CPM 7900 (California Pellet Mill 7900) Operation and Maintenance Instructions CPM Europe BV Distelweg 89 1013 HD AMSTERDAM The Netherlands Document Number: CPM 7900-001 Issue Date: 19th of June, 2009 All rights reserved © 2007 CPM Europe BV 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 ii Document Number: CPM 7900-001 Issue Date: 19th of June, 2009 California Pellet Mill 7900 Operation and Maintenance Instructions P 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 through 5, except for chapter 3, are important For the maintenance engineer chapters through 8, including chapter 3, are important Always print these Operation and Maintenance Instructions in color Read these Operation and Maintenance Instructions (especially Chapter 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 engineers are authorized to maintain, respectively, the CPM 7900 Always keep these Operation and Maintenance Instructions near the CPM 7900 Document Number: CPM 7900-001 Issue Date: 19th of June, 2009 Preface iii P iv Preface California Pellet Mill 7900 Operation and Maintenance Instructions Document Number: CPM 7900-001 Issue Date: 19th of June, 2009 California Pellet Mill 7900 Operation and Maintenance Instructions C Contents Preface iii Introduction 1.1 1.2 1.3 1.4 1.5 Manufacturer Related documents Machine-identification/CE-mark Warranty Liability Safety precautions 2.1 2.2 2.3 2.4 2.5 2.6 1-1 2-1 Warning symbols 2-1 Warning pictorials 2-2 Operator 2-4 Maintenance engineer 2-4 Safety precautions 2-5 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 Installation 3.1 3.2 1-1 1-1 1-2 1-2 1-3 3-1 Safety precautions Important installation topics 3.2.1 Hoisting the CPM 7900 3.2.2 Placing the CPM 7900 3.2.3 Installing the CPM 7900 3.2.4 Aligning the CPM 7900 Document Number: CPM 7900-001 Issue Date: 19th of June, 2009 3-1 3-1 3-2 3-3 3-4 3-8 Contents v C Description 4.1 4.2 4.3 4.4 4.5 4.6 California Pellet Mill 7900 Operation and Maintenance Instructions Function of the machine 4-1 Description of the product 4-1 Basic configuration of the CPM 7900 4-2 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 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 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 Operation 5.1 5.2 5.3 5.4 5.5 4-1 5-1 Before starting 5-1 Powering up 5-2 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 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 Starting production 5-47 5.5.1 Starting-up the initial run 5-47 vi Contents Document Number: CPM 7900-001 Issue Date: 19th of June, 2009 California Pellet Mill 7900 Operation and Maintenance Instructions 5.6 5.7 5.8 5.9 6-1 7-1 Safety precautions 7-1 Transporting and storing the CPM 7900 7-1 Disposal 8.1 8.2 8.3 5-48 5-49 5-50 5-52 5-52 Safety precautions 6-1 Spare parts book 6-2 Housekeeping for pellet mills 6-4 Housekeeping for conditioners and feeders 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 Transport 7.1 7.2 5.5.2 Starting-up a new die Starting full production Stopping production During production Shutting down Maintenance 6.1 6.2 6.3 6.4 6.5 C 8-1 Safety precautions 8-1 Disposing of the CPM 7900 8-1 Environmental aspects 8-1 Document Number: CPM 7900-001 Issue Date: 19th of June, 2009 Contents vii C viii Contents California Pellet Mill 7900 Operation and Maintenance Instructions Document Number: CPM 7900-001 Issue Date: 19th of June, 2009 California Pellet Mill 7900 Operation and Maintenance Instructions 1 Introduction This chapter gives information about the CPM 7900 and the accompanying Operation and Maintenance Instructions 1.1 Manufacturer The California Pellet Mill 7900 is manufactured by: CPM Europe BV Distelweg 89 1031 HD AMSTERDAM The Netherlands Phone +31 (0)20 - 49 46 111 Fax +31 (0)20 - 63 64 294 Internet www.cpmeurope.nl Email info@cpmeurope.nl 1.2 Related documents In addition to these Operation and Maintenance Instructions the following document comes with the California Pellet Mill 7900: • Declaration of Conformity in accordance with Appendix IIB of the Machine Directive (98/37/EEG) Document Number: CPM 7900-001 Issue Date: 19th of June, 2009 Introduction 1-1 California Pellet Mill 7900 Operation and Maintenance Instructions 1.3 Machine-identification/CE-mark The machine is identified as the California Pellet Mill 7900 • The California Pellet Mill 7900 is abbreviated known as the CPM 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 7930 30-4 7930-4 / 5902 / 621 2007 315 KW / 1500 RPM 0000-0001-01-03 Figure 1-1: Machine-identification plate of Pellet Mill 7900 The California Pellet Mill 7900 is supplied according to the CE-mark • This means that the California Pellet Mill 7900 meets the essential health and safety requirements of the European Union 1.4 Warranty The CPM 7900 is subject to CPM Europe BV warranty terms and conditions This warranty is only valid if: • • • 1-2 Introduction The Operation and Maintenance Instructions of the CPM 7900 are observed The CPM 7900 is operated and maintained in accordance with the specifications Genuine CPM-parts are used Document Number: CPM 7900-001 Issue Date: 19th of June, 2009 ... Pellet Mill 7900 Operation and Maintenance Instructions P Preface These Operation and Maintenance Instructions inform the operator and maintenance engineer about the safe operation and maintenance, ... For the maintenance engineer chapters through 8, including chapter 3, are important Always print these Operation and Maintenance Instructions in color Read these Operation and Maintenance Instructions. .. California Pellet Mill 7900 Operation and Maintenance Instructions Document Number: CPM 7900-001 Issue Date: 19th of June, 2009 California Pellet Mill 7900 Operation and Maintenance Instructions 1 Introduction