01.0 - 22146.002E - Hydraulic System

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Machine manual
en-22146.002-E
ulicsystemofthe P
h actuator for guillotine gates
Code word
YAMAVER 5
Order number
01 382
AAT item
501 08 08
Machine manual
Hydraulic system of the POLYCOM with actuator for guillotine gate
Contents
Contents
1 Technical data ............................................
1 -1
2 Safety
...................................................
2 -1
3 Components and mode of functioning
.....................
3 -1
3.1 Components
..............................................
3 -1
3.2 Mode of functioning
........................................
3 -10
3.3 Local control box
..........................................
3 -10
3.4 Local control box for the guillotine gates of the mill feed system ..
3 -13
4 Transport and assembly
..................................
4 -1
4.1 Transport and storage instructions
...........................
4 -1
4.2 Assembly .................................................
4 -1
5 Lubrication
..............................................
5 -1
6 Preparation for test run
...................................
6 -1
6.1 Checks prior to the test run
6.2 Filling the hydraulic system
6.3 Test run of the POLYCOM
.................................
.................................
..................................
6 -1
6 -2
6 -14
7 Commissioning and operation
............................
7 -1
7.1 Commissioning ............................................
7.2 Operation .................................................
7 -1
7 -3
8 Maintenance
.............................................
8 -1
8.1 Inspection
8.2 Servicing
................................................
.................................................
8 -1
8 -2
8.3 Trouble shooting ...........................................
8.4 Repair ....................................................
8 -3
8 -7
9 Spare parts
..............................................
9 -1
10 Appendix
................................................
10 -1
10.1 Technical drawings .........................................
10.2 Subsuppliers documentation ................................
10 -1
10 -1
Machine manual
Technical data
Hydraulic system of the POLYCOM with actuator for guillotine gate 1--1
1 Technical data
NOTE
Information concerning the electrical equipment is contained in the separate electrical documentation or in the subsupplie
Information on the intended use
LYCOM .... No. 22140.001
( Chapter 501 - Volume 4 )
Basic data
Year of manufacture
............................................... 2006
Weight of hydraulic power unit ...................................... 660 kg
Maximum operating pressure ...................................... 170 bar
Roll paralleling control ................................................ yes
Hydraulic oil reservoir (1.0)
Volume ......................................................... 800 litre
Pump (11.0)
Type
.......................................... 855 IPC 5/3 - 40 / 10 - 401
Delivery rate stage A ........................................ 59.0 litre/min
Delivery rate stage B ........................................ 14.8 litre/min
Electric motor (8.0)
Type
............................................... 852 / 0015 VEM S01
Power ........................................................... 22 kW
Plunger cylinder (60.1 to 60.4)
Type
........................................... PLB 600 - 100 - M 3705.5
Piston diameter .................................................. 600 mm
Piston stroke .................................................... 100 mm
Technical data
1--2
Machine manual
Piston accumulator (53.1 and 53.2)
Type
........................................... AK 70 - 280 - 18 / 0 / S / 3
Gas volume .................................................... 71.4 litre
Nitrogen quality ................................ 99.99 percent by volume N 2
Backward travel cylinder (64.1 to 64.4)
Type
............................................. PLB 140 - 105 - M 4439
Piston stroke .................................................... 105 mm
Hydraulic cylinder (81.1 and 81.2) for the actuator of the guillotine gates
Type
....................................... MM 125 / 70 - 750 - M 4947 A
Piston diameter ................................................... 70 mm
Piston stroke .................................................... 750 mm
Machine manual
Safety
2 Safety
NOTE
Be sure to comply with the general safety instructions in the supplement Important notes on the documentation.
Use
The hydraulic system is a component of the POLYCOM high -pressure grinding roll.
Be sure to comply with the stipulations concerning the intended use in section
Technical data.
Any use other than the intended use is forbidden. POLYSIUS AG is not responsible for damage resulting from any use other
The intended use also includes the observance of the instructions in the machine manual and the compliance with the mainte
Transport and assembly
All transportation instructions in this machine manual refer exclusively to transportation of the machine at the plant site.
Only use suitable hoisting and lifting equipment which is in serviceable order and has a sufficient load bearing capacity.
Never work under a suspended load.
Operation
Any safety checks before or during operation depend on the relevant national
regulations. The plant management is responsible for the performance and recording of such checks.
If changes in the machine or its operating behaviour relevant to safety occur, shut it down immediately.
To protect the drives, the POLYCOM high -pressure grinding roll must not be started if there is mill feed material in the roll ga
Be sure to comply with the information about the special conditions when starting the POLYCOM with hot feed material that
Safety
2--2
Machine manual
Maintenance
Ensure that all machines and motors whose operation might endanger persons
or equipment are switched off and safeguarded against restarting for the entire duration of the maintenance work.
Ensure that all rotating parts of the machine have come to a complete standstill before you remove any protection devices or
Before performing any work on the machine, make sure that there is no danger of suffering burns when touching the machine
Keep the machine free of oily and combustible substances and materials. Never use gasoline or other easily inflammable sub
Switch off the power supply to the electrical components before commencing any maintenance work.
The hydraulic system is specially designed for the supplied machine and may, therefore, not be used for any other machine w
Make sure that the hydraulic piping is relieved of pressure before disconnecting it.
Never use the pumps of the hydraulic system for emptying or filling the oil tank.
If you drain hydraulic oil at operating temperature, you risk scalding yourself.
Only use pure nitrogen and never oxygen for filling the piston accumulators.
After all maintenance work, check that there are no leaks in connecting points and connections.
If you carry out electrical welding on any part of the machine, never conduct the welding current through plain or antifriction b
The plant management must ensure that all rotating parts are protected against accidental contact.
Remount all protection devices when maintenance work has been finished. Make absolutely sure that no persons are inside t
3 Components and mode of functioning
The required grinding forces of the POLYCOM high -pressure grinding roll are generated by the hydraulic system and transfe
The hydraulic system of the POLYCOM has the following main functions:
to push the floating roll unit forward and back
to generate the contact pressure required for comminution of the feed material
to form a hydropneumatic spring system
to actuate the guillotine gates at the mill feed system

