2. Operation and Maintenance Instructions

Document Number: CPM 7900-001 Issue Date: 19th of June, 2009C vi Contents California Pellet Mill 7900 Operation and Maintenance Instructions 4 Description.. Document Number: CPM 7900-001

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CPM 7900 (California Pellet Mill 7900)

Operation and Maintenance Instructions

Document Number: CPM 7900-001Issue Date: 19th of June, 2009

CPM Europe BV

Distelweg 89

1013 HD AMSTERDAM

The Netherlands

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Document Number: CPM 7900-001 Issue Date: 19th of June, 2009

ii

No part of this publication may be reproduced, stored in an automated database or retrieval system, or published in any form or any way whatsoever, be it electronically, mechanically, by means of printing, photocopying or recording, or by any other method without prior written permission from the manufacturer

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Document Number: CPM 7900-001

Issue Date: 19th of June, 2009

P

Preface iii

California Pellet Mill 7900

Operation and Maintenance Instructions

Preface

These Operation and Maintenance Instructions inform the operator and maintenance

engineer about the safe operation and maintenance, respectively, of the California

Pellet Mill 7900 (abbreviated known as the CPM 7900).

• For the operator chapters 1 through 5, except for chapter 3, are important.

important

Always print these Operation and Maintenance Instructions in color.

Read these Operation and Maintenance Instructions (especially Chapter 2 about the

Safety Precautions) carefully, before putting the CPM 7900 into use or before carrying out any operation on the CPM 7900 Only then optimal safety can be obtained Only

qualified operators are authorized to operate and only qualified maintenance

engi-neers are authorized to maintain, respectively, the CPM 7900.

Always keep these Operation and Maintenance Instructions near the CPM 7900.

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iv Preface

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Contents v

Contents

Preface iii

1 Introduction 1-1

1.1 Manufacturer 1-1 1.2 Related documents 1-1 1.3 Machine-identification/CE-mark 1-2 1.4 Warranty 1-2 1.5 Liability 1-3

2 Safety precautions 2-1

2.1 Warning symbols 2-1 2.2 Warning pictorials 2-2 2.3 Operator 2-4 2.4 Maintenance engineer 2-4 2.5 Safety precautions 2-5 2.6 Safety provisions 2-11 2.6.1 Emergency stop button 2-12 2.6.2 Safety covers 2-13 2.6.3 Pellet chamber with interlock 2-14

2.6.3.1 How to open the pellet chamber 2-15 2.6.3.2 How to close the pellet chamber 2-16 2.6.4 Shear pin security 2-17 2.6.5 Oil flow switch 2-18 2.6.6 Low grease alarm 2-19

3 Installation 3-1

3.1 Safety precautions 3-1 3.2 Important installation topics 3-1 3.2.1 Hoisting the CPM 7900 3-2

3.2.2 Placing the CPM 7900 3-3

3.2.3 Installing the CPM 7900 3-4

3.2.4 Aligning the CPM 7900 3-8

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vi Contents

4 Description 4-1

4.1 Function of the machine 4-1 4.2 Description of the product 4-1 4.3 Basic configuration of the CPM 7900 4-2

4.4 Description of the pelleting process 4-4 4.4.1 Conveying the product 4-5 4.4.2 Removing tramp metal 4-6 4.4.3 Conditioning the product 4-7 4.4.4 Densifying the product to pellets 4-8 4.5 Components of the CPM 7900 4-10

4.5.1 Die 4-10 4.5.2 Rollers 4-10 4.5.3 Feed chute 4-11 4.5.4 Deflector and wipers 4-11 4.5.5 Knives or breaker bars 4-12 4.5.6 Roller temperature sensors 4-12 4.5.7 Lubrication system with oil cooler 4-13 4.5.8 Lineator 4-16 4.6 Operating devices 4-17 4.6.1 Emergency stop button 4-17 4.6.2 Hoist for lifting die and rollers 4-18 4.6.3 Control cabinet of lineator 4-19

5 Operation 5-1

5.1 Before starting 5-1 5.2 Powering up 5-2 5.3 Checking functioning of equipment parts 5-2 5.3.1 Checking rotation of all driven equipment 5-3 5.3.2 Checking lubrication system with oil cooler 5-4 5.3.3 Checking lubrication system for automatic grease supply 5-5 5.3.4 Checking functioning of safety switches 5-5 5.4 Preparing CPM 7900 for production 5-6

