Page 1

Training
Components description
Hydraulic Plan
… attached to the Skid

Hydraulic pipes … between Mill & Skid

Mill Hydraulic
… around the Mill
… on the Zero level

Mill Hydraulic Skid

… usually in the Basement
Components description
Hydraulic Plan
… attached to the Skid

Hydraulic pipes … between Mill & Skid

Mill Hydraulic
… around the Mill
… on the Zero level

Mill Hydraulic Skid

… usually in the Basement
Components description

4 x Hydraulic Cylinders

BE in front of the Rollers  2 x working cylinders … WS

behind the Rollers  2 x fixed cylinders … FS

Further definition: Motor Side … MO

WS BE FS BE Bucket Elevator Side … BE

FS MO WS MO
MO
Components description

4 x Hydraulic Cylinders
in depends of the sense of rotation of the grinding table:
in front of the Rollers  2 x working cylinders … WS
behind the Rollers  2 x fixed cylinders … FS

in depends of the location: Motor Side … MO

WS BE FS BE Bucket Elevator Side … BE

… upper
… middle
… lower

FS MO WS MO

Ultrasonic Limit Switches

way measurement 2 x 3 devices on both
at all 4 hydraulic cylinders working cylinders
Components description Ultra Sonic
Tie Rod
to the
Bed Depth Roller Pair

Ultra Sonic Bed Depth Measurement Measurement

Reflective
Plate
Fastening
Nuts

Holding device
LED Window for the US Piston
Measuring Rod
Connection Transducer
US Transducer

Ultrasonic Hydraulic
Measuring Cylinder
Plug for Transducer
Connecting
Cable

Program Connector
incl. Temperature
Socket for
Connecting Cable
Connecting Cable
Components description
Hydraulic 1Skid
x Hydraulic Skid contents:

- one oil tank

- two oil pumps
pump 1  to supply the fixed side cylinders
pump 2  to supply the working side cylinders
- five oil cartridge filters
four filter  one in each line
one filter  in the return line
- four valve blocks
WS BE FS BE two blocks  for the fixed side Cylinders
two blocks  for the working side Cylinders

FS MO WS MO

Pump 1 Reservoir Pump 1

Components description
Hydraulic 1Skid
x Hydraulic Skid contents:

- one oil tank

- two oil pumps
pump 1  to supply the fixed side cylinders
pump 2  to supply the working side cylinders
- five oil cartridge filters
four filter  one in each line
one filter  in the return line
- four valve blocks
WS BE FS BE two blocks  for the fixed side Cylinders
two blocks  for the working side Cylinders

FS MO WS MO

Pump 1 Reservoir Pump 1

 Hydraulic 1Skid
x Hydraulic Skid contents:
Components description - one oil tank
- two oil pumps
Pump 1  to supply the fixed side cylinders
Pump 2  to supply the working side cylinders
- five oil cartridge filters
four filter  one in each line
one filter  in the return line
- four valve blocks
WS BE FS BE two blocks  for the fixed side Cylinders
two blocks  for the working side Cylinders

FS MO WS MO

Pump 1 Reservoir Pump 1

 Valve Block
Components description The 4 valve blocks each contents:

8 electrically actuated solenoid valves

4 working pressure valves Y1, Y3, Y5, Y7
each working pressure valves has one
de-energized  normal
pressure limiting safety valveopen
for 180 bar

energized  valve closed

4 starting pressure valves Y2, Y4, Y6, Y8
each starting pressure valves has one
de-energized
pressure shut-off normal
valve closed 60 bar
for normally
mechanically pre-adjusted
energized  valve open

Y2 Y4 Y6 Y8
60bar 60bar 60bar 60bar

Y1 Y3 Y5 Y7
180bar 180bar 180bar 180bar

Pump 1 Reservoir Pump 2

 Components of aComponents
valve block of a valve block:
Components description The 4 valve blocks each contents:
8 electrically actuated solenoid valves
4 working pressure valves Y1, Y3, Y5, Y7
each working pressure valves has one
pressure limiting safety valve for 180 bar

4 starting pressure valves Y2, Y4, Y6, Y8

each starting pressure valves has one
pressure shut-off valve for normally 60 bar
mechanically pre-adjusted

Y2 Y4 Y6 Y8
60bar 60bar 60bar 60bar

Y1 Y3 Y5 Y7
180bar 180bar 180bar 180bar

Pump 1 Reservoir Pump 2

 Components of aComponents
valve block of a valve block:
Components description
working pressure valves Y1, Y3, Y5, Y7
pressure limiting safety valve 180 bar
starting pressure valves Y2, Y4, Y6, Y8
pressure shut-off valve 60 bar
check valve
In between the working and the starting pressure valves there
are in cartridge
each line onefilter  check valve
each line is also equipped with an oil  cartridge filter

