BA 475-0143 en

Technical Machinery Documentation State: 03.
2012
Index of the operating BA 475-0143 en
instructions Page 1 of 1
State 03.2012 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BA 475-0143-01 en

* Introduction
* Explanation of symbols and references
* Field of application
* Copyright
State 03.2012 Safety and health . . . . . . . . . . . . . . . . . . . . . . . . . . .BA 475-0143-02 en
* Explanation of symbols and references
* Safety references
* Use as directed
Previous edition:
State 03.2012 Design and functioning . . . . . . . . . . . . . . . . . . . . . . . .BA 475-0143-03 en

* General description
* Design
State 03.2012 Transport and storage. . . . . . . . . . . . . . . . . . . . . . . . .BA 475-0143-04 en
* Safety
* Packing
* Degree of decomposition
* Sensitiveness
* Scope of supply
* Intermediate storage of roller press sub-assemblies
* Storage
* Dismantling and disposal
State 03.2012 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BA 475-0143-05 en
* General references
* Installation conditions
* Installation
* Preparation to the tests without material and the interlocking tests
* Tests without material and interlocking test without material
State 03.2012 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . .BA 475-0143-06 en
* Safety
* References
* Trial run with feed material
* Sampling
* Miscellaneous
* Electrical monitoring systems
State 03.2012 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BA 475-0143-07 en
* Safety
* Normal operation
* Pressing device
* Feeding device
* Shutting down the roller press
* Starting the roller press after EMERGENCY-OFF disconnection
Modifications in this edition:
* Changing the roller speed

* Behaviour upon failures
* Measures prior to and after an extended standstill
* General to the sequence of measuring, controlling and interlocking
* Checklist failures
State 03.2012 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BA 475-0143-08 en
* Maintenance and inspection
* Repair
State 03.2012 Spare-parts keeping and after-sales service. . . . . . . . . . . . .BA 475-0143-09 en
* Spare parts keeping
* After-sales service addresses
Technical Machinery Documentation State: 03.2012
General BA 475-0143-01 en
Page 1 of 3
Contents
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Explanation of symbols and references. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Field of application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Previous edition:
1. Introduction
This information has been written for being read and observed in all items by those
responsible for the Humboldt-Wedag roller press and for the persons who perform works
on this machine.
The complete technical documentation must always be kept near the roller press.
Particular details on the use of the roller press are pointed out in these operating
instructions.
Only with knowledge of these operating instructions, a trouble-free operation of the roller
press can be ensured. Therefore, it is very important that these operating instructions are
really know to the persons in charge.
The manufacturer will not be liable for defects and operational failures caused by the non-
observance of these operating instructions.
If problems should occur during operation, please contact our after-sales service or the
spare parts department or one of our representations; they will be readily prepared to
assist you (see chapter "Spare parts keeping and after-sales service").
The present operating instructions only refer to the roller press.
Compared with representations and data in these operating instructions, we reserve
the right to technical modifications necessary to improve the roller press.
Note!
The illustrations are not binding for the execution!

Page 2 of 3; BA 475-0143-01 en
General
2. Explanation of symbols and references
2.1 Safety symbol
This symbol is found at all safety references in these operating

instructions regarding risks for limb and life of persons. Observe
these references and behave most carefully in such cases. Also
inform all other users of these safety references. Beyond the
references given in these operating instructions, the generally
applicable regulations regarding safety and accident prevention
must be considered.
2.2 Attention reference
Caution!
This reference is found in these operating instruction at items to

be particularly observed so that directives, instructions,
references and the correct curse of the works are observed and
damage to or the destruction of the machine and/or other plant
sections are avoided.
2.3 Reference
Note!
This reference draws your attention to general operating

instructions which must be particularly observed.
2.4 Ear protection reference

instructions where, due to the influence of noise, a hearing damage
can develop. Observe this reference and absolutely wear your
personal protection aids, e.g. ear protection.
Page 2 of 3; BA 475-0143-01 en
BA 475-0143-01 en; Page 3 of 3
General
3. Field of application
Caution!
The roller press has been designed only for the field of
application indicated under "Customer-specific characteristic and
technical data / Field of application".
Prior to using the roller press beyond the contractually agreed

field of application (see chapter "Customer-specific characteristic
and technical data / Field of application"), the after-sales service
of the KHD Humboldt Wedag AG (for address, see chapter
"Spare-parts keeping and after-sales service) must be consulted
as, otherwise, the warranty will lapse.
4. Copyright
The copyright to these operating instructions remains with the Humboldt Wedag GmbH. These
instructions are meant for the installation-, operating- and supervision staff. It contains rules and
drawings of technical nature which must, nor completely nor partly, be multiplied, distributed or
used without authorization for competition purposes or disclosed to others, unless expressly
approved. The non-observation of the above will entail damages.
Humboldt Wedag GmbH