3.1 Components
NOTE
Some details of the drawings in this manual may not be identical with the drawings supplied under the contract as listed in secti
The hydraulic system essentially consists of the following components:
the hydraulic power unit with the hydraulic oil tank, the pump, the return flow filter and the associated controllers and indicator
the valve blocks
the plunger cylinders
the backward travel cylinders
the piston accumulators with the nitrogen filling devices
and the terminal box.
L
R
B.22146.002 -0
Figure 1
L=lookingatthepistonaccumulatorsleft-handsideofthePOLYCOM
L=lookingatthepiston accumulatorsright-handsideofthe POLYCOM
Items shown in the drawing of the hydraulic system
1.0 Hydraulic oil reservoir
2.0 Drain cock
3.0 Ventilation filter
4.0 Oil level indicator
5.0 Heater
6.0 Temperature sensor
7.0 Level switch
8.0 Electric motor
9.0 Pump support
10.0 Coupling 11.0 Pump
12.0 Return flow filter
13.0 Non-return valve
14.0 Hose
15.0 Hose
17.0 Valve block
18.0 Pressure valve with magnetic relief
19.1 Minimess connection
19.2 Minimess connection
20.1 Minimess pressure gauge connection
20.2 Minimess pressure gauge connection
21.1 Pressure gauge
21.2 Pressure gauge
22.1 Valve block with non -return valve
22.2 Valve block with non -return valve
23.0 4/2 -port directional control valve
24.0 Pressure limiting valve
25.0 Ball valve
Figure 2
Items shown in the drawing of the hydraulic system (continuation)
35.1 Valve block
35.2 Valve block
36.1 Pressure filter
36.2 Pressure filter
38.1 Orifice plate
38.2 Orifice plate
39.1 Non -return valve hydraulically unlockable in the valve block
39.2 Non -return valve hydraulically unlockable in the valve block
40.1 Ball valve
40.2 Ball valve
41.1 Intermediate plate with two non -return valves
41.2 Intermediate plate with two non -return valves
43.1 Valve block
43.2 Valve block
43.3 Valve block
43.4 Valve block
44.1 Flow regulation valve
46.1 Orifice plate
46.2 Orifice plate
50.1 Connection block
50.2 Connection block
Figure 3
Items shown in the drawing of the hydraulic system (continuation)
52.1 Throttle block
52.2 Throttle block
53.1 Piston accumulator
53.2 Piston accumulator
54.1 Nitrogen filling device
54.2 Nitrogen filling device
55.0 Adapter for nitrogren filling
56.0 Nitrogen filling hose
59.1 Pressure monitor
59.2 Pressure monitor
60.1 Plunger cylinder
64.1 Backward travel cylinder
65.1 Ball valve
65.2 Ball valve
70.0 Terminal box
74 Pressure valve
100 Local control box
Figure 4
Items shown in the drawing of the hydraulic system (actuator of the guillotine
valves)
76.0 Connection plate
77.1 Lowering brake valve in the valve block
77.2 Lowering brake valve in the valve block
80.1 Ball valve
80.2 Ball valve
81.1 Hydraulic cylinder with integral travel measuring device
81.2 Hydraulic cylinder with integral travel measuring device
Figure 5
3.2 Mode of functioning
The following functions are performed by the hydraulic system:
Pressureless circulation of the hydraulic oil in the hydraulic power unit

Flushing of the plunger cylinders and the backward travel cylinders
Shifting of the floating roll against the spacers and build -up of start -up pressure
Opening the roll gap (backward travel)
Pressure control during operation
Roll paralleling control (special design)
Guillotine gates of mill feed system OPEN
Guillotine gates of mill feed system CLOSED
Guillotine gates of mill feed system CLOSED after EMERGENCY OFF
NOTE
For a detailed description of the individual functions, see sections Preparation for test run as well as Commissioning and Opera
3.3 Local control box
With the local control box that is included in the scope of supply and is mounted near the POLYCOM, the following functions c
1. Skewing indication 0 -20 mm
2. Fast pressure build -up left -hand side
3. Slow pressure build -up left -hand side
4. Opening of roll gap left -hand side
5. Pressure reduction left -hand side
6. Signal lamp, reset button
7. Emergency off button
8. Fast pressure build -up right -hand side
9. Slow pressure build -up right -hand side
10. Opening of roll gap right -hand side
11. Pressure reduction right -hand side
Figure 6
Functions of the local control box
The functions can be performed independently of each other for the left -hand and
the right -hand side, but they can also be simultaneously performed on both sides by simultaneously pressing the correspondin
For example, during forward movement of the floating roll on the right side (by means
of slow or fast pressure build -up): If the floating roll on the right side has been advanced to the limit value of skewing, which is
With the additional function Pressure reduction which activates the solenoid valves
y7 to y10, the main pressure cylinders can be bled in local operating mode. For this purpose, the respective pushbuttons Fast
Simultaneous bleeding on both sides (left/right) is not necessary in the local
operating mode.
3.4 Local control box for the guillotine gates of the mill feed system
Functions of the local control box
for the guillotine gates of the mill feed system
For the guillotine gates of the mill feed system, a separate local control box with 4
pushbuttons is provided.
With these pushbuttons, the two guillotine gates can be opened and closed independently of each other.
Figure 7
4 Transport and assembly