Y2 Y4 Y6 Y8
60bar 60bar 60bar 60bar

Y1 Y3 Y5 Y7
180bar 180bar 180bar 180bar

Pump 1 Reservoir Pump 2

 Components of aComponents
valve block of a valve block:
Components description
working pressure valves Y1, Y3, Y5, Y7
pressure limiting safety valve 180 bar
starting pressure valves Y2, Y4, Y6, Y8
pressure shut-off valve 60 bar
check valve
cartridge filter
contamination
The Filter indicator
cartridges are equipped with differential pressure
measurements acting as  contamination indicator
Local operation devices:
pressure gauge
flow control valve
ball valve

Y2 Y4 Y6 Y8
60bar 60bar 60bar 60bar

Y1 Y3 Y5 Y7
180bar 180bar 180bar 180bar

Pump 1 Reservoir Pump 2

 Hydraulic Program

generally the hydraulic program is working in two major stages:

when the start up operation is finished:

by mill start command:

after and
a short
the:delay:
 No-load start up operation

Step 1: De-Energize all Valves and Motors

to ensure that the Program will be reset and every thing is pressure free.

(Step 2: Scavenging)
when the mill has been at a standstill for 2 to 4 hours, but just once per 24
hours, the pistons of the hydraulic cylinders are drawn into their end
positions (alternately always 2 x), in order to ensure an exchange of oil in
the area of the seals.
Step 3: Pressurise to Starting Pressure
in all other cases, the starting procedure begins with pressurization to the
start-up pressure.
Step 4: Balancing the Roller Pair Units
by means of the ultrasonic measuring devices

Step 5: Release to Starting Pressure

during Balancing the system builds up more pressure,
in order to lower the torque for the main motor by the start-up
 Normal operation

Step 6: Stand by Operation

If there is no Start Command for the auxiliary drive within 15 Minutes, than
Stop all Pumps and De-Energize all Solenoid Valves, in order to not overheat
the hydraulic oil

by the Operator
Step 7: Restart all Pumps and Energize all Valves
with the Start Command for the auxiliary drive to prevent the Roller Pair
Units to come out of balance
Step 8: Pressurise to Working Pressure
after the mill main drive has been running for approx. 1 minute
(adjustable, one complete table turn) pressurizing to working pressure by
operate the fixed side cylinders
Step 9: Balancing the Roller Pair Units
by means of the limit switches
Step 1:
Step 1: De-Energize

WS BE FS BE

Y2 Y4 Y6 Y8
60 bar 60 bar 60 bar 60 bar

Y1 Y3 Y5 Y7
FS MO WS MO 180 bar 180 bar 180 bar 180 bar

Pump 1 Reservoir Pump 1

Step 1:
Step 1: De-Energize

WS BE FS BE

Y2 Y4 Y6 Y8
60 bar 60 bar 60 bar 60 bar

Y1 Y3 Y5 Y7
FS MO WS MO 180 bar 180 bar 180 bar 180 bar

Pump 1 Reservoir Pump 1

Step 3: Pressure
Step 3: Starting

The pumps are running and...

… all valves Y1, Y3, Y5, Y7 and Y2, Y4, Y6, Y8

are energized

WS BE FS BE
The hydraulic cylinders will be pressurised
according the adjusted value on the relief
valves Y2,Y4,Y6 and Y8

Y2 Y4 Y6 Y8
60
60bar
bar 60 bar 60 bar 60 bar

Y1 Y3 Y5 Y7
FS MO WS MO 180 bar 180 bar 180 bar 180 bar

Pump 1 Reservoir Pump 1

Step
Step 4:
3:
The pumpsofare
Balancing therunning and...
roller pair units by means
of the ultrasonic measuring devices.
… all valves Y1, Y3, Y5, Y7 and Y2, Y4, Y6, Y8
The measured values of the are ultrasonic
energized
measuring devices are compared. If the
WS BE FS BE
The hydraulic
difference between cylinders will beside
the working pressurised
and the
according the adjusted value on the relief
fixed side of one roller pair unit is not greater
than 50 mm, thevalves Y2,Y4,Y6
hydraulic andare
cylinders Y8
balanced.

Y2 Y4 Y6 Y8
60
60bar
bar 60 bar 60 bar 60 bar

Y1 Y3 Y5 Y7
FS MO WS MO 180 bar 180 bar 180 bar 180 bar

Pump 1 Reservoir Pump 1

 Step 4: Balancing
Step 4:

The measured values of the ultrasonic

measuring devices are compared
If the measured value at the working cylinder
is more than 50 mm greater than the
measured value at the fixed cylinder ...
WS BE FS BE
… relief valve Y5 and pressure valve Y2 are
energized

Y2 Y4 Y6 Y8
60 bar 60 bar 60 bar 60 bar

Y1 Y3 Y5 Y7
FS MO WS MO 180 bar 180 bar 180 bar 180 bar

Pump 1 Reservoir Pump 1

 Step 4: Balancing
Step 4:

The measured values of the ultrasonic

measuring devices are compared
If the measured value at the working cylinder
is more than 50 mm greater than the
measured value at the fixed cylinder ...
WS BE FS BE
… relief valve Y5 and pressure valve Y2 are
energized

