Roller Mill Similago II Manual

MACHINE INDUSTRY AND TRADE INC.
FLOOR AND FEED TECHNOLOGY
User Manual
SINGLE and DOUBLE ROLLER MILL
SIMILAGO II
www.alapala.com
SIMILAGO II
OPERATION SHEET for FOUR and EIGHT CYLINDER ROLLER MILL
This sheet is punctured from left side! Take off the sheet and attach it near the machine.
This sheet is for reminder purposes and does not replace detailed guidelines and DAVG (Similago II) user manual information.
Security Maintenance
Keep your hand out of milling chamber. Dont forget weekly oil maintenances, machine grease oiling
Do the cleaning only with assisting devices, with a broom for quarterly and yearly oil change.
example.
Dont take off covers and protectives. (Check the maintenance program in user manual!)
Remove the covers and protectives only when the machine is
not working for review purposes then immediately put them
back. Operation
Machines with gear or chain transmission equipments Check these daily:
transmission chamber can only be opened from the top side
when the machine is not working. Input milling milling chamber output - feeding.
Remote Controller Troubleshooting

Turns off the machine and lock main button. Check the Troubleshooting Guide in user manual.
It is required to prevent machine from accidentally getting
started during every maintenance and general maintenance.
Cylinder Changes
Steel rope may cause the cylinder to drop on your foot by
breaking. During the detachment of the cylinder, check the steel
rope for damages and breaks before using.
SIMILAGO II
This sheet is punctured from left side! Take off the sheet and attach it near the machine.
Keep your hand out of milling chamber. Dont forget weekly oil maintenances, machine grease oiling
Do the cleaning only with assisting devices, with a broom for quarterly and yearly oil change.
example.
Dont take off covers and protectives. (Check the maintenance program in user manual!)
Remove the covers and protectives only when the machine is
not working for review purposes then immediately put them
back. Operation
when the machine is not working. Input milling milling chamber output - feeding.
Remote Controller Troubleshooting

Turns off the machine and lock main button. Check the Troubleshooting Guide in user manual.
It is required to prevent machine from accidentally getting
started during every maintenance and general maintenance.
Cylinder Changes
Important Notes Single / Double DAVG - SIMILAGO II
A ) Documentation G ) Preventing Accidents
This user manual is prepared for the personnel who are responsible for operating and Relevant guidelines in the given documentation about preventing accidents must be
observing the machines and equipment by ALAPALA or your facility. For this reason, it observed and applied. ALAPALA always strives to design its machines suitable for latest
is necessary for this user manual to be delivered to the relevant people. international safety standards. Before the production begins, customer must show special
security and safety regulations to ALAPALA. If these causes extra cost, it will be covered
by the customer.
B ) Receiving
H ) Maintenance / Cleaning
It is necessary to make a visual control after the machines are received. If any damage
related to shipping is detected, relevant clauses in the supply contract must be
executed to determine the damage claim. Repair expenses will be covered by risk Maintenance can only be made by the personnel who have a command of the guidelines
bearer party. given in the documentation. These guidelines purpose is to preserve machine,
equipment or facility value, keep the depreciation at lowest and ensure long and efcient
C )Storage / Maintenance lifetime of factory and equipment. Cleaning must be done according to the legal
legislation and guidelines in the given document.
Machines and equipment which are not going to be assembled immediately must be
stored in big cases or chests, protected from air and other factors. Damage occurring I ) Copyrights
during the storing will be discussed only according to the supply contract.
Our rights in this document and mentioned issues are reserved. Receiver who accepted
the document also accepts these rights. Receiver accepts that he will not publish the
document or its content wholly or partially, not give it to the other third parties without our
D ) Assembly / Installation written or any other authorization and use the content aside from its purpose.
ALAPALA machines and machine components assembly and installation can only be
made by personnel trained for this purpose. Relevant personnel are responsible for J ) Guarantee
observing the guidelines received with the equipment at assembly and installation
Guarantees are given for contractual agreements and valid if only original ALAPALA
spare parts are used. Producer cannot be held responsible for damages caused by
E ) Different Models application of your companys personnel, not complying to guidelines or operational
mistakes of untrained personnel.
If guidelines are mentioning different models of the same machine, the guidelines
prepared for the delivered model are applied. If the changes to the machine creates
improvement, ALAPALA keeps the right to make changes to the machine until delivery.
K ) Guideline Necessity
User or owner of ALAPALA machines and facilities is obligated for giving orders to
F ) Starting and Adjusting personnel about using machines and equipment according to the operation guidelines
and inform them of the dangers about the operation of machines and installations. If
Starting and adjusting can only be made by trained personnel. Before rst start, requested, ALAPALA can give training for the price.
authorized personnel must have a command of the guidelines and operation manual.
Before rst start, oiling guidelines, for example lling chamber oil, must be applied.
Single / Double DAVG - SIMILAGO II Operation Sheet
Watch your hands Electric danger Clean regularly
Lifting Point Dont use without protection Stay away
Use suitable equipment Remote Controller ATEX
Warning Periodic oiling Milling cylinders
Smoking or approaching with

Dont touch Switch
re is forbidden
Periodic Control Warning moving part Important note
Maintenance and Repair In case of panic Optional
Use personnel protection Ask when doubtful STOP Warning

Symbols Single / Double DAVG - SIMILAGO II
SIMILAGO II
This sheet is punctured from left side. Take off the sheet and attach it near the machine.
Keep your hand out of milling chamber Dont forget weekly oil maintenances, machine grease oiling
Do the cleaning only with assisting devices, with a broom for once in three months and yearly oil change.
example.
Dont take off covers and protectives ( Check the maintenance program in user manual! )
Remove the covers and protectves only when the machine is not
working for review purposes then immediately put them back.
Operation
when the machine is not working.. Input milling milling chamber output - feeding.
Remote Controller
Troubleshooting
Turns off the machine and lock main button
Check the troubleshooting guide in user manual.
It is required to prevent machine from accidentally started
during every maintenance and general maintenance.
Cylinder Changes
Single / Double DAVG - SIMILAGO II Index
01 SECURITY 2.2 Structure 09
2.2.1 Main Components 09 - 12

1.1 Security Guidelines 03
2.2.2 Air Pressured Pistons 13
1.2 Worker Safety 03
2.2.3 Aspiration 13
1.3 Usage Procedure 03
2.3 Function 13
1.3.1 Introduction 03
2.3.1 Feeding and Product Input 13
1.3.2 Protection Against Blasts, Precautions, Safety 04
2.3.2 Milling 14
1.4 Electricity Connection 04
2.3.3 Output 14
1.5 System Security 04
2.3.4 Control 14
1.6 Eroded Part Management 04
2.3.5 Oiling 14
1.7 Machine Safety 04
2.4 Technical Specications 15
1.7.1 Opening Machine Body 04
2.4.1 Performance 15
1.7.2 Sample 04
2.4.2 Machine Drive 15
2.4.3 Speed Variations 15

02 TRANSPORTATION
2.4.4 Air Pressure 15
3.1 Lifting With Crane 23 2.4.5 Atmosphere Heat 15
3.1.1 Guideline For Lifting With Crane 23 2.4.6 Electricity Connection 15
3.2 Weight 23 2.4.7 Noise Data 15
3.3 Weight And Volume 23 2.5 Dimensions 16-19
03 SPECIFICATIONS 04 ASSEMBLY
4.1 Placing 27
2.1 Denition 07
4.1.1 Environment conditions 27
2.1.1 Type code explanation 08
4.1.2 Vertical place changing 27
2.1.2 Model sheet 08
4.1.3 Placing machine 27
2.1.3 Model types 08
4.2 Assembling main components 28
Index Single / Double DAVG - SIMILAGO II
4.2.1 Product input 28 6.2 Operation 39
4.2.2 Product output 28 6.2.1 Setting 39
4.2.3 Direct drive engines 28 6.2.2 Control 39
4.3 Electric connections 28 6.3 Error Codes and Troubleshooting 40
4.3.1 Safety Switch 28 6.4 Panel Introduction 41
4.3.2 Terminal Box 29 6.4.1 General Panel Parts 41
4.3.3 Sensors 29 6.4.2 Menu Buttons 41
4.4 Pressured Air Connections 29 6.4.3 Sub menu buttons 41
6.5 Panel zellikleri 42
05 STARTING 6.5.1 Trend Sayfas 42
6.5.2 Ayarlar Mens 43

5.1 First Start 33
Level Sets 44
5.2 Controls 33 Drver Set 45
5.2.1 Cylinder Gap Control 33
Main Motor Sets 46
5.2.2 Milling Cylinder Gap Adjustment and Control 33
Graphic Page 47
5.2.3 Bladed Scraper Gap Adjustment and Brushed 34
Alarm Page 48
5.2.4 Scraper Control 34
Plc Ladder Page 49
5.2.5 Oiling 34
Plc Test Page 50
5.2.6 Roller Bearing 34
Panel Selection 51
5.2.7 Milling Gap 34
Power & Plc Input 52
5.3 Adjustment 35
Plc Module Input 53
5.3.1 Input Cylinder Gap And Rotation Speed 35
Plc Analog Input 54 - 55
5.3.2 Milling Cylinders Gap Adjustment 35
Plc Output & Valve Manuel 56
Inverter & Motor 57

