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Roller Mill Similago II Manual
Roller Mill Similago II Manual
User Manual
SINGLE and DOUBLE ROLLER MILL
SIMILAGO II
www.alapala.com
SIMILAGO II
OPERATION SHEET for FOUR and EIGHT CYLINDER ROLLER MILL
This sheet is punctured from left side! Take off the sheet and attach it near the machine.
This sheet is for reminder purposes and does not replace detailed guidelines and DAVG (Similago II) user manual information.
Security Maintenance
Keep your hand out of milling chamber. Dont forget weekly oil maintenances, machine grease oiling
Do the cleaning only with assisting devices, with a broom for quarterly and yearly oil change.
example.
Dont take off covers and protectives. (Check the maintenance program in user manual!)
Remove the covers and protectives only when the machine is
not working for review purposes then immediately put them
back. Operation
Machines with gear or chain transmission equipments Check these daily:
transmission chamber can only be opened from the top side
when the machine is not working. Input milling milling chamber output - feeding.
Cylinder Changes
Steel rope may cause the cylinder to drop on your foot by
breaking. During the detachment of the cylinder, check the steel
rope for damages and breaks before using.
SIMILAGO II
OPERATION SHEET for FOUR and EIGHT CYLINDER ROLLER MILL
This sheet is punctured from left side! Take off the sheet and attach it near the machine.
This sheet is for reminder purposes and does not replace detailed guidelines and DAVG (Similago II) user manual information.
Security Maintenance
Keep your hand out of milling chamber. Dont forget weekly oil maintenances, machine grease oiling
Do the cleaning only with assisting devices, with a broom for quarterly and yearly oil change.
example.
Dont take off covers and protectives. (Check the maintenance program in user manual!)
Remove the covers and protectives only when the machine is
not working for review purposes then immediately put them
back. Operation
Machines with gear or chain transmission equipments Check these daily:
transmission chamber can only be opened from the top side
when the machine is not working. Input milling milling chamber output - feeding.
Cylinder Changes
Steel rope may cause the cylinder to drop on your foot by
breaking. During the detachment of the cylinder, check the steel
rope for damages and breaks before using.
Important Notes Single / Double DAVG - SIMILAGO II
This user manual is prepared for the personnel who are responsible for operating and Relevant guidelines in the given documentation about preventing accidents must be
observing the machines and equipment by ALAPALA or your facility. For this reason, it observed and applied. ALAPALA always strives to design its machines suitable for latest
is necessary for this user manual to be delivered to the relevant people. international safety standards. Before the production begins, customer must show special
security and safety regulations to ALAPALA. If these causes extra cost, it will be covered
by the customer.
B ) Receiving
H ) Maintenance / Cleaning
It is necessary to make a visual control after the machines are received. If any damage
related to shipping is detected, relevant clauses in the supply contract must be
executed to determine the damage claim. Repair expenses will be covered by risk Maintenance can only be made by the personnel who have a command of the guidelines
bearer party. given in the documentation. These guidelines purpose is to preserve machine,
equipment or facility value, keep the depreciation at lowest and ensure long and efcient
C )Storage / Maintenance lifetime of factory and equipment. Cleaning must be done according to the legal
legislation and guidelines in the given document.
Machines and equipment which are not going to be assembled immediately must be
stored in big cases or chests, protected from air and other factors. Damage occurring I ) Copyrights
during the storing will be discussed only according to the supply contract.
Our rights in this document and mentioned issues are reserved. Receiver who accepted
the document also accepts these rights. Receiver accepts that he will not publish the
document or its content wholly or partially, not give it to the other third parties without our
D ) Assembly / Installation written or any other authorization and use the content aside from its purpose.
ALAPALA machines and machine components assembly and installation can only be
made by personnel trained for this purpose. Relevant personnel are responsible for J ) Guarantee
observing the guidelines received with the equipment at assembly and installation
Guarantees are given for contractual agreements and valid if only original ALAPALA
spare parts are used. Producer cannot be held responsible for damages caused by
E ) Different Models application of your companys personnel, not complying to guidelines or operational
mistakes of untrained personnel.
If guidelines are mentioning different models of the same machine, the guidelines
prepared for the delivered model are applied. If the changes to the machine creates
improvement, ALAPALA keeps the right to make changes to the machine until delivery.
K ) Guideline Necessity
User or owner of ALAPALA machines and facilities is obligated for giving orders to
F ) Starting and Adjusting personnel about using machines and equipment according to the operation guidelines
and inform them of the dangers about the operation of machines and installations. If
Starting and adjusting can only be made by trained personnel. Before rst start, requested, ALAPALA can give training for the price.
authorized personnel must have a command of the guidelines and operation manual.
Before rst start, oiling guidelines, for example lling chamber oil, must be applied.
Single / Double DAVG - SIMILAGO II Operation Sheet
SIMILAGO II
OPERATION SHEET for FOUR and EIGHT CYLINDER ROLLER MILL
This sheet is punctured from left side. Take off the sheet and attach it near the machine.
