MANUAL

PM 919
02.04.09 rev.2
DIMENTION SKETCH

PM 919 XW directly coupled main motor.

 ☛IMPORTANT! IMPORTANT! IMPORTANT!

ANDRITZ FEED & BIOFUEL A/S URGE EVERYBODY

WHO GET IN CONTACT WITH THE MACHINE TO READ
THIS OPERATING MANUAL TO PREVENT PERSONAL
INJURY OR MATERIAL DAMAGE.

☛RESPECT WARNING SIGN!

INTRODUCTION

Please follow the instructions in this manual.

ANDRITZ FEED & BIOFUEL A/S has paid much attention to production and design in
order to make our products as safe and reliable as possible.

Should you, contrary to expectation, get any problems with your ANDRITZ FEED & BIOFUEL
product please contact the company that made the instalments or
ANDRITZ FEED & BIOFUEL A/S.

In case you have any comments to our equipment and/or this manual we kindly ask you to
contact us at one of the following addresses:

ANDRITZ FEED & BIOFUEL A/S

Glentevej 5-7
6705 Esbjerg Ø
Danmark

Tel. : +45 72 160 300

Fax.: +45 72 160 301
CONTENTS:
1. INSTALLATION Page
Security provisions 1.1
Application – maltreatment 1.2
General description, bolt mounted die 1.4
General description, roller adjustment 1.5
General description, safety coupling 1.6
General description, transmission 1.7
General description, mounting of die 1.7
General description, greasing 1.7
Working areas 1.8
Noise measurement 1.9
Tool list 1.10
Fixation moment, bolt mounted die 1.16
Transport and lifting devices 1.20
Mounting instruction 1.22
2. MOUNTION AND OPERATION
Mounting of coupling and main motor 2.1 – 2.2
Exchange of die. Bolt mounted 2.12 – 2.14
Roller, exchange 2.15 – 2.17
Roller, adjustment 2.18
Pellet length 2.20
Knife adjustment 2.21
Inlet duct, mounting 2.25
Forced feeder, mounting 2.26
Forced feeder, belt drive 2.27
Automatic lubrication system, mounting 2.30
Automatic lubrication system, connection 2.31
Automatic lubrication system, 1 press 2.32
Automatic lubrication system, 2 presses 2.33
Automatic lubrication system, 3 presses 2.34
Automatic lubrication system, grease sensor 2.35 – 2.36
Oil lubrication system 2.37 – 2.38
Mechanical overload protection, shear pin 2.40
Check before first starting up and after repair 2.45
Start and stop of press 2.50
Check before starting up at daily operation 2.55
Oil level in gear box 2.56
Magnet in gear box 2.57
Check during operation 2.60
Hydraulic roller adjustment, function 2.70 – 2.71
Hydraulic roller adjustment, hydraulic diagram 2.72
Hydraulic roller adjustment, grease diagram 2.73
Hydraulic roller adjustment, replacement of roller, dismounting 2.74 – 2.75
Hydraulic roller adjustment, replacement of roller, montage 2.76 – 2.77
Hydraulic roller adjustment, start-up and stop 2.78
3. MAINTENANCE Page
Maintenance diagram 3.1
Lubrication intervals – bolt mounted die - automatic lubrication 3.3
Manuel lubrication 3.4
Grease/oil types 3.10
Die crane 3.12
Blocking 3.15
Cleaning of the machine 3.20

4. DISMOUNTING
Dismounting, scrapping 4.1
INSTALLATION

Page
Security provisions 1.1
Application - maltreatment 1.2
General description, clamp mounted die 1.3
General description, bolt mounted die 1.4
General description, roller adjustment 1.5
General description, safety coupling 1.6
General description, transmission 1.7
General description, mounting of die 1.7
General description, greasing 1.7
Working areas 1.8
Noise measurement 1.9
Tool list 1.10
Fixation moment, clamp mounted die 1.15
Fixation moment, bolt mounted die 1.16
Transport and lifting devices 1.20
Mounting instruction 1.22

01.12.18. PM 919 Page 1.0

SECURITY PROVISIONS

WARNINGS

) IMPORTANT! IMPORTANT! IMPORTANT!

IT IS PURCHASER´S/MAIN CONTRACTOR´S
RESPONSIBILITY THAT BEFORE TAKING INTO
OPERATION THE PELLET MILL IS INSTALLED
CORRECTLY IN ACCORDANCE WITH AT ANY
TIME VALID SECURITY AND HEALTH
REGULATIONS

On some easy-to-open hatches safety swithes with electrical locking are optionally
mounted.

These have a time-delayed declutchment in order to ensure against the casting time of the
machinery. These safety swithes must under no circumstances be decoupled or by-
passed.

All mounted guards and hatches must be securely fixated when the conditioner is in
operation.

It must be ensured that electro motors are not started and that the steam valve is not
opened while operation or repair works are done. This is done by locking the contactors or
the starting devices or by signing.

If operational disturbances are heard or in any way felt, these must be taken care of
immediately, no matter if one can solve the problems oneself or if a technician from
ANDRITZ SPROUT A/S must be contacted.

) BYPASSING OF THE ABOVE SECURITY PROVISIONS MAY CAUSE

SERIOUS PERSONAL INJURY

01.12.18. PM 919 Page 1.1

UTILIZATION AREA/MALTREATMENT

The pellet mill is designed for pelleting animal feed from organic ingredients. If you have
any doubt about the pelletability of the raw material, Andritz Sprout's technical department
might be contacted for further information.

