Professional Documents
Culture Documents
2 en 0508
2 en 0508
Operating instructions
Impact machine
Preface
These operating instructions document the Impact machine MJZG.
The operating instructions have to be handed over to those persons who are
responsible for the operation and the supervision of these devices.
These operating instructions contain the information required for the user regarding
installation, operation and maintenance.
Description of activities that do not require any special knowledge have been
omitted.
Repair instructions that exceed the normal maintenance work are not provided.
The machine meets all acknowledged safety regulations. However, improper use
can involve physical danger for the user.
Highest priority, therefore, has been given to safety.
The symbols below are used to highlight specific information regarding safety:
Danger!
Risk of injury to persons.
Caution!
Warning of material damage.
Note:
Important information or instructions.
Important information
• Procedures upon receipt
Inspect the equipment visually in accordance with the delivery contract as soon
as it has been received.
• Storage
Equipment that is not installed immediately must be stored protected against
weather and other influences.
• Installation
The assembly and installation of the machine and machine equipment must
only be carried out by observing all installation instructions supplied.
• Design versions
If different designs are described in the documentation provided, only the infor-
mation concerning the version supplied will apply. We reserve the right to make
modifications due to technical progress up to the time of delivery.
• Duty of instruction
Commissioning and maintenance must only be done by trained specialists.
Prior to the initial start-up the operating personnel must familiarize themselves
with the documentation provided.
Table of contents
1 Safety .......................................................................................................... 1-1
1.1 Safety of persons ......................................................................................................... 1-1
1.2 Connecting to the electrical mains ................................................................................ 1-1
1.3 Explosion protection ..................................................................................................... 1-1
1.4 Safety concept ............................................................................................................. 1-1
2 Description ................................................................................................. 2-1
2.1 Designated use ............................................................................................................. 2-1
2.2 Identification ................................................................................................................. 2-1
2.2.1 Nameplate ........................................................................................................ 2-1
2.2.2 Type key ........................................................................................................... 2-1
2.3 Type variations .............................................................................................................. 2-2
2.4 Function ....................................................................................................................... 2-3
2.5 Noise data .................................................................................................................... 2-3
3 Transport .................................................................................................... 3-1
3.1 Handling with a crane .................................................................................................... 3-1
3.2 Transport weights and volumes ..................................................................................... 3-2
4 Installation .................................................................................................. 4-1
4.1 Site conditions .............................................................................................................. 4-1
4.1.1 Vertical version ................................................................................................. 4-1
4.1.2 Horizontal version ............................................................................................. 4-1
4.2 Machine drive ............................................................................................................... 4-2
4.3 Electrical connection .................................................................................................... 4-3
4.4 Electrical wiring ............................................................................................................. 4-3
4.5 Installation in gravity spouting ....................................................................................... 4-4
4.6 Purging the seal ............................................................................................................ 4-5
4.6.1 Purging air (from fan) ........................................................................................ 4-5
4.6.2 Purging air (from compressed air) ..................................................................... 4-5
5 Commissioning .......................................................................................... 5-1
5.1 Checklist for verifying EU conformity ............................................................................ 5-1
5.2 Initial start-up ............................................................................................................... 5-2
5.3 Start-up ........................................................................................................................ 5-2
6 Operation .................................................................................................... 6-1
1 Safety
1.1 Safety of persons
• Safety covers must always be installed and locked. Open or removed safety
covers are danger spots for crushing and cutting injuries.
• Always keep safety devices in good working condition. Safety devices must not
be bridged over or put out of operation.
• Maintenance work at the machine or parts thereof must only take place with the
installation at a standstill. It is absolutely imperative and without exception that
the installation is switched off and that the switch is locked!
Explosion hazard!
If the machine is permitted to operate in potentially explosive zones in
accordance with the nameplate, it is absolutely imperative that the hazard
instructions marked with the EX symbol are adhered to in order to maintain
ignition protection.
2 Description
The impact machine MJZG is used as a steriliser for:
• Semolina and flour prior to silo storage or shipping.
It serves to kill off insects and their eggs in order to improve the storage properties
of the treated products.
Explosion hazard!
In potentially explosive zones the machine must only be operated with the
corresponding authorization.
2.2 Identification
2.2.1 Nameplate
Note:
Do not remove or cover up the nameplate!
The data marked with «*» are embossed into the nameplate according to the
machine specifications.
Non-explosion-proof version
ATEX marking
Explosion-proof version
Marking Ex-machine
Double flow
Size
Code
2.4 Function
The product is fed to the impact machine via the centrally positioned inlet (1),
grasped by the pin rotor (2) and subjected to intensive impacting. The product is
then collected again in the spiral-shaped cast-iron housing (3) and discharged via
the tangentially positioned outlet.