Y2 Y4 Y6 Y8
60 bar 60 bar 60 bar 60 bar

Y1 Y3 Y5 Y7
FS MO WS MO 180 bar 180 bar 180 bar 180 bar

Pump 1 Reservoir Pump 1

 Step 4: Balancing
Step 4:

The measured values of the ultrasonic

measuring devices are compared
If the measured value at the working cylinder
is more than 50 mm greater than the
measured value at the fixed cylinder ...
WS BE FS BE
… relief valve Y5 and pressure valve Y2 are
energized

Y2 Y4 Y6 Y8
60 bar 60 bar 60 bar 60 bar

Y1 Y3 Y5 Y7
FS MO WS MO 180 bar 180 bar 180 bar 180 bar

Pump 1 Reservoir Pump 1

 Step 4: Balancing
Step 4:

When the difference between the working and Y2 Y4 Y6 Y8

the fixed side of the roller carrier is less than 50 60 bar 60 bar 60 bar 60 bar

mm, the balancing will be terminated.

Y1 Y3 Y5 Y7
180 bar 180 bar 180 bar 180 bar
The same take place with the Roller Carrier
on the Motor Side.

Pump 1 Reservoir Pump 1

 Step 5: Starting Pressure
Step 5:
During the balancing the hydraulic builds up a
higher pressure than the starting pressure.
In order to lower the torque for the main Motor
by the start-up the pressure needs to be
reduced to the starting pressure.
When the pressure in each line reach the value
WS BE FS BE of the pre-adjusted starting pressure (± offset)
the first stage of the hydraulic sequence is
finished and the program gives the ….

Y2 Y4 Y6 Y8
60 bar
60bar 60bar
60 bar 60bar
60 bar 60bar
60 bar

Y1 Y3 Y5 Y7
FS MO WS MO 180 bar 180 bar 180 bar 180 bar

Pump 1 Reservoir Pump 1

 Release Signal for mill start
Step 5:

WS BE FS BE

Y2 Y4 Y6 Y8
60 bar
60bar 60bar
60 bar 60bar
60 bar 60bar
60 bar

Y1 Y3 Y5 Y7
FS MO WS MO 180 bar 180 bar 180 bar 180 bar

Pump 1 Reservoir Pump 1

 Release Signal for mill start
Step 5:

WS BE FS BE

Y2 Y4 Y6 Y8
60 bar
60bar 60bar
60 bar 60bar
60 bar 60bar
60 bar

Y1 Y3 Y5 Y7
FS MO WS MO 180 bar 180 bar 180 bar 180 bar

Pump 1 Reservoir Pump 1

 Release Signal for mill start
Step 5:

WS BE FS BE

Y2 Y4 Y6 Y8
60 bar
60bar 60bar
60 bar 60bar
60 bar 60bar
60 bar

Y1 Y3 Y5 Y7
FS MO WS MO 180 bar 180 bar 180 bar 180 bar

Pump 1 Reservoir Pump 1

8 Pressurizing to the working pressure.

The fixed sides will be pressurized to the working pressure.

Three limit switches control the working side

rods position.

9
By pressurizing the fixed sides, the piston rods of the
working sides are drawn upwards.
Then, the working sides will be pressurized by being drawn
downwards till the central limit switches are reached.
 Pressurizing to the working
pressure
When...the
thepump
limit A
values
is switched
of pressure
on
After the main drive has been
are
and
reached,
10 s later,
the pump
the pressure
is switched
valves
off,
running for approx. 1 minute.
an the
Y1 and
valves
Y3 are
are de-energized
activated
Working
pressure

Working
pressure

A B
 Pressurizing to the working
pressure
...the piston rods of the working sides
WhenBy
andpressurizing
the
thelimit switches
valves the fixed
„Y5“ „I“ and
and sides
„Y7“„IV“
are drawn towards the limit switches
are reached,
to theare
working
the pump
pressure...
„B“ is started
energized
„I“ and „IV“

IV

A B
 Pressurizing to the working
pressure
...the
The pump
piston„B“
rodsis are
switched
drawnoff
and the
When thevalves
central„Y5“
limitand „Y7“
switches
and the towards
pressure valves
„II“ andare„V“
energized
are reached,...
„Y5“
the and
limit „Y7“
switches
are de-energized
„II“ and „V“

II

A B
 Mill in Operation
When
When
When
andDuring
the
limit
limit
limit
pressure
the
switch
switch
switch
mill„III“
in
„II“
operation,
„I“the
isis reached,
cylinder
reached
reached,
and the working pressure
„Y5“
is reduced
is
pressure
pump
de-energized
the roller
„B“
until
relief
ispair
limit
started
valve
and
units
switchpump
and
„Y6“„II“
„B“
at the fixed sides controlled
are continuously
responds
„Y5“
isisswitched
energized
energized
again
balanced
off

I
II
II
III

A B
Mill in Operation
If the working pressure
Pump
until the
„A“MAX
is started
value
at the bucket elevator fixed side
and pressure isvalve
reached
„Y1“ is energized
drops below an adjustable MIN value

A B