This sheet is for reminder purposes and does not replace detailed guidelines and DAVG (Similago II) user manual information.
Security Maintenance
Keep your hand out of milling chamber Dont forget weekly oil maintenances, machine grease oiling
Do the cleaning only with assisting devices, with a broom for once in three months and yearly oil change.
example.
Dont take off covers and protectives ( Check the maintenance program in user manual! )
Remove the covers and protectves only when the machine is not
working for review purposes then immediately put them back.
Operation
Machines with gear or chain transmission equipments Check these daily:
transmission chamber can only be opened from the top side
when the machine is not working.. Input milling milling chamber output - feeding.
Remote Controller
Troubleshooting
Turns off the machine and lock main button
Check the troubleshooting guide in user manual.
It is required to prevent machine from accidentally started
during every maintenance and general maintenance.
Cylinder Changes
Steel rope may cause the cylinder to drop on your foot by
breaking. During the detachment of the cylinder, check the steel
rope for damages and breaks before using.
Single / Double DAVG - SIMILAGO II Index
03 SPECIFICATIONS 04 ASSEMBLY
4.1 Placing 27
2.1 Denition 07
4.1.1 Environment conditions 27
2.1.1 Type code explanation 08
4.1.2 Vertical place changing 27
2.1.2 Model sheet 08
4.1.3 Placing machine 27
2.1.3 Model types 08
4.2 Assembling main components 28
Index Single / Double DAVG - SIMILAGO II
01
SIMILAGO II
Security
Security Single / Double DAVG - SIMILAGO II
Explosion
Important Note Only approved machines and devices are used in areas with explosion risk.
If instructions are not followed, machines operation and performance are (check the label)
not guaranteed. If you see this label, it means the machine can be used in Ex-areas.
This symbol denes ATEX sign. This sign shows which Ex-area and inner
area the machine can be used.
Before installing machine at Ex-area inner area, the things to be careful
1.2 Operator Security
about are that there should be no aming areas around the machine, no
metal or rock entering into the machine.
Protective covers must be kept assembled and closed when the machine
is operating. Open or lacking protective caps may cause injuries.
Special protection sign for explosions
Group It Belongs To ( II )
Machines security functions must not be deactivated. Category ( 3 )
Explosive area letter code due to gas, vapour and smoke ( D )
Harf Kodu ( D )
It must be deactivated during machines maintenance, repair and II 3 D } MAIN SIGN
lubrication processes.
EEx d IIB T1 } COMPLEMENTARY SIGN
Protective gears like shoes, clothes, glasses and others must be Heat Class
used. Gas Group
Protection Method ( Against Explosions )
Clothes must be chosen in a way not to get stuck in moving parts Suitability to European Norms ( Ex-Products )
and according to the instructions.
03
Single / Double DAVG - SIMILAGO II Security
Use a feeding line according to the legislations. STOP Pneumatic valve must be closed before starting to maintenance or repair
processes.
Make sure that voltage and frequency are suitable according to the Feeding cylinder driving engine must be shut down with security switch and
information on control unit. secured with a padlock.
In case of single phase electricity feed, make sure that controller feeding 1.7.2 Sample
line connections are done according to the connection scheme.
It is possible to open milling chamber cover while machine is working to
get sample.
1.5 System Security
Apart from taking samples, machine can only be opened by experts and
DAVG Similago II 4 and 8 cylinder mills are the complementary part of a facility and with special equipment.
should be regarded as a part of systems security concept.
In case the machines are used outside of this security concept, operator must Machine must be shut down for all the work done to the milling chamber.
redene the danger that may be caused by the machine and necessary precautions
must be taken to ensure security.
Cylinders entrance points are protected with protection plates. These
1.6 Eroded Part Management plates must not be removed in any condition.
Only original spare parts must be used. In case the original spare parts are not used,
machine might not realize the expected functions and not give the expected
performance.
04
DAVG
02
SIMILAGO II
Transport
Transportation Single / Double DAVG - SIMILAGO II
Warning
Machines transportation must be done with experts who are trained and
experienced. > 60
You can use crane for loading and unloading.
For carrying DAVG Similago II with a crane, two G1 Pipe threaded two
geared holes are on the machine.
Two gaskets
Transportation Warning
Use crane and lifting equipment at the right angle and position according to 3.3 Transport Weight and Volume
their design and lifting capacity.
23
Tek Katl / ift Katl DAVG - SIMILAGO II Tama
24
DAVG
03
SIMILAGO II
Specication
Specications Single / Double DAVG - SIMILAGO II
2.1 Denition
Mill, including the front body output bunker through the cylinder, is produced with Double walled isolated cover which can be easily removed or attached
double walled and isolated against condensation and adhesion. without a screw connection that works with a weight system that can be
closed without latches, designed and patented by Alapala for control.
Mill, with minimum part removal thanks to its side covers which are based upon Transparent polycarbonate glass, which can be removed easily from
opening system, enables fast and easy accessibility option and, via the cover on outside without removing any other part, though which product can be
the cylinder, enables fast cylinder removal. seen from outside easily, product input and product feeding system.