06 SETTINGS
Panel & Ethernet Line 58
6.1 Standard Operation 39 Main Motor Signal 59
Single / Double DAVG - SIMILAGO II Index
Main Motor Signal (Pasage B ) 60 7.7 Changing Cylinder Block 77
Terminal 61 Preparations Needed Before

7.7.1 77 - 79
Removing the Block
Indicator Box 62 Removing Drive Parts
7.7.2 80
Power & Plc Input 63 7.7.3 Starting Removal of Mill Block 81 - 82
Indicator Box 64 7.7.4 Assembling Lifting Equipment 83
Plc Output & Valve Manuel 65 7.7.5 83 - 85
Removing Mills
Inverter & Motor 66 7.7.6 Pressured Hydraulic Assembling and Expander 85
Panel & Ethernet Line 67 7.8 Top Block Assembly 86
Man Motor Signal 68 7.9 Cylinder Roller Assembly and Removal 87
Terminal 69 7.10 Feeding Roller Drive Strap Setting 88
Indicator Box 70 7.11 Brushes Scraper Setting 88
7.12 Adjusting First Grinding Mill Gap 88

07 MAINTENANCE 7.13 Bladed Scraper Setting 89
7.14 Removing Bladed Scrapers 89

7.1 Maintenance 73
7.15 Removing Brushed Scrapers 89
7.2 Control and Maintenance 73
7.3 Repair Plan 74

08 SPARE PARTS
7.4 Cleaning 74
7.4.1 Product Input 75 8.1 Spare Part 93
7.5 Oiling 75 Mill and Chamber Group 93 - 101
7.5.1 Milling Cylinders Rolling 75 Feeding Group 102 - 105
7.5.2 Milling Gear Plan Bearing 76 Stripper Group 106 -107

7.5.3 Lubrication 76 Pneumatic / Lock - Handles 108
7.5.4 Roller Lubrication 76
Oil to Use for Oiling Feeding
7.5.5 76
Reduced Engine
7.6 Roller Change 76

DAVG
01
SIMILAGO II
Security
Security Single / Double DAVG - SIMILAGO II
Introduction It is necessary to use respiratory mask against dust inhalation.
DAVG Series Similago II is produced according to the designated technical

security rules. It has the possibility to cause danger to the operator if used out of Earplugs must be used against the hearing loss due to loud noise.
procedures and guidelines. Thats why maximum security systems have been
developed for Similago II. During repair operations, electric and pneumatic systems must be
1.1 Security Instructions deactivated or turned off.
All switches must be in off position.

Warning
STOP May cause death or serious injuries if neglected.
1.3 Operation Procedure

Attention
May cause serious material damage or production error if neglected. DAVG Similago II 4 and 8 cylinder rolling mills can only be used for grain milling, the
product is not designed for other purposes. To mill another product, consultation to
Alapala is needed.
Explosion
May cause death, serious injuries and costly material damages if neglected. 1.3.1 Introduction
Explosion
Important Note Only approved machines and devices are used in areas with explosion risk.
If instructions are not followed, machines operation and performance are (check the label)
not guaranteed. If you see this label, it means the machine can be used in Ex-areas.
This symbol denes ATEX sign. This sign shows which Ex-area and inner
area the machine can be used.
Before installing machine at Ex-area inner area, the things to be careful
1.2 Operator Security
about are that there should be no aming areas around the machine, no
metal or rock entering into the machine.
Protective covers must be kept assembled and closed when the machine
is operating. Open or lacking protective caps may cause injuries.
Special protection sign for explosions
Group It Belongs To ( II )
Machines security functions must not be deactivated. Category ( 3 )
Explosive area letter code due to gas, vapour and smoke ( D )
Harf Kodu ( D )
It must be deactivated during machines maintenance, repair and II 3 D } MAIN SIGN
lubrication processes.
EEx d IIB T1 } COMPLEMENTARY SIGN
Protective gears like shoes, clothes, glasses and others must be Heat Class
used. Gas Group
Protection Method ( Against Explosions )
Clothes must be chosen in a way not to get stuck in moving parts Suitability to European Norms ( Ex-Products )
and according to the instructions.
03
Single / Double DAVG - SIMILAGO II Security
1.3.2 Protection, Precaution, Security Against Explosion

1.7 Machine Security
Explosion 1.7.1 Opening Machine Body

Cylinder mill must be at the suitable place for ATEX regulations, post must be
attached to side trimels, near barrage sensors so that ow can happen
through cylinder mill when too many products are placed. Machines body can only be opened by special equipment.
Engine feeding is according to the rules sent to mills.
While opening the machines body, machine must be turned off. It is
Connect to invers and control like engine producer sent required for machine to be secured with a special lock and shut down from
(thermistor observing ). security switch.
Control intervals and Maintenance intervals must be done according to the
instructions sent by engine supplier.
It is dangerous and forbidden for machine to be closed from control panel
remotely with a software.
1.4 Electrical Connection Warning

A security switch which separates electrode and protected with a lock must
Follow the safety rules designated by authority. be placed into the machine.
Use a feeding line according to the legislations. STOP Pneumatic valve must be closed before starting to maintenance or repair
processes.
Make sure that voltage and frequency are suitable according to the Feeding cylinder driving engine must be shut down with security switch and
information on control unit. secured with a padlock.
In case of single phase electricity feed, make sure that controller feeding 1.7.2 Sample
line connections are done according to the connection scheme.
It is possible to open milling chamber cover while machine is working to
get sample.
1.5 System Security
Apart from taking samples, machine can only be opened by experts and
DAVG Similago II 4 and 8 cylinder mills are the complementary part of a facility and with special equipment.
should be regarded as a part of systems security concept.
In case the machines are used outside of this security concept, operator must Machine must be shut down for all the work done to the milling chamber.
redene the danger that may be caused by the machine and necessary precautions
must be taken to ensure security.
Cylinders entrance points are protected with protection plates. These
1.6 Eroded Part Management plates must not be removed in any condition.
Only original spare parts must be used. In case the original spare parts are not used,
machine might not realize the expected functions and not give the expected
performance.
04
DAVG
02
SIMILAGO II
Transport
Transportation Single / Double DAVG - SIMILAGO II
3.1 Lifting with Crane 3.2 Transport Weight
Warning
Machines transportation must be done with experts who are trained and
experienced. > 60
You can use crane for loading and unloading.
For carrying DAVG Similago II with a crane, two G1 Pipe threaded two
geared holes are on the machine.
What given along with machine to lift with crane;
Two G1 pipe geared lifting ring
Two gaskets
Transportation Warning
Use crane and lifting equipment at the right angle and position according to 3.3 Transport Weight and Volume
their design and lifting capacity.
3.1.1 Instruction For Lifting With Crane Transportation Warning

Use crane and lifting equipment at the right angle and position according to
Remove the plastic cover ( 1 ) their design and lifting capacity.
Place the gasket and screw it ( 2 ) TECHNICAL SPECS
Put on lifting ropes ( 3 ) MODEL mm cylinder

Feeding Gross Volume
Weight (Kg)
Engine (Kw) (m3)
Angle between lifting ropes must be 60 maximum.
DAVG 4x 250 / 800 2920 3000 7.4
After lifting is done, remove the gasket and crew, put the plastic DAVG 4x 250 / 1000 3140 3442 8.1
cover back on.
DAVG 4x 250 / 1250 3380 3709 9.1
(1) 0.75
DAVG 8x 250 / 800 5252 5565 8.8
(2) (3)
DAVG 8x 250 / 1000 5770 6107 9.8
DAVG 8x 250 / 1250 6550 6916 10.9
23
Tek Katl / ift Katl DAVG - SIMILAGO II Tama
24
DAVG
03
SIMILAGO II
Specication
Specications Single / Double DAVG - SIMILAGO II
2.1 Denition
Purpose: Milling machine consists of ve main functional parts. These are;