The material must never contain hard foreign bodies, such as stones, bolts, nuts, etc. It
must be ensured that such foreign bodies are separated before the compound reaches the
press. This may be done with magnets and stone traps at the mill. Furthermore the inlet
duct may be provided with permanent magnets.

When using the machinery for other than pelleting of compounds Andritz Sprout takes no
responsibility for damages.

01.12.18. PM 919 Page 1.2

GENERAL DESCRIPTION

BOLT MOUNTED DIE

01.12.18. PM 919 Page 1.4

GENERAL DESCRIPTION

By means of a speed-controlled dosing screw A the raw material is delivered to the

conditioner K on top of the press. The speed control, that may be manual or automatic, will
determine the main motor's load. During the material's passage of the conditioner, adding
of water, steam, binder, molasses etc. can be done.

Via the chute T, or alternatively an forced feeder with paddles, the material falls from the
mixer into a rotating feed cylinder J, which is adapted on front of the rotating die M. The
chute T may be provided with a dump chute which opens and lets out the compound at any
overload, thus avoiding blocking. Due to the centrifugal force the cylinder will bring the
material into rotation. Three stationary material distributors G, acting as scrapers of the
cylinder's inside, lead the material, so it is delivered into the die just in front of the freely
rotating press rollers R.

In the pressing chamber the material is rolled and extruded outwards through the die's
radial channels into the pellet chamber. Here it is cut into pellets of suitable length by
stationary, adjustable knives.

The excentric roller shafts are at the inner end supported in the flange of the non-rotating
main shaft H and at the outer end in the roll holding plate I.

Roller Adjusting - mechanical

The press rollers are adjusted to a minimum clearance between roller and the die's inner
race. The clearance is regularly adjusted to compensate for wear on die and rollers.

01.12.18. PM 919 Page 1.5

GENERAL DECRIPTION

Safety coupling - shear pin

The roller main shaft H, which is embedded in the main shaft, is in its rear free end
provided with a shear pin hub D which is prevented from rotating by means of 2 shear pins
mounted in hardened bushings.

If the roller pressure exceeds a given value - f.ex. in case of the presence of a foreign body
in the pellet chamber of simply because of overload - the shear pins will break after which
the main shaft with rollers and roll holding plate starts rotating together with the die.

At the movement of the safety coupling disc a switch W is influenced which turns off the
power of the pellet mill main motor. At the same time the conditioner and the feed screw
stop.

H
D

01.12.18. PM 919 Page 1.6

GENERAL DESCRIPTION

Transmission

The main shaft is supported in a reduction gear box. The input shaft is driven directly by a
electromotor. Bearings and gears are oil lubricated by the oil content of the gear box.

Mounting of die (illustration on page 1.4)

The die is fixated onto the die housing S by means of tapered wear rings with 20 pcs. bolts
which are fixating the die into a tapered wear ring inside the die housing. On the front edge
of the die a stiffener ring P is bolted on, also with tapered wear ring. This is transferred
when the die is exchanged.

Lubrication of rollers and main shaft bearings

The rollers and the roller main shaft bearing are grease lubricated through drillings in the
roller main shaft. The connection of a distributor block in its free end takes place through a
swivel allowing the roller main shaft to rotate until the press stops in case the safety
coupling is triggered. The grease supply may take place by means of an automatic
lubrication system.

04.06.28. PM 919 Page 1.7

WORKING AREAS

On an operating machine the normal working areas are situation immediately in front of the
machine at the pellet chamber.

When the machine is stopped, all of it should be regarded as working area, as all cleaning,
lubrication, and adjustment takes place here. More information about this can be collected
in the corresponding sections.

01.12.18. PM 919 Page 1.8

NOISE MEASUREMENT

The sound power level from a Andritz Sprout pellet mill PM919 is determined by measuring
according to the specifications in ISO 9614-2:1996, ”Acoustics - Determination of sound
power levels of noise sources using sound intensity”.

The measurements were carried out on a pellet mill in an existing production plant.
The measurements showed the following results stated in dB(A) re 1pW.

63 Hz 125 Hz 250 Hz 500 Hz 1 kHz 2 kHz 4 kHz 8 kHz A

LwA 73 86 89 94 92 92 88 78 99

The measure inaccuracy is ± 4 dB.

02.05.24. PM 919 Page 1.9

TOOL LIST

1 1 Allen key 005843

1,5 NV – 12mm

2 1 Allen top 3/4" 005852

14 NV

3 1 Allen top 3/4" 005851

17 NV

4 1 Allen top 3/4" 005941

19 NV

5 1 Top ½" 039370

24 NV
ONLY 2 ROLLER HYDRAULIC
ADJUSTMENT SYSTEM
6 1 Top 3/4" 064869
46 NV

7 1 Power top ½" 023249

30 NV

8 1 Top 3/4" 041926

30 NV

9 1 Top 3/4" 053007

36 NV

10 1 Extension 200 mm 005849

¾” – ¾”
11 1 Slide grip 3/4" 005853
firkant

04.10.27. PM 919 Page 1.10

TOOL LIST

12 2 Spanner 037450
NV 55

13 2 Spanner 033593
NV 30

14 2 Spanner 005943
NV 36
ONLY 2 ROLLER SYSTEM

15 1 Torqure wrench 3/4" 023248

60-300 Nm

16 1 Torqure wrench 3/4" 023245

400-1000 Nm

17 1 Connection quadrangle 005850

3/4" x 3/4"

