Automatic lubricator LUB 1&2

PM30-615-717-919-1219
PMV717-919
Manual type: User manual Date of issue: March 2012
Master version no.: 01, GB Distribution: Machine documentation

Contact: ANDRITZ FEED & BIOFUEL A/S

Division: Machine documentation
Machine responsible: Engineering
Glentevej 5-7
6705 Esbjerg, Denmark
Phone: +45.72.160-300
Fax: +45.72.160-301
E-mail: Andritz-fb.dk@andritz.com
www.andritz.com

Confidential document. All rights reserved. No duplication or disclosure to third parties permitted without the written consent
of ANDRITZ FEED & BIOFUEL A/S
 Table of contents

Contents
EXPLANATION OF CHAPTERS AND SYMBOLS 3
INTRODUCTION 4
1.1 Mechanical user manual 4
1.2 Guidelines for the use of the manual 4
1.3 Instructions in the use of the manual 4
1.4 Field of application 5
1.5 Guarantee 5
1.6 Manufacturer 5

FUNCTIONAL DESCRIPTION 6
4.1 Machine functioning 6
4.2 Machine components 7

INSTALLATION AND MAINTENANCE 8

5.1 Miscellaneous 8
5.2 Before installation 8
5.3 Installation instructions 8
5.5 Installation chart for drum lubrication of one mill 9
5.6 Installation chart for drum lubrication of two mills 10
5.7 Installation chart for drum lubrication of three mills 11
5.8 Mounting of automatic lubricator 12
5.9 Connection of grease distribution unit, two-roll-system 13
5.10 Connection of grease distribution unit, three-roll-system 15
5.11 Installation of grease sensor 16
5.12 Setting of grease amount and break time 17

DIRECTIONS FOR USE 18

6.1 Safety during use of lubricants 18
6.2 Application 19
6.3 Daily checklist 20

DISMANTLING 21
8.1 Dismantling and scrapping 21

Drum LUB
March 2012 En rev.01
Confidential document. All rights reserved. No duplication or disclosure to third parties permitted without the
written consent of ANDRITZ FEED & BIOFUEL A/S side 2
 Table of contents

EXPLANATION OF CHAPTERS AND SYMBOLS

= Introduction

= Safety

= Technical data

= Functional description

= Erection and transport

= Directions for use

= Maintenance

= Dismantling and scrapping

= List of spare parts

= Supplier annexes

Subject to all rights!

Andritz Feed & Biofuel A/S reserves the right to make changes in illustrations and information in this user

manual as a consequence of technical development. Furthermore, any translation is subject to reservations.

Copyright Andritz Feed & Biofuel A/S

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March 2012 En rev.01
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 INTRODUCTION

INTRODUCTION

1.1 Mechanical user manual

This manual is a mechanical user manual, which forms part of Andritz Feed
& Biofuels technical documentation. It is intended to facilitate the process of
getting to know and utilize the machine in the best way possible. The user
manual contains important instructions regarding safe and economical use of the
machine. Observance of these instructions will minimize risks, repair costs and
wasted time and also increase the reliability and life of the machine.

In addition to this user manual, the machine fitter is responsible for the
elaboration of an installation manual.

1.2 Guidelines for the use of the manual

The user manual should be read and used by all the persons, who work with the
machine, e.g. in the following areas:

Operation: (erection, remedy of errors during the working procedure,

maintenance, removal of operational and auxiliary equipment etc.).
Maintenance: (service, inspection, repair etc.).
Transport: (machine lifting etc.).

In addition to this user manual, national and local safety prescriptions in force are
to be observed.

1.3 Instructions in the use of the manual

This user manual has been divided into chapters and sections. Therefore,
the table of contents or the index pages at the back of the manual should be
consulted in order to provide a general view of the manual.

Means: Machinery instruction.

Means: Important information about the most efficient use of the machine.

Means: Reference to another section or appendix.

Means: Safety information/warning regarding provisions and prohibitions in order

to avoid serious injuries or damage.

Means: Prohibition of using the machine in an inappropriate and reckless way as

regards safety.

Drum LUB
March 2012 En rev.01
Confidential document. All rights reserved. No duplication or disclosure to third parties permitted without the
written
written consent
consent of
of ANDRITZ
ANDRITZ FEED
FEED & & BIOFUEL
BIOFUEL A/S
A/S side 4
 INTRODUCTION

1.4 Field of application

The automatic grease lubricating system is constructed to lubricate the bearings
on Andritz Feed & Biofuels pellet mills.

