 x per shift
3 Check of the oil level in the reservoir (1) 1 x per shift
4 Check of the pumps (7.1 and 7.2) for 1 x per shift
abnormal running noises
5 Check of the gas pressure in the piston weekly Depressurise the

accumulators at the pressure gauges of the oil side of the
nitrogen filling units (40.1 to 40.4) piston accumulators
(32.1 to 32.4)
6 Inspection work at the piston accumulators According to
(32.1 to 32.4) manufacturer’s
instructions
7 Inspection work at the hydraulic cylinders According to
(30.1 to 30.4) manufacturer’s
instructions
Page 73

Servicing
5 Oil sampling and check for ageing and every 26 weeks Max. contamination
lubricity by the oil supplier acc. to ISO 18/15,
NAS 1638 class 9
6 Functional check of the hydraulic system yearly
7 Maintenance work at the hydraulic According to

cylinders(30.1 to 30.4) manufacturer’s
instructions
8 Maintenance work at the piston According to
accumulators (32.1 to 32.4) manufacturer’s
instructions
9 Recurring check of the piston accumulators in accordance Pressure vessel

by an expert according to the pressure with the national regulations § 10
vessel regulations regulations or in accordance
with the national
regulations
Page 74

Electric motor (10.1 or - Oil level in the reservoir (1) Top up oil
10.2) is too low
does not start Check the temperature
- Oil temperature is above sensor (29)
75 °C
Check the temperature
- Oil temperature is below sensor (29) and radiator (28)
10 °C
Exchange the filter cartridge
- Contamination of the of the contaminated filter
return flow filter (25) or
filter (18.1 to 18.4)
Oil pressure too high - Roller mill too full Check mill operation
Display
Pressure monitor - Balancing of the roller pair Replace defective hydraulic
(61.1 to 61.4) signals units is not performed due to cylinder or piston accumulator
a defective hydraulic cylinder
or piston accumulator
Page 75

Hydraulic oil temperature Radiator (28) has not been Check and repair the radiator;
is too low switched on or is defective check the setting and control
system
Display temperature Power supply is interrupted
Sensor (29) Check the power supply
Hydraulic oil temperature The radiator (28) is not Check the setting of the
is too high switched off temperature monitor
Display temperature Switching to depressurized Check control system

Sensor (29) circuit is defective
These pressure valves are
Pressure valve (12.1 to 12.4) sealed safety valves.
or pressure valve in the Defective pressure valves
valve block (33.1 to 33.4) have to be replaced.
is defective
-The working pressure is too
Duration of balancing of the high, reset working pressure
roller pair units is too long -Replace defective hydraulic
cylinder or piston accumulator
Page 76

Hydraulic oil level is too low Leakage in the hydraulic Seal the leakage and top up
Display system oil
Oil level indicator (4) and
level switch (6)
The piston in the piston Pressure drops on the gas Find and remedy the leakage;
accumulator (32.1 to 32.4) side of a piston accumulator compensate pressure drops
reaches the end position (32.1 to 32.4) by topping up with nitrogen
Display
Uneven running of the
roller mill
Formation of foam in the The hydraulic system was Seal the leak; deaerate the
hydraulic oil (visible on the not hydraulic system;
oil level indicator) sufficiently deaerated or air the hydraulic oil has to be
is exchanged
being sucked through a leak
Page 77
Main drive
Mill housing
Grinding table
Page 78

Main Drive Unit
Page 79

Main Drive Unit
Flowsheet Lubrication
unit of the Main Gear
unit
Page 80

Main Drive Unit Standard unit
1.0 Horizontal driving flange
1.1 Tilting pad thrust bearing
2.0 Coupling
3.0 Main motor
4.0 Overrunning clutch
5.0 Auxiliary gear unit
6.0 Auxiliary motor
7.0 Safeguard
8.0 Oil supply system
9.0 Vibration monitor
10.0 Gear unit bed plate
11.0 Base frame for the

main motor
Page 81

Main Drive Unit
Technical data's Main gear unit

Power output 3150 kW
Output speed 23,17 rpm
Input speed 994 rpm
Total weight 63,8 t
Total oil quantity 7000 l
Oil Viscosity CLP OIL ISO VG 320
Page 82

Main Drive Unit
Set points of the lubrication System

Lubrication oil pressure < 0,7 bar Mill stop
Oil temperature 60°C Alarm
Oil temperature 70°C Mill stop
Axial bearings
Bearing temperature 70°C Alarm
Bearing temperature 75°C Mill stop
Lubrication high pressure

Pressure < 8,0 bar Alarm loaded conditions
Pressure < 2,0 bar Alarm unloaded conditions
Filter contamination
Differential pressure1,75 bar High pressure System
Differential pressure3,15 (4,5) bar Circulation System
Page 83