18 1 Lifting tackle for die 032415

19 1 Lifting tackle for roller 032417

ONLY 3 ROLLER SYSTEM
1 Lifting tackle for roller 065715
ONLY 2 ROLLER SYSTEM
20 4 Hex. Screw M24 008762
(dismount. of die)

21 1 Screwdriver 025392

04.10.27 PM 919 Page 1.11

TOOL LIST

22 1 Key Atlas 030576

23 1 Key Telemecanique 040181

24 2 Bolt for die mounting 044359

25 1 Turning rod 032423

26 Brackets for roller exchange 032424

When the die is mounted.
(3 Pcs. by 3 ROLLER SYSTEM)
(2 Pcs. by 2 ROLLER SYSTEM)

27 Brackets for roller exchange 080087

When the die is dismounted.
(3 Pcs. by 3 ROLLER SYSTEM)
(2 Pcs. by 2 ROLLER SYSTEM)
28 8 Shear pin 051150

29 1 Extension 57mm 066105

¾” – ½”
ONLY 2 ROLLER HYDRAULIC
ADJUSTMENT SYSTEM
30 4 Hex. Screw M24 031406
(dismount. of die)
ONLY 2 ROLLER HYDRAULIC
ADJUSTMENT SYSTEM

04.10.27 PM 919 Page 1.12

FIXATION TORQUES AND ADJUSTING OF DISTANCES
BOLT MOUNTED DIE

06.01.03. PM 919 Page 1.16

TRANSPORT AND LIFTING DEVICES

ANY HANDLING SHALL TAKE PLACE ACCORDING TO

SAFETY REGULATIONS

Weight

11800 kg Incl. rollers and die, excl. main motor

13800 kg Incl. rollers and die, main motor

(motor, f.ex.: 200 kW ABB, 1480 rpm.)

2 Stk. M36
eye bolts.

2 Stk. M36
eye bolts.

Support S-M no. 017349 and 062973 are always used at transport, and when the motor is
dismounted.

06.01.03. PM 919 Page 1.20

TRANSPORT AND LIFTING DEVICES

2 Stk. M36
eye bolts.

Weight

9300 kg Without rollers and die.

Rollers and die should not
be mounted, as the
machine then becomes
unstable (turns over)

06.01.03. PM 919 Page 1.21

TRANSPORT AND LIFTING DEVICES

General instructions for lifting and moving

At any lifting the lifting material should be protected against sharp edges on the machine.
Straps and chains which are placed around sharp edges on machine parts must always be
protected with sufficient gasket, either with a rounded steel angle or with 2 pieces of wood.

Lifting the machine

1. All loose parts must be removed, and guards, covers etc. must be closed and fixated
before lifting in order to avoid them falling down.

2. Conditioner with mounted feed screw must always be lifted separately. The assembly
between the conditioner and the press does not have the necessary strength to lift
the press.

3. It must be ensured that the lifting material is not pulled in an oblique angle and that it
is adequately fixated. The machine should not be drawn over the surface as the
lifting material may then be damaged, and the press may go into unforeseen
swingings when the lifting is started. If the press is to be moved on the surface, rolls
or similar should be mounted under the base. It should be ensured that the stability is
alrigth. For example die and rollers should not be mounted, if the main motor is not
placed on the base, else wise the press may fall forwards.

4. Placing of the press should take place on a surface with sufficient stability and
strength for the total weight of the machine.

Any handling must always take place according to safety regulations.

01.12.18. PM 919 Page 1.22

INSTALLATION INSTRUCTION

General installation instruction

In order to avoid the transmission of noise and vibrations from the pellet mill, the base must
have a large volume, f.ex. a thick concrete deck. If this is not possible, for example if the
pellet mill is to be placed on a steel framework, one may chose to place the machine on
machine shoe or, better yet, on correctly dimensioned vibration absorbers. However, as a
minimum plates of vibration damping rubber should always be used as intermediate layer.

In general it can be said that an unsuitable base may intensify the noise from the pellet mill
considerably.

1. Flexible connection which does not transfer vibrations.

2. Pipe connections through compensators.

3. Vibration and noise damping base under the machine either along the edge of the
base frame, or under the pellet mill itself if it is mounted without base frame.

4. Vibration and noise damping intermediate layer at base bolts.

5. If the machine is mounted with base frame, this should be filled with asphalt or
similar.

01.12.18. PM 919 Page 1.23

MOUNTING AND OPERATION
Page
Mounting of coupling and main motor 2.1 – 2.2
Exchange of die. Bolt mounted 2.12 – 2.14
Roller, exchange 2.15 – 2.17
Roller, adjustment 2.18
Pellet length 2.20
Knife adjustment 2.21
Inlet duct, mounting 2.25
Forced feeder, mounting 2.26
Forced feeder, belt drive 2.27
Automatic lubrication system, mounting 2.30
Automatic lubrication system, connection 2.31
Automatic lubrication system, 1 press 2.32
Automatic lubrication system, 2 presses 2.33
Automatic lubrication system, 3 presses 2.34
Automatic lubrication system, grease sensor 2.35 – 2.36
Oil lubrication system 2.37 – 2.38
Mechanical overload protection, shear pin 2.40
Check before first starting up and after repair 2.45
Start and stop of press 2.50
Check before starting up at daily operation 2.55
Oil level in gear box 2.56
Magnet in gear box 2.57
Check during operation 2.60
Hydraulic roller adjustment, function 2.70 – 2.71
Hydraulic roller adjustment, hydraulic diagram 2.72
Hydraulic roller adjustment, grease diagram 2.73
Hydraulic roller adjustment, replacement of roller, dismounting 2.74 – 2.75
Hydraulic roller adjustment, replacement of roller, montage 2.76 – 2.77
Hydraulic roller adjustment, start-up and stop 2.78