The automatic grease lubricating system ensures a constant and correct amount
of lubricant, which optimizes the functioning of the bearing. When lubricating
the bearing correctly in this way, the bearing seal will also be protected against
external impurities.

The system is controlled by means of an external control.

- LUB1 is intended for the automatic greasing of one mill.

- LUB 2 is intended for the automatic greasing of two or three mills.

The grease temperature has to be min. +5C to ensure the mechanical

functioning of the lubricating system.

1.5 Guarantee
The sales contract specifies the guarantee, which Andritz Feed & Biofuel A/S,
Denmark, grants from the date of delivery. Wear parts and general wear of the
equipment shall not be covered by this guarantee. The standard guarantee does
not cover equipment, which has been damaged due to the fact that it was used
for other purposes or in other conditions than those, for which it was offered.
The standard guarantee does no cover damage, misuse or lack of maintenance,
which infringe the recommendations given in the Andritz Feed & Biofuel manuals.

Andritz Feed & Biofuel has been very attentive to fabrication and design in order
to make the product as safe and reliable as possible. Should you, contrary to
expectation, experience problems with your Andritz Feed & Biofuel product,
please contact the company, which is responsible for the installation of the
equipment, or Andritz Feed & Biofuel. On inquiry please indicate the machine
serial number on the machine nameplate.

1.6 Manufacturer
DENMARK ANDRITZ FEED & BIOFUEL A/S
Glentevej 5-7
DK-6705 Esbjerg
Denmark
Tel. +45 72 16 03 00
Fax +45 72 16 03 01
email: andritz-fb.dk@andritz.com
www.andritz-fb.com

Drum LUB
March 2012 En rev.01
Confidential document. All rights reserved. No duplication or disclosure to third parties permitted without the
written
written consent
consent of
of ANDRITZ
ANDRITZ FEED
FEED & & BIOFUEL
BIOFUEL A/S
A/S side 5
 FUNCTIONAL DESCRIPTION

FUNCTIONAL DESCRIPTION

4.1 Machine functioning

function The drum lubrication and the controls LUB 1 or LUB 2 constitute a complete
lubricating system, which is designed to be mounted on a 208 L grease drum.
From here the grease is pumped via a pneumatically driven grease pump to
the lubrication points in the mill. The correct distribution of grease is ensured by
means of the mechanical grease distribution unit placed on the mill and on the
panel, respectively. The system has an independent control that takes care of
the presence of sufficient grease in the grease container and the addition of the
set amount of grease to the lubrication points (see chapter 5 for setting of grease
amounts and break times).

LUB 1 LUB 2
1 the Green
and yellow
buttons
lights for
4 each mill in
2 operation.
3 Furthermore,
5 there is a
signal display

8 6 The grease inlet

7 on the mill varies
according to the
mill type.

Secundary grease
distribution unit on
the mill. The grease
is distributed to
rolls and bearings
screen. via hoses and pipes.

rear end of mill

Grease pump. The
grease amount
per stroke is 2.8
cm3/minute.

Drum LUB
March 2012 En rev.01
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 FUNCTIONAL DESCRIPTION

4.2 Machine components

Operation 1 The operation box is used for the setting of lubrication time, break time and
box grease amount.

Yellow 2 The yellow button lights, when grease is being added, and it is off during
button break time. The yellow button for the grease sensor flashes to indicate an
empty level.

Green 3 The green button lights, when the mill is being lubricated. Additional
button lubrication can be achieved by pushing the green button down for a few
seconds. The green button flashes in case of a grease distributor defect.

Grease 4 The pneumatically driven grease pump pumps the grease from the grease
pump tank to the primary grease distribution unit at regular intervals.

Primary 5 The grease pump sends the set grease amount to the primary grease
grease unit distribution unit that distributes the grease to 1, 2 or 3 of the secondary
grease distribution units.

Secondary 6 The grease is distributed from the secondary grease distribution unit direct
grease unit to the lubrication points in the mill.

Lubrication 7 Lubrication of bearings and roll retainer shaft bearing and/or main shaft
point bearing.

Grease 8 The inductive sensor signals, when it has reached the bottom of the grease
sensor tank.

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written consent of ANDRITZ FEED & BIOFUEL A/S side 7
 TRANSPORT AND INSTALLATION

INSTALLATION AND INSTALLTION

5.1 Miscellaneous
This chapter contains instructions for correct installation and maintenance of
the automatic grease lubricating system for mills. Observance of the below
instructions will optimize the functioning of rolls and bearings in the mill,
provided that the automatic lubricating system is being maintained correctly.

Solvents may never be used for the cleaning of the lubricating system. It is
recommended to use compressed air or benzine/kerosene for the cleaning.