It is used milling the grain through cylindrical ball to turn them into our.
Hauling body is very sensitive with the parallelism processed on CNC
counter as bench type which chambers and cylinders are attached directly
Working Principle:
and produced from highly durable special quality carbon steel.
Milling the grain while passing through two cylinders, of which layer is grinded,
blasted or geared, according to its purpose.
It has the structure for high efciency, high performance, efcient and
Structure: effective working, durable and long life, sensitive and strong structure that
It has very rst-rate specications like the sensitivity to adjust each phase of the requires minimum maintenance.
milling to get maximum efciency and strong body which will stay in its location.
Hygienic milling chamber which is free from sides and details that can
gather dust, control the overheating of the cylinders due the air circulation
Inner parts of the mill, which dont directly get in contact with the product and has
by its aerodynamic structure, cylinders do the milling process which are
the possibility of sticking via dust emission, are made from stainless steel
driven differentially with special proled straps on the turnbuckle pully.
material.
Mill, including the front body output bunker through the cylinder, is produced with Double walled isolated cover which can be easily removed or attached
double walled and isolated against condensation and adhesion. without a screw connection that works with a weight system that can be
closed without latches, designed and patented by Alapala for control.
Mill, with minimum part removal thanks to its side covers which are based upon Transparent polycarbonate glass, which can be removed easily from
opening system, enables fast and easy accessibility option and, via the cover on outside without removing any other part, though which product can be
the cylinder, enables fast cylinder removal. seen from outside easily, product input and product feeding system.
Diffuser anchor at the back, differentially driven spreader cylinder at front
Thanks to tested belt drive, it gives the advantages of silent working, removing the for product to be spread on cylinders surface equally and feeding system
oil maintenance and dirtiness. Also, it enables the cylinders to be chance really with manually adjustable valve to adjust products spread thickness.
fast as a set and also the ability to be removed one by one.
Mechanic parts, mechanic electro mechanic setting and pneumatic control
All single and double layer mill are consisting of two parallel passaged, which
mechanisms group.
each of which has a pair of cylinders.
Strong bedding, double line barrel moving conoid ringed cylinders, hard
Mill machines are produced in two basic structures according to its to area of use: layer thickness is 25 mm. high quality produced with centrifugal casting
these are; method.
Special alloyed casted cylinders; 500-550 Brinel hardness for B passages,
430-470 Brinel hardness for C passages, homogenous.
Single layer for single usage
By deactivating the sifting operation, two layered machine for mass Pneumatic controlled radial fast mechanism for fast opening and closing of
usage. the cylinders gap.
07
Single / Double DAVG - SIMILAGO II Specications
Designed especially for sensitive adjustment of cylinder gap with strong 2.1.3 Model Variations
and precise ne tune mechanism and mercurial claw indicator turning
cylinder which can keep its position in micron values.
Remote control and automatic start possibility with servo drive addition to
ne tune mechanisms standard structure, as an option.
Electronic Control System: System enables DAVGs adjustment to most

suitable and efcient feeding ow automatically according to products
ow; thanks to this, blockage and intermittent working are prevented.
According to the fullness of product input section, linear calculating

capacitive stick sensor sends signal to PLC, which manages the feeding
cylinders speed according to the programmed logic so that the suitable
feeding can be made
2.1.1 Type Code Explanations
DAVG 4X 250 / 800

Cylinder length
Cylinder diameter
Single Layer DAVG Single Layer SIMILAGO II DAVG Double Layer SIMILAGO II
Mill ( Product Code )
2.1.2 Model Plate

CYLINDER 250
mm Net (Kg) mm Gross for 2 (Kg) For 2 case dimensions (Case dimension)
800 250 565 68 x 170 x 48 cm

1
SIMILAGO II 1000 335 740 68 x 195 x 48 cm
Type DAVG 1250 420 920 68 x 220 x 48 cm
2 Year
Model 1 Serial
Number
Type, Year, Serial Number 2 ALAPALA MACHINE INDUSTRY AND TRADE INC. P.O. BOX 54
19001 ORUM / TRKYE
Machine - No. 3 Tel : + 90 ( 364 ) 254 95 60 (5 Lines)
II 3D T4 Fax : + 90 ( 364 ) 254 92 90 - 213 17 42
ATEX - ID Denition 4
4 3
08
2.2 Structure
2.2.1 Main Components

Side Covers
Product Input
Feeding Systemi
Milling Section
Cylinder Setting ( Fine Tune )
Output Section
09
DAVG - SIMILAGO II, 4 Cyl. Mill BREAKING PASSAGE LSO PASSAG

Geared cylinder mill input Straight cylinder mill input
3 Sensor
Product Input 1
4 Distribution screw
5 Feeding cylinder
Flow Adjust Valve 6
Broom Scraper 7 8 Slow milling cylinder
9 Fast milling cylinder
Fine Tune Unit

(El ark tme araln
10 Adjustable bladed scraper
ayarlamak iin) 11
Aspiration line
13 ( Airow )
Trimel
(Direct output) 14
Inverter, PLC
and automation group
15
11
11 10
10
DAVS-C - SIMILAGO II, 8 Cyl. Mill Side Covers
Product Input
Feeding System
Milling Section
CylinderSetting ( Fine Tune )

Output Section
11
BREAKING PASSAGE LISO PASSAGE

Geared cylinder mill input Straight cylinder mill input
3 Sensor
Product input 1 4 Distribution Screw
5 Feeding Cylinder
Flow Adjust Valve 6

8 Slow Milling Cylinder
Fast Milling Cylinder 9
Broom Scraper Fine Tune Unit
11
(To adjust hand wheel
7 milling gap)
Fine Tune Unit

(To Adjust Hand Wheel Milling Gap) 7
8 Slow Milling Cylinder
Fast Milling Cylinder 9 10 Adjustable bladed scraper
Aspiration Line
(Airow) 13
Trimel
(Direct output) 14 15 PLC - Inverter
12
2.2.2 Air Pressured Pistons 2.3.1 Feeding and Product Input
Some parts tip points have air pistons to enable movement. Aforementioned It consists of a glass bell immobilized with a strong steel frame. Product
pistons work under huge inner pressure. Thats why shock absorbers must not be ow must be seen with naked eye. A blockage sensor is used that controls
forced to open and exposed to heat over 100 C the product ow at product input section. In case of a product ow faster
than product procession speed, it stops product ow to prevent blockage
of system.
As the product coming into the machine ows through a stable dimension,
Adjustment Piston it has to be guided to cylinders for good spread. Milling cylinders feeding
function group elements do this.
Front Cover latch
Upper cylinder which has spiral anchors on top enables product to be
spread blatantly lower cylinder which has gears enables product to be
guided as a straight ow towards milling cylinders.
Air Input and Spread Fitting Lower cylinder gears are produced and designed spiral proled gears
according to the processed units particle structure.
Cylinders take their power from a reducer engine. Reducer engine choice
changes according to product process. There are two independent feeding
group and two separate reducer engine diagonally in a mill.
Product input
Optional Spec. 2.2.3 Aspiration
To enable milling cylinders absorb the air before the cylinder gap chamber, a
channel system is placed under milling cylinders.
2.3 Function
Milling system, which consists of parallel cylinders that automatically open and
close with an electric controlled pneumatic system, works by milling the grains
between two cylinders.
13
2.3.2 Milling 2.3.5 Regular Flow Control and Dust Emission
According to cylinder being Liso or Breaking, cylinders outer surface is Pneumatic absorbed air ow in mill and dust circulation caused by the product is
produced as centrifugal casting with suitable thickness and hardness steel, bypassed by itself thanks to a special pipe system.
its inner wall is also produced with centrifugal casting as one piece.
Breaking cylinders hard outer surfaces are processed with gear proles
according to diagram and passage requirements. Lisa cylinders are also
sandblasted to get the desired surface smoothness according to diagram
and passage specications after suitable camber is made.
Feeding
Cylinder
Cylinder Gap Adjust
2.3.3 Control
Regular product ow is carried out by feeding cylinders which are

sensitively designed with suitable gear prole and turning with suitable
reduction. This is an important factor of this mills efcient and regular
work.
2.3.4 Output
Milled grain is transferred with pneumatic system from output funnel and
stored.
Product Output
PLC - Inverter
Injectors
14
2.4 Technical Specs 2.4.5 Environment Heat
2.4.1 Performance ENVIRONMENT HEAT

o
Working Heat 0 ... + 50 C
CYLINDER SPEED POWER (kW) CYLINDER DI
o
Closed Heat - 10 ... + 60 C
CRUSHING 500 - 550 rpm 7.5 - 45 kW
250
MILLING 400 - 450 rpm 7.5 - 18.5 kW
2.4.6 Electricity Connection
2.4.2 Machine Drive MODL BALANTI

Both controllers ( without special output ) 24 V DC 20 W
TYPE DIA (mm) CHNL NARROW FAN STRAP
Feeding mill engine inverter 380 ... 500 V AC - ca.2.6 A
Single 7.5 - 45
355 SPB Milling cylinder engine
Double 7.5 - 18.5 380 ... 500 V AC
( Electricity demand according to usage )
2.4.3 Speed Variations 2.4.7 Noise Data
Cylinder speed is adjusted via special straps. Redactor can be attached. DATA
CYLINDER DIA (mm) Sound Level Leq = 92 dB (A)w

GEAR RATIOS
250 Equal sound level around machine Leq = 75dB (A)
1 : 1,04 1 : 1,23 1 : 1,51 1 : 2,0 1 : 2,50 1 : 2,9 - -
1 : 1,04 1 : 1,27 1 : 1,59 1 : 2,07 1 : 2,50 1 : 3,03 1 : 3,51 1 : 3,75 Gauging surface Leq = 17 dB
300
Constant sound pressure level (2) Leq = 77 dB (A)
2.4.4 Air Pressure

GAUGING CONDITION
Air pressure requires ltered and oil free ( 5 m). Passage C1
Work Power 15 kW
AIR PRESSURE
Working Press 6 bar Product eff 1.6 t / h / m
Pressured Air Demand ca. 0.5 Nm3 /h Product Hardwheat
Milling cylinder 250 mm
15
2.5 Dimensions
DAVG - 76C - 4x250x1000 DAVG - 76D - 4x250x1250
695
171 411 171
1030
16
DAVG - 76H - 8x250x1000 DAVG - 76J - 8x250x1250

463
463
1826 2076
1929
1929
1280
1280
695
695
1866
1616 171 411 171
171 411 171 1030
1030
17
DAVG - 76C - 4x250x1000 ( Inner Suction ) DAVG - 76D - 4x250x1250 ( Inner Suction )
Optional Spec Optional Spec
695
695
813 813
18
DAVG - 76C - 4x250x1000 ( Inner Suction ) DAVG - 76J - 8x250x1250 ( Inner Suction )
Optional Spec Optional Spec
463
463
1826
2076
1929
1929
1280
1280
695
695
1866 1616
813
813
19
2.3.5 Oiling
Machine does not need to be generally re-oiled. But some parts need to
be oiled from time to time.
Feeding must be supported with constantly oiled bearers. This is

also valid for milling cylinder chambers and straps tension pulleys.
Milling cylinders chambers are lled with oil in the factory.