04.06.28. PM 919 Page 2.0

MOUNTING OF MAIN MOTOR

DIRECTLY COUPLED

Mounting of coupling

Place the coupling parts loosely on the

shafts of press and motor (Fig. 1).

The motor is fixated to the base

By using shims between the base and

the motor food, the height can be
adjusted and the vertical alignment
can be made.
Fig. 1
The horizontal alignment can be made
by moving the motor/base.

The alignment is checked with a

straightedge (Fig. 2) and a feeler blade
(Fig. 3) according to below stated
values. While this is done, the motor
shaft is turned 1 step of 90o to ensure
correct running round.

Fig. 2

Alignment values
Parallelity 0,33 mm
Angel deficiance 0,33 mm
Distance J 3 ±1 mm

Fig.3

01.12.18. PM 919 Page 2.1

MOUNTING OF MAIN MOTOR

DIRECTLY COUPLED

After correct alignment the sealing ring

is placed (Fig. 4).

Fig. 4

Fill grease into spaces between the

teeth and mount the spring (Fig.5).

Fig. 5

Fill up with grease around the spring

and lubricate the hub (Fig. 6).

Fig. 6

Housing halves are pushed into place

and tightened together (Fig. 7).

After correct alignment of the motor,

the intermediate layers under the base
are welded to the motor base and the
press base.

Fig. 7

01.12.18. PM 919 Page 2.2

MOUNTING/EXCHANGE OF DIE
BOLT MOUNTED DIE
M24-600 Nm M24-600 Nm
¾”UNC-350Nm ¾”UNC-350Nm

10 stk. M24 (3/4”UNC) for fixation of feed cone

F on reinfor-cement ring B. Are also used for
pulling off reinfor-cement ring B.

12 stk. M24 (3/4”UNC) for fixation of

reinforcement ring B on the die N.

04.06.28. PM 919 Page 2.12

MOUNTING/EXCHANGE OF DIE
BOLT MOUNTED DIE

Dismantling of Die
1. Loosen the screws B1 and remove the feed cylinder.

2. Swing the rollers away from the die.

3. Screw the cylinder screws out and place the lift hook N1 in the reinforcement ring with
a cylinder screw B2.

4. Place 2 of the dismantled screws B1 in the push-off holes and screw them in until the
reinforcement ring B is loose and can be dismantled.

5. Place the lifting hook N1 in the die with a cylinder screw B2.

6. Loosen and remove the screws B3 together with the washers.

7. Push off the die by use of screws B3: screw them in from the rear Page of the main
shaft and pull out the die horizontally.

BE AWARE THAT THESE SCREWS HAVE BEEN REMOVED

AGAIN BEFORE THE NEW DIE IS MOUNTED!
Mounting of Die
1. Before the mounting check that the contact surfaces of die, fixing ring and main shaft
are completely clean and dry.
1.

2. Press the die on the die housing and fasten it with the screws B3 and washers as
shown on page 2.12.

3. Mount the reinforcement ring B on the die. Be sure that the contact surfaces are
completely clean and dry before mounting. Insert the screws C and fasten them as
shown on page 2.12.

4. Swing the rollers back and adjust them as described on page 2.18.

5. Mount the feed cylinder.

04.06.28. PM 919 Page 2.13

MOUNTING/EXCHANGE OF DIE
BOLT MOUNTED DIE

Replacement of Wear Ring

1. Pry out the wear ring with a screwdriver.

2. Press a wedge in and continue to loosen the wear ring all the way round with
the screwdriver till the wear ring can be removed.

3. Check that the contact surfaces are completely clean and dry.

4. Pull the ends of the new wear ring together and place it carefully so that the
recess slides in position in the track of the die housing/reinforcement ring.

Reinforcement ring Die Die housing

Reces
Wear ring

04.06.28. PM 919 Page 2.14

REPLACEMENT OF ROLLER

01.12.18. PM 919 Page 2.15

REPLACEMENT OF ROLLER

DISMANTLING

Illustration, see previous page

1. Loosen the M12 bolt on the support and loosen the 3 M20 bolts (I) and dismantle the
holder (H) with the feed plows.

) IMPORTANT:
BEFORE THE ROLL HOLDER PLATE (F) IS DISMANTLED ALL 3
ROLLERS MUST BE SECURED FROM FALLING OUT.

When the die is mounted: Use the brackets (R1) to secure the rollers.

When the die is dismantled: Use the brackets (R2) to secure the rollers.

) WARNING:
RISK OF PERSONAL INJURY IF THESE INSTRUCTIONS ARE NOT
FOLLOWED.