5.4.1 Installing the die 5-7 5.4.2 Installing the rollers 5-19 5.4.3 Adjusting the rollers 5-35

5.4.3.1 Adjusting the rollers manually 5-36 5.4.3.2 Adjusting the rollers with the lineator 5-37 5.4.3.3 Confirming properly adjusted rollers 5-37 5.4.4 Adjusting the lineator rollers relative to each other 5-38 5.4.5 Checking and replacing the wipers 5-42 5.4.6 Checking and adjusting the deflector 5-44 5.4.7 Adjusting the knives or breaker bars 5-45 5.5 Starting production 5-47 5.5.1 Starting-up the initial run 5-47

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5.5.2 Starting-up a new die 5-48 5.6 Starting full production 5-49 5.7 Stopping production 5-50 5.8 During production 5-52 5.9 Shutting down 5-52

6 Maintenance 6-1

6.1 Safety precautions 6-1 6.2 Spare parts book 6-2 6.3 Housekeeping for pellet mills 6-4 6.4 Housekeeping for conditioners and feeders 6-5 6.5 Maintenance activities 6-6 6.5.1 Maintenance for the die 6-9 6.5.2 Maintenance for the rollers 6-10 6.5.3 Maintenance for the gear box 6-11 6.5.4 Maintenance for the oil lubrication system 6-15 6.5.5 Maintenance for the magnet 6-18 6.5.6 Maintenance for the die clamps 6-19 6.5.7 Maintenance for the feed cone 6-20 6.5.8 Maintenance for the dust seal 6-21 6.5.9 Inspection of the safety switches 6-22 6.5.10 Maintenance for the knives or breakers bars 6-23 6.5.11 Maintenance for the wipers 6-25 6.5.12 Maintenance for the deflector 6-26 6.5.13 Maintenance for the driving key 6-27 6.5.14 Maintenance for the quill wear insert 6-29 6.5.15 Maintenance for the stiffening ring 6-31 6.5.16 Maintenance for the feeder 6-41 6.5.17 Maintenance for the conditioner 6-42

7 Transport 7-1

7.1 Safety precautions 7-1 7.2 Transporting and storing the CPM 7900 7-1

8 Disposal 8-1

8.1 Safety precautions 8-1 8.2 Disposing of the CPM 7900 8-1

8.3 Environmental aspects 8-1

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viii Contents

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1

In addition to these Operation and Maintenance Instructions the following document

comes with the California Pellet Mill 7900:

Direc-tive (98/37/EEG)

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1-2 Introduction

1.3 Machine-identification/CE-mark

The machine is identified as the California Pellet Mill 7900.

The year of manufacture is of the CPM 7900 is indicated on the machine-identification plate of the CPM 7900 This machine-identification plate is displayed below.

Figure 1-1: Machine-identification plate of Pellet Mill 7900

7930 30-4 7930-4 / 5902 / 621 2007

315 KW / 1500 RPM 0000-0001-01-03

The California Pellet Mill 7900 is supplied according to the CE-mark.

safety requirements of the European Union

1.4 Warranty

The CPM 7900 is subject to CPM Europe BV warranty terms and conditions This

war-ranty is only valid if:

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1

The warranty of the Pellet Mill 7900 is void immediately in the event of:

The manufacturer of the CPM 7900 is not liable for unsafe situations, accidents and

damage which are caused by:

stated in these Operation and Maintenance Instructions

these Operation and Maintenance Instructions

and/or non-genuine CPM-parts

The manufacturer of the CPM 7900 is not liable for consequential damage of CPM

7900 malfunctions, such as damage to products, operational interrupts, loss of

pro-ductivity, et cetera

Alterations and/or modifications to the Pellet Mill 7900 may be possible in certain

cir-cumstances However, alterations and/or modifications are only allowed with written

permission of CPM Europe BV.

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1-4 Introduction

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A suggestion to carry out tasks easier.

Draws attention to potential problems.

Draws attention to damage to the machine

if the instructions are not carried out carefully.

Draws attention to serious injuries to the operator

if the instructions are not carried out carefully.

