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• Edwar André Pgal

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Maintenance of Square Plansifter Warning: It is required to shut down the machine and lock up the main swich in addition to observing the safety rules Attention: Only eligible or authorized profesional is alowed to opérate the square plansifter for inicial startup,trial run and adjustment. Regular Maintenance The door of square plansifter is made of high-quality glass reinforced plastic (1) while the internal Wall of sieve box is made of insulating material (2) and high –quality lining material.Such a composite structure is very sensitive to impact; therefore,never try to clean up the stock cannel with Sharp hammer or any other similar tool,which would cause much worse damage tan the stock. Clean up the internal surface with neutral soap wáter if necessary

Be sure to check the cables for any wear and the fasteners for any looseness regularly. Be sure to check the condition of sealing elements regularly.When making an internal check,clean up all the sealing elements with banister brush and replace the broken or inelastic sealing timely.Never try to reuse any broken sealing element by applying overpressure.

Check the plansifter for any plug frequently,If any,take immediate measures.Be cautions!Never try to star up the plansifter which is clogged or full of stock.Neither try to run the plansifter without load for long;otherwise,the insert frame and cleaning block will suffer from unneccesary wear.If the plansifter has to be down for a few days,be sure to remove the fabric barrels from both the charge and discharge ports or the inspection cover,thus to assure good ventilation of the plansifter and flour cannel. To assure sifting efficiency, it is recomended to feed regularly so that each section will receive the load of the same volumen.Serious flow fluctuatin will affect the sifting effect .If it is an air conveyer that deliver stock behindd the sieve box,then the conveying pipe must be well ventilated to prevent the passage of sieve box from any air current.the pressure difference between the sieve cover and the sifted stock make negative affect to the sifting uniformity. Routine Maintenance Procedure Routine Maintenance procedure for initial operation(preventive maintenance after the machine is started up initially)

After one -day running, Lubricate the bearings again , and Hold down the sieve frame once again. After one –week running, Hold down the sieve frame and the glass reinforced plastics door again, And Measure the rotary diameter and make adjustment if necessary.

After one-month running, Tighten up the hold-down plate bolts of suspensión rod, Check all the bolts and screws for any looseness and reliability, Check the condition of belt tensión Check the power supply cables for any wear and the fasteners for any looseness,and Measure the height of the sieve frame.

PERIODICAL ROUTINE MAINTENANCE PROCEDURE Monthly Check the hold-down and sealing condition of sieve frame and sieve sections.

Every other and 3 months, Lubricate the bearings again

Biannually Check the condition of V belt and the tensión of V belt,and Check the cables for any wear.

Anually Replace the lubricant for the upper and lower bearings, Check the suspensión rod and the hold-down condition,and Measure the height of the sieve frame.

Every other year Check all the bolts and screws for any looseness and reliability, Check the verticality of plansifter with a plumb, Measure the speed and the diameter of rotation, Lubricate all the required points, Replace the V belt(With consideration of safety),and Replace the safety device of cable wires(with consideration of safety)

Attention: It is required regularly to Clean up the sieve box,sieve sections and discharge port in addition to replacing fabric barrel, Check the worn conditions of sieve frame,bolting cloth,cleaning blocks and expellers. Check the conditions of all the sealings elements,and Check the cables for any ageing.

12 years later Replace the GRP suspensión rod and electric cables.

Lubrication Drive bearing Every bearing has been filled in with about about 1 kg antifriction bearing grease in the manufacturer´s Factory.For the sake of safety,it is recomended to refill 40 g. lubricating grease into each bearing at the initial use of the plansifter and additional 40 g later on at intervals of three months.At least 1 kg lubricating grease is required for each replacement of bearing.The temperatura rise of bearing in not allowed to exceed 35°C and the máximum temperatura of bearing should never exceed 70 °C.Be

sure to replace the accumulated old lubricating grease with new new lubricant as specified every year.

Top hold-down device Be sure to drop a few drips of lubricating oil into the top hold-down screw rod every year.

Lubricant type Recommendation: 3#lithium base grease or molybdenum disulphide grease HH-N32(Lubricant for food machinery)

CAUTION: It is strictly forbidden to mix up the lubricants of different soap bases,which would weaken the lubrification and cause premature failure of bearing.