01.12.18. PM 919 Page 2.16

2. When the rollers have been secured dismantle the roll holding plate (F).

3. The rollers are dismantled by use of the lifting hook (K), which hangs in the hoist
above the press. To the lifting hook belongs 3 shackles with different length so all
rollers can be removed with the die mounted without turning the main shaft.

4. Clean and check the bushes in the roller main shaft. Clean and lubricate the roll pin
ends at the O-rings. Replace the old O-rings (O) with new ones.

5. Turn the roller - when it hangs in the lifting hook - so that the eccentric turns to the
right side. (Turning clockwise there is less distance to the die).

MOUNTING:
6. Mount the roller

7. Clean and lubricate the bushing in the roll holding plate with special grease containing
Molybdenumdisulphide or the like.

8. Mount the roll holding plate (F). Insert the M20 bolts (E) and fasten them to a torque
of 334 Nm.

9. Mount the holder (H) with the feed plows and the 3 M20 bolts (I) 174 Nm.

10. Mount the M12 bolt for the support (S).

11. Remove the roller retaining brackets R1 - R2.

12. Adjust the rollers separately. Follow the instructions about roller adjustment.

Note that normally replacement of die and roller is done

simultaneously because worn parts do not function optimal
with new parts or with parts with another wear pattern.

01.12.18. PM 919 Page 2.17

ROLLER ADJUSTMENT

1. Loosen the bolt (B) and loosen the lock-nut (J). The roller is now adjustable by
means of the adjusting bolt (J).

2. Check that the inside of the die and the rollers are clean and free of material.

) IMPORTANT:
TURN THE ROLLER CLOCKWISE SO THAT - BY MEANS OF THE
ADJUSTING BOLT - IT IS POSSIBLE TO DIMINISH THE DISTANCE
BETWEEN ROLLER AND DIE.

If the roller adjustment arm (A) cannot be adjusted further remove it and turn it a bit
anticlockwise. Fine adjustment with the adjusting bolt (J) is now possible again.

4. Adjust the roller to be in least possible distance from the die, check the distance with
a thin brass plate or the like. We recommend that the roller and die is turned to make
sure that there is no contact. The rollers must not touch the die. Any contact between
roller and die will cause a peening - to some extent.

) WARNING:
IT IS HIGHLY DANGEROUS TO ADJUST THE ROLLERS WITH THE
MOTOR RUNNING.

If the roller has been adjusted too far inwards it can be knocked back by knocking on the
roller adjustment arm (A). The roller adjustment arm can also be removed and the supplied
turning rod then used to turn the roller. Use also the turning rod if the machine has blocked.

5. After the roller adjustment tighten the roller adjustment arm (A) with the bolt (B)
with 174 Nm, and lock the adjustment bolt (J) with the lock nut.

01.12.18. PM 919 Page 2.18

PELLET LENGHT
Pellet length (Scraper knife)

Press-
zone

The pellet length is determined by the following:

1. Distance to the die.

2. Material quantity.

The pellet ends make fines.

2 ends 4 ends 6 ends

The pellet length is partly determined by the knife distance from the die and partly by the
material quantity which is lead between the die and the roller.

An uneven pellet length may be owing to a poor distribution of the material either to the
individual roller or over the whole width of the race. It might also be caused by the knife not
being sharp, so that the pellet is not cut but knocked off in random length.

Please notice that the knives must be pulled out if the front door is to be opened. Before
start-up they must be adjusted or pushed back to the fixed position again.

01.12.18. PM 919 Page 2.20

KNIFE ADJUSTMENT

The motor MUST be stopped before starting adjusting the pellet knives.
1. Push the knife in against the die and lock it.
2. Push the stop collar against the knife base and lock it.
3. Retract the knife until the desired distance is achieved between the stop collar and
the base. Lock the knife again.
4. Loosen the stop collar and push it down to contact with the base and lock it again.

By using this method, it is very easy to reset the knives to the same position, when they
have been retracted.

Die Knife Base

01.12.18. PM 919 Page 2.21

MOUNTING OF INLET DUCT

At delivery of a mill with the conditioner mounted, the inlet duct is adapted to ensure that
the flange connetion at the conditioner outlet is tight. It is therefore not necessary to adjust
the inlet flange or the location of the hinges. This is why the duct is merely hooked on the
welding hinges.

At a mill without the conditioner mounted, the flange on the inlet duct must be adjusted, so
that the flanges shut tight at closed inlet duct/front door.

If the inlet duct is provided with dump chute this must have air connected to the cylinder
according to the functional description in the control.

Safety switch, if mounted, and corresponding activation key should be adjusted so that a
signal is given at closed position. This must be integrated in the safety system of the
control (see description of this).

01.12.18. PM 919 Page 2.25

TURNING GEAR ASSEMBLY

Turning gear is used to turn the die backwards and forwards during roller adjustment to
insure that the rolls and the die do not touch each other. Turning gear is also used to
reverse the die free of the rolls to ease removal of stuck feed or foreign bodies. Or used in
connection with other services where turning the die is desirable.

Turning gear consists of bracket (A), gear motor (B) and electrical activated (24V DC)
toothed coupling (C) with return spring. When the toothed coupling is equipped with 24V
DC the teeth throw into gear.

Before turning gear is employed it has to be ensured that:

1. The turning gear is aligned according to instruction below.

Gear motor (B) and console (A) are secured with pins upon alignment.