4.1 Transport and storage instructions
The machine is transported in single parts or in subassemblies. It must be ensured that suitable lifting equipment is employed f
When they arrive at the site, all parts must be inspected for transport damage and placed on wooden beams with the provision
Motors, couplings, measurement and control equipment must be stored in well ventilated buildings and must be protected again
4.2 Assembly
General notes
The following assembly instructions do not detail the individual steps for assembling the machine units but rather give an overvi
Changes in the planning of the plant during the processing of the contract may lead to deviations from these assembly instructi
NOTE
It is a prerequisite of our warranty that final assembly and assembly inspection are undertaken by an assembly specialist from P
We recommend that the assembly work is supervised from start to finish by specialists from POLYSIUS AG.
A careful selection of the tools and appliances as well as the assembly personnel to be employed is important for the correct pe
CAUTION
If you carry out electrical welding on any part of the machine, never conduct the welding current through plain or antif
Always directly connect the welding current return lead to the part being welded.
Transport and assembly
4--2
Machine manual
Sequence of assembly
Make absolutely sure that the hydraulic power unit is mounted in conformity with the general arrangement drawing.
Ensure that the space available for operation and maintenance is large enough to allow easy access to all parts.
The hydraulic power unit is completely preassembled, cleaned and checked for proper functioning before it is delivered.
Due to the efficiency of the energy conversion, heat dissipation is always necessary. Therefore ensure that the place of install
Mount the connecting piping between the hydraulic power unit and the pressure hydraulic system (piston accumulator, plunge
The maximum permissible piping length between the hydraulic power unit and the high -pressure grinding roll is 20 m.
The leak oil piping between the lower plunger cylinders and the hydraulic oil reservoir must have a decline of at least 5 %. The
Assembly instructions regarding the piping
Generally, the supply connections are made by the plant owner.
Install the piping in accordance with the project-related general arrangement drawing for piped services. Be absolutely sure to
Bending radius referred to the centre line of the pipe
Pipe diameter
Wall thickness
Bending radius
Bend the pipes in cold condition, deburr and clean by blowing out with compressed
air.
Ensure utmost cleanliness during installation of the piping!
Fastening the piping
Pipe diameter
Distance between clamps
Fasten the piping at its ends and before the hose connections. Fasten pipe bends
directly after the bends.
When selecting the piping and hoses, take full consideration of the maximum operat-
ing pressure, the permissible flow velocity or permissible flow resistance and the employed pressure medium. Be sure to compl
Ensure that the pipe unions are easily accessible. You must lay the piping with the aid of the piping diagram in order to avoid pi
After welding, you must dismount and pickle the piping. Make sure that it is thor- oughly cleaned before connection to the housi
Free all the units from preservatives, check them for ease of movement and mount them in the correct mounting position free o
WARNING
Never tighten leaking connections and pipe unions while the system is under pressure.
Lead -sealed units may only be opened with the written authorisation of POLYSIUS AG.
If an electric motor is mounted by the customer, attachment of the coupling and the
alignment have to be performed according to the instructions of the coupling manufacturer. The shaft ends may only transmit to
Machine manual
Lubrication
5 Lubrication
NOTE
The POLYSIUS table of lubricants with the lubricant reference numbers is contained in the supplement Important notes on
It is the responsibility of the lubricant supplier to select appropriate lubricants corresponding to the reference numbers. POLYS
The use of a lubricant not explicitly stated in the table of lubricants has to be previously approved by POLYSIUS AG.
The supplement Important notes on the documentation also contains the generally valid Notes on lubrication.
Ensure that the lubricants are stored, used and disposed of in an
environmentally -friendly manner and observe your national environmental legislation when handling lubricants.
Lubrication chart
Lubrication points
No.
The different makes of lubricant corresponding to the lubricant reference numbers are shown in the table of lubricants in the supplement Important notes o
Explanation of the numbers
Also observe the instruction of the manufacturer Hoven Hydraulik.
6 Preparation for test run