Diffuser anchor at the back, differentially driven spreader cylinder at front
Thanks to tested belt drive, it gives the advantages of silent working, removing the for product to be spread on cylinders surface equally and feeding system
oil maintenance and dirtiness. Also, it enables the cylinders to be chance really with manually adjustable valve to adjust products spread thickness.
fast as a set and also the ability to be removed one by one.
Mechanic parts, mechanic electro mechanic setting and pneumatic control
All single and double layer mill are consisting of two parallel passaged, which
mechanisms group.
each of which has a pair of cylinders.
Strong bedding, double line barrel moving conoid ringed cylinders, hard
Mill machines are produced in two basic structures according to its to area of use: layer thickness is 25 mm. high quality produced with centrifugal casting
these are; method.
Special alloyed casted cylinders; 500-550 Brinel hardness for B passages,
430-470 Brinel hardness for C passages, homogenous.
Single layer for single usage
By deactivating the sifting operation, two layered machine for mass Pneumatic controlled radial fast mechanism for fast opening and closing of
usage. the cylinders gap.
07
Single / Double DAVG - SIMILAGO II Specications
Designed especially for sensitive adjustment of cylinder gap with strong 2.1.3 Model Variations
and precise ne tune mechanism and mercurial claw indicator turning
cylinder which can keep its position in micron values.
Remote control and automatic start possibility with servo drive addition to
ne tune mechanisms standard structure, as an option.
2 Year
Model 1 Serial
Number
Type, Year, Serial Number 2 ALAPALA MACHINE INDUSTRY AND TRADE INC. P.O. BOX 54
19001 ORUM / TRKYE
Machine - No. 3 Tel : + 90 ( 364 ) 254 95 60 (5 Lines)
II 3D T4 Fax : + 90 ( 364 ) 254 92 90 - 213 17 42
ATEX - ID Denition 4
4 3
08
Specications Single / Double DAVG - SIMILAGO II
2.2 Structure
Product Input
Feeding Systemi
Milling Section
Output Section
09
Single / Double DAVG - SIMILAGO II Specications
3 Sensor
Product Input 1
4 Distribution screw
5 Feeding cylinder
Flow Adjust Valve 6
11
11 10
10
Specications Single / Double DAVG - SIMILAGO II
Product Input
Feeding System
Milling Section
11
Single / Double DAVG - SIMILAGO II Specications
3 Sensor
5 Feeding Cylinder
Aspiration Line
(Airow) 13
Trimel
(Direct output) 14 15 PLC - Inverter
12
Specications Single / Double DAVG - SIMILAGO II
Some parts tip points have air pistons to enable movement. Aforementioned It consists of a glass bell immobilized with a strong steel frame. Product
pistons work under huge inner pressure. Thats why shock absorbers must not be ow must be seen with naked eye. A blockage sensor is used that controls
forced to open and exposed to heat over 100 C the product ow at product input section. In case of a product ow faster
than product procession speed, it stops product ow to prevent blockage
of system.
As the product coming into the machine ows through a stable dimension,
Adjustment Piston it has to be guided to cylinders for good spread. Milling cylinders feeding
function group elements do this.
Front Cover latch
Upper cylinder which has spiral anchors on top enables product to be
spread blatantly lower cylinder which has gears enables product to be
guided as a straight ow towards milling cylinders.
Air Input and Spread Fitting Lower cylinder gears are produced and designed spiral proled gears
according to the processed units particle structure.
Cylinders take their power from a reducer engine. Reducer engine choice
changes according to product process. There are two independent feeding
group and two separate reducer engine diagonally in a mill.
Product input
To enable milling cylinders absorb the air before the cylinder gap chamber, a
channel system is placed under milling cylinders.
2.3 Function
Milling system, which consists of parallel cylinders that automatically open and
close with an electric controlled pneumatic system, works by milling the grains
between two cylinders.
13
Single / Double DAVG - SIMILAGO II Specications
According to cylinder being Liso or Breaking, cylinders outer surface is Pneumatic absorbed air ow in mill and dust circulation caused by the product is
produced as centrifugal casting with suitable thickness and hardness steel, bypassed by itself thanks to a special pipe system.
its inner wall is also produced with centrifugal casting as one piece.
Breaking cylinders hard outer surfaces are processed with gear proles
according to diagram and passage requirements. Lisa cylinders are also
sandblasted to get the desired surface smoothness according to diagram
and passage specications after suitable camber is made.
Feeding
Cylinder
2.3.3 Control
Milled grain is transferred with pneumatic system from output funnel and
stored.