Dismounting and Mounting of Bearing

Dismounting of bearing Caution: Be sure to observe the safety rules about machinery startup and shutdown. After the square plansifter is opened,support the balance weight safely with lifting jacks or Wood blocks,Never try to dismount two bearings simultaneously. If the driving shaft is still fixed at one end and stay at the same point.it will be much easier to mount or dismount all the bearings.

Dismounting of upper bearing Remove the protective Hood of V belt(6); Loosen the bolts of motor fixed disk (4) and the adjustor screw rod(3); Move away the motor disk and take off the V belt(8); Remove the large belt pulley of V belt(9);

Loosen the fixting bolt of bearing seat and remove the taper pin(20); Eject the complete set of bearing seat (19) off from the transmission steel frame with the aid of three screw rods; Unscrew the bearing cap (12);and Force the bearing (14) and the bearing sleeve (13) off with the tool. Dismounting of lower bearing Caution: Take measures to prevent the lower bearing from dropping off before try to dismount it

Push the support frame from the floor to approach the bearing seat.Place it on some sacks which will assure the support rack and the bearing to move easily and securely; Loosen the fixing bolt of bearing seat and remove the taper pin(20); Force the complete set of bearing seat(19) off from the transmission Steel frame with the aid of three screw rods,as shown above:

Unscrew the bearing cap; and Force the bearing and the bearing sleeve off with the tool,as shown in Fig 29.

Mounting of Bearing Force the bearing sleeve into the cleaned new bearing and fill in lubricant .Force the bearing into the cleaned bearing seat.Make sure the bearing jacket to fi tinto the bearing seat tightly and suitably.Put the bearing cap in place and fill the gap of the upper part up with the lubricant dedicated for roller bearing.Coat the lubricating grease around the bracing ring of the bearing.Make sure the surface and gap of bearing are full of lubricating grease and fit the bearing in place

Mounting of upper bearing Make sure neither damage nor notch on the assembled bearing. Be sure no contaminant inside the chamber formed by the bearing seat;otherwise,replace it. Check the seal ring for any damage.

Clean up the fitting surface of the driving shaft and coat lubricating grease around before thrust the complete set of bearing into place.Take care when fit the seal ring(15)in place.Make sure no damage on it Align the bolt holes and tighten up the bolts of bearin seat as required. Fit the locating sleeve(11) and the large belt pulley on. Fit the V BELT BACK AND TIGHTEN up the bolts of motor fixed disk before secure the protective Hood.

Mounting of lower bearing Make sure neither damage not notch on the assembled bearing Be sure no contaminant inside the chamber formed by the bearing seat;otherwise,replace it. Check the seal ring for any damage. Clean up the fitting surface of the driving shaft and coat lubricating grease around before thrust the complete set of bearing into place.It should be noted to prevent the bearing from dropping off with the aid of lifting jacks or a frame.Take care when fit the seal ring in place.Make sure no damage on it. Align the bolt holes and tighten up the bolts of bearing seat as required.

MAINTENANCE OF V BELT SEE FIG 26, for the tensión adjustment of V belt. Excessively tensioned V belt will cause bearing failure or fracture of motor shaft,excessively slack V belt will deteriorate the wearing of V belt and disturb the startupof plansifter,causing large fluctuation,slow rotary movement of plansifter and reduced sifting efficiency. Please check the tensión of V belt one month after the belt is replaced and check again later on biannually. No V belt is allowed to work over two years or 15000 hours Never replace only a single belt and the four belts should be replaced together since they run the same time lenght.When replacing V belt,remember to clean and check the large and small belt pulleys.Remove the adhesions and replace the worn belt pulley.

Maintenance of SIEVE FRAME

The hold-down device of sieve frame consists of vertical hold-down device and horizontal hold-down device.Before applying them . the sieve frames should be piled in good order against the back guide.The clearance between the top face of the 1st tier of sieve frame and the bottom face of the top sieve frame is not allowed to be more tan 20mm.Adjust the vertical hold-down devices on both sides of the sieve box so as to remain the top sieve frame level before roughly tighten the hold-down bolts with a wrench.The horizontal hold-down device is used to press down the sieve frame tightly and horizontally.After the sieve frame is held down hoizontally,tighten up the upper hold –down bolts to the torque of 30 NM .with a torque wrench and screw up the lock nut,as shown in fig 30 AND FIG 31

ATTENTION: DO NOT USE any other tool but torque wrench to hold down the sieve frame;otherwise,the top sieve frame and the hold-down device may suffer from damage.If the vertical hold-down device is tightened up with torque wrench to 30 Nm,the top sieve frame will go down by 50 mm.In case of failure to hold down the sieve frame effectively at this momento , it is recomended to use spacer frame as solution.