Separator
Main drive
Mill housing
Grinding table
Page 84

Separator SEPOL
Page 85

Separator SEPOL
Drive shaft
Mill outlet gas duct
Guide vane adjustment
Guide vanes
Sepol housing
Sepol rotor
Page 86

housing
guide vanes
rotor
guide vane ring upper bearing arrangement
Page 87

Separator SEPOL
Techincal data‘s
Type RMR 435
Diameter of the rotors 4350 mm
Direction of rotor rotation (top view) right
Weight of the rotor 12400 kg
Wear plates in the housing yes
Eye bolt
Size M 36
Bearing capacity 16000 kg
Quantities of lubricants for initial filling

Upper bearing 3500 g
Lower bearing 7500 g
Separating air
Flow rate 870000 m3/h
Page 88

Separator SEPOL
Item numbers for the housing
1.1 Discharge bend

1.2 Separator cover
1.3 Upper part of housing
1.4 Middle section of housing
1.5 Lower part of housing
1.6 Tailings cone
1.7 Adjusting device for guide vanes
1.8 Scale for adjusting device
1.9 Guide vanes
1.10 Support for tailings cone
1.11 Inspection flap
1.12 Inspection flap
1.13 Name plate with bracket
1.14 Wear protection if installed
Page 89

Separator SEPOL
Drive unit
Type A
Gear unit
Type B3 SV 09
Drive power 152 kW
Output speed 15 -- 86 1/min
Coupling
Type N--EUPEX A200
Connecting element (6) for the separator
cardan shaft Type 587.55 -- 0.01
Page 90

Separator SEPOL
Item numbers for the rotating parts
2.3 Rotor
2.4 Shrunk--on disk or locking device for rotor
2.5 Drive shaft
2.6 Rotor blades
2.10 Upper bearing unit
2.30 Lower bearing unit
2.40 Support for the lower bearing unit
Page 91

Separator SEPOL
Item numbers for the rotating parts,

upper bearing unit (2.10)
2.11 Drive bracket only for geared motor

2.12 Locknut
2.13 Spacer ring
2.14 Spherical roller thrust bearing
2.15 Spacer sleeve
2.16 Seal for spherical roller thrust bearing
2.17A Bearing housing for cardan shaft
2.17B Bearing housing for geared motor
2.18 Spacer
2.19 Seal for spacer
2.21 Sealing disc only for cardan shaft
2.22 Seal for sealing disc
2.5 Drive shaft
Page 92

Separator SEPOL
Item numbers for the rotating parts,

lower bearing unit
2.31 Pre loading cover

2.32 Clamping element for lower bearing
2.33 Labyrinth ring
2.34 Self--aligning roller bearing
2.35 Bearing housing, at bottom
2.36 Bearing cover plate
2.37 Locking washer
2.38 Lubrication pipe
2.39 Wear protection of the lubrication pipe
2.40 Support for the lower bearing unit
Page 93

Separator SEPOL Lower bearing
Grease to bearing
Grease to
labyrinth seal
Page 94

Separator SEPOL
Setting and adjustment

Basic setting of the guide vanes with
the adjusting device Basic setting of the rotor blades
Page 95

Maintenance - separator
Inspection
1 Check for abnormal noises daily
2 Check of the bolted connections every 4 weeks
3 Check of the antifriction bearings including the every 4 weeks
labyrinth seals for sufficient supply of lubricant every 1000

operating hours
4 Check for wear

- of the wear plates (1.14), if installed
- of the rotor (2.3)
- of the rotor blades (2.6)
5 General check of the separator for leaks every 4 weeks

Page 96

Servicing
1 Replacement of the wear plates (1.14) as required if installed
in the housing
2 Replacement or rehabilitation of the as required

- rotor blades (2.6)
- guide vanes (1.9)
3 Maintenance work at the drive unit consult separate

machine manual
Page 97

Imbalance in the rotor blades (2.6) are worn install new rotor blades
separator out
clean the rotor
non--uniform cakings at the
rotor (2.3) repair the support for the
lower bearing unit
support for the lower bearing
unit is defective
Sound at the upper or the bearings units(2.10 or - check the lubrication

lower 2.30) are insufficiently pipes
bearing unit (2.10 or supplied with lubricant - relubricate the bearing
2.30) units
labyrinth ring (2.33) is
defective replace the labyrinth ring
the labyrinth seals are - check the lubrication

insufficiently supplied with lubrican pipes
- relubricate the labyrinth
seal
Page 98

The material to be the rotor speed is not correct reset the rotor speed
separated
is too coarse or too fine incorrect adjustment of the reset the guide vanes
guide vanes
Page 99

Maintenance - separator drive
Inspection

1 General visual check for every 4 weeks
- cracks
- leaks
- damage
2 Check for abnormal noises at the daily

- electric motor (1)
- gear unit (3)
3 Check of the temperatures at the daily

- electric motor (1)
- gear unit (3)
4 Inspection work on According to

- electric motor (1) manufacturer’s
- gear unit (3) instructions
Page 100

Inspection
5 Check of oil level in gear unit (3) every 4 weeks
6 Check of According to
- the coupling (2) manufacturer’s
- the connecting element (6) instructions
Page 101