At rst start, mill must be started empty and oiled after control.
Feeding cylinder geared engine is lled with synthetic oil in the
factory.
This lling is enough for 100.000-hour work.
Cylinder chambers are delivered after oiling.
Weekly
Monthly
Quarterly
20
DAVG
04
SIMILAGO II
Assembly
Assembly Single / Double DAVG - SIMILAGO II
4.1 Installation To ease the location of the machine with machine support plate, 4 M12
screws (or pins) can be installed to each one of the mounts before
4.1.1 Installation Area Conditions installation.
To prevent machines vibration spreading to whole building,
For the installation area of the machine, installation space, surface, surface aforementioned assembly supports must be removed after machine is
carriage capacity must be considered one by one and suitable conditions installed.
must be provided.
There are four D13 mm in diameter holes are present on machines mount
DAVG Similago II machines must be built on shared body so that the base. To prevent machine from bending, mill body must be installed to the
balanced and non-vibrating surface conditions can be met. points where equipment is designated.
Machine can only be assembled on wood or steel prole according to Additional equipment must be installed on earthquake prone zones.
customer demand.
4.1.2 Horizontal Location Change

Mill is installed aligning on rubber
and body.
DAVG Similago II should only be changed its place with the carrying
carcass assembled in Alapala facilities.
Carrying carcass can be removed after the machine is brought to

its location.
Castering scaffold can be used for changing location.
4.1.3 Placing Machine
To get the maximum level of sound insulation, DAVG Similago II must be Body is xed to the ground
with 4 M12 steel pin.
places on 65 mm heighted vibration absorbing rubber steel support plate.
To place the machine on a balanced surface, vibration absorbing rubber

plates can be placed which is available at mill support plates.
Aforementioned absorbents can be 20 or 30 mm thick. To prevent machines vibrations transfer to
building, it is placed on vibration absorbent Optionally, 65 mm height building
rubber body. connection body is brought to the
For Single 4x250 DAVG, 30mm outside of mill mounts and 20 mm thick location where the mill is going to be
plate are placed. (4 x 30 mm or 4 x 20 mm for each machine). installed.
Important Note
For Double 8x250 DAVG, 30 mm plate both inside and outside of mounts Additional xing equipment must be installed on earthquake prone zones.
are placed. (8 x 30 mm for each machine). This is valid for this machines all models.
27
Single / Double DAVG - SIMILAGO II Assembly
4.2 Assembling Main Components
4.2.1 Product Input Assembly

CURSOR VALUES 4 CYL MILL 8 CYL MILL
Input pipes connections must be done with clamps.
LC 800 mm 4,4 ... 5,9 m3 / min 4,7 ... 8,5 m3 / min
It must be ensured that after machines installation, suction pipe is placed LC 1000 mm 5,7 ... 7,3 m3 / min 5,5 ... 10,5 m3 / min
well into the felt gasket.
LC 1250 mm 7,3 ... 9,1 m3 / min 7,5 ... 13,0 m3 / min
To ensure impermeability of inputs feeding section, connection place must

be covered with acrylic impermeability paste. 4.2.3 Direct Drive Engine
During rst milling process, inner suction must be closed so that dust wont Via connection to output pipe,
be mixed with product. At this point, a suction system must be connected
to machines input. Air suction necessary for mill changes according to mills length and mill speed. In
case of using pneumatic conveyor, air leakage at sluices must be added to the
4.2.2 Product Output Assembly values above.
Product output differentiates according to diagram and project and there are a lot
of different versions. Output section is designed as single, double and triple and is 4.3 Electric Connections
xed to the machines lower section with M8 screws. Similago II is delivered without electric control panel and connections. Similago II
has the below as electric connection equipment:
Assembly Method :
Connection parts must be assembled to their places, starting from collection 24 V DC; 20 W: for both controllers (without additional outlet).
bunkers lower section.
380...500 V AC 2,6 A: For both frequency convertor of feeding engines.
Output Hopper
It will be assembled by ALAPALA or customer according to the design of
380...500 V AC: For milling cylinders drive engines. (Consumption both for
the machine.
passing and load).
Discharge Cone
150 mm diameter output bunkers discharge cone is installed with clamp.
1 A type current transformer installed to control unit (optional)
Then 120 mm diameter reducer cones are installed. Hoppers
impermeability must be tested in order to keep the air leakage at minmum
level at mills lower section. 4.3.1 Safety Switch
Suction Pipe Service switch that works to split feeding drive engine from all poles must be
Suction pipe Ensure air impermeability here too. connected to frequency convertor.
28
Assembly Single / Double DAVG - SIMILAGO II
4.3.2 Terminal Box
Connections stated below must be done to the terminal box found 03 03

Paketleme Temizleme
underneath the openable surface plate.
Deirmen
Emergency stop (separate conn.) 03
External 24V power source 10 10

09 09
Frequency convertor controller connection

09
05 09
Engine ow indicator (optional) 03 03
07
Serial interface (if demanded) 01 02 04
03 03 08 03
Validity signal 03
06
4.3.3 Sensors
Sensors stated below is connected to 01 Screw Compressor 02 Cylinder Valve

(works with alt. current)
Terminal box emergency stop 03 Pressured Switch
(separate conn.) 02 Control Panel (can be used for mill clutch)
4.4 Pressured Ar Connections 03 Cylinder Valve 03 Standard Pressured Airow

(one for each mill)
There is a pressured air connection for each machine available right behind main 04 Air Tank
ows surface plates openable plate, for clutch and coupler cylinders. To ensure 04 Silencer
the connection to current legris connector, it is necessary to use a exible plastic 05 Manometer (Pressure gauge)
hose with 6/4 mm in diameter. When connectors screws are removed, a G 05 Ventilators
connection will be visible. Connected pressured air must be cut with cylinder valve 06 Waste Water Discharge Valve
during maintenance. 06 Engine Dumper
07 Drier
07 Differential Pressure Indicator
08 Filter
08 Differential Pressure Switch
09 Conditioner
09 Bag Filter
10 Pneumatic Valve
29
Tek Katl / ift Katl DAVG - SIMILAGO II Montaj
30
DAVG
05
SIMILAGO II
Operating
Operating Single / Double DAVG - SIMILAGO II
DAVG Similago II's operations, trial start and settings must only be carried out by
expert, authorized and qualied personnel.
5.1 First Start Fixing Part
Setting Hour So.

Warning
All foreign matters that might have fell to the feeding unit must be cleaned
during rst start and installation. Setting Hour
Cylinders are protected against erosion with product. This protective must be
removed before usage.
Fixing lever
CYL GAP SETTING

Breaking function grinding 0,15 - 0,50 mm
Liso function grinding 0,1 mm
5.2.2 Grinding Cylinder Gap Setting and Control
Warning
5.2 Controls Ensure that grinding cylinders do not touch each other during operation.
Grinding cylinder gap must be control with a thickness gauge stick and
Important Note
cylinders must be set as 0,3 mm when installing to the machine.
To ensure a good air isolation, all pipe connection elements and equipment
must be connected tightly.
Check that pressurized air system is completely impermeable.