Since the elasticity of sealing element will change in the service period,which will cause the sieve frame to move down a Little bit and consequently reduce the total height ,it is recommended to measure the total height of the sieve frame one month after the machine is started up and in regular maintenance afterwards.Add spacer frame if necessary so as to assure the vertical hold-down device will hold the sieve frame safely and effectively.

The sieve frames have been consecutively numbered in the manufacturer´s Factory,as shown in fig 32 , which is purposed to prevent sieve frames from confusión and facilitate the operation.In case of technological change,it is required to correct the numbers immediately. Be sure to clean up the base plate of sieve box at the discharge port before mounting the sieves frames , so as to assure they will contact each other tightly.

Tilt the sieve frame forwards and place its rear end inwards to the máximum of the sieve box.And then lower the front end and place i ton the base plate before pus hit tightly and stably. When piling the sieve frames by numbers,never try to slide the upper sieve frame on the lower sieve frame,which might cause damage to the seal ring at the bottom of sieve frame. The seal ring of the door may keep in service for many years.In case of ant wear or elastic failure, be sure to replace all the seal rings. The felt seal for the guide plate of sieve frame in the rear of the sieve box should be replaced timely ;otherwise ,the horizontal holddown device might fail to function effectively ,as shown in fig 33 and fig 34.

Be sure to clean up the adhesions inside the sieve frames, otherwise, they might cause clogging of sieve scheme.Never try to use rubber hammer or similar tool or any Sharp tool to clean these surfaces.Never knock the sieve frame on the floor or on any other board. Replace the worn felt seal ring timely,not individually but replace all completely at the same level.

Be sure to clean up the stock inside and outside the grooves of sieve frames timely,thus to prevent any sieve frame from plugging.Extra cares must be taken if the sieve box is used to handle sticklyor oily stock. A expeller is provide for each section of the collecting tray of sieve frame,which is used to clean up the tray continuously ,In case of missing or fault,the stock on the sieve bottom might not move or not be screened;therefore:be sure to replace the expeller if necessary. Be sure to handle the sieve frames gently.In storage,let the bolting cloths face with each other.Never let the bolting cloth contact the wire cloth ;otherwise,the bolting cloth might be damaged .Make sure the bolting cloth remain tight all the time.

Important Precautions

Important Precautions STORAGE

If it is imposible to install the delivered machine at the planned location immediately ,be sure to store the machine under a shelter safe from bad weather,dampness,corrosión or any other hazards. Installation This machine shall be installated in accordance with the installation specifications. Startup and Commissioning Only trained profesional is allowed to star up and commission this machine.Before start it up.operator must get familiar with all the precautions and operating instructions in the documents provided by the manufacturer

Maintenance and Cleaning The preventative maintenance can only be taken by professionals who are familiar with the instructions in the documents provided by the Manufacturer in advance.These instructions are prepared for the machine to remain in good conditions,less wear and longer service life.As for machine cleaning,please follow the instructions in the provided by the Manufacturer.

Personal Protection All the machines manufactured by Hebei Pingle Flour Machinery Group Co.,Ltd. Have been equipated with effective safety device in conformance with the present technical level in the Manufacturer´s Factory.They should be used as per the instructions. It is the user´s responsibility to enforcethe regulations set forth in this user´s manualfor operators´ personal safety. If any employed machine operator has no the competence to comprehend this user´s manual,it is the employer´sduty to explain to hi mor her what arehazardous and where should be given particular care to. Machine or part cleaning and lubricating work should be done only after the machine is shut down.If it is necessary to climb up to the top of the machine or enter the machine for cleaning purpose,be sure withouth exception to shut off the aire duct of the equipment,shut down the equipment and lock the switch at off position.

Please seriously follow the other instructions in this manual about accident prevention.

No one but the profesional who knows how to opérate this machine is allowed to do so. Safety Precautions.