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2-2 Safety precautions

2.2 Warning pictorials

The following warning pictorials can be found on the CPM 7900:

• HIGH VOLTAGE, on the main motor

due to the hazard of being exposed to high voltage

Figure 2-1: Pictorial ‘HIGH VOLTAGE‘

• CRUSHING HAZARD, on the gear box

due to the crushing hazard of the fast rotating gears

Figure 2-2: Pictorial ‘CRUSHING HAZARD‘

• HAZARD OF GETTING ENTANGLED, on the pellet chamber

due to the hazard of getting entangled between the rotating die and the rollers

Figure 2-3: Pictorial ‘HAZARD OF GETTING ENTANGLED‘

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• CRUSHING HAZARD, on the feeder and conditioner

due to the crushing hazard of the rotating parts of the gear drive

Figure 2-4: Pictorial ‘CRUSHING HAZARD‘

• CRUSHING HAZARD, on the feeder and conditioner

due to the crushing hazard of the rotating screw conveyor and paddle shaft

Figure 2-5: Pictorial ‘HAZARD OF GETTING ENTANGLED‘

• HIGH TEMPERATURE, on the feed chute, gear box, feeder and conditioner

due to the hazard of getting burned by hot parts of the CPM 7900.

Figure 2-6: Pictorial ‘HIGH TEMPERATURE‘

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• MAGNETIC FIELD, on the magnet between the feeder and the conditioner

due to the hazard of getting exposed to the strong magnetic field of the magnet

Figure 2-7: Pictorial ‘MAGNETIC FIELD‘

• HOT STEAM ESCAPE (OR LEAKAGE), on the steam inlet

due to the hazard of getting burned by steam escaping from the steam inlet

Figure 2-8: Pictorial ‘HOT STEAM ESCAPE (OR LEAKAGE)‘

2.3 Operator

Only qualified personnel are allowed to operate the CPM 7900.

The safety precautions in these Operation and Maintenance Instructions should be respected

Deviation from the precautions can cause unacceptable risks.

The operator must be acquainted with the contents of chapters 1 through 5, except for chapter 3 Read these chapters carefully before carrying out any operations on the

CPM 7900.

2.4 Maintenance engineer

Only specially trained personnel are allowed to maintain the CPM 7900.

The safety precautions in these Operation and Maintenance Instructions should be respected

Deviation from the precautions can cause unacceptable risks.

The maintenance engineer must be acquainted with the contents of chapters 1through 8, including chapter 3 Read these chapters carefully before carrying out any

operations on the CPM 7900.

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2.5 Safety precautions

The CPM 7900 meets the safety and health requirements of the European Union This means that the CPM 7900 can be operated and maintained safely if all safety pre-

cautions are observed

Stay alert for dangerous situations.

Dangerous situations can STILL occur due to injudicious or negligent use.

Observe the following general safety precautions:

• Always read these Operation and

Mainte-nance Instructions before putting the CPM

7900 into use or before carrying out any

operation on the CPM 7900.

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• Always lock out and tag out (known as

LOTO) the CPM 7900 according to the

available LOTO-procedure before ing out any maintenance activities

Keep bystanders away.

Do NOT permit unauthorized personnel to operate the CPM 7900.

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2

• Never power ON the CPM 7900 if persons are in contact with the machine.

• Never start the CPM 7900 if persons are in contact with the machine.

Beware ! The CPM 7900 may start-up automatically.

• Always power OFF the CPM 7900 before carrying out maintenance activities.

Beware ! The CPM 7900 will never stop immediately.

The supply of bulk material, the CPM 7900 itself, and the discharge of pellets must always run out before stopping.

• Always keep your work area clean.

- Make sure your work area is free of dust and dirt

- Never smoke or use naked light near the CPM 7900, since accumulated dust

and dirt (when working with dry bulk material) may create explosion hazards

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• Never operate and maintain the machine if you have a pacemaker.

The magnet has a very strong magnetic field.

It may be dangerous for persons with pace makers and may damage electrical devices (such as watches), chip cards and credit cards.

• Always replace damaged or defective machine parts before putting the CPM

7900 into use again.

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Observe the following specific safety precautions:

The mill may get stuck when throwing objects into the inspection opening of the feed chute.