NOTE
It is a prerequisite of our warranty that the first test run is carried out in the presence of and according to the instructions of spec
6.1 Checks prior to the test run
After completing the assembly work and prior to the first test run, check all parts of the plant according to the list below. Make a
Have the checks been carried out according to the checklist included in the separate machine manual for the high -pressure
Have the checks been carried out according to the checklist included in the separate machine manual Drive for POLYCOM ?
Have the checks been carried out according to the checklist included in the separate machine manual Grinding material feed
Are all pipe unions properly tightened?
Has the leak oil piping from the plunger cylinders to the hydraulic oil reservoirs been laid with adequate decline?
Have all the units been freed from preservatives, checked for ease of movement and mounted in the correct mounting positio
Have the connecting ducts between the hydraulic power unit and the pressure hydraulic system (piston accumulator, plunger
Is the suction piping of the pump (11.0) tightly connected?
Has the direction of rotation of the electric motor (8.0) for the pump been checked?
The direction of rotation of the electric motor must correspond to the direction indicating arrow on the electric motor or pump su
Is the inside of the hydraulic oil reservoir dust free and dry?
Has all hydraulic piping been properly fastened?
6.2 Filling of the hydraulic system
NOTE
In the hydraulic circuit diagrams, all magnets are shown in de -energised condition.
Filling of the piston accumulators (53.1 and 53.2) with pure nitrogen.
For nitrogen quality, see section Technical data.
DANGER
The piston accumulator will explode if you fill it with oxygen. There is mortal danger.
Always and exclusively use pure nitrogen for filling the piston accumulators.
Check whether the oil side of the piston accumulator has been relieved of pressure.
Open the ball valve (40.1 or 40.2).
Connect the steel nitrogen bottle with the nitrogen filling hose (56.0) to the nitrogen filling device (54.1 or 54.2).
Fill the piston accumulator (53.1 or 53.2) by carefully opening the stop cock on the steel nitrogen bottle. The nitrogen flows via
Then close the stop cock on the steel nitrogen bottle and read off the attained pressure at the pressure gauge.
Repeat this procedure until the required initial filling pressure is attained.
If the pressure is excessive, you can reduce it by opening the valve on the nitrogen filling device (54.1 or 54.2).
After a waiting time of approx. 5 minutes, during which temperature equalisation takes place, check the filling pressure again
The gas pressure in the piston accumulators must be below the start -up pressure P0 required later. (Pgas P0 - 10 bar)
Close the stop cock on the steel nitrogen bottle and remove the nitrogen filling hose (56.0).
Close the ball valve (40.1 or 40.2).
Filling in hydraulic oil
Make absolutely sure that all auxiliary equipment used to fill the installation with hydraulic oil is clean.
Connect the filling pump provided by the customer to connection (E) on the hydraulic oil reservoir (1.0). (Connection fitting DK
Fill in the hydraulic oil (for type see lubrication chart in section Lubrication) up to the marking on the oil level indicator (4.0).
The hydraulic oil flows through the return flow filter (12.0) into the hydraulic oil reservoir.
During the commissioning phase, you must check the oil level constantly. If the oil level falls, hydraulic oil has to be topped up im
The oil quantities withdrawn from the hydraulic oil reservoir by filling the plunger cylinders and the piston accumulators, must no
Oil heating
NOTE
The heaters (5.0) are only installed if ambient temperatures below 10 C are expected.
When the control voltage is switched on, the heater must also be switched on in order to keep the oil temperature within the req
Pressureless circulation
Switch on the electric motor (8.0) of the pump (11.0). (The pump is a double pump with the stages A and B.)
The solenoids [Y1] of the pressure valve (18.0) and [Y2] of the 4/2-port directional control valve (23.0) are de -energised.
The pump (11.0) delivers hydraulic oil into the valve block (17.0).
The hydraulic oil of stage A flows via the pressure valve (18.0) and the return flow filter (12.0) back into the hydraulic oil reserv
The hydraulic oil of stage B flows through the 4/2-port directional control valve (23.0) back into the hydraulic oil reservoir (1.0).
Stage B is safeguarded by the pressure limiting valve (24.0) [p B = 180 bar]. Keep this condition for at least 3 seconds to allow a
The pump must not be started if the system is pressurised.
Make sure that the pump is not started frequently (more than five times per hour) as this causes heavy wear.
a
Figure 8
Flushing the hydraulic piping
Prior to the first commissioning and after repair work on the hydraulic system, the piping has to be carefully flushed:
Shift the floating roll against the spacers with the aid of mounting jacks.
Constantly check that the floating roll is uniformly shifted. Permissible skewing must be less than 8 mm.
Open the ball valves (25.0; 40.1 and 40.2)
Switch on the electric motor (8.0), the pump (11.0) delivers in pressureless circulation.
Energise the solenoids [Y5 and Y6] of the 4/3-port directional control valves (42.1 and 42.2) and [Y1] of the pressure valve (18
The hydraulic oil flows from the stages A and B of the pump through
the non -return valves (22.1 and 22.2),
the ball valve (25.0),
the hydraulic piping from the hydraulic power unit to the POLYCOM ,
the pressure filters (36.1 and 36.2),
the 4/3-port directional control valves (42.1 and 42.2) of connection P to A,
the ball valves (40.1 and 40.2),
into the tank piping [ T] and therefore back into the hydraulic oil reservoir (1.0).
The flushing period is 12 hours. When the electrical clogging indicator of the pressure filters (36.1 and 36.2) responds, the flu
NOTE
Check the oil temperature during the flushing process!
If the oil temperature reaches 60 C, interrupt the flushing process and let the oil cool down.
To conclude the flushing process
the solenoids [Y1 + Y2 and Y5 + Y6] have to be simultaneously de -energised;
the electric motor (8.0) must be switched off;
the ball valves (40.1 and 40.2) have to be closed.
B.22146.002-- 20a
Figure 9
Venting the actuator of the guillotine gates
Open the ball valves (80.1 to 80.4).
Energise the solenoids [Y12 and Y14] of the 4/3-port directional control valves (79.1 and 79.2).
Switch on the electric motor (8.0), the pump delivers in pressureless circulation.
Energise the solenoid [Y2] of the 4/2-port directional control valve (23.0).
Open the Minimess connections at the hydraulic cylinders (81.1 and 81.2) one after the other until only hydraulic oil free from
B.22146 -21
Figure 10
Venting the actuator of the guillotine gates (continuation)
De -energise the solenoids [Y12 and Y14] of the 4/3-port directional control valves (79.1 and 79.2).
Open the Minimess connections at the hydraulic cylinders (81.1 and 81.2) one after the other until only hydraulic oil free from
B.22146.002-- 21a
Figure 11
Venting the plunger cylinders
Energise the solenoids [Y7 to Y10] of the 2/2-port directional control valves (45.1 to 45.4).
Energise the solenoid [Y2] of the 4/2-port directional control valve (23.0).
Flushing period approx. 2 hours
NOTE
When the plunger cylinders are vented, they press the floating roll up to the spacers. Constantly check that the floating roll is un
B.22146.002-- 20b
Figure 12
Bleeding the backward travel hydraulic system
The electric motor (8.0) is still switched on and the pump (11.0) delivers.
De -energise the solenoids [Y5 and Y6] of the 4/3-port directional control valves (42.1 and 42.2).
Open the ball valves (65.1 and 65.2).
Open the Minimess connections at the backward travel cylinders (64.1 to 64.4) one after the other until only hydraulic oil free
Switch off the electric motor (8.0).
NOTE
After bleeding the hydraulic system, all solenoids have to be de -energised.
During commissioning, the hydraulic system has to be bled several times in order
to achieve good bleeding. Air -entrainment in the hydraulic system has a negative effect on the hydraulic system functioning an
B.22146.002-- 20c
Figure 13
6.3 Testrunofthe POLYCOM
NOTE
For the test run, be sure to also comply with the instructions in the machine manuals for the high -pressure grinding roll, the PO
The test run should be performed for at least 4 hours at a hydraulic pressure of approx. 50 bar.
NOTE
In order to protect the unit against overloading, the pressure limiting valves (37.1 and 37.2) are sealed by the TV (Tec
Make absolutely sure that the setting of these pressure limiting valves is never changed, as this would endanger the s
Checks during the test run of the hydraulic system
Check all piping and screwed connections for leaks.
Check the oil level in the hydraulic oil reservoir.
Check the return flow filter (12.0) and the pressure filters (36.1 and 36.2) for clogging.
Check the pump (11.0) for unusual running noises
Check the safety interlocks of the hydraulic system for proper functioning
Oil temperature
Oil level
Filter clogging
Check the following functions of the hydraulic system:
Shifting of the floating roll against the spacers and build -up of start -up pressure
Opening of the roll gap (backward travel)