Servicing
1 Servicing work on gear unit (3) According to
manufacturer’s
instructions
2 Servicing work on electric motor (1) According to

manufacturer’s
instructions
3 If the torsional clearance at the coupling (2) as required According to

is too large, the coupling packs have to be manufacturer’s
replaced instructions
4 Servicing work on connecting element (6) According to

manufacturer’s
instructions
Page 102

Gear unit (3) gets too hot Not enough oil in gear unit Top up oil or change oil
Speed of electric motor (1) Speed control defective Repair speed control
cannot be adjusted in accordance with
manufacturer’s instructions
Electric motor (1) gets too - Electric motor overloaded - See machine manual of
hot SEPOL separator
- Dust and dirt particles in
cooling system - Clean cooling system of
electric motor
Page 103

Water spray system
Items in the drawings
1 Injection pipes
1.1 Piping
1.2 Hose
1.3 Straight--way valve
1.4 Water meter (horizontal)
1.5 Water meter (vertical)
2.0 Water tank
2.1 Shut--off valve (water supply)
2.2 Drain valve
2.3 Float switch
3 Change--over filter
4.0 Motor pump unit
4.1 Motor
4.2 Coupling
4.3 Overflow valve
4.4 Drain plug
5 Contact pressure gauge
6 Drain and vent valves
7 Solenoid valve
8 Motorised control valve for injection pipe
9 Flow meter for injection pipe
10 Pressure gauge for injection pipes
Page 104

Lifting device
Separator
Main drive
Mill housing
Grinding table
Page 105

Lifting device
Page 106

Lifting device
Lifting apparatus for dismounting device
Type EH 40
Air requirement 11m³/min
Air pressure 6 bar
Lifting capacity 2 x 420 kN
Lifting height 9000 mm
Weight (Lifting apparatus) 4460 kg
Tightening torque for
connecting bolts of mounting
hoist beams with housing 3800 Nm
Tightening torque for
connecting bolts of mounting
hoist beams with the fish plates 1650 Nm
Page 107

Lifting device
Dismantling of a
roller pair in progress
Page 108

Lifting device
2.1 Two mounting

hoist beams, internal
2.2 Mounting hoist beam,
external
2.3 Lifting apparatus
2.4 Safety stops
2.5 Fish plates
2.6 Compressed - air hose
Page 109
The End

Roller Mills Maintenance

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Roller Mills Maintenance

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Page 1

Roller mill RM 54/27– Songifa

+ High drying capacity

Roller mill RM 54/27– Songifa

Raw Mill Assemblies

Roller mill RM 54/27– Songifa

Roller mill RM 54/27– Songifa

Roller mill RM 54/27– Songifa

with chute optimised

Roller mill RM 54/27– Songifa

Roller mill RM 54/27– Songifa

Heating with hot air requires the following indications

Roller mill RM 54/27– Songifa

Overload torque set when being

Roller mill RM 54/27– Songifa

Wear on top of the

Wear inside the housing

Roller mill RM 54/27– Songifa

Heated feed chute

Roller mill RM 54/27– Songifa

Roller mill RM 54/27– Songifa

Roller mill RM 54/27– Songifa

Roller mill RM 54/27– Songifa

Roller mill RM 54/27– Songifa

Roller mill RM 54/27– Songifa

Roller mill RM 54/27– Songifa

Roller pair Feed Chute

Roller mill RM 54/27– Songifa

Roller mill RM 54/27– Songifa

Roller mill RM 54/27– Songifa

Roller mill RM 54/27– Songifa

Roller mill RM 54/27– Songifa

Roller mill RM 54/27– Songifa

Roller mill RM 54/27– Songifa

Roller mill RM 54/27– Songifa

Roller mill RM 54/27– Songifa

Roller mill RM 54/27– Songifa

Confining air system

Rotating part Static part

Positive air pressure to avoid dust penetration

Roller mill RM 54/27– Songifa

Oil circulation system

Roller mill RM 54/27– Songifa

Oil circulation system

Filter contamination checked by

Metal detector to separate particles

Roller mill RM 54/27– Songifa

Recording of the wear

Roller mill RM 54/27– Songifa

Roller mill RM 54/27– Songifa

Maximum wear on roller tyres

Roller mill RM 54/27– Songifa

Roller mill RM 54/27– Songifa

Force application to the roller pair units

Roller mill RM 54/27– Songifa

Force application to the roller pair units

• Roller Pairs are delivered with

Permissible shifting of hooks

Roller mill RM 54/27– Songifa

When the roller pair units have been turned around,

Roller mill RM 54/27– Songifa

Polysius personnel must be present at the first time.

Roller mill RM 54/27– Songifa

Sequence of Roller bearing exchange