5.2 Before installation

CHECKLIST On delivery from Andritz Feed & Biofuel the automatic lubricating system has
been assembled and prepared for mounting with the mill.

Check that all fittings are present.

Check that all connection points for grease are clean and clean them, if
necessary.

Flush grease pipes and hoses with a grease gun to provide passage and
check for leaks.

Pump grease into the grease connection point and check that the grease
reaches the roll/bearing.

Check that the grease type in use has the correct viscosity to ensure that
the grease can be pumped out to the lubrication points (see the lubricant
chart in the mill manual).

5.3 Installation instructions

The lubricator may not be welded direct onto the machine bed, which may
flexible cause vibrations. The lubricator can either be mounted onto a frame with
pipe
vibration dampers or onto a separate rack.

The pump is connected to panel, power, air and primary grease distribution unit.
Strip Power, air and grease pump are to be connected according to the installation
chart.

pipe Correct attachment and adjustment of the grease hoses take place at the end
bracket of the installation, taking into consideration the machine setup and possible
movable attachment points on the machine. The grease hoses have to be
protected against wear by means of flexible pipes and pipe brackets.

It is important to avoid bending or squeezing the grease hoses during the

installation of the lubricating system.

Drum LUB
March 2012 En rev.01
Confidential document. All rights reserved. No duplication or disclosure to third parties permitted without the
written consent
written consent of
of ANDRITZ
ANDRITZ FEED
FEED & & BIOFUEL
BIOFUEL A/S
A/S side 8
 TRANSPORT AND INSTALLATION

5.5 Installation chart for drum lubrication of one mill

The following installation principle applies to the use of the lubricating system in
one pellet mill:

air in
air,
adjustable,
approx. 3 bar

control

grease hose

Grease out to grease

distribution unit on mill

Pos. Description (lubricator with counter, 1 mill, complete)

1 Primary grease distribution unit (SSV6-12)
2 Panel
3 Lubrication control
4 Inductive sensor
5 Grease tank, approx. 200 kg
6 Pump
7 Grease sensor, adjustable, 200 l, complete

Drum LUB
March 2012 En rev.01
Confidential document. All rights reserved. No duplication or disclosure to third parties permitted without the
written consent
written consent of
of ANDRITZ
ANDRITZ FEED
FEED & & BIOFUEL
BIOFUEL A/S
A/S side 9
 TRANSPORT AND INSTALLATION

5.6 Installation chart for drum lubrication of two mills

The following installation principle applies to the use of the lubricating system in
two pellet mills:

air in

air,
adjustable,
approx. 3 bar

control

grease hose

Grease out to
grease distribution
unit on mill 1
Grease out to
grease distribution
unit on mill 2

Pos. Description (lubricator with counter, 2 mills, complete)

1 Primary grease distribution unit (SSV6-12)
2 Panel
3 Lubrication control
4 Inductive sensor
5 Grease tank, approx. 200 kg
6 Pump
7 Grease sensor, adjustable, 200 l, complete

Drum LUB
March 2012 En rev.01
Confidential document. All rights reserved. No duplication or disclosure to third parties permitted without the
written consent
written consent of
of ANDRITZ
ANDRITZ FEED
FEED & & BIOFUEL
BIOFUEL A/S
A/S side 10
 TRANSPORT AND INSTALLATION

5.7 Installation chart for drum lubrication of three mills

The following installation principle applies to the use of the lubricating system in
three pellet mills:

air in

air,
adjustable,
approx. 3 bar control

grease hose

Grease out to
grease distribution
unit on mill 1 Grease out to
grease distribution
unit on mill 2
Grease out to
grease distribution
unit on mill 3

Pos. Description (lubricator with counter, 3 mills, complete)

1 Primary grease distribution unit (SSV6-12)
2 Panel
3 Lubrication control
4 Inductive sensor
5 Grease tank, approx. 200 kg
6 Pump
7 Grease sensor, adjustable, 200 l, complete

Drum LUB
March 2012 En rev.01
Confidential document. All rights reserved. No duplication or disclosure to third parties permitted without the
written consent
written consent of
of ANDRITZ
ANDRITZ FEED
FEED & & BIOFUEL
BIOFUEL A/S
A/S side 11
 TRANSPORT AND INSTALLATION

5.8 Mounting of automatic lubricator

The drum lubrication system consists of a complete lubricator, which has to
be connected to the rotary joint of the grease distributor. The lubricator is
accompanied by an inductive sensor.

The grease temperature has to be min. +5C to ensure the mechanical

functioning of the lubricating system.