If faults are found during the test run, it must be interrupted and resumed after the
faults have been eliminated.
WARNING
The hydraulic piping is subjected to a high system pressure. If oil spurts out, it may injure you or cause a fire.
Be sure to depressurise the hydraulic system first [Open the ball valves (40.1 and 40.2)] and then tighten the leaky con
Upon completion of the test run, be sure to retighten all the screwed connections
of the piping system, even if they are not leaky. Make absolutely sure that the hydraulic system has been depressurised before
7 Commissioning and operation
7.1 Commissioning
NOTE
In order to protect the unit against overloading, the pressure limiting valves (37.1 and 37.2) are sealed by the TV (Tec
Make absolutely sure that the setting of these pressure limiting valves is never changed, as this would endanger the s
Setting and adjustment
Setting the pressure valve (18.0), is set to 180 bar by the manufacturer.
Close the ball valve (25.0)
Start the electric motor (8.0) (pressureless circulation)
Undo the counternut at the pressure valve
Energise the solenoid Y1 of the pressure valve (18.0)
Read the pressure off at the pressure gauge (21.1)
Set the pressure to the required value by turning the setting spindle clockwise - -> pressure increase
counter -clockwise - -> pressure reduction
After setting the required pressure, secure the position of the setting spindle by tightening the counternut and de -energise the
Setting the pressure limiting valve (24.0), is set to 180 bar by the manufacturer.
Close the ball valve (25.0)
Start the electric motor (8.0) (pressureless circulation)
Undo the counternut at the pressure valve
Energise the solenoid Y2 of the pressure limiting valve (24.0)
Read the pressure off at the pressure gauge (21.2)
Set the pressure to the required value by turning the setting spindle clockwise - -> pressure increase
counter -clockwise - -> pressure reduction
After setting the required pressure, secure the position of the setting spindle by tightening the counternut and de -energise the
Setting the throttle at the throttle block (52.1 and 52.2)
With the setting of the throttles in the throttle blocks (52.1 and 52.2), it is possible to influence the smooth running (vibrations) o
It is always necessary to start the first commissioning with open throttles. If rough running occurs during operation, you should f
Do not try to reduce the vibrations by reducing the throttle cross -section until these measures remain unsuccessful. Since throt
Undo the counternuts at the throttle blocks
Adjust the throttles by turning the setting spindles clockwise - -> close
counter -clockwise - -> open
After the adjustment, secure the setting spindles by tightening the counternuts.
7.2 Operation
Simplified description of the functional sequences:
The ball valve (25.0) is open;

The ball valves (40.1 and 40.2) are closed;
All solenoids [Y1 to Y15] are de -energised.
roll against the spacers and building up of start -up pressure
The solenoids [Y5 and Y6] of the 4/3-port directional control valves (42.1 and 42.2)
are energised.
The solenoids [Y1] of the pressure valve (18.0) and [Y2] of the 4/2-port directional control valve (23.0) are energised.
The piston rods of the plunger cylinders (60.1 to 60.4) extend and shift the floating roll in the direction of the fixed roll up to the
The piston rods of the backward travel cylinders (64.1 to 64.4) are simultaneously retracted. The displaced hydraulic oil is forc
When a pressure of 5 bar below p0 is attained, the solenoid [Y1] of the pressure valve (18.0) is de -energised.
Stage A of the pump therefore delivers in pressureless circulation. The pressure build -up up to the start -up pressure is now
When the start -up pressure is attained, the solenoid [Y2] of the 4/2 -port directional control valve (23.0) is de -energised.
are de -energised.
The electric motor (8.0) of the pump is switched off.
The solenoid [Y11] of the 2/2-port directional control valve (45.5) is energised for 2 seconds.
The pressure of the left -hand and right -hand side of the POLYCOM is therefore compensated.
Opening of the roll gap (backward travel)
The solenoids [Y7 to Y10] of the 2/2-port directional control valves (45.1 to 45.4) are energised.
The pressure in the plunger cylinders (60.1 to 60.4) is slowly reduced.
are energised.
The solenoid [Y2] of the 4/2-port directional control valve (23.0) is energised.
Stage B of the pump delivers the hydraulic oil through the 4/3-port directional control valves (42.1 and 42.2) connection P to B to t
The backward travel is monitored by the travel measuring device. If one side advances 4 mm, the respective solenoid [Y3 or Y4
After the floating roll has reached the end position, the solenoids [Y2 to Y4 and Y7 to Y10] are de -energised.
The electric motor (8.0) remains switched on for another 10 minutes, the hydraulic oil is filtered in pressureless circulation du
A function program of the POLYCOM can be restarted at any time during this
process.
Flushing the plunger cylinders
Flushing the plunger cylinders is necessary in order to exchange the hydraulic oil and bleed the hydraulic system:
before commissioning
after every longer stoppage of the hydraulic system and
after more than 24 operating hours.
During the next start, the flushing process starts first and then the pressure is built up to start -up pressure; the flushing process
The solenoids [Y5 and Y6] of the 4/3-port directional control valves (42.1 and 42.2) are energised.
The solenoids [Y1] of the pressure valve (18.0) and [Y2] of the 4/2-port directional control valve (23.0) are energised.
The piston rods of the plunger cylinders (60.1 to 60.4) extend and shift the floating roll in the direction of the fixed roll up to the
The piston rods of the backward travel cylinders (64.1 to 64.4) are simultaneously retracted. The displaced hydraulic oil is forc
After the floating roll has reached the spacers, the pressure at the pressure monitors (59.1 and 59.2) increases. At a pressure
Flushing the lower plunger cylinders
The hydraulic oil flows into the piston accumulators (53.1 and 53.2), through the plunger cylinders (60.1 and 60.3) and flow regu
When the start -up pressure at the pressure monitors (59.1 and 59.2) is attained, the solenoid [Y1] of the pressure valve (18.
If the pressure falls to approx. 20 bar, the solenoid [Y1] of the pressure valve (18.0) is re -energised.
This flushing process takes approx. 3 minutes.
The solenoids [Y7 and Y8] of the 2/2-port directional control valves (45.1 and 45.3) are de -energised.
Flushing the upper plunger cylinders
The hydraulic oil flows into the piston accumulators (53.1 and 53.2), through the plunger cylinders (60.2 and 60.4) and flow regu
When the start -up pressure at the pressure monitors (59.1 and 59.2) is attained, the solenoid [Y1] of the pressure valve (18.
If the pressure falls to approx. 20 bar, the solenoid [Y1] of the pressure valve (18.0) is re -energised.
This flushing process takes approx. 3 minutes.
Flushing the backward travel cylinders
This flushing process has to be carried in local operation once a month or after every longer stoppage of the hydraulic system.
Operate the local switch Forward travel so that the floating roll is shifted against the spacers.
Operate the local switch Backward travel and hold for the duration of the flushing process (approx. 5 minutes).
Close the ball valves (65.1 and 65.2) after the flushing process.
Open the roll gap by operating the local switch Backward travel.
Disconnect the electric motor (8.0) of the pump (11.0).
Flushing after exchange of the filter cartridges in the pressure filters (36.1 and 36.2)
This flushing process has to be carried in local operation after each exchange of the filter cartridges.
Operate the local switch Forward travel and hold for the duration of the flushing process (approx. 5 minutes).
Release the local switch after 5 minutes.
Close the ball valves (40.1 and 40.2) after the flushing process.
Pressure control during operation
With the pressure control system, the hydraulic pressure P is controlled as a function of the roll gap during operation.
Starting conditions
Skewing is < s permissible
The pressure is simultaneously changed on both sides
During operation with pressure control, the electric motor (8.0) remains in operation after the start -up pressure P0 has been atta
Pressure control system ON
Pressure increase
The solenoid [Y2] is energised for t = x seconds; the period x is defined during commissioning.
If PA max. has been reached, the solenoid [Y2] of the 4/2-port directional control valve (23.0) is de -energised.
Pressure reduction
The solenoids [Y9 and Y10] of the 2/2-port directional control valves (45.2 and 45.4) are energised for t = x seconds; the pe
Pressure control system OFF
After t = 2 minutes, the electric motor (8.0) is switched off.
Starting conditions
The floating roll is in contact with the spacers.
The pressure build -up to start -up pressure P 0 is concluded.
The electric motor (8.0) is switched on, the pump (11.0) delivers in pressureless circulation.
Open the guillotine gates
The hydraulic oil flows into the hydraulic cylinders (81.1 and 81.2) and opens the guillotine gates. By means of the flow regulatio
Due to the lowering brake valves (77.1 and 77.2), the guillotine gates can be kept in every intermediate position, also after the p
When the proximity switches are reached, the guillotine gates are opened and the solenoids [Y13; Y15 and Y2] of the 4/3-por
The electric motor (8.0) is switched on, the pump (11.0) delivers in pressureless circulation.
Close the guillotine gates
The hydraulic oil flows into the hydraulic cylinders (81.1 and 81.2) and closes the guillotine gates.
When the proximity switches are reached, the guillotine gates are closed and the solenoids [Y12; Y14 and Y2] of the 4/3-port
1--1
documentation or in the subsuppliers documentation.