2. Main engine (D) and turning gear of the mill are, as to control, connected thus there
is mutual blockage. Meaning that it is not possible to start the main engine of the mill
when the turning gear is active and the other way round it is not possible to activate
the turning gear when the main engine of the mill is running. To ensure that the main
engine is stopped, it is necessary to connect a standstill guard via the motor starter,
which forms part of the mutual blockage.

The main engine of the mill MUST be stopped before the turning gear is activated.

03.03.26. PM 919 Page 2.28

MOUNTING OF AUTOMATIC LUBRICATION SYSTEM

Drum lubrication

The drum lubrication system consists of a complete lubricating automat which must be
connected directly to the grease distributor swivel. With the lubricating automat an
inductive sensor follows, which is mounted as shown in 2.35.

The grease temperature must min. be +5°C in order to ensure the mechanical function of
the lubricating system.

04.06.28. PM 919 Page 2.30

 CENTRAL GREASE LUBRICATION

Inlet
The hose connection to the grease distributor must be fixated so that it does not turn
around at a possible overload.

The control pin indicates that lubrication takes place (the pin moves in and out of the
nipple).
Roller 3
Roller 1

Roller 2
Bearing for
roller main shaft

Inlet
01.12.18. PM 919 Page 2.31
CENTRAL GREASE LUBRICATION

Inlet

The hose connection to the grease distributor must be fixated so that it does not turn
around at a possible overload.

The control pin indicates that lubrication takes place (the pin moves in and out of the
nipple).
Roller 2
Roller 1

Bearing for
roller main shaft

Inlet
02.11.04. PM 919 Page 2.31
LUBRICATION

DRUM LUBRICATION - 2 PRESSES

Air inlet
Air control
app. 3 bar Control

Grease hose

Inlet
Press 1

Inlet
Press 2

Pos.
1 Lubrication automat with counter, 2 presses, complete, incl. pos. 2-4
2 Panel, 2 stk. presses
3 Lubrication control
4 Inductive sensor
5 Pump central, complete for 200 kg barrel, incl. pos. 6-7
6 Pump central
7 Grease sensor, adjustable, 200 l, complete

03.10.17. PM 919 Page 2.33

DRUM LUBRICATION

GREASE SENSOR, ADJUSTABLE, NO. 028474

Pos.
1 Lock ring U22 x 1,2 DIN 471
2 Pipe for grease sensor
3 Bushing for grease sensor
4 Hex. screw M8 x 20 DIN 933
5 Shaft nut KM8
6 Inductive sensor XS1-M18MA230
7 Forskruning PG 9

03.10.17. PM 919 Page 2.35

GREASE SENSOR

When the grease bin is full the grease sensor plate will be placed in the top of the bin with
the inductive sensor in the bottom (fig. 1).

When the inductive sensor is placed in the bottom of the grease bin, an alarm is activated
(fig. 2).

To be able to use all of the grease in the grease bin the sensor pipe is pulled to its top
position (fig. 3).

When the inductive sensor reaches the bottom of the grease bin again, the alarm is re-
activated, which indicates that the bin is empty and must be changed (fig. 4).

fig. 1 fig. 2 fig. 3 fig. 4

01.12.18. PM 919 Page 2.36

OIL LUBRICATION SYSTEM

The gearbox is equipped with an integrated oil lubrication unit, for lubrication of the pellet
mill’s main bearings and gears.

Integrated
lubrication system
in gearbox

The lubrication unit is designed to work within an oil temperature interval of 10  to 70. If
there is any risk of the oil temperature getting below 10 a heating coil shall be fitted to the
gearbox. Likewise if there is a risk of the oil temperature getting higher then 70 an oil
cooling unit shall be installed. The maximum system pressure is set to 30 bar.
A pressure switch placed after the filter monitors the oil pressure. If the oil pressure drops
below 2 bars the pellet mill will shot down. The lubrication units filtering system consists of
a filterhousing with a bypass valve and a exchangeable filter. A pressure switch monitors
the differential pressure at the filter. At a differential pressure of 5 bars an alarm will go off,
warning the operator that the filter should be change. If this alarm is ignored the bypass
valve will lead the oil past the filter when the differential pressure is higher the 6 bars. This
is not recommendable as it can lead to severe damages to the bearings and the gear.
When an oil change is made the filter should also be change.

Oil types
The following oil type can be used.

Fabrikant Mineralsk Syntetisk

Mobil Mobilgear 630 GLYGOYLE HE 220
Shell OMALA OIL 220 OMALAOIL HD 220
Klüber KLÜBEROIL GH 6-220
KLÜBEROIL 4 UH1-220 N
FOODGRADE

04.05.09 PM 919 Page 2.37

OIL LUBRICATION SYSTEM

DIAGRAM
5 4 2
3

FIG 1

Pos. Beskrivelse
1 Motor 4 pole AC-motor
2 Pump with safety valve . System pressure 30
Bar. Nom. Flow 26 L/min
3 Filter 12my. with diff. pressure monitoring and
bypass
4 Pressure switch
5 Divider block

02.04.09 PM 919 Page 2.38

OIL LUBRICATION SYSTEM

FUNCTIONAL DIAGRAM

29.05.09 PM 919 Side 2.39

MECANICAL OVERLOAD PROTECTION

EXCHANGE OF SHEAR PIN

The exchange of a shear pin which is not broken is done by loosening screw A and
removing the fork B. Then the shear pin C can be removed and exchanged.