The pellet chamber may get damaged when releasing the clamps while the CPM 7900 is running.

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The machine parts inside the pellet chamber (especially the die) may get damaged.

Production stop (No emergency situation)

The pellet chamber will be piled with product and must

be cleaned entirely before restarting production on the CPM 7900.

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2.6 Safety provisions

The CPM 7900 is equipped with the following safety

provisions that protect the operator and/or the machine:

3. Safety interlock switch

5. Oil flow switch

It is not allowed to disable, deactivate or dismantle safety provisions.

The CPM 7900 may not be started (and must be switched OFFimmediately) if one of the safety provisions are defective.

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2.6.1 Emergency stop button

Figure 2-9: Emergency stop button

In case of danger for human (or damage to the machine):

the entire pelleting production line, including the CPM 7900.

The CPM 7900 is equipped with one emergency stop button (delivered separately), but the entire pelleting production line may be equipped with a number of emergency stop buttons.

After an emergency stop, the production is terminated immediately

The pelleting production line, including the CPM 7900, will then fall into safe mode

Except for the P(L)C, all machine parts will have been switched off, run dead, or pressurized, respectively

de-Only use the emergency stop button in dangerous situations (or damage to the machine).

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2.6.2 Safety covers

Figure 2-10: Safety covers

The CPM 7900 is equipped with safety covers:

The safety covers must always be placed around the machine Only if necessary, for instance when maintenance activities have to be done, these safety covers may be

removed from the CPM 7900 by authorized personnel After such maintenance

activ-ities, the safety covers must always be replaced before running production again

The safety covers may only be removed temporarily for maintenance activities by authorized personnel.

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2.6.3 Pellet chamber with interlock

Figure 2-11: Pellet chamber with trapped key interlock switch

The CPM 7900 is equipped with a pellet chamber:

The pellet chamber gives access to the die and the rollers

The pellet chamber has a trapped key interlock switch that must be used in tion with a safety box (also with a trapped key interlock switch) located at another place

combina-This means that the pellet chamber can only be accessed if:

On the other hand, the CPM 7900 can only run production if:

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Only if necessary, the pellet chamber may be opened for inspection, adjustment and maintenance activities by authorized personnel After these activities, the pellet cham-ber must be closed and locked before running production again

The pellet chamber may only be opened temporarily for inspection, justment and maintenance activities by authorized personnel.

ad-The trapped key interlocking of the pellet chamber forces the operator to follow a determined sequence of actions that will ensure that all hazards inside the pellet chamber have been eliminated before operators can become exposed to these haz-ards

pre-2.6.3.1 How to open the pellet chamber

Do the following to OPEN the pellet chamber:

• Stop the CPM 7900.

• Wait until the CPM 7900 has come to a complete stop, and the red light is ON

hold it down, and turn the safety key.

The safety key can only be removed when the green light ON the safety box is ON.

• Remove the safety key from the interlock switch [A] the safety box.

• Place the (same) safety key in the interlock switch [B] of the pellet chamber.

• Unlock the interlock switch of the pellet chamber by turning the safety key [C].

• Remove the lock pin [D] from the interlock switch of the safety door.

• Release the two pellet chamber clamps [E].

• Open the pellet chamber [F].

Figure 2-12: How to open the pellet chamber

D C

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2.6.3.2 How to close the pellet chamber

Do the following to CLOSE the pellet chamber:

• Close the pellet chamber [A].

• Fasten the two pellet chamber clamps [B].

• Position the lock pin [C] in the interlock switch of the pellet chamber.

• Lock the interlock switch of the pellet chamber by turning the safety key [D].

• Remove the safety key from the interlock switch [E] of the pellet chamber.

• Replace the (same) safety key in the interlock switch [F] of the safety box.

• Lock the interlock switch of the safety box by turning the safety key [G].

The safety key is locked (and trapped) when the red light ON the safety box is ON.

Figure 2-13: How to close the pellet chamber

F E

Safety key

A B

B

G

The CPM 7900 can be (re)started after locking the interlock switch of the safety box.

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2.6.4 Shear pin security

Figure 2-14: Shear pin security

The CPM 7900 is equipped with a shear pin security:

When the shear pins break, the micro switch at the back will automatically switch off

the main motor of the CPM 7900 to prevent consequential damage to the CPM 7900.