2--1
n the documentation.
amage resulting from any use other than the intended use. All other use is at the owners own risk.
and the compliance with the maintenance instructions.
f the machine at the plant site.

ufficient load bearing capacity.
immediately.
ere is mill feed material in the roll gap and the floating roll is pressed against the fixed roll.
LYCOM with hot feed material that is contained in the machine manual of the High -pressure grinding roll.
the maintenance work.

ou remove any protection devices or open any flaps.
ng burns when touching the machine and that no hot material is in the machine when inspection and service covers are opened.
oline or other easily inflammable substances for cleaning the machine.
nance work.
not be used for any other machine without the express consent of POLYSIUS AG.
current through plain or antifriction bearings, other movable connections or measuring devices. Always directly connect the welding current r
ely sure that no persons are inside the plant component before you properly close the inspection and service covers.
by the hydraulic system and transferred by the plunger cylinders to the floating roll unit.
d under the contract as listed in section 10.1 Technical drawings.
associated controllers and indicators;

s well as Commissioning and Operation.
OLYCOM, the following functions can be performed:

aneously pressing the corresponding keys left and right. The skew monitoring system is active for all functions, also in local operating mode
the limit value of skewing, which is 4 mm, further forward movement on the right side is no longer possible; the floating roll must first be str
e, the respective pushbuttons Fast pressure build -up and Pressure reduction on the left side or on the right side must be simultaneously
of each other.
table lifting equipment is employed for lifting the parts from the transport vehicles and transferring them to the storage area.
n wooden beams with the provision of suitable protection against moisture, soiling and damage. Never place the parts directly on the groun
uildings and must be protected against moisture.
achine units but rather give an overview of the work to be performed.

ations from these assembly instructions.
ken by an assembly specialist from POLYSIUS AG.

m POLYSIUS AG.
ployed is important for the correct performance of the work.
ding current through plain or antifriction bearings, other moving connecting elements or measuring devices, in order to prevent da
ral arrangement drawing.
sy access to all parts.
ctioning before it is delivered.
efore ensure that the place of installation is adequately ventilated. (heat accumulation in niches!) The subsoil must offer sufficient stability. (
system (piston accumulator, plunger cylinder with accessories) and connect them to the respective connections specified in the hydraulic s
essure grinding roll is 20 m.
have a decline of at least 5 %. The leak oil must be drained off pressureless - separately from the return piping.
piped services. Be absolutely sure to comply with the provided instructions!
pressure medium. Be sure to comply fully with the accident prevention regulations or the respective national safety instructions. Bend the p
e piping diagram in order to avoid piping errors. Be sure to mount the pipe unions in accordance with the manufacturers instructions. Make
aned before connection to the housing. Make absolutely sure that no re- sidual dirt gets into the hydraulic system.
the correct mounting position free of stresses and easily accessible. Do not remove the plugs from the devices until immediately before co
The shaft ends may only transmit torques and must not be subjected to axial or radial load.
5--1
the supplement Important notes on the documentation. The supplement is to be found in this folder or at the beginning of the overall docum
g to the reference numbers. POLYSIUS AG is not responsible for the correctness of this data.
pproved by POLYSIUS AG.
otes on lubrication.
n when handling lubricants.
Qty. Designation
1 Hydraulicoilreservoir
1 Electric motor
bricants in the supplement Important notes on the documentation. The supplement is to be found in this folder or at the beginning of the overall documentation.
according to the instructions of specialists from POLYSIUS AG.
t according to the list below. Make absolutely sure that any material remnants, tools and assembly aids have been completely removed.
chine manual for the high -pressure grinding roll?
chine manual Drive for POLYCOM?
chine manual Grinding material feed device for POLYCOM ?
with adequate decline?