1 2
Fig. 2.5
Measured values
1) Permanent sound pressure level at workplace Leq = --- dB (A)
Equivalent sound pressure level in area around the Leq = 79 dB (A)
machine
2) Acoustic power level Lw = 89 dB (A)
Measuring surface measure Ls = 15 dB
Measuring method:
1) according to ISO 6081 2) Sound intensity in conformity with ISO 9614
3 Transport
Note:
The transport must only be handled by persons who are familiar with and trained
for this task.
Note:
Screw the eye bolt all the way in to make sure it is secure.
The traction angle of the ropes must not exceed 60°.
Danger!
Never stand under the suspended load.
Fig. 3.2
Fig. 3.1
Caution!
Check the lifting equipment to make sure it meets the necessary design and loading
capacity criteria.
Note:
Always comply with the transport weights given in the delivery papers!
4 Installation
4.1 Site conditions
Space requirement, floor openings, supporting surfaces and floor loads according
to separate planning documents.
MJZG-43
MJZG-51
MJZG-43
MJZG-51
Weld in place
Fig. 4.8
Caution!
Use fixing screws with a minimum quality grade of 8.8.
Note:
The MJZG impact machine is only supplied with a mounted flange motor
(due to running in and balancing of the impact wheel).
The running connection of the motor with direct-on-line starting can be of the star
or delta type.
Star-delta starting
Fig. 4.9
Caution!
The plant must be locked as follows:
If the pneumatic system fails, the MJZG impact machine must be switched off too.
If the MJZG impact machine fails, the feed must be switched off immediately.
Note:
When the product inlet is clear, air is sucked in and expelled by the impact machine
at a rate of X m³/min.
possibly with
bypass tube ieakage air inlet
product outlet
Fig. 4.10
Caution!
The seal of the impact machine MJZG-51, MJZG-51D and MJZG-62D
must be purged with air.
For this purpose, the machine is provided with a purging air connection.
The purging air is supplied either by the pneumatic empty-air conductor
(internal air) or by the mains (compressed air).
air lock
fan MJZG
restrictor
purging air
Fig. 4.11
air lock
fan MJZG
Pmin. = 4 bar
Fig. 4.12
Caution!
The purging air pressure must be set to 2.5 bar.
In case of a failure of the purging air supply, switch off the product feed
and machine immediately.
5 Commissioning
Commissioning of the machine, trial run and settings may only be carried out by
suitably qualified and authorised personnel.
Danger!
Before carrying out any inspection work on the machine in the idle state,
always switch off the control power switch and remove the key. Also switch
off all the main switches and lock them with a personal padlock.
Fig. 5.1
5.3 Start-up
Attention!
The impact machines MJZG-51, MJZG-51D and MJZG--62D must not be
put into operation without first purging the seal with air.
(no seal purging in MJZG-43)
6 Operation
Note:
Check the machine periodically for abnormal noises during operating hours.
If you hear an abnormal noise, stop the machine immediately and get an
authorised operator to investigate and rectify the fault.
The Impact machine MJZG is practically vibration-free due to the balancing
of the impact wheel.
If you feel strong vibrations on touching the housing, switch off the machine
immediately.
In this case, the impact wheel must be dismounted (see Chapter 7.2) and
re-balanced (for permissible residual unbalance, see Chapter 7.5).
Caution!
If the MJZG impact machine becomes full due to a backlog and this causes the
motor to fail, empty the machine completely before putting it back into operation.
If flour dust emerges from the ventilation slits of the machine (between
housing and motor), the seal must be replaced immediately (see Chapter 7.8).
7 Maintenance
Maintenance of the machine may only be carried out by suitably qualified and
authorised personnel.
Danger!
Only carry out maintenance, cleaning and inspection tasks when the machine
is stationary (all machine movements stopped).
The service or local switch must be set to «0» and locked.
Note:
Check the machine periodically for abnormal noises. If you hear anything abnormal,
stop the machine immediately, investigate the cause and and rectify the fault.
If using the machine for highly abrasive products, the inspection should be
performed at shorter intervals depending on the amount of wear.
7.2.1 Disassembly
Undo screws (1) and remove labyrinth ring (2). The distributor wheel (3) can now
be dismounted after undoing the screw (4).
7.2.2 Assembly
Assembly takes place in reverse order to disassembly.
Caution!
The cams (A) of the driver plate (5) must be inserted in the corresponding slots (B)
of the distributor wheel (3).
3 5 A B 6 2 3 4 1
Fig. 7.1 Fig. 7.2
5 5 1
Fig. 7.3
2 4 3
Fig. 7.4
7.3.3 Assembly
Attention:
The impact wheel requires static rebalancing every time it undergoes any modifica-
tion (for permissible residual unbalance, see sections 7.4 and 7.5).