Product Output
PLC - Inverter
Injectors
14
Specications Single / Double DAVG - SIMILAGO II
Cylinder speed is adjusted via special straps. Redactor can be attached. DATA
1 : 1,04 1 : 1,27 1 : 1,59 1 : 2,07 1 : 2,50 1 : 3,03 1 : 3,51 1 : 3,75 Gauging surface Leq = 17 dB
300
Constant sound pressure level (2) Leq = 77 dB (A)
Work Power 15 kW
AIR PRESSURE
Working Press 6 bar Product eff 1.6 t / h / m
15
Single / Double DAVG - SIMILAGO II Specications
2.5 Dimensions
695
171 411 171
1030
16
Specications Single / Double DAVG - SIMILAGO II
463
1826 2076
1929
1929
1280
1280
695
695
1866
1616 171 411 171
171 411 171 1030
1030
17
Single / Double DAVG - SIMILAGO II Specications
DAVG - 76C - 4x250x1000 ( Inner Suction ) DAVG - 76D - 4x250x1250 ( Inner Suction )
Optional Spec Optional Spec
695
695
813 813
18
Specications Single / Double DAVG - SIMILAGO II
DAVG - 76C - 4x250x1000 ( Inner Suction ) DAVG - 76J - 8x250x1250 ( Inner Suction )
Optional Spec Optional Spec
463
463
1826
2076
1929
1929
1280
1280
695
695
1866 1616
813
813
19
Single / Double DAVG - SIMILAGO II Specications
2.3.5 Oiling
Machine does not need to be generally re-oiled. But some parts need to
be oiled from time to time.
Weekly
Monthly
Quarterly
20
DAVG
04
SIMILAGO II
Assembly
Assembly Single / Double DAVG - SIMILAGO II
4.1 Installation To ease the location of the machine with machine support plate, 4 M12
screws (or pins) can be installed to each one of the mounts before
4.1.1 Installation Area Conditions installation.
To prevent machines vibration spreading to whole building,
For the installation area of the machine, installation space, surface, surface aforementioned assembly supports must be removed after machine is
carriage capacity must be considered one by one and suitable conditions installed.
must be provided.
There are four D13 mm in diameter holes are present on machines mount
DAVG Similago II machines must be built on shared body so that the base. To prevent machine from bending, mill body must be installed to the
balanced and non-vibrating surface conditions can be met. points where equipment is designated.
Machine can only be assembled on wood or steel prole according to Additional equipment must be installed on earthquake prone zones.
customer demand.
To get the maximum level of sound insulation, DAVG Similago II must be Body is xed to the ground
with 4 M12 steel pin.
places on 65 mm heighted vibration absorbing rubber steel support plate.
Important Note
For Double 8x250 DAVG, 30 mm plate both inside and outside of mounts Additional xing equipment must be installed on earthquake prone zones.
are placed. (8 x 30 mm for each machine). This is valid for this machines all models.
27
Single / Double DAVG - SIMILAGO II Assembly
It must be ensured that after machines installation, suction pipe is placed LC 1000 mm 5,7 ... 7,3 m3 / min 5,5 ... 10,5 m3 / min
well into the felt gasket.
LC 1250 mm 7,3 ... 9,1 m3 / min 7,5 ... 13,0 m3 / min
Product output differentiates according to diagram and project and there are a lot
of different versions. Output section is designed as single, double and triple and is 4.3 Electric Connections
xed to the machines lower section with M8 screws. Similago II is delivered without electric control panel and connections. Similago II
has the below as electric connection equipment:
Assembly Method :
Connection parts must be assembled to their places, starting from collection 24 V DC; 20 W: for both controllers (without additional outlet).
bunkers lower section.
380...500 V AC 2,6 A: For both frequency convertor of feeding engines.
Output Hopper
It will be assembled by ALAPALA or customer according to the design of
380...500 V AC: For milling cylinders drive engines. (Consumption both for
the machine.
passing and load).
Discharge Cone
150 mm diameter output bunkers discharge cone is installed with clamp.
1 A type current transformer installed to control unit (optional)
Then 120 mm diameter reducer cones are installed. Hoppers
impermeability must be tested in order to keep the air leakage at minmum
level at mills lower section. 4.3.1 Safety Switch
Suction Pipe Service switch that works to split feeding drive engine from all poles must be
Suction pipe Ensure air impermeability here too. connected to frequency convertor.
28
Assembly Single / Double DAVG - SIMILAGO II
07
Serial interface (if demanded) 01 02 04
03 03 08 03
Validity signal 03
06
4.3.3 Sensors
29
Tek Katl / ift Katl DAVG - SIMILAGO II Montaj
30
DAVG
05
SIMILAGO II
Operating
Operating Single / Double DAVG - SIMILAGO II
DAVG Similago II's operations, trial start and settings must only be carried out by
expert, authorized and qualied personnel.
Cylinders are protected against erosion with product. This protective must be
removed before usage.
Fixing lever
Warning
5.2 Controls Ensure that grinding cylinders do not touch each other during operation.
Grinding cylinder gap must be control with a thickness gauge stick and
Important Note
cylinders must be set as 0,3 mm when installing to the machine.
To ensure a good air isolation, all pipe connection elements and equipment
must be connected tightly.
During rst start, make sure that minimum feeding cylinders gap is set as
below 0,15 0, 50 mm for breaking function, 0, 1 mm for liso function and
gaps are parallel to feeding cylinders.