unted in the correct mounting position, free of stresses and easily accessible?
ystem (piston accumulator, plunger cylinder with accessories) been correctly mounted?
ow on the electric motor or pump support.

device (54.1 or 54.2).
itrogen bottle. The nitrogen flows via the nitrogen filling device (54.1 or 54.2) into the piston accumulator.
the pressure gauge.
evice (54.1 or 54.2).

ace, check the filling pressure again and correct, if required.
uired later. (Pgas P0 - 10 bar)
reservoir (1.0). (Connection fitting DK0L -28)

ing on the oil level indicator (4.0).
s, hydraulic oil has to be topped up immediately.

nd the piston accumulators, must not be topped up.
eep the oil temperature within the required range. The heater is switched on via a temperature monitor at an oil temperature below 10 C; th
e stages A and B.)

valve (23.0) are de -energised.
2.0) back into the hydraulic oil reservoir (1.0). The pressure valve (18.0) is set to 180 bar.
into the hydraulic oil reservoir (1.0).
tion for at least 3 seconds to allow a lubricating film to build up in the pump (11.0) and possibly accumulated air to escape to the hydraulic o
uses heavy wear.
s to be carefully flushed:
s than 8 mm.
2) and [Y1] of the pressure valve (18.0) and [Y2] of the 4/2-port directional control valve (23.0).
ers (36.1 and 36.2) responds, the flushing process has to be interrupted by de -energising the solenoids [Y1] of the pressure valve (18.0) a
ther until only hydraulic oil free from bubbles comes out, and close again.
ther until only hydraulic oil free from bubbles comes out, and close again.
antly check that the floating roll is uniformly shifted. Permissible skewing must be less than 8 mm. In the case of skewing, the solenoid [Y5
he other until only hydraulic oil free from bubbles comes out, and close again.
the hydraulic system functioning and may cause damage to seals and other components.
e high -pressure grinding roll, the POLYCOM drive and the POLYCOM mill feed system.
d 37.2) are sealed by the TV (Technical Inspection Authority).

ged, as this would endanger the safety and proper functioning of the system. The lowering brake valves (77.1 and 77.2) are set by
njure you or cause a fire.

2)] and then tighten the leaky connections and pipe unions.
tem has been depressurised before doing the retightening.
d 37.2) are sealed by the TV (Technical Inspection Authority).

ged, as this would endanger the safety and proper functioning of the system. The lowering brake valves (77.1 and 77.2) are set by
the counternut and de -energise the solenoid Y1.

the counternut and de -energise the solenoid Y2.
ce the smooth running (vibrations) of the POLYCOM .

ccurs during operation, you should first try to make the running smoother with process -specific measures (uniform material feed rate, bin fi
res remain unsuccessful. Since throttling of the oil routes increases the temperature of the hydraulic oil, the throttles should not be closed m
(23.0) are energised.

e direction of the fixed roll up to the spacers. This process is monitored by the travel measuring device. If one side leads by 4 mm, the respe
d. The displaced hydraulic oil is forced through the 4/3-port directional control valves (42.1 and 42.2) back into the hydraulic oil reservoir.
) is de -energised.
p up to the start -up pressure is now slower and only by means of stage B.
alve (23.0) is de -energised.
ompensated.
42.1 and 42.2) connection P to B to the backward travel cylinders (64.1 to 64.4). When the piston rods are extended, the pressure in the pip
m, the respective solenoid [Y3 or Y4] is de -energised until synchronism is attained again.
0] are de -energised.
iltered in pressureless circulation during this period.
d the hydraulic system:
rt -up pressure; the flushing process takes approx. two times 3 minutes.
l valve (23.0) are energised.

e direction of the fixed roll up to the spacers. This process is monitored by the travel measuring device. If one side leads by 4 mm, the respe
d. The displaced hydraulic oil is forced back through the 4/3-port directional control valves (42.1 and 42.2 connection B to T) into the hyd
1 and 59.2) increases. At a pressure of approx. 20 bar, the solenoid [Y2] of the 4/2-port directional control valve (23.0) is de -energised.
linders (60.1 and 60.3) and flow regulation valves (44.1 and 44.3) and back into the hydraulic oil reservoir (1.0).
enoid [Y1] of the pressure valve (18.0) is de -energised.
e -energised.
linders (60.2 and 60.4) and flow regulation valves (44.2 and 44.4) and back into the hydraulic oil reservoir (1.0).
enoid [Y1] of the pressure valve (18.0) is de -energised.
de -energised.
r stoppage of the hydraulic system.
ss (approx. 5 minutes).
(approx. 5 minutes).
he roll gap during operation.

e start -up pressure P0 has been attained and the pump (11.0) delivers in pressureless circulation.
0) is de -energised.
e -energised.
energised for t = x seconds; the period x is defined during commissioning.
gates. By means of the flow regulation valves (78.1 and 78.2), the oil flow rate and therefore the opening speed of the guillotine gates can b
ntermediate position, also after the pump (11.0) has been switched off.
ids [Y13; Y15 and Y2] of the 4/3-port directional control valves (79.1 and 79.2) and the 4/2-port directional control valve (23.0) are de -ener
ds [Y12; Y14 and Y2] of the 4/3-port directional control valves (79.1 and 79.2) and the 4/2-port directional control valve (23.0) are de -energ
ervice covers are opened.
s directly connect the welding current return lead to the part being welded.
service covers.
unctions, also in local operating mode, with the exception of the pressure reduction function.
ssible; the floating roll must first be straightened by actuating the key Pressure build -up left side.
the right side must be simultaneously pressed. This bleeding facility is very helpful particularly in the initial phase of commissioning .
m to the storage area.