Assembly takes place in the reverse order to disassembly. In the case of the
distributor wheel (MJZG-51D/-62D), the safety precautions described in section
7.2.2 must be observed.
When assembling the housing and housing cover, the screws must be tightened
with a torque wrench and the following tightening torques (Ma) must be observed:
MJZG-43: Ma = 80 Nm
MJZG-51: Ma = 190 Nm
MJZG-51D: Ma = 190 Nm
MJZG-62D: Ma = 190 Nm
2, 3
6
min. 4
2
Fig. 7.5
If measurement «Z» is greater than 2 mm, the bolts are too worn and must
be replaced.
1 2
Fig. 7.6
3 1 2
Fig. 7.7
Fig. 7.8
2
4
1
Fig. 7.9
7.6.2 Assembly
Assembly takes place in reverse order to disassembly. When assembling the
housing, make sure the torque specified in section 7.5 is strictly adhered to.
7.7.1 Disassembly
The housing cover (1) is dismounted by undoing the screws (2).
2
Z
7.7.2 Assembly
Assembly takes place in reverse order to disassembly. When assembling the
housing cover, make sure the torque specified in section 7.5 is strictly adhered to.
7.8.1 MJZG-43
1 2 4 10
Fig. 7.12 Fig. 7.13
7
6
5
9
10
Fig. 7.14
Fig. 7.15
Fig. 7.16
1 2 1
Fig. 7.17
5 12 13
Fig. 7.18
4 13
Fig. 7.19
5 12 11 10
Fig. 7.20
Caution!
The set of seals must be replaced every time the motor is dismounted.
2 3 4 1
6 8
Fig. 7.21 5
Caution!
Seal set:
• The screws (8) must be uniformly tightened so that the sealing lips (5)
cannot rotate.
• The sealing lips (5) must face away from the motor.
7.9 Lubrication
Fig. 7.22
7.10 Disposal
The disposal of the machine and the relevant components has to take place
according to the locally applicable regulations.
Once the machine is definitively taken out of operation make sure all components
are professionally disposed of or recycled in the interest of the environment:
• Fluids (diesel, motor and gear oil etc.)
• Toxic refuse (e.g. batteries, electronic components)
• Separate plastic materials
• Separate metal parts according to type of metal
8 After-sales service
8.1 Spare parts
When ordering spare parts, please refer to the following page.
Please note that special production and delivery specifications often exist for
non-Bühler components, and that the spare parts supplied by us always conform
to the latest state of the art.
Ordering procedure
Spare part orders must contain at least the following information:
Note:
This information is necessary in order to avoid incorrect deliveries.
In case of doubt, please send in a dimensioned sketch with an accompanying
description.
When ordering spare parts without a part number, please state the assembly
number and item number in the parts list instead.
Motors or gears:
Please state the motor or gear number in all queries or spare part requests
(orders).
8.2 Address
Bühler AG
Ersatzteildienst Grain Processing
CH-9240 Uzwil, Switzerland
Fax +41 71 955 34 17
Bühler AG
Ersatzteildienst Engineered Products
CH-9240 Uzwil, Switzerland
Fax +41 71 955 36 60
MJZG-43
Quantity Part number
Shaft seal 2 UNN-44038-043
Hub 100L/112M 28 1 MJZG-30012-01
Hub 132S/M 38 1 MJZG-30011-01
Hub 160L/M42 1 MJZG-30010-01
Housing cover 1 MJZG-10002-01
Impact bolt 80 MJZD-50068-01
Pin rotor 1 MJZG-82006-81
MJZG-51
Quantity Part number
Hub 132S/M 38 1 MJZG-30052-01
Hub 160L/M 42 1 MJZG-83046-01
Hub 180L/M 48 1 MJZG-83046-02
Housing cover 1 MJZG-10003-01
Impact bolt 80 MJZG-50020-02
Pin rotor 50 Hz 1 MJZG-82012-81
Pin rotor 60 Hz 1 MJZG-82026-81
MJZG-51D
Quantity Part number
Hub 160L/M 42 1 MJZG-83046-01
Hub 180L/M 48 1 MJZG-83046-82
Hub 200L/M 55 1 MJZG-83046-83
Hub 225M 55 1 MJZG-83047-81
Impact ring 1 MJZG-20009-01
Impact bolt L=66 80 MJZG-50020-01
Impact bolt L=30 4 MJZG-50020-02
Pin rotor 50 Hz 1 MJZG-82030-81
Pin rotor 60 Hz 1 MJZG-82031-81
MJZG-62D
Quantity Part number
Hub 280M 65 1 MJZG-83048-81
Impact ring 1 MJZG-84004-81
Impact bolt L=66 95 MJZG-50020-01
Impact bolt L=30 4 MJZG-50020-02
Pin rotor 50 Hz 1 MJZG-81024-81
Pin rotor 60 Hz 1 MJZG-82036-81