Cylinder gaps coarse tuning must be carried out with take-up not over draw bolt. Operating
5.2.1 Cylinder Gap Control lever on setting mill, the gap between middle of the pin and setting mill xing in must be set
as approximately 200 mm.
Make sure that feeding cylinders do not touch each other.
During rst start, make sure that minimum feeding cylinders gap is set as
below 0,15 0, 50 mm for breaking function, 0, 1 mm for liso function and
gaps are parallel to feeding cylinders.
33
Single / Double DAVG - SIMILAGO II Operating
5.2.3 Bladed Scraper Setting and Control 5.2.5 Oiling
With a pitch, 3/100 thickness gauging stick or a two paper tape with same Grinding cylinder cylinders are oiled in one way;
thickness, check whether bladed scrapers are parallel to each other when
installed. Check the gap is at least 2 mm when blades and grinding cylinders are From central oil block,
installed
Via greaser on top of cylinder chamber cover.
Scraper Pressure Gap
Cylinder chambers and oil block feeding cylinder pipes are lled with oil in
Scraping Part
the factory.
5.2.6 Cylinder Chamber

Scraping Part Adj. Screw
Similago II cylinder chambers are oiled with grease oil. Technical

Weight Adj. Fixing Screw specications of suitable oil must be used for oiling.
Before rst start of Similago II, cylinder chambers must be oiled with 40 g
lithium based oil for security reasons.
5.2.4 Brushed Scraper Setting 5.2.7 Grinding Gap

Set brushed scrapers as nearly touching to grinding cylinders. Setting of product ow section is shown on the scheme below. If the output part is
installed, gear adjustment stick found on outer part of surface plate must be used
for adjustment. Stick must be xed with lock nut.
Brush
Brush Pressure Adj. Screw
Fixing Screw
34
Operating Single / Double DAVG - SIMILAGO II
5.3 Setting
5.3.2 Grinding Cylinders Gap Adjustment
Principles regarding the adjustment and operation of feeding and grinding
cylinders are explained. Grinding cylinders gap is adjusted via two hand levers on each side.
5.3.1 Feeding Cylinder Gap and Rotation Speed
Eccentric shaft (2) is

moved with switch Until Valve gap (3)
aligns with feeding
cylinder, it will be
Fixing screw is
turned left-right.
(1) loosened.
Hand lever used for grinding cylinders

When alignment is set, xing Gap adjustment
screw (a1) screwed.
Hand levers one complete turn equals to approximately 0,042 mm

cylinder movement.
After installing the cylinders, indicator must be chosen an easy position to
remember.
To adjust the position indicators, the small screw at center on the frill. First
gap adjustment is shown on .
Then position indicator must be opened as per above.
After the adjustment is complete, adjustment screw must be screwed and

position indicator must be closed.
Doing this process will change the setting if desired.

Feeding gap (3)
differentiates Feeding gap (3) is
according to product increased or decreased by
and product volume. turning setting button (4)
left and right.
35
Single / Double DAVG - SIMILAGO II Operating
36
DAVG
06
SIMILAGO II
0 1
11
1
10 12 2
9 3
8 4
7 6 5
Settings
Settings Single / Double DAVG - SIMILAGO II
Warning
In case there is enough product in input section, milling cylinders, a bit later than
STOP SIMILAGO II shall not be started without its protective equipment. feeding cylinders, start working. Cylinders separate automatically after product is
Removing protective covers and housing are forbidden. nished. Product level can also be entered manually via control panel.
For going through control procedures, aforementioned equipment can only
be removed when machine is not working and must be attached back
Grinding cylinders, via prestressed strings, attached to strapped turnbuckle in two
immediately. roller chambers. This exible structure prevents possible foreign matter from
damaging the cylinders. Cylinder gap can be adjusted via hand lever.
Warning
Do not touch the gap between mills. Do the cleaning just with cleaning Cylinders heat must be stable all around the cylinder. For control, authorized
equipment, like broom. personnel must open the cover of control section upwards. Grinding cylinders
heat must be measured with device, without touching.
Warning
During maintenance and remote controlled adjustment, to prevent mill unit
operate via remote controller unwillingly, shut down and lock main switch.
Warning
Do not try to measure rotating cylinders heat with hand.
Important Note
Product Flow must be checked every day.
Keep inside and outside of the machine clean. Ensure that products do not Feeding cylinders rotation speed, product level in cylinders and engines
stuck to grinder or machine surfaces. runtime can be seen from control panel.
User interface enables to see the information and intervene to the machine
Warning via computer.
In case of neglect, serious material damage or faulty product can happen.
6.2 Operation
Similago IIs operation, error codes, repair solutions, machine setting and control
panel usage schemes are covered in this section. 6.2.1 Setting
Machine settings can be done from the setting buttons on the machine or via main
We strongly recommend you to use this information as a guide to operate your control panel.
machine.
6.1 Standard Operation 6.2.2 Control
Machine is operated via electronic controller. Feeding cylinder rotation speed is To do feeding gap setting, gap must be designated as 90 degrees. At these
adjusted automatically with a mechanic clutch system electronically according to conditions, setting will be checked automatically.
product quantity.
Combination and separation of grinding cylinders are done via solenoid valve or
pneumatic cylinder.
39
Single / Double DAVG - SIMILAGO II Settings
6.3 Error Codes and Solution

ERROR PROBABLE CAUSE PRECAUTION
ERROR PROBABLE CAUSE PRECAUTION Product stuck on entry
Grinding section suction pipe is Clean with a soft brush starting from
clogged grinding section
The screen is not readable 24 V conrmation is not realized. Conrm 24 V
Clamping arm behind the hand-wheel
Tighten it as much as possible
Grinding cylinders are not rotating See Grinding cylinders not rotating is not tightened
Ball gap changes while the machine
is working
Set frequency conventor correctly, set
Product accumulates on entry Grinding cylinders arent rotating slowly. Locknut on the connection pin is loose Tighten it
Max rotational speed
24 V conrmation is not realized. Conrm 24 V Pressured air supply does not work or
Check compressor and pneumatic grid
is under <4,5 bar
Motor switch is turned OFF Turn it ON
Ball valve is closed Open the valve
Control is Manuel Change it into AUTOMATIC
Product on entry is too few Wait until there is sufcient product
Grinding cylinders go to clutch mode
Frequency conventor or power source
Check and x it. Change it into AUTOMATIC
of the motor is broken Control is Manuel
Motor is too hot and cannot cool off Reduce the space so that rotation speed Plug of the solenoid valve is loose Check and tighten it
itself of the motor can increase
Pneumatic cylinder is broken Change the cylinder
Feeding cylinders arent rotating Frequency conventor is broken or Check and change it, cool the control
overheated panel better Fix the bearing cover
Cylinders touch to side walls Bearing cover is placed wrongly
(Checked with radial channel)
Drive belt may be torn Change it
Foreign object in the material to be Place a magnetic detector before the
There is bloating
DMS is broken Change it grinded rst grinding
Foreign matters among feeding cylinder Remove it Product cone is too deep Set a higher NIVMIN value
No product to grind on cylinder tips
Bearing shell is broken Change it Pallets are xed too straight Fix it
Product shows itself from underneath Bearing shell is too oily
Cylinder gap is too small Open it Fix it
the deector
Distribution bridge may be clogged Clean it Grinding cylinder chambers are There is wrong or old oil in the bearing
Oil it again / change them
heating shell
Rotation speed of feeding balls are Clean the ball scrapers and set them
Feeding cylinders leave trace too slow again Insufcient bearing gap Fix it
Foreign matter at entrance Push the section back and clean Insufcient grinding Cylinders are not xed to the chamber Change it
Feeding cylinders rotation speed is

Clean ball scrapers and reset Knife-scrapers worn quickly Grinding pressure is too high Place the weight stick closer to the knife
very slow
Machine is making dust
Product stuck on cylinder Set a higher NIVMIN value Product is stuck on geared cylinder Brush scrapers are worn Reset them or change them
Cylinder gap suction is blocked Clean it Product is stuck to straight cylinder Scrapers are worn or placed wrongly Reset / change / x them
Product accumulated between upper and
Remove the product Crushed material stucked in product One side of the channels is Check clutch and disc coupling / Set
lower grinding balls
Gathering probes between cylinders feeding off-position the pallets
are alarming ( only for 8 mills )
Sensor is set too tight Set the sensor Eccentric does not move properly Add oil to the related lubricant point
40
6.4 Panel Introduction
6.4.1 General Panel Sect. 6.4.2 Menu Buttons

Panel interface sections for DAVG Similago II machines. Menu buttons used for DAVG Similago II machines;
Alarm Warning S. Machine Sit.

Manuel Automatic System Working
Starts System ( Shown in gray )
MANUEL
STOPPING Total Runtime Tracking System Ending

Settings Page ( shown in gray)
SETTINGS TOTAL and Control
Trend Values Selected Menu But.