33
Single / Double DAVG - SIMILAGO II Operating
With a pitch, 3/100 thickness gauging stick or a two paper tape with same Grinding cylinder cylinders are oiled in one way;
thickness, check whether bladed scrapers are parallel to each other when
installed. Check the gap is at least 2 mm when blades and grinding cylinders are From central oil block,
installed
Via greaser on top of cylinder chamber cover.
Scraper Pressure Gap
Cylinder chambers and oil block feeding cylinder pipes are lled with oil in
Scraping Part
the factory.
Before rst start of Similago II, cylinder chambers must be oiled with 40 g
lithium based oil for security reasons.
Fixing Screw
34
Operating Single / Double DAVG - SIMILAGO II
5.3 Setting
5.3.2 Grinding Cylinders Gap Adjustment
Principles regarding the adjustment and operation of feeding and grinding
cylinders are explained. Grinding cylinders gap is adjusted via two hand levers on each side.
To adjust the position indicators, the small screw at center on the frill. First
gap adjustment is shown on .
35
Single / Double DAVG - SIMILAGO II Operating
36
DAVG
06
SIMILAGO II
0 1
11
1
10 12 2
9 3
8 4
7 6 5
Settings
Settings Single / Double DAVG - SIMILAGO II
Warning
In case there is enough product in input section, milling cylinders, a bit later than
STOP SIMILAGO II shall not be started without its protective equipment. feeding cylinders, start working. Cylinders separate automatically after product is
Removing protective covers and housing are forbidden. nished. Product level can also be entered manually via control panel.
For going through control procedures, aforementioned equipment can only
be removed when machine is not working and must be attached back
Grinding cylinders, via prestressed strings, attached to strapped turnbuckle in two
immediately. roller chambers. This exible structure prevents possible foreign matter from
damaging the cylinders. Cylinder gap can be adjusted via hand lever.
Warning
Do not touch the gap between mills. Do the cleaning just with cleaning Cylinders heat must be stable all around the cylinder. For control, authorized
equipment, like broom. personnel must open the cover of control section upwards. Grinding cylinders
heat must be measured with device, without touching.
Warning
During maintenance and remote controlled adjustment, to prevent mill unit
operate via remote controller unwillingly, shut down and lock main switch.
Warning
Do not try to measure rotating cylinders heat with hand.
Important Note
Product Flow must be checked every day.
Keep inside and outside of the machine clean. Ensure that products do not Feeding cylinders rotation speed, product level in cylinders and engines
stuck to grinder or machine surfaces. runtime can be seen from control panel.
User interface enables to see the information and intervene to the machine
Warning via computer.
In case of neglect, serious material damage or faulty product can happen.
6.2 Operation
Similago IIs operation, error codes, repair solutions, machine setting and control
panel usage schemes are covered in this section. 6.2.1 Setting
Machine settings can be done from the setting buttons on the machine or via main
We strongly recommend you to use this information as a guide to operate your control panel.
machine.
6.1 Standard Operation 6.2.2 Control
Machine is operated via electronic controller. Feeding cylinder rotation speed is To do feeding gap setting, gap must be designated as 90 degrees. At these
adjusted automatically with a mechanic clutch system electronically according to conditions, setting will be checked automatically.
product quantity.
Combination and separation of grinding cylinders are done via solenoid valve or
pneumatic cylinder.
39
Single / Double DAVG - SIMILAGO II Settings
24 V conrmation is not realized. Conrm 24 V Pressured air supply does not work or
Check compressor and pneumatic grid
is under <4,5 bar
Motor switch is turned OFF Turn it ON
Ball valve is closed Open the valve
Control is Manuel Change it into AUTOMATIC
Product on entry is too few Wait until there is sufcient product
Grinding cylinders go to clutch mode
Frequency conventor or power source
Check and x it. Change it into AUTOMATIC
of the motor is broken Control is Manuel
Motor is too hot and cannot cool off Reduce the space so that rotation speed Plug of the solenoid valve is loose Check and tighten it
itself of the motor can increase
Pneumatic cylinder is broken Change the cylinder
Feeding cylinders arent rotating Frequency conventor is broken or Check and change it, cool the control
overheated panel better Fix the bearing cover
Cylinders touch to side walls Bearing cover is placed wrongly
(Checked with radial channel)
Drive belt may be torn Change it
Foreign object in the material to be Place a magnetic detector before the
There is bloating
DMS is broken Change it grinded rst grinding
Foreign matters among feeding cylinder Remove it Product cone is too deep Set a higher NIVMIN value
No product to grind on cylinder tips
Bearing shell is broken Change it Pallets are xed too straight Fix it
Product shows itself from underneath Bearing shell is too oily
Cylinder gap is too small Open it Fix it
the deector
Distribution bridge may be clogged Clean it Grinding cylinder chambers are There is wrong or old oil in the bearing
Oil it again / change them
heating shell
Rotation speed of feeding balls are Clean the ball scrapers and set them
Feeding cylinders leave trace too slow again Insufcient bearing gap Fix it
Foreign matter at entrance Push the section back and clean Insufcient grinding Cylinders are not xed to the chamber Change it
Cylinder gap suction is blocked Clean it Product is stuck to straight cylinder Scrapers are worn or placed wrongly Reset / change / x them
Product accumulated between upper and
Remove the product Crushed material stucked in product One side of the channels is Check clutch and disc coupling / Set
lower grinding balls
Gathering probes between cylinders feeding off-position the pallets
are alarming ( only for 8 mills )
Sensor is set too tight Set the sensor Eccentric does not move properly Add oil to the related lubricant point
40
Settings Single / Double DAVG - SIMILAGO II
Main Panel
Aktif Alan
Section
Alarm Page
ALARM
Menu Section
SETTINGS GRAPHIC ALARM MANUEL TOTAL
LEVEL Work level PLC LADDER Ladder Regarding
SET PAGE
settings Machines Work
SPEED
ALARM
Alarm Control
--- and Reset
Incoming Product
Main Engine Indicator Level Indicator
41
Single / Double DAVG - SIMILAGO II Settings
Shows incoming
products level
Alarm Warning
SPEED CURRENT
100 79
Remote / Local
Remote :Speed is adjusted Feeding start / stop shows
according to product auto.. if feeding mill is rotating or not
Local : Manual value.