Before making a check to the machine that requires shutdown of the machine for safety purpose,be sure to shut off the air duct of the equipmentas well as the feed/discharge ports,and lock the switches at OFF position.

Always assign the profesional who is familiar with the machine to do the relevant check, e.g, an electrician or a repairman. Be sure to carry out the required preventative maintenance work on Schedule; otherwise,the machinemight be subject to damage. Always take good care when doing other cleaning Works and never give a chance tol et open flameo r a spark contact the fine dust.Attention:Dust Explosion Hazard!

ROLLER MILL MAINTENANCE LUBRICATION Before the long-idle roller mil is put into service,be sure to refill lubricant to every lubricating point.The major lubricating ponts are shown in the table below.

The major lubricating points for normal maintenance are shown in the table below.

In case of temperatura abnormality ,be sure to refill lubricant timely.If the problema persists,replace the bearing.

Check of Driving and Rotatable Parts

Check the temperatura and noise of grinding roll bearing frequently.Take immediate care in case of overtemperature or abnormal noise.It is regarded as normal if the Temperatura of bearing is lower tan 60 °C .Besides,check for any leak at the oil seal. Frequently check the roll clearance adjusting mechanism of grinding roll for its sensitivity.Make sure the eccentric mechanism and the fine adjustment mechanism rotatable smoothly and reliably. Frequently check the tensión of doublé tooth belt and make timely adjustment in case of excessive loose or tight. Frequently check the neumatic components,pipelines and adapters for any damage or air leakage.Replace it timely if any.Make sure the air supply system Works normally. Remove and discharge the foreign material and cooling wáter in the pipeline and the air filtering tank regularly,thus to assure cleaned air fed by the air aupply system.

Regular Replacement of Grinding Rolls After a grinding roll is used for a period of time , the crest angle of fluted roll will become blunt and the surface roughness of smooth roll will run down ,affectingthe grinding effect. In case of high current of main motor or por grinding effect,it might be the time to replace grinding roll Only let competent manufacturer salvage used grinding rolls. Be sure to prevent the related components from bumping or damage when replacing grinding rolls.Particular care must be taken to protect the tooth belt pulley of fast roll and slow roll. Warning: Be sure to cut off all the power supply to the roller mil before replacing a grinding roll.

Always place a warming sign like “Maintenance Is in Process and Do not Switch Power On” at a visible place near the power switch. Disassembly procedure of grinding roll Open or remove the side door Remove the fine adjustment handwheel Remove the guard plate and striker plate Remove the retainer in both sides Unscrew the fixing bolts of front bafle plate and remove the front bafle plate Take off the V belt Remove the cleaning devices like cleaning brush or scraper Loosen the fastening bolts of tensioner Trun the eccentric shaft until the driving belt is taken off Take off the driving Wheel Remove the pull road assembly Unscrew the fixing bolts of separate slow-roll bearing seat Move the rear slow roll and the bearing to the dedicated bogie. Unscrew the fixing bolts of separate slow-roll bearing seat Move the rear slow roll and the bearing tothe dedicated boggie

Assembly procedure of grinding roll The assembling procedure of grinding roll is reverse to the disassembling procedure earlier disassembled parts should be assembled later First fit the gaskets over the axle heads of fast rolls,slow rolls ,retainers and belt seats before mkount the internal bearing cover Mount the grinding rolls into the roller mil Mount the pull rod assembly and tune the roll clearanceof rolls(refer to section 5.2.Adjustment of Grinding Roll) Mount the driving Wheel and the doublé tooth belt. Mount the roll cleaning devices. Fit the V belt Mount the front bafle plate. Mount the retainer,striker plate and guard plateo n both sides. Mount the fine adjustment handwheel at last. Attention The left bearing (the bearing at the end of tensioner) serves as the locating bearing.The boss height of inner bearing cover at the locating end is 4 mm,the boss heights of inner and outer bearing covers at the non-locating end n the right side are 3mm

Assembly Method and Technical Requirements of Grinding –roll Bearing(See fig 40 for the asssembly of grinding –roll bearing) The assembly of grinding –roll bearing is very important , for its assembling precisión affects directly the running temperatura,noise level and radial runout of the roll.