COMPRESSED
AIR Compressed air is connected to the air hose at 3-4 bar.

Grease On delivery from Andritz Feed & Biofuel the grease distribution unit(s) is/
distribution are mounted on the mill. During maintenance the following facts have to be
unit considered:

A complete outlet coupling is placed in the outlets to be used.

Plug type (4), which is placed at the piston, is characterized by its bevelled
edge. These plugs may never be removed. Plug type (12) may never be
replaced by plug type (4).
Brass cone (6) must always be used together with a valve-body (7). Brass
cone (6) closes the connecting canal (10) and may never be used with plug
type (12).
In the distribution units SSV6 to SSV22 the outlets 1 and 2 may not be
plugged, as a blocking of these outlets may cause a total blocking of the
entire grease distribution unit.
Fittings and plugs have to be mounted and tightened according to the
installation description for the grease distribution unit.

The hose connection to the grease distributor has to be attached in a way that it
cannot rotate in case of an overload.

Pos. Description
1 Grease distributor SSV-8K
2 Rotary joint
3 Plug
4 Union nut
5 Seal
6 Cutting ring
7 Hose 6, 1.5 m
10 Control pin

Drum LUB
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written consent
written consent of
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FEED & & BIOFUEL
BIOFUEL A/S
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 TRANSPORT AND INSTALLATION

5.9 Connection of grease distribution unit, two-roll-system

PM30 access

Port 4 Port 3
Roll 1 Roll 2
Port 1 bearing
Port 2 Bearing for
for roll retainer
main shaft
shaft

PM717
PM919
port 1 + 2
PM1219 Roll 2

port 1
Roll 1
Port 8 bearing
for roll retainer
shaft

access

Drum LUB
March 2012 En rev.01
Confidential document. All rights reserved. No duplication or disclosure to third parties permitted without the
written consent
written consent of
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ANDRITZ FEED
FEED & & BIOFUEL
BIOFUEL A/S
A/S side 13
 TRANSPORT AND INSTALLATION

PMV717
Port 1 + 2 bearing
PMV919 for roll retainer
shaft

Port 2
Roll 2
Port 1
Roll 1

Port 8 Bearing
for main shaft

access

PM615 Port 1+2 bearing

for roll retainer
shaft

Port 8
Roll 2 Port 7
Roll 1

access

Drum LUB
March 2012 En rev.01
Confidential document. All rights reserved. No duplication or disclosure to third parties permitted without the
written consent
written consent of
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FEED & & BIOFUEL
BIOFUEL A/S
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 TRANSPORT AND INSTALLATION

5.10 Connection of grease distribution unit, three-roll-system

PM717 Port 1 + 2
PM919 Roll 2 Port 1+2
Roll 1
PM1219

Port 3
Port 8 bearing
Roll 3
for roll retainer
shaft

access

PMV717
Port 1 + 2 bearing
PMV919 for roll retainer
shaft

Port 2
Roll 2
Port 1
Roll 1

Port 5
Roll 3
Port 8 Bearing
for main shaft

access

Drum LUB
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FEED & & BIOFUEL
BIOFUEL A/S
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 TRANSPORT AND INSTALLATION

5.11 Installation of grease sensor

grease With a full grease container, the grease sensor plate will be at the top of the
sensor container and the inductive sensor will be at the bottom (fig. 1).
When the inductive sensor reaches the bottom of the grease container, an
alarm will be activated (fig. 2). The sensor pipe has to be placed in the top
position (fig. 3) to be able to use the last grease in the grease container.
When the inductive sensor reaches the bottom of the grease container again,
the alarm will be activated, which means that the container is empty and needs
to be replaced (fig. 4).

Fig. 1 Fig. 2 Fig. 3 Fig. 4

DRUM LUBRICATION - GREASE SENSOR, ADJUSTABLE

Pos. Description
1 Snap ring U22x1,2 DIN471
2 Pipe for grease sensor
3 Bushing for grease sensor
4 Hexagon head screw M8x20 DIN933
5 Shaft nut KM8
6 Inductive sensor XS1-M18MA230
7 Fitting PG9

Drum LUB
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FEED & & BIOFUEL
BIOFUEL A/S
A/S side 16
 TRANSPORT AND INSTALLATION

5.12 Setting of grease amount and break time

When not using a control from Andritz Feed & Biofuel, the customers own
control has to comply with the values indicated by Andritz Feed & Biofuel as
regards lubrication time, break time and grease amount.

In case the system is delivered with a control from Andritz Feed & Biofuel,
lubrication time, break time and grease amount have been set before delivery.
The adjustment procedure for the settings appears from the control manual.