42
Settings Single / Double DAVG - SIMILAGO II
DRIVER PAGE
Work level settings LEVEL SETS ALARM PAGE Alarm control and reset
Inverter speed settings DRIVER SET PLC LADDER PAGE Ladder view
Trend values GRAPHIC PAGE PANEL SELECTION Machine panel service settings
Single / Double
Shows if machine type single or SINGLE A SIDE Shows machines situation
double
MAIN PAGE
System working passive System ending passive
43
Single / Double DAVG - SIMILAGO II Settings
LEVEL SETS
( Low level )
Grinding start level
( Starts at designated level )
0 0 0 Level value ( incoming product level)
( Top level)
Sensor calibration setting
Grinding stop level
( Stops at designated level Calibration Page
SINGLE A SIDE
44
Settings Single / Double DAVG - SIMILAGO II
DRIVER SET
45
Single / Double DAVG - SIMILAGO II Settings
0 0 0 operating ratio
SINGLE A SIDE
46
Settings Single / Double DAVG - SIMILAGO II
GRAPHIC PAGE
47
Single / Double DAVG - SIMILAGO II Settings
BACK
ALARM AND LOGIC PAGE Remote control
Active / Deactivation
SENSOR PROB ERROR REMOTE CONTROL ACTIVE
Main engine controls
SERIAL CABLE CONNECTION FAULT Active / Deactive yapma
MAIN MOTOR ACTIVE ALARMS
INVERTER ERROR
ALARM RESET
SINGLE A SIDE
Lights up for cable connection fault. Lights up when piston position is wrong.
Lights up for control and energy loss. Lights up when max level is too high.
48
Settings Single / Double DAVG - SIMILAGO II
Going back to
BACK
LADDER PAGE previous page
SINGLE A SIDE
49
Single / Double DAVG - SIMILAGO II Settings
Going back to
BACK
LADDER PAGE previous page
LEVEL
Physical Input and
Output indicator on PLC
Shows the quantity
Input I0 I1 I2 I3 I4 I5 I6 I7 I8 # level of the product
I0 I1 I2 I3 I4 I5 I6 I7
ANALOG
Physical Input and
Shows voltage values
Output indicator on PLC
Output #
o0 o1 o2 o3 o4 o5 o6
SINGLE A SIDE
50
Settings Single / Double DAVG - SIMILAGO II
PANEL SELECTION
SELECTION PAGE
BACK
Previous page
51
Single / Double DAVG - SIMILAGO II Settings
52
Settings Single / Double DAVG - SIMILAGO II
53
Single / Double DAVG - SIMILAGO II Settings
54
Settings Single / Double DAVG - SIMILAGO II
55
Single / Double DAVG - SIMILAGO II Settings
56
Settings Single / Double DAVG - SIMILAGO II
57
Single / Double DAVG - SIMILAGO II Settings
58
Settings Single / Double DAVG - SIMILAGO II
59
Single / Double DAVG - SIMILAGO II Settings
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Settings Single / Double DAVG - SIMILAGO II
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Single / Double DAVG - SIMILAGO II Settings
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Settings Single / Double DAVG - SIMILAGO II
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Single / Double DAVG - SIMILAGO II Settings
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Settings Tek Katl / ift Katl DAVG - SIMILAGO II
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Single / Double DAVG - SIMILAGO II Settings
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Settings Single / Double DAVG - SIMILAGO II
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Single / Double DAVG - SIMILAGO II Settings
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Settings Single / Double DAVG - SIMILAGO II
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Single / Double DAVG - SIMILAGO II Settings
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DAVG
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SIMILAGO II
Maintenance
Maintenance Single / Double DAVG - SIMILAGO II
7.1 Maintenance
Machines maintenance period must be carried out by expert and trained GAP CONTROLLER / MAINTENANCE NOTE
personnel
Bladed scraper
Monthly
Danger Brushed scraper
STOP All maintenance, cleaning and repair works must be done after machine is
completely stopped. (machines functions must be deactivated). Check the tension of all drive straps
Main switch that cuts the ow at all poles must be at 0 condition and locked Grinding cylinder chamber :
Clean the oil in steel chambers and ll with new
with a lock.