If the shear pin C is broken, again loosen screw A and remove the fork B. The outer part of
the broken shear pin is removed, and the other part is pushed out through the back side.

After exchanging the shear pin the fork is mounted again

04.06.28. PM 919 Page 2.40

CHECK BEFORE FIRST STARTING UP AND AFTER REPAIR

- Oil level on gear box:

- Start and stop sequence of:

Pellet mill.
Oil lubrication system.
Conditioner.
Feed screw,

- Speed regulation of feed screw.

- Direction of rotation of:

Feed screw.
Conditioner.
Pellet mill,

- Tension of bolts for die mounting.

- Roller adjustment.

- Belt tensioning of belt drive on conditioner.

- Mounting of shear pin.

- Control of safety switches on conditioner, front door, inlet duct and shear pin collar.

- Control of speed guards for conditioner and forced feeder (if mounted).

- Grease lubrication. -Control the function of the automatic lubrication system.

-Relubricate other lubrication points in order on lubrication
chart

04.06.28. PM 919 Page 2.45

START AND STOP OF PRESS

Start the production, at first only with small material flow (man. starting up), until the holes
in the die are filled. Then open the steam addition gradually and slowly add more material,
depending on how well the die receives. Watch the amp. consumption on the main motor.
Material and steam is added until max. load on the press is reached.

Please note: Some time will pass before it is possible to see an influence of the
increase/decrease of the steam quantity.

Optimum production cannot be expected until the cascade mixer and the die reach the
operation temperature.

A possible addition of grease and molasses can be done, and the steam quantity can be
adjusted so that the required pellet quality can be reached.

Pay attention that vibrations, caused by blocked press channels, are not tolerated. The
content in the blocked holes might harden very quickly, and this is why interference should
be made, i.e. by adding hard oil-wetted pellets or grain (oats, cory). The overload system
will not in all cases prevent operating with a die with a certain number of blocked holes. In
this case the blocked channels must be cleaned by drilling.

After a sudden operation stop a quick re-start is important, as the risk of a total blocking of
material in the die is evident.

Stopping

Adjust the feed screw speed to 0. Open the inspection hatch of the material duct and add
oily material (pellets) in sufficient quantity to fill all press channels. This will facilitate next
starting up and prevent corrosion.

Check that all holes contain oily material (this can be seen of the colour). Any blocked
holes should be drilled out. Damaged hole edges in the die should be mended.

01.12.18. PM 919 Page 2.50

CHECK BEFORE STARTING UP AT DAYLY OPERATION

- Oil level on gear box:

- Grease lubrication system.

- Front door. The door is opened and inspected:

Dies, rollers, and the distance between these, wear.

- Bolt mounting of the die and stiffener ring

- Roller adjustment.

- Belt tensioning of belt drive on conditioner.

- Pellet knives.

- Cleaning of pellet chamber, inlet duct, conditioner and feed screw.

03.10.17. PM 919 Page 2.55

OIL LEVEL IN GEARBOX

Inspection glass for

visual inspection of gear
lubrication. Oil has to run
on inspection glass
during operation.

Inspection glass for

visual inspection of
oil and lubrication of
rear bearings

Maximum
Minimum

The oil level is marked for minimum and maximum.

The oil level must be inspected every day before start up and after repair

06.01.03. PM 919 Page 2.56

MAGNET IN GEARBOX

Magnet

The gearbox is equipped with a magnet for picking up metal filings. The magnet must be
cleaned once a week.

Contact immediately ANDRITZ SPROUT if there are many metal filings at the bottom
150 mm of the magnet.

06.01.03. PM 919 Page 2.57

CHECK DURING OPERATION

- Frequent control of lubrication systems.

- Control of pellet quality.

- Control of fines percentage.

- Listen for unusual noises.

- Temperature control.

- Control of steam and possible molasses/fat addition.

In case of clamp mounted die during operation it would be an advantage to prepare a new
die for mounting, i.e. mount the stiffener ring and the adaptor ring. This means that an
exchange can be done very quickly.

01.12.18. PM 919 Page 2.60

MAINTENANCE

Page
Maintenance diagram 3.1
Lubrication intervals – bolt mounted die - automatic lubrication 3.3
Manuel lubrication 3.4
Grease/oil types 3.10
Die crane 3.12
Blocking 3.15
Cleaning of the machine 3.20

03.10.17. PM 919 Page 3.0

03.10.17.
Oilchange gearbox
8000h/1 year
1. time 300h/1 month.
MAINTENANCE DIAGRAM

Cleaning of magnet
120 h/1 week

Grease for worm die

PM 919
hoist 500 h/1 month

General inspection o
Die hoist 8000h/1 year

Roller adjustment 120

h/1 week
2 years
3 years
4 years

1 week
1 month
2 weeks
2 months
3 months
4 months
5 months
6 months
7 months
8 months
9 months
10 months
11 months
12 months

Page 3.1
LUBRICATION INTERVALS – AUTOMATIC LUBRICATION

BOLT MOUNTED DIE

Oil filling

Oil consumption, gearbox: 1litre per 200 running hour.