er place the parts directly on the ground.
uring devices, in order to prevent damage to these parts.

subsoil must offer sufficient stability. (vibrations!)
onnections specified in the hydraulic system diagram.
D mm 10
s mm 1.5
R mm 20
mm 6 to 14 15 to 22
mm 900 1200
ational safety instructions. Bend the pipes in cold condition, if possible, and deburr them properly. You must clean heat-treated pipes me-
the manufacturers instructions. Make certain that the bend radii of hydraulic hoses are not too small. Make absolutely sure that there are n
ulic system.
e devices until immediately before connecting the pipes.
r at the beginning of the overall documentation . Each lubricant has a clear reference number to which the lubrication instructions in this sect
ing of the overall documentation.
s have been completely removed.

at an oil temperature below 10 C; the heater is switched off at 30 C.
ulated air to escape to the hydraulic oil reservoir (1.0).

ds [Y1] of the pressure valve (18.0) and [Y2] of the 4/2-port directional control valve (23.0) and the electric motor (8.0), and the correspond
he case of skewing, the solenoid [Y5 or Y6] of the 4/3-port directional control valves (42.1 or 42.2) on the leading side must be de -energise
ke valves (77.1 and 77.2) are set by the supplier and the setting must not be changed.
ke valves (77.1 and 77.2) are set by the supplier and the setting must not be changed.
ures (uniform material feed rate, bin filling level etc.).
il, the throttles should not be closed more than is absolutely necessary.
e. If one side leads by 4 mm, the respective solenoid [Y5 or Y6] is de -energised until synchronism is attained again.
back into the hydraulic oil reservoir.
are extended, the pressure in the piping increases and the non -return valves (39.1 and 39.2) are opened via the orifice plates (38.1 and 38
e. If one side leads by 4 mm, the respective solenoid [Y5 or Y6] is de -energised until synchronism is attained again.
42.2 connection B to T) into the hydraulic oil reservoir.
ntrol valve (23.0) is de -energised.
ing speed of the guillotine gates can be adjusted in a determined range.
onal control valve (23.0) are de -energised.
nal control valve (23.0) are de -energised.

nitial phase of commissioning .
12 16 20
1.5 2.5 2
23 30 36
22 23 to 28
1500
ou must clean heat-treated pipes me- chanically, then pickle them and wet them with oil. Make absolutely sure that the finished pipes are clo
Make absolutely sure that there are no kinks, twists or chafing points.
the lubrication instructions in this section relate. The table gives a complete list of the suppliers and products approved by POLYSIUS AG.
Quantity (ltr, kg) per lubrica
Lubricant ref. no. Initial filling
13 800
In accordance with the manufacturers instructions

ectric motor (8.0), and the corresponding filter element has to be replaced.
the leading side must be de -energised until synchronism is attained again.

ttained again.
ened via the orifice plates (38.1 and 38.2). The hydraulic oil from the piston accumulators (53.1 and 53.2) and from the plunger cylinders (60
ttained again.
25 28 30 42
2.5 2.5 3 3.5
44 40 50 60
30 to 38 40 to 48
2000 2500
ely sure that the finished pipes are closed with plugs until installation. Be careful to mount the piping free of stresses, and fasten longer sec
oducts approved by POLYSIUS AG.

Quantity (ltr, kg) per lubrication point Lubrication intervals (weeks)
filling Topping up Topping up
800
.2) and from the plunger cylinders (60.1 to 60.4) flows back into the hydraulic oil reservoir.
50
3.5
150
ree of stresses, and fasten longer sections by means of pipe clamps. It is advisable to provide venting devices at the highest points of the p
First change Further changes
1000 h 1000 h
devices at the highest points of the piping system.

01.0 - 22146.002E - Hydraulic System

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to form a hydropneumatic spring system

to actuate the guillotine gates at the mill feed system

Pressureless circulation of the hydraulic oil in the hydraulic power unit

4 Transport and assembly

6 Preparation for test run

the ball valve (25.0),

Opening of the roll gap (backward travel)

Guillotine gates of mill feed system OPEN

Guillotine gates of mill feed system CLOSED

The ball valve (25.0) is open;

documentation or in the subsuppliers documentation.

f the machine at the plant site.

the maintenance work.

associated controllers and indicators;

OLYCOM, the following functions can be performed:

achine units but rather give an overview of the work to be performed.

ken by an assembly specialist from POLYSIUS AG.

piped services. Be absolutely sure to comply with the provided instructions!

according to the instructions of specialists from POLYSIUS AG.

with adequate decline?

ow on the electric motor or pump support.

evice (54.1 or 54.2).

reservoir (1.0). (Connection fitting DK0L -28)

s, hydraulic oil has to be topped up immediately.

e stages A and B.)

uses heavy wear.

d 37.2) are sealed by the TV (Technical Inspection Authority).

njure you or cause a fire.

tem has been depressurised before doing the retightening.

d 37.2) are sealed by the TV (Technical Inspection Authority).

the counternut and de -energise the solenoid Y1.

ce the smooth running (vibrations) of the POLYCOM .

(23.0) are energised.

d the hydraulic system:

l valve (23.0) are energised.

r stoppage of the hydraulic system.

he roll gap during operation.

energised for t = x seconds; the period x is defined during commissioning.

m to the storage area.

uring devices, in order to prevent damage to these parts.

s have been completely removed.

ulated air to escape to the hydraulic oil reservoir (1.0).

onal control valve (23.0) are de -energised.

nal control valve (23.0) are de -energised.

Lubricant ref. no. Initial filling

In accordance with the manufacturers instructions

the leading side must be de -energised until synchronism is attained again.

oducts approved by POLYSIUS AG.

filling Topping up Topping up

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