End System
GRAPHIC Reporting Page SETTINGS
( Shown in yellow)
Main Panel
Aktif Alan
Section
Alarm Page
ALARM
Machine Type SINGLE A SIDE Passage Type

6.4.3 Sub Menu Buttons
LEVEL DRIVER MAIN PLC LADDER PLC TEST PANEL

Sub Menu buttons used for DAVG Similago II machines.
SET SET MOTOR SET
ALARM
PAGE PAGE SELECTION Sub Menu Sect.
Menu Section
SETTINGS GRAPHIC ALARM MANUEL TOTAL
LEVEL Work level PLC LADDER Ladder Regarding
SET PAGE
settings Machines Work
DRIVER PLC TEST PLCs Input / Output

SET Inverter Speed Set. PAGE
LEVEL
Value Test
---
MAIN Main Engine and PANEL Machine Panel
MOTOR SET SELECTION
Transformator Values Service Settings
SPEED
ALARM
Alarm Control
--- and Reset
Incoming Product
Main Engine Indicator Level Indicator
41
6.5 Panel Specs
6.5.1 Trend Page
Shows incoming
products level
Alarm Warning
Area shows machines

STOPPING
LEVEL situation
87
Feeding mills Main engines ow percentage

Speed
SPEED CURRENT
100 79
Remote / Local
Remote :Speed is adjusted Feeding start / stop shows
according to product auto.. if feeding mill is rotating or not
Local : Manual value.
REMOTE FEEDING STOP

Single / Double Passage type
Shows if machine type single or SINGLE A SIDE
A Side / B Side
double
Sub menu buttons used for DAVG Similago II machines;
42
6.5.2 Settings Menu
Shows the page

youre in
Alarm warning
DRIVER PAGE
Work level settings LEVEL SETS ALARM PAGE Alarm control and reset
Inverter speed settings DRIVER SET PLC LADDER PAGE Ladder view
Main engine and transformer values PLCs nput / output

MAIN MOTOR SETS PLC TEST PAGE
value test
Trend values GRAPHIC PAGE PANEL SELECTION Machine panel service settings
Single / Double
Shows if machine type single or SINGLE A SIDE Shows machines situation
double
MAIN PAGE
System working passive System ending passive
Back to main Turkish/English

page language
Sub menu buttons for DAVG Similago II machines;
43
LEVEL SETS
Shows the page

youre at
Alarm warning
Button for going back

BACK
LEVEL PAGE % Text to previous page
Maximum level alert MILLING START MILLING STOP ENGINE

( Alarms when over LEVEL LEVEL OPERATING RATIO
designated level )
( Low level )
Grinding start level
( Starts at designated level )
0 0 0 Level value ( incoming product level)
( Top level)
Sensor calibration setting
Grinding stop level
( Stops at designated level Calibration Page
SINGLE A SIDE

ALARM
SET SET MOTOR SET PAGE PAGE SELECTION
nverter Alarm control Ladder view of PLCs Machine

speed Main engine and reset machine work nput / output panel service
settings and situation value test settings
transformer
setting
44
DRIVER SET
Shows the page

youre at
Alarm warning situation
Button for going

BACK
DRIVER PAGE back to previous page
INVERTER MINIMUM INVERTER MAXIMUM MAXIMUM INVERTER REDUCTOR RPM

FREKANS FREKANS FREKANS NOMINAL
Inverters minimum Transformation area between

work frequency engine and reducer
0 0 0 0
Inverter maximum Frequency maximum level
frequency
SINGLE A SIDE

ALARM
45
MAIN MOTOR SETS
Shows the page

youre at
Alarm warning

BACK
MAIN MOTOR PAGE to previous page
ENGINE CURRENT TRANSFORMER ENGINE

LABEL CURRENT RATIO OPERATING RATIO
Engine label current indicator Engine
0 0 0 operating ratio
Transformer current ratio
SINGLE A SIDE

ALARM
Work level settings
46
GRAPHIC PAGE
Shows the page

youre at
Alarm warning

BACK
GRAPHIC PAGE to previous page
Trend change indicator

( graphical view of current level
and speed values)
Button for going Level alarm shows speed values

back to previous as numeric.
page
DURDUR DEER GRME
SINGLE A SIDE

ALARM
47
ALARM PAGE Alarm warning
BACK
ALARM AND LOGIC PAGE Remote control
Active / Deactivation
SENSOR PROB ERROR REMOTE CONTROL ACTIVE
Main engine controls
SERIAL CABLE CONNECTION FAULT Active / Deactive yapma
MAIN MOTOR ACTIVE ALARMS
INVERTER ERROR
MAIN MOTOR CURRENT ERROR Ignoring piston check error

PISTON CHECK ACTIVE
PISTON POSITION ERROR
MAX LEVEL ERROR ERROR SYSTEM STOP ACTIVE

Deactivating alarm system
( work no matter what)
ALARM RESET
SINGLE A SIDE

ALARM
Resetting alarm
SENSOR PROB ERROR MAIN MOTOR CURRENT ERROR
Lights up for sensor problems. Lights up when main engine ow reaches

maximum.
SERIAL CABLE CONNECTION FAULT PISTON POSITION ERROR
Lights up for cable connection fault. Lights up when piston position is wrong.
INVERTER ERROR MAX. LEVEL ERROR
Lights up for control and energy loss. Lights up when max level is too high.
48
PLC LADDER PAGE
Shows the page

youre at
Alarm warning
Going back to
BACK
LADDER PAGE previous page
SINGLE A SIDE

ALARM
49
PLC TEST PAGE
Shows the page

youre at
Alarm warning
Going back to
BACK
LADDER PAGE previous page
LEVEL
Physical Input and
Output indicator on PLC
Shows the quantity
Input I0 I1 I2 I3 I4 I5 I6 I7 I8 # level of the product
I0 I1 I2 I3 I4 I5 I6 I7
ANALOG
Physical Input and
Shows voltage values
Output indicator on PLC
Output #
o0 o1 o2 o3 o4 o5 o6
SINGLE A SIDE

ALARM
50
PANEL SELECTION
Shows the page

youre at
Alarm warning
SELECTION PAGE
HOME PAGE SELECTION

Panel tube and side choice
Green lit button means
SINGLE A SIDE
PANEL IP ADDRESS IP it is selected.
SINGLE B SIDE Panel tube and side choice

PLC IP ADDRESS Controller IP
Chosen PLC address DOUBLE A SIDE

( PLC machines IP is entered
and controlled. )
DOUBLE B SIDE

ALARM
BACK
Previous page
51
POWER & PLC INPUT DOUBLE CONTROL 1
52
PLC MODULE INPUT DOUBLE CONTROL 2
53
PLC ANALOG INPUT DOUBLE CONTROL 3
54
PLC ANALOG INPUT DOUBLE CONTROL 4
55
PLC OUTPUT & VALVE MANUEL DOUBLE CONTROL 5
56
INVERTER & MOTOR DOUBLE CONTROL 6
57
PANEL & ETHERNET LINE DOUBLE CONTROL 7
58
MAIN MOTOR SIGNAL DOUBLE CONTROL 8
59
MAIN MOTOR SIGNAL (Pasage B ) DOUBLE CONTROL 9
60
TERMINAL DOUBLE CONTROL 10
61
INDICATOR BOX DOUBLE CONTROL 11
62
POWER & PLC INPUT SINGLE CONTROL 1
63
INDICATOR BOX SINGLE CONTROL 2
64
Settings Tek Katl / ift Katl DAVG - SIMILAGO II
PLC OUTPUT & VALVE MANUEL SINGLE CONTROL 3
65
INVERTER & MOTOR SINGLE CONTROL 4
66
PANEL & ETHERNET LINE SINGLE CONTROL 5
67
MAIN MOTOR SIGNAL SINGLE CONTROL 6
68
TERMINAL SINGLE CONTROL 7
69
INDICATOR BOX SINGLE CONTROL 8
70
DAVG
07
SIMILAGO II
Maintenance
Maintenance Single / Double DAVG - SIMILAGO II
7.1 Maintenance
Machines maintenance period must be carried out by expert and trained GAP CONTROLLER / MAINTENANCE NOTE
personnel
Bladed scraper
Monthly
Danger Brushed scraper
STOP All maintenance, cleaning and repair works must be done after machine is
completely stopped. (machines functions must be deactivated). Check the tension of all drive straps
Main switch that cuts the ow at all poles must be at 0 condition and locked Grinding cylinder chamber :
Clean the oil in steel chambers and ll with new
with a lock.
Two months after rst start
Grinding cylinder chamber :
Check the impermeability of input and output points, tighten them
Important Note if necessary.
Machine requires almost no maintenance and it doesnt require any
intervention when its casing is closed. Oil turnbuckle
Maintenance work must be carried out in periods specied in maintenance Cylinder mill, injector 40 g oil
chart.
Strap corrosion / change the faulty strap
Once in three months
Check the stiffness of these straps
Warning Main drive strap
Right appliance of maintenance works is necessary for safe and problem Feeding cylinder drive strap
free operation.
Cylinder mill chamber:
Oil change, clean the oil in steel chambers and put new oil.
Every Year
7.2 Control and Maintenance
Bladed and brushed
GAP CONTROLLER / MAINTENANCE NOTE

Her 25000 saatlik alma sonras Besleme topu tahrik kayn deitirin
Pressured Ar Feeding
Mill chamber heat:

If over >70 C , change / open the beds
Danger
Weekly
Visual control of feeding mill drive strap STOP Open strap, chamber and cylinder groups cover and lids when the machine
is completely stopped.
Clean the product and dust leftover on product section and
machine roller chamber / support
Check clutch function
Oiling noise, heat and cylinder chambers
73
Single / Double DAVG - SIMILAGO II Maintenance
7.3 Maintenance 7.4 Cleaning
GAP MACHINE PART PRECAUTION Open body clamps with a special wrench and turn.
With an integrated gassed silencer, loosen the turning bolt then lift the two covers
Pressured air supply Check if there are any product between roll and chassis.
at the upper side up
Lower covers are protected with 2 levered holders and stopping plate. Lift grinding
Roll and chasis Remove the product from deactivaed machine. sections cover and open the control cover holders.
Loosen the levered holders and lift off the hood on holding plate. Then body can
Feeding cylinder strap after over working Visual check be removed from front. (For DAVG, rst the cover on the top must be lifted to lift
Weekly
the body.)
Feeding cylinder strap after normal work Visual check
Inner and outer motion Check the activation shelter
Feeding reservoir Visual check for leakage
Adjusting automatic valve Check the function

Important Note
Make sure you put the covers at the right places during assembly.
Knife Scrapers Check
Brush Scrapers Check
Monthly Product and machine space

Kir ve birikintileri temizleyin.
(Coating area, Stands)
Check the heat

Besleme ve tme toplar
* Roller 70 C
iletim konumu
* Grinding cylinder max 95 C
1
Two months after
Operation and over operation strap Check strap stiffness
operation
Operations feeding cylinders Check strap stiffness

3 months 2
Operation and over operation cylinders Check oil situation
2.500 hour operation Operation feeding cylinders Change oil
10.000 hour operation Over operation feeding cylinder Change it
15.000 hour operation Operating feeding cylinders Control it
25.000 hour operation Operation cylinders Change it 3
1 - 2 - 3 - 4 - 5 numbered covers
4 are put to open status and xed
5
74
7.4.1 Product Input

GAP PRECAUTION NOTES
Bots are removed to clean input section ( 1 ), steel frame removed ( 2 ), Before rst start 5g oil for each mount
Fiberglass glass removed ( 3 )
1 This is viable for milling channels that require 2
Every 6000 hours 20 g oil per grinding mill 500 min pre mill speed and at least 50 - 70 C
roller heat.
1 1 This is viable for milling channels that require 2

Every 6000 hours 20 g oil per grinding mill 700 min pre mill speed and at least 50 - 70 C
2 roller heat.
3
1 This is viable for milling and breaking 2
Every 2000 hours 20 g oil per grinding mill channels that require 700 min pre mill speed
and at least 70 - 95 C roller heat.
After mill change Fill the rollers with oil before removing Dont oil roller cover.
7.5 Oiling Chart

1 Work time can be read from machine controller. 2 Oiling period must be adjusted to other rotation speeds.i.e; 100 min
7.5.1 Grinding Cylinder Rollers rotation increase required %15 less time for oiling.
Cylinder rollers oiling is done through central oiling block when the machine is turned on.
Machines with no central oiling option, will use the greaser on tope of the roller chamber cover.
In case of doubt, it is advisable to oil after every 4.000 hour of work.
In case of doubt, it is advisable to oil after every 4.000 hour of work.
Important Note
Following the oiling of four-cylinder mill, use 2x20 g oil for each oiling block.
Use 4x20g oil for eight-cylinder mill.
Levered oiling gun which is delivered with machine, pumps 1g oil every time.
Heat up to 50 C does not hurt the nger.
Warning
Over oiling the rollers cause roller heat to increase. Weekly
To prevent overheating, roller chambers must be cleaned after a maximum Monthly

10 oiling.
3 Month
75
7.5.2 Mill Cylinder Oiling Chart 7.5.4 Feeding Mill Geared Engine
Mill cylinders are oiled with an oil suitable for high pressure like mineral or Important Note
synthetic oil. Till 70C chamber heat, bilge oil viscosity must be at least ISO VG Check producer document for more detailed information .
100, above 70C chamber heat at least ISO VG 220 suitability needed. Ensure the
miscibility of the soaped lithium based oil, lled by producer. Check the geared engine regularly and change if necessary, for example:
Check mill gasket at least at every 15.000 hours (2 years) for oil leak.
Warning Open the cover of engine section. If there is oil at the inner parts, mil gasket
Oil center must be suitable for oiling.
must be changed.
Oiling chart Gap

After 10.000 hours of operation
SUPPLIER MINERAL BASIS GREASE OIL MINERAL OR SYNTHETIC BASIS GREASE OIL
( Bearing housing temperature to 70 C ) ( up to 100 C chamber heat) Change geared engines oil,
Geared engine oil chart
Agip Autol Top 2000 Bio
Blaser Blasolube 492 Blasolube 306

Ol viscosity value specied on value plate designated the oil. (ISO VG degree)
ESSO Unirex EP2 Unirex SHP 460 Specied viscosity level is designated according to the contract.
Klber Klberplex BE31-102 Klberplex BE31-222 Klbersynth UH1 14-222 (H1)
Shell Mobilgrease XHP 222

* Mobilith SHC PM
Mobil Shell Albida EP2 Cassida Grease EPS 2 (H1) 7.5.5 Oil Used for Oiling Feeding Reducer Engine
Valvoline Multilube EP-2 Geralyn 2 (USDA-H1) deiimi
Fuchs Renolit CX-EP2 As it needs to have a long life, gears are lled with synthetic oil. Oils viscosity
level must be ISO VG 220.
* First lling at factory
7.5.3 Mill Oiling and Greasing Plan 7.6 Mill Change

Poz. GAP PIECE TO BE OILED QUANTITY
Danger
20003000 Cylinder mills
1 Hour work (Stressed cylinders and grinding head)
40 g. oil
STOP All maintenance, cleaning and repair works are carried out after machine is
completely stopped. (machines all function must be deactivated).
1 20 g. oil
Hour work (Normal stressed cylinders and crushing ) Main switch that cuts the ow at all poles must be at 0 condition and locked
with a lock.
1 30 g. oil
Hour work ( Les stressed cylinders )
1200 hours after Cylinder mills

Important Note
2 rst start (Normal stressed cylinders and crushing canal )
Total oil change
Before opening the mill:
Cut mills energy.
60007000 Cylinder mills Cut grinders energy.
Total oil change
Hour work ( Less stressed cylinders )
Make sure that grinding mill is not going to be powered up.
Every year Clutch/Coupler eccentric pin 4 g. oil
76
7.7 Changing cylinder block
7.7.1 Preparation before removing the cylinder block
Danger
STOP Stop cylinder mill. Make sure that it wont work.
Warning
Air shouldnt pass through pipes
Cover bolts are loosened then

xed on open status.
The bolts shown with arrow

are loosened and part is
removed.
Cover bolts are loosened and

xed on open status.
77
Bolts of the parts shown with

arrow are loosened.
78
Scraper blade group is removed
Chain is loosened
and removed by
79
Important Note
Ya borularn kartn. Borular, buji konektr zerinden ayrma halkalarna
kuvvet uygulayarak gevetilmelidir.
7.7.2 Removing Drive Parts
11 Connection bolts shown at num 11

cover are removed.
Bolts shown with arrows are removed.
80
7.7.3 Starting Mill Block Removal
Remove the draw bolt with foreign matter
Remove the xing screws of front cylinder body

Bolts shown with arrows are removed.
81
Snap ring shown with

Loosen the bolts arrow is removed.
shown with arr.
82
7.7.4 Assembly of Lifting and Removing Equipment 7.7.5 Removing Mills
Optionally, cylinder car equipment is for mill cylinders lifting and carriage.
Cylinder car height adjustment is made,

aligned to the lower chasis top level, part
shown with arrow xed to the chassis.
Bolt shown with arrow is loosened After checking the height, bolt is tightened.
and mill turned a quarter. On the high condition.
Check the height with your eyes This process is done for both left and right all 4 mills
83
Chamber group
Chamber group is pulled upon the car.
Bolts shown with red arrows are xed to the car.
Parts shown with green arrow are loosened for

both sides and removed from the body
Protector removed. Stiffness pulley rotated and strap removed
84
7.7.6 Pressured Hydraulic Assembly and Removal Equipment
It is done the opposite way of cylinder removal process. Be careful with the
sequence.
Important Note
Setting must be done when cylinders are in clutch position.
When assembling the cylinder block, rst cylinder gap must be reset.
Operating lever on the adjustment mill with a frill, set the gap approximately
200 mm between the center of the pin on operating lever and xing pin on
adjustment mill.
Spacer bolts Chamber bolts and
loosened and screws are loosened. When loosening the bolt, tighten special bolt as the desired gap is found to
removed. Pipes are
removed. measure with thickness stick
Breaking channel grinding gap : 0,15 mm - 0,50 mm Liso channel grinding
gap: upto0,1 mm
Lock the bolt tightly
Cylinder placed on conoid part on

grinding cylinder..
Special equipment is xed to the

Front cylinder group taken Setting group guided part.
removed.
Apply pressure up to 900cc to
hydraulic pump.
Pump apparatus is aligned and

xed to the hole 48 mm far from
Back cylinder removed grinding cylinder tip
Secured with a bolt.
Pressure applied until cylinder comes out..
85
7.8 Cylinder Block Assembly

Things to watch out during assembly:
1 Make a straight alignment. 1 2

2 Make the rst gap setting ( Sentil ),
3
Assembly instructions:
3 Align bolt hack with the cylinder cover which will be upon one another.
4 Place the cylinder on the surface rail on the pin.
5 Graining cylinder gap
4
Can be rotated easily
No axial gap.
No bending on camshaft
Cylinder gap setting at clutch situation (rst setting) :
Breaking grind gap 0,15 - 0,50 mm

Liso grinding gap 0,10 mm
Lever position: there must be 200 m distance between lever and brace.
Last setting of cylinder gap setting using the hand lever will be done with hand
lever.
5
86
7.9 Cylinder Roller Assembly and Removal

Then clean the cylinder mill and slightly oil.
To make the cylinder change healthily, cylinders rollers must be attached in First of all, oil the cylinder surfaces with wedged seal bolts. Bolts must be
workshop, oiled and their impermeability to dust must be ensured. installed in a way that seals smooth surface is opposite to the cylinder.
Cylinder roller assembly.