Type Value counter Break timer Alarm timer Grease amount

[sec.] [sec.] [cm3/24t]
PM30 5 360 30-45 1440
PM615 3 650 30-45 479
PM717 5 600 30-45 864
PM919 5 450 30-45 1152
PMV717 5 600 30-45 864
PMV919 5 450 30-45 1152

Drum LUB
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written consent
written consent of
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ANDRITZ FEED
FEED & & BIOFUEL
BIOFUEL A/S
A/S side 17
 DIRECTIONS FOR USE

DIRECTIONS FOR USE

6.1 Safety during use of lubricants

When handling lubricants, the following rules have to be observed:

Avoid excessive and repeated contact with the skin.

Absorb the oil by means of technical measures.
Change clothes, which have been in contact with oil. Wash and remove the
oil from the skin in case of skin contact.
Do not allow oil to leak into soil or water.
Dispose of lubricants according to the rules in force.

Reference is made to the safety data sheet for the specific product for further
details about product safety, toxicity and handling.

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written consent of ANDRITZ FEED & BIOFUEL A/S side 18
 DIRECTIONS FOR USE

6.2 Application
The system takes care of lubricating the mill with the correct amount of grease
at the right time. The grease is pumped from the grease container (1) to the
primary grease distribution unit (2), which is placed on the panel (3). Then the
grease is transported further on to the secondary grease distribution unit, which
is placed on the mill in question, and from here the grease will be distributed to
the various lubrication points.

The grease distribution unit is equipped with an inductive sensor (4) that gives
an impulse to the control (5) for each dosage of a certain amount of grease. The
pump (6) is driven by compressed air and starts, when the magnetic valve (7) is
activated.

The grease container (tank) has an inductive grease sensor inside (8) that
gives a signal to the control, when the grease container is empty, by making an
impulse, when it touches the bottom, which results in an alarm to the control.

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 DIRECTIONS FOR USE

Alarm When the main motor is activated, a timer in the control will start at 360
seconds. When this period has expired, the magnetic valve is activated, which
will start up the pump. The pump is active, until the inductive sensor (4) has
registered five impulses, after which the pump is deactivated. The count-down
of 360 seconds is reset to zero and starts again, when the magnetic valve and
the pump are activated.

In case five impulses are not registered within 30 seconds after the activation
of the magnetic valve and the pump, an alarm will be given to indicate an error
in the automatic grease lubrication system. If the alarm is acknowledged by the
operator, the pump will start again, and if the five impulses from the inductive
sensor are not registered once more within 30 seconds, a new alarm will be
given. The alarm will stop the feeder screw in the mill in question.

error A blocking somewhere in the system will affect the primary distributor, which
detection will start an alarm.(all pistons in the unit will stand still). The simplicity of the
construction makes a blocked access to a lubrication point difficult to ignore.

The grease distributor is provided with a marker pin (see below). The marker
pin is placed at the end of the piston and follows the motions of the piston. The
marker pin for the grease distributor has to move slowly back and forth, when
the pump is in operation. Otherwise, the system is blocked somewhere between
the grease distributor and the lubrication points. A blocking can also be found by
checking the system for leaks of lubricants.

marker pin

6.3 Daily checklist

Step Action

1 Check for leaks in grease distribution unit, grease inlets and grease hoses.
2 Check the functioning of the pump by starting up a manual lubrication by means of
the green button.
3 Check that all lubrication points are lubricated with fresh and clean grease.
4 Check that the marker pin can move in the piston of the various grease units.

Drum LUB
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 DISMANTLING

DISMANTLING

8.1 Dismantling and scrapping

At each dismantling of the machine, e.g. in connection with removal or
scrapping, the safety rules in force at the time in question must be observed.

The dismantling should take place in the opposite order of the mounting. It is
important to suspend/support each component properly before loosening its
bolted connections.

In case of scrapping the machine, all environmentally damaging parts should be

isolated and sent to destruction. This applies to the following parts:

Oil
Grease from lubricating.
Rubber from couplings, seals, etc.

All electrical components should be sent to a recycling plant. The rest of the
machine can be cleaned and sent to a scrapdealer.

In case the conditioner is resold to another party than Andritz Feed & Biofuel,
the seller is responsible that the present manual accompanies the machine to
its new owner.

For the remounting after a removal it is important to read the chapter

Transport and installation.

Drum LUB
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Confidential document. All rights reserved. No duplication or disclosure to third parties permitted without the
written consent of ANDRITZ FEED & BIOFUEL A/S side 21