Replenishment after 2000 running hour

Interval Lubrication
quantity
1 Oil change, gearbox 300 h or after ½ year (first time) 90 litre
OIL FORCE LUBRICATION SYSTEM
Oil change, gearbox 8000 h or once a year (sub-sequent) 90 litre
OIL FORCE LUBRICATION SYSTEM
3 Oil draining, gearbox At exchange (300/8000 h)
4 Grease, central lubric. Automatic, approx. 1 kg/24 h
5 Spec. grease roll pin At roller exchange
10 Grease, worm for hoist 500 h/1 month
winding

06.01.03. PM 919 Page 3.3

MANUAL LUBRICATION
The mill is designed with manual remote lubrication, which makes it possible to lubricate
rollers and bearings while the mill is running.
The manual remote lubrication is placed at the rear of the mill in the main shaft and
consists 4 lubricating fittings for lubrication of roller and front main bearing.

NOTE:

ALWAYS REMEMBER to clean

lubricating fittings and lubrication
pistol before the lubricating.

To avoid contramination make sure

that the lubrication containers are
closed.

Press roller

Front main bearing

Press roller Press roller

Interval Lubrication quantity

20 Grease, press roller Once every 4th hour 55 g per roller, approx
330 g per day
21 Grease, front main Once a day 42 gr.
bearing

01.12.18. PM 919 Page 3.4

GREASE TYPES

LUBRICANTS
MANUFAC- GREASE FOR PRESS ROLLERS GEAROIL FOR PRESS BOX
TURER
MINERAL SYNTHETIC

MOBILOIL MOBILGREASE XHP 222 MOBIL GEAR 629 GLYGOYLE HE220

SHELL ALBIDA EP 2 OMALA OIL 150 OMALA OIL HE220

KLÜBER STABUTHERM GH 461 KLÜBEROIL GEM 1-150 N KLÜBEROIL GH 6-220

KLÜBERFOOD NH1 64-422** KLÜBEROIL 4 UH1-220 N** KLÜBEROIL 4 UH1-220 N**

Foodgrade Foodgrade Foodgrade

LUBRICANTS RECOMMENDED BY THE OIL COMPANIES.

DO NOT BLEND MENTIONED GREASE AND OIL TYPES.

**REGISTERED USDA H1
(for food)

1) DO NOT BLEND WITH PG-OIL

05.03.10. PM 919 Page 3.10

BLOCKINGS

A blocking of the mill may have many reasons. Lacking adjustment of rollers, uneven
material distribution, worn roller/die, too large quantity of material, too high or too low meal
temperature, etc. Furthermore blockings in the shape of foreign bodies, such as stones,
bolts, nuts or the like may also occur.

At a normal blocking caused by overload the press main motor and the preceding
machinery stop. The overload protection is not necessarily activated, as when it is a matter
of blocking foreign bodies.

After a blocking it is necessary to free the die as quick as possible in order to avoid that the
material hardens and blocks the die holes. In order to free the die it is recommended to
dismount the feed cylinder and the distributors, as this will make more space available. The
blocked material is removed by suction or possibly with a chisel. However, pay attention
not to damage the die. After the cleaning the rollers and the die should be checked for
damages.

Before start-up the checklist for daily operation on page 2.55 should be consulted.

04.06.28. PM 919 Page 3.15

CLEANING OF MACHINE

For the sake of the function of the machine and the occurence of bacteria and micro
organisms, it is very important that the machine is frequently cleaned.

All parts in contact with the feed should be cleaned, e.g. the feed system, the conditioner,
the inlet duct, the front door and any ducting.

All clinging feed should be carefully removed as lacking cleaning may result in a pulsation
of the feeding, mixing at recipe change, blocking of the press, resulting from large, wet
lumps falling into the rollers, lumps of unpelleted material may be carried further into the
plant (cooler and sieve) and then end in the silos. Furthermore the doors and hatches
should be carefully cleaned as elsewise leaks may occur.

Finally the actual hygienic rules should always be kept.

01.12.18. PM 919 Page 3.20

DISMOUNTING

Page
Dismounting, scrapping 4.1

01.12.18. PM 919 Page 4.0

DISMOUNTING

Any demounting, either at moving or scrapping, must take place according to safety
regulations.

The demounting itself takes place in the opposite order of the mounting. It is important that
a component is properly hinged/supported before the bolt connections are loosened.

If the press framework is demounted from the base, it is important to demount rollers and
die, as the machine will elsewise become unstable (may turn over).

At a possible scrapping all environmentally harmfull parts must is isolated and sent to
destruction. This goes for:

Oil from gear motors.

Grease from lubricating automat and rollers.
V-belts.
Rubber from couplings, sealings etc.
The rest of the machine is cleaned and sent to a scrap dealer.

At re-mounting after a moving it is important to read section Installation in the instruction

book.

01.12.18. PM 919 Page 4.1

SPARE PARTS ORDERING

When ordering spare parts please state ID.NO. and ORDER NO. listed on the machine
tag.

Please fill in a copy of this page and fax a copy to ANDRITZ FEED & BIOFUEL A/S
att. Aftermarket.

Fax. +45 7216 0301

Tlf.: +45 7216 0300
E-Mail: andritzsprout.dk@andritz.com

Example:

Description Item Qty

Cylinder screw M24x45 004259 8
Front plate 045034 1

Description Item Qty

COMPANY
CONTACT PERSON
ADDRESS
PHONE
FAX NO.

MACHINE ID. NO.

ORDER NO.

PELLET MILL ID.NO.

ORDER NO.

06.03.09 PM 30 Page 5.05