Two months after rst start
Grinding cylinder chamber :
Check the impermeability of input and output points, tighten them
Important Note if necessary.
Machine requires almost no maintenance and it doesnt require any
intervention when its casing is closed. Oil turnbuckle
Maintenance work must be carried out in periods specied in maintenance Cylinder mill, injector 40 g oil
chart.
Strap corrosion / change the faulty strap
Once in three months
Check the stiffness of these straps
Warning Main drive strap
Right appliance of maintenance works is necessary for safe and problem Feeding cylinder drive strap
free operation.
Cylinder mill chamber:
Oil change, clean the oil in steel chambers and put new oil.
Every Year
7.2 Control and Maintenance
Bladed and brushed
Weekly
Visual control of feeding mill drive strap STOP Open strap, chamber and cylinder groups cover and lids when the machine
is completely stopped.
Clean the product and dust leftover on product section and
machine roller chamber / support
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Single / Double DAVG - SIMILAGO II Maintenance
GAP MACHINE PART PRECAUTION Open body clamps with a special wrench and turn.
With an integrated gassed silencer, loosen the turning bolt then lift the two covers
Pressured air supply Check if there are any product between roll and chassis.
at the upper side up
Lower covers are protected with 2 levered holders and stopping plate. Lift grinding
Roll and chasis Remove the product from deactivaed machine. sections cover and open the control cover holders.
Loosen the levered holders and lift off the hood on holding plate. Then body can
Feeding cylinder strap after over working Visual check be removed from front. (For DAVG, rst the cover on the top must be lifted to lift
Weekly
the body.)
Feeding cylinder strap after normal work Visual check
1 - 2 - 3 - 4 - 5 numbered covers
4 are put to open status and xed
5
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Maintenance Single / Double DAVG - SIMILAGO II
After mill change Fill the rollers with oil before removing Dont oil roller cover.
Cylinder rollers oiling is done through central oiling block when the machine is turned on.
Machines with no central oiling option, will use the greaser on tope of the roller chamber cover.
In case of doubt, it is advisable to oil after every 4.000 hour of work.
Important Note
Following the oiling of four-cylinder mill, use 2x20 g oil for each oiling block.
Use 4x20g oil for eight-cylinder mill.
Levered oiling gun which is delivered with machine, pumps 1g oil every time.
Heat up to 50 C does not hurt the nger.
Warning
Over oiling the rollers cause roller heat to increase. Weekly
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Single / Double DAVG - SIMILAGO II Maintenance
7.5.2 Mill Cylinder Oiling Chart 7.5.4 Feeding Mill Geared Engine
Mill cylinders are oiled with an oil suitable for high pressure like mineral or Important Note
synthetic oil. Till 70C chamber heat, bilge oil viscosity must be at least ISO VG Check producer document for more detailed information .
100, above 70C chamber heat at least ISO VG 220 suitability needed. Ensure the
miscibility of the soaped lithium based oil, lled by producer. Check the geared engine regularly and change if necessary, for example:
Check mill gasket at least at every 15.000 hours (2 years) for oil leak.
Warning Open the cover of engine section. If there is oil at the inner parts, mil gasket
Oil center must be suitable for oiling.
must be changed.
Mobil Shell Albida EP2 Cassida Grease EPS 2 (H1) 7.5.5 Oil Used for Oiling Feeding Reducer Engine
Valvoline Multilube EP-2 Geralyn 2 (USDA-H1) deiimi
Fuchs Renolit CX-EP2 As it needs to have a long life, gears are lled with synthetic oil. Oils viscosity
level must be ISO VG 220.
* First lling at factory
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Maintenance Single / Double DAVG - SIMILAGO II
Danger
STOP Stop cylinder mill. Make sure that it wont work.
Warning
Air shouldnt pass through pipes
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Single / Double DAVG - SIMILAGO II Maintenance
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Maintenance Single / Double DAVG - SIMILAGO II
Chain is loosened
and removed by
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Single / Double DAVG - SIMILAGO II Maintenance
Important Note
Ya borularn kartn. Borular, buji konektr zerinden ayrma halkalarna
kuvvet uygulayarak gevetilmelidir.
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Maintenance Single / Double DAVG - SIMILAGO II
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Single / Double DAVG - SIMILAGO II Maintenance
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Maintenance Single / Double DAVG - SIMILAGO II
Optionally, cylinder car equipment is for mill cylinders lifting and carriage.