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2.6.5 Oil flow switch

Figure 2-15: Oil flow switch

The CPM 7900 is equipped with an oil flow switch:

• To protect the CPM 7900 in case the oil flow to the main shaft bearing is too little.

When the oil flow switch is activated, this switch will automatically switch off the main

motor of the CPM 7900 to prevent consequential damage to the CPM 7900.

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2.6.6 Low grease alarm

The CPM 7900 is equipped with a low grease alarm:

bearing, and if available, the lineator is too little

When the low grease alarm is activated, the production must be stopped immediately

See the manual of the lubrication system for automatic grease supply.

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3

Always check the functioning of the CPM 7900 before putting the CPM

7900 into use or before carrying out any operation on the CPM 7900.

3.2 Important installation topics

When installing the CPM 7900, the following installation topics are important.

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3-2 Installation

3.2.1 Hoisting the CPM 7900

• Attach the cables to:

- The hoisting holes at the back of the base plate

• Attach the sling under the support frame of the conditioner.

As an alternative:

- Attach the crane hook on top of the main motor.

- Attach the sling under the support frame of the conditioner.

See the hoisting instructions how to hoist the CPM 7900.

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3.2.2 Placing the CPM 7900

The site floor must be designed

by qualified structural engineers

• Place the CPM 7900 on a suitable floor.

• Attach the base plate of the CPM 7900 to the floor with six anchor bolts.

- If desirable, position (optional) vibration dampers underneath the edges of the

base plate of the CPM 7900.

Make sure the site floor is able to absorb the vibrations of the CPM 7900.

Make sure the site floor is flat, vibration-free, and able to handle the static and dynamic load of the CPM 7900 installation.

If the site floor is not able to absorb the vibrations of the CPM 7900, the bearings may damage due to excessive vibrations.

Vibration damper

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3.2.3 Installing the CPM 7900

Only qualified personnel are authorized to install the CPM 7900 on site.

• Level the CPM 7900.

• Take the dimensions of the CPM 7900 into account.

- Provide enough room for passages.

- Provide enough room for the required working area.

CPM Europe BV provides the general dimensions together with the CPM delivery.

See the provided general dimension drawing of your CPM 7900.

• Provide enough room around the CPM 7900 for maintenance activities, such as:

- Removing the conditioner (and/or its rotating shaft with paddles)

- Transporting equipment parts, such as the die and the rollers

Make sure the pellet chamber is able to swing open fully.

Make sure the main shaft of the CPM 7900 can be removed completely.

Make sure the complete length of the rotating shaft can be removed from the feeder and the conditioner.

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• Install the CPM 7900 according to the installation specifications.

See the Electric Diagram in Annex 2.

See the Electric Check List in Annex 2.

See the Electric Diagram of the trapped key interlock switch in Annex 2.

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- If necessary, install the main motor.

See the Coupling Instructions in Annex 2 for installing the main motor.

- If available, install the optional pneumatic hoist for hoisting the die and the

- If necessary, install the feeder and conditioner.

See the Feeder and Conditioner Installation Instructions in Annex 2.

Only qualified personnel are authorized

to install the feeder and conditioner.

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- If available, install the steam system (to be connected to the conditioner).

If available:

See the Installation Instructions of the steam system.

Depending on the pellet capacity of the CPM 7900, CPM Europe BV will advise which steam system is best to use.

Underpressure or overpressure situation

The pellet chamber and the feed chute may never be operated in and/or exposed to

an underpressure situation (< 1.0 bar) or an overpressure situation (> 1.0 bar) This may cause oil leakage and damage of the gear box, and will void the warranty

An underpressure situation can be solved by installing an air lock.

Air Lock Cooler

Pellet Mill

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3.2.4 Aligning the CPM 7900

• Check the pellet chamber alignment.

- If necessary, adjust/center the dust cone seal to contact the feed cone lip.

- If necessary, adjust/center the pellet chamber with the gear box front liner

to form a tight seal

Make sure the pellet chamber and the gear box front liner are in close contact all around the circumference.

Make sure the dust cone seal and the feed cone lip are in close contact all around the circumference.

Always check the pellet chamber alignment after shipping or hoisting the CPM 7900.

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