Warning
For this, changing parts stated below is necessary for each cylinder roller; Fixed rollers must always be assembled to transmission side. Thats why
roller covers must be assembled with 7.5 mm gap.
Gears pressed to the tip of the cover is assumed as the bolted back roller
4 dust seals cover.
4 oil sealed inner cover for xed cylinder and moving chamber. There is 7.5 mm gap at xed cylinders cylinder cover and 3.5 mm gap at
moving cylinder cover.
Oil all cylinder covers seal rings with Molykote.
4 22315 EK cylindrical cylinder roller
4 safety washers and bolts Push back cylinder covers (be careful with xed cylinders and moving
cylinders).
4 oil sealed and greaser outer cover for xed cylinder and moving
chamber. Cylindrical cylinder rollers 22315 EK which were produced by SKF or FAG,
are unassembled, have a cylinder gap between 0.05 and 0.090 mm. tighten
16 M12 x 100 xing screws these with the help of safety bolt until around 0,035 and 0.045 mm. (rough
surface will face cylinder). minimum gap must be at least 0.10 mm to
4 distance holder barrel and 2 o-ring enable balanced cylinders to be moved by hand. likewise, outer ring must
be moved easily with rotational movement. To measure the cylinder gap,
push the stick beyond the two pulley conveyor.
This parts are necessary for assembling rollers on cylinders, setting, oiling and
protecting against dust.
To tighten the safety washer, theres a special spanner and opening lever
First of all, install cylinder rollers on a strong connection chassis (max which were provided to you. then, put the bolt on the opposite sides of the
weight: approximately 800 kg) as if theyre going to be assembled to for roller over mill. This way mill wont be bent during tightening or loosening.
cylinder mill. Cylinder numbers are on the right side of drive strap.
After cylinders are installed and locked properly, add approximately 250 g
Check the grooved cylinders grooves, grooves location and incline and oil. Apply Specied amounts half to the cylinder cover, where the oil goes
their curves if theyre on straight mills. This information is marked on from the oiler.
cylinder mills surface.
87
Place o-ring to the side of each one of the mill transmission and attach 7.11 Brushed Scraper
assemble holder shells to all mount points.
Brushed scrapers are attached from each side with clips.
Front cylinder cover bolts must be oiled. Be careful with the necessary gap.
7.5mm gap is envision for xed cylinders and it will be on the left side of the Press the brushes to mill to scrape all the product leftovers.
mill. Gap for moving cylinder is 3.5 mm and it will be on the right side of the
mill. Fix all these parts using 95 x M10 xing screws. 7.12 Setting the rst gap between grinding
Important Note
Setting will be done when the mills are in clutch position.
7.10 Setting feeding Mill Drive Straps

First gap will be needed to be reset again while attaching mill block.
Operating lever on the adjustment mill with a frill, set the gap approximately
200 mm between the center of the pin on operating lever and xing pin on
adjustment mill.
When loosening the bolt, tighten special bolt as the desired gap is found to
measure with thickness stick.
Breaking mill gap : 0,15 - 0,50 mm

Liso milling gap : up to 0,1 mm
Lock locking bolt..
Engine holders (A) 3 xing bolts are loosened..
Until it is stiff, (C) engine holder (B) is turned over back screw.
Sentil
Slightly tighten the loosened bolts.
With a prestress measurement device (D) check straps prestress .
B1 Breaking value: 140 10 Hz; (2 milled drv)

B2...B5 Break and Liso value: 165 10 Hz; (3 milled drv)
If the values are right, tighten the three bolts.
88
7.13 Bladed Scraper 7.15 Removing Brushed Scraper
Blades parallel setting to mill is done via the buttery screw on the top of cutting Loosen and remove the back chain with stiff chain on the left with hand.( 1 ), lift the
stick or the adjustment screw located between mills inclined cutting stick. pressure weight shown with three with and (2) slide brush downwards. It is removed
by pulling from front. If wanted, pressure weight group can be removed from
When in coupler, the minimum gap between blades and grinding mill is going to be juncture by moving it upwards. ( 3 )
2 mm. when in clutch, opposite balance must be set in a way that grinding mills
erosion is minimized.
7.14 Removing Bladed Scraper
To remove bladed scrapers,

(1)Loosen and remove the back chain on the left with hand. (2) turn and loosen
the safety washer at scraper juncture point. (3) loosen and turn the safety
washer a few times. First pull the front scraper group, then behind and remove
3
3
2
2
1
1
89
90

Roller Mill Similago II Manual

Загружено:

Сведения о документе

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Roller Mill Similago II Manual

Загружено:

Авторское право:

Доступные форматы

MACHINE INDUSTRY AND TRADE INC.

FLOOR AND FEED TECHNOLOGY

Remote Controller Troubleshooting

Remote Controller Troubleshooting

A ) Documentation G ) Preventing Accidents

Watch your hands Electric danger Clean regularly

Lifting Point Dont use without protection Stay away

Use suitable equipment Remote Controller ATEX

Warning Periodic oiling Milling cylinders

Smoking or approaching with

Periodic Control Warning moving part Important note

Maintenance and Repair In case of panic Optional

Use personnel protection Ask when doubtful STOP Warning

01 SECURITY 2.2 Structure 09

2.2.1 Main Components 09 - 12

2.4.3 Speed Variations 15

4.2.1 Product input 28 6.2 Operation 39

4.2.2 Product output 28 6.2.1 Setting 39

4.2.3 Direct drive engines 28 6.2.2 Control 39

4.3 Electric connections 28 6.3 Error Codes and Troubleshooting 40

4.3.1 Safety Switch 28 6.4 Panel Introduction 41

4.3.2 Terminal Box 29 6.4.1 General Panel Parts 41

4.3.3 Sensors 29 6.4.2 Menu Buttons 41

4.4 Pressured Air Connections 29 6.4.3 Sub menu buttons 41

6.5 Panel zellikleri 42

05 STARTING 6.5.1 Trend Sayfas 42

6.5.2 Ayarlar Mens 43

Inverter & Motor 57

Main Motor Signal (Pasage B ) 60 7.7 Changing Cylinder Block 77

Terminal 61 Preparations Needed Before

Man Motor Signal 68 7.9 Cylinder Roller Assembly and Removal 87

Terminal 69 7.10 Feeding Roller Drive Strap Setting 88

Indicator Box 70 7.11 Brushes Scraper Setting 88

7.12 Adjusting First Grinding Mill Gap 88

7.14 Removing Bladed Scrapers 89

7.3 Repair Plan 74

7.4.1 Product Input 75 8.1 Spare Part 93

7.5 Oiling 75 Mill and Chamber Group 93 - 101

7.5.1 Milling Cylinders Rolling 75 Feeding Group 102 - 105

7.5.2 Milling Gear Plan Bearing 76 Stripper Group 106 -107

7.6 Roller Change 76

Introduction It is necessary to use respiratory mask against dust inhalation.

DAVG Series Similago II is produced according to the designated technical

All switches must be in off position.

1.3 Operation Procedure

1.3.2 Protection, Precaution, Security Against Explosion

Explosion 1.7.1 Opening Machine Body

1.4 Electrical Connection Warning

3.1 Lifting with Crane 3.2 Transport Weight

What given along with machine to lift with crane;

Two G1 pipe geared lifting ring

3.1.1 Instruction For Lifting With Crane Transportation Warning

Place the gasket and screw it ( 2 ) TECHNICAL SPECS

Put on lifting ropes ( 3 ) MODEL mm cylinder

DAVG 8x 250 / 1250 6550 6916 10.9

Purpose: Milling machine consists of ve main functional parts. These are;

Electronic Control System: System enables DAVGs adjustment to most

According to the fullness of product input section, linear calculating

2.1.1 Type Code Explanations

DAVG 4X 250 / 800

2.1.2 Model Plate

800 250 565 68 x 170 x 48 cm

Type DAVG 1250 420 920 68 x 220 x 48 cm

2.2.1 Main Components