Bolt shown with arrow is loosened After checking the height, bolt is tightened.
and mill turned a quarter. On the high condition.
Check the height with your eyes This process is done for both left and right all 4 mills
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Single / Double DAVG - SIMILAGO II Maintenance
Chamber group
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Maintenance Single / Double DAVG - SIMILAGO II
It is done the opposite way of cylinder removal process. Be careful with the
sequence.
Important Note
Setting must be done when cylinders are in clutch position.
When assembling the cylinder block, rst cylinder gap must be reset.
Operating lever on the adjustment mill with a frill, set the gap approximately
200 mm between the center of the pin on operating lever and xing pin on
adjustment mill.
Spacer bolts Chamber bolts and
loosened and screws are loosened. When loosening the bolt, tighten special bolt as the desired gap is found to
removed. Pipes are
removed. measure with thickness stick
Breaking channel grinding gap : 0,15 mm - 0,50 mm Liso channel grinding
gap: upto0,1 mm
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Single / Double DAVG - SIMILAGO II Maintenance
3 Align bolt hack with the cylinder cover which will be upon one another.
4
Can be rotated easily
No axial gap.
No bending on camshaft
Lever position: there must be 200 m distance between lever and brace.
Last setting of cylinder gap setting using the hand lever will be done with hand
lever.
5
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Maintenance Single / Double DAVG - SIMILAGO II
To make the cylinder change healthily, cylinders rollers must be attached in First of all, oil the cylinder surfaces with wedged seal bolts. Bolts must be
workshop, oiled and their impermeability to dust must be ensured. installed in a way that seals smooth surface is opposite to the cylinder.
4 oil sealed inner cover for xed cylinder and moving chamber. There is 7.5 mm gap at xed cylinders cylinder cover and 3.5 mm gap at
moving cylinder cover.
Oil all cylinder covers seal rings with Molykote.
4 safety washers and bolts Push back cylinder covers (be careful with xed cylinders and moving
cylinders).
4 oil sealed and greaser outer cover for xed cylinder and moving
chamber. Cylindrical cylinder rollers 22315 EK which were produced by SKF or FAG,
are unassembled, have a cylinder gap between 0.05 and 0.090 mm. tighten
16 M12 x 100 xing screws these with the help of safety bolt until around 0,035 and 0.045 mm. (rough
surface will face cylinder). minimum gap must be at least 0.10 mm to
4 distance holder barrel and 2 o-ring enable balanced cylinders to be moved by hand. likewise, outer ring must
be moved easily with rotational movement. To measure the cylinder gap,
push the stick beyond the two pulley conveyor.
This parts are necessary for assembling rollers on cylinders, setting, oiling and
protecting against dust.
To tighten the safety washer, theres a special spanner and opening lever
First of all, install cylinder rollers on a strong connection chassis (max which were provided to you. then, put the bolt on the opposite sides of the
weight: approximately 800 kg) as if theyre going to be assembled to for roller over mill. This way mill wont be bent during tightening or loosening.
cylinder mill. Cylinder numbers are on the right side of drive strap.
After cylinders are installed and locked properly, add approximately 250 g
Check the grooved cylinders grooves, grooves location and incline and oil. Apply Specied amounts half to the cylinder cover, where the oil goes
their curves if theyre on straight mills. This information is marked on from the oiler.
cylinder mills surface.
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Single / Double DAVG - SIMILAGO II Maintenance
Place o-ring to the side of each one of the mill transmission and attach 7.11 Brushed Scraper
assemble holder shells to all mount points.
Brushed scrapers are attached from each side with clips.
Front cylinder cover bolts must be oiled. Be careful with the necessary gap.
7.5mm gap is envision for xed cylinders and it will be on the left side of the Press the brushes to mill to scrape all the product leftovers.
mill. Gap for moving cylinder is 3.5 mm and it will be on the right side of the
mill. Fix all these parts using 95 x M10 xing screws. 7.12 Setting the rst gap between grinding
Important Note
Setting will be done when the mills are in clutch position.
Operating lever on the adjustment mill with a frill, set the gap approximately
200 mm between the center of the pin on operating lever and xing pin on
adjustment mill.
When loosening the bolt, tighten special bolt as the desired gap is found to
measure with thickness stick.
Until it is stiff, (C) engine holder (B) is turned over back screw.
Sentil
Slightly tighten the loosened bolts.
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Maintenance Single / Double DAVG - SIMILAGO II
Blades parallel setting to mill is done via the buttery screw on the top of cutting Loosen and remove the back chain with stiff chain on the left with hand.( 1 ), lift the
stick or the adjustment screw located between mills inclined cutting stick. pressure weight shown with three with and (2) slide brush downwards. It is removed
by pulling from front. If wanted, pressure weight group can be removed from
When in coupler, the minimum gap between blades and grinding mill is going to be juncture by moving it upwards. ( 3 )
2 mm. when in clutch, opposite balance must be set in a way that grinding mills
erosion is minimized.
3
3
2
2
1
1
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Single / Double DAVG - SIMILAGO II Maintenance
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