Clean up the disassembled bearing,round nuts and check washers thoroughly. Use 3# lithium base grease. Be sure to separate the bearing bushing fromthe rolling element before refilling grease to the bearing.Do not turn the bushing back to place until the gap between rolling elemntsis full of grease. Be sure to clean up the extra grease and foreignmatter on the surface of internaland external bushings and axle headcompletely before mount the axle head to the bearing When lockingthe round nut , be sure to measure the bearing clearance in the mean time.The bearing clearance after the round

nut is locked should be assured in the range of 0.03 to 0.04 mm (the mínimum clearance of model 22315EK bearing is 0.025 mm). When mounting the bearing cover, make sure the amount of refilled grease not exceed 50 % of the cavity.

Attention; If the reserved clearance is too Little after the bearing is locked in place or the grease refilled under the bearing cover is too much it might cause exccesive temperatura rise of runningbearing ore ven damage the bearing.

The lubricant might become deteriorated at a high temperatura for a long period.The dteriorated lubricant will stick the bearing and the axle head together firmly,making it disassemble the bearing.

TECHNICAL REQUIREMENTS OF MOUNTING TOOTH BELT PULLEY FOR FAST ROLL AND SLOW ROLL Adjust the roll clearance to the preset value after grinding roll is replaced Mount the belt pulley of slow roll and adjust the position of belt pulley so that the outer end face of the belt pulley is aligned with the outher end face of tensioner.Screw up the lock sleeve. Mount the belt pulley of fast roll.After the lock sleeve is screwed up make sure the outer end faces of the belt pulleys for the fast rolls and slow rolls are aligned with each other.Check the misplacement between the two pulleys with a ruler and make sure it is not more tan 0.1 mmm (fig 41) Attention: Excessive misplacement between the tooth belt pulleys of fast roll and slow roll will cause premature wear of doublé toothbelt and damage.

Phenomenon: When roller mil is working normally,if black poder is found dropping from the doublé tooth belt,it implies the misplacement between the tooth belt pulleys of fast roll and slow roo lis too much.Immediately shut down the roller mil and adjust the position of belt pulleys.

MAINTENANCE OF DOUBLE TOOTH BELT BETWEEN GRINDING ROLLS. Remember to adjust the driving doublé tooth belt between grinding rolls,which directly affects the service life of belt.Adjust the tensión of belt once after the machine has ran for 24 hours initially with reference to the initially conditions of the machine.Later on, be sure to check and adjust the doublé tooth belt once a week at least.

Check and Maintenance of Air supply System Check the air reservoir and the pipe for any condensation wáter once a week at least.If any, check whether the automatic discharge valve is functional.Drain the condensation wáter timely with the manual draining valve.Check all the adapters of pipe line for any leak.Fix it up if any,thus to prevent the air aupply pressure from going down due to air leak.

Frequent Cleaning of Roller Mill I t is very important the roller mil clean.Excessive dust on roller mil will affect not only the cleanness but also the normal operation of machine.The operators aare responsable for cleaning roller mills frequently.It is recommended to clean the plexiglass door with a brush,the external surface with a whiskbroom or cotton yarn and the driving parts inside the roller mil with purging air gun.As for the dust and contaminant , it is recommended to wipe them off with a wet rag Maintain the ground clean. SAFETY PROTECTION To completely preventequipment damage and personal injury,the the operator of this roller mil is requested to observe the following operating instructions strictly. This roller mil is designed fro profesional personnel to opérate,who however shall not power on the machine until he or she has read through and understood all the contents of this user´s manual. After the roller mil gets into normal operation,be sure to close its side door. Prior to overhaul,adjustment ,check or maintenance of the machine, be sure to cut off all the power supplies to the roller mil. Do not try to clean or lubricate the roller mil or its any part until the roller mil is completely still. Take corresponding protective measures to the power supply and the control circuite(e.g., using automatic break relay or switch) so as to prevent the roler mil from unexpected restart when power supply is restored after power failure.

Be very cautious when sampling so as to prevent accident from happening.Generally, it is recommended to simple from the chute or the Hopper under the roller mil from instead of the roller mil inside.. Clean up the dust ,dirt and rsidual stock on the machine frequently and maintain thecleanness of the machine and environment , thus to enhace production reliability and safety and to prevent dust explosión Observe the other safety operating instructions required in user´s Factory.