Colonia-Allee 3
51067 Köln
Germany
Phone: +49 (0)221 6504-0

URL: http://www.khd.com
BA 475-0143-01 en; Page 3 of 3

Safety and health BA 475-0143-02 en
Page 1 of 5
Contents Page
1. Explanation of symbols and references. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Safety symbol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Attention reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Ear protection reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Safety references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 General safety references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Previous edition:
2.2 Safety references for persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.3 Safety references for machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Use as directed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. Explanation of symbols and references
1.1 Safety symbol
This symbol is found at all safety references in these

operating instructions regarding risks for limb and life of
persons. Observe these references and behave most
carefully in such cases. Also inform all other users of these
safety references. Beyond the references given in these
operating instructions, the generally applicable regulations
regarding safety and accident prevention must be
considered.
1.2 Attention reference
Caution!
This reference is found in these operating instruction at

items to be particularly observed so that directives,
instructions, references and the correct curse of the works
are observed and damage to or the destruction of the
machine and/or other plant sections are avoided.
Page 2 of 5; BA 475-0143-02 en
Safety and health
1.3 Reference
Note!
This reference draws your attention to general operating

instructions which must be particularly observed.
1.4 Ear protection reference

instructions where, due to the influence of noise, a hearing damage
can develop. Observe this reference and absolutely wear your
personal protection aids, e.g. ear protection.
2. Safety references
2.1 General safety references
• The roller press has been built according to the proven technical standards and is
operationally safe. However, the machine may cause dangerous situations, if it is improperly
operated by untrained staff or if it is not used for the specified application or if it is not
commissioned and operated as directed.
• In addition, the safety references of the suppliers as per suppliers' documentation must be
observed (see section "List of the separate documentations").
• The competences for assembly, disassembly or re-installation, commissioning, operation and

maintenance must be clearly determined and observed to avoid unclear competences under
the aspect of safety.
• During any works regarding installation, dismantling and reinstallation, commissioning,

operation, conversion, matching and maintenance, observe the disconnection and safety
procedures laid down in the Technical Machine Documentation.
• Operating modes which would jeopardize the safety of the roller press or of persons working
near it must be avoided.
• On the user's premises, cleanliness and clearness in the area of the roller press must be
ensured by suitable directives and checks.
• Unauthorized conversions and changes influencing the safety of the roller press are not
admissible.
• Platforms, ladders, stairs etc. must be kept free from contaminations.
• For the operation of the roller press, in any case, the local safety and accident prevention
regulations will apply.
Page 2 of 5; BA 475-0143-02 en
BA 475-0143-02 en; Page 3 of 5
Safety and health
2.2 Safety references for persons
• The roller press may only be mounted, operated, maintained and repaired by authorized,
trained and familiarized staff. This staff must have received a special training on the possible
dangers by the person responsible for a specific working area.
• Any person who, on the premises of the operator, is in charge of assembly, dismantling and
reinstallation, operation and maintenance (inspection, maintenance, repair) of the roller press
must have read and understood the complete operating instructions and, in particular, the
"Safety" instructions and the respective chapter-related safety references.
Caution!
It is recommended to the operator to have this confirmed in

writing in every individual case.
• The operating staff is obliged to immediately give notification of changes occurring to the
roller press which affect its safety.
• The operator has to oblige himself to always keep the roller press in a proper condition.
• Works at the hydraulic and electrical facilities may only be executed by skilled personnel.
Wear the prescribed personal ear protection.
Wear protective clothing.
BA 475-0143-02 en; Page 3 of 5

Page 4 of 5; BA 475-0143-02 en
Safety and health
2.3 Safety references for machinery
• Prior to starting the works, safeguard the drives and auxiliary devices against undesired
connection. This is possible with the lockable local switch (see section "Operation / Safety
disconnection").
• Generally, upon all works requiring to enter the roller press or concerning the rollers, not only
all main switches of the motors must be set to "OFF" and the main fuses be isolated, but also
the local switch must be locked.
• The instruction to disconnect or connect the main fuse must be given in writing and
countersigned by the responsible electrician after completion of the works.
• Guards, flaps and doors as well as parts of the platform and cover plates of the lining and
feeding device are only permitted to be opened or removed upon a standstill of the secured
drives.
• Prior to starting after repairs, check, whether all guards, flaps and doors as well as parts of the
platform and cover plates of the lining and feeding device are mounted.
• The general safety regulations for the handling of lifting equipment and the transport of loads
will apply.
• The carrying capacity of the lifting facilities must at least correspond to the weight of the
heaviest individual element to be lifted (refer to "Customer-specific characteristic and
technical data").
• Only suitable and properly functioning lifting tools may be used.
• Install the specified falling guards for platforms, landings, maintenance platforms etc.
• For transporting and dismantling or installing of the individual roller press components, use
the slinging points indicated in the descriptions of the individual sub-assemblies.
• After the installation or repair of electrical components, test the protective measures applied
(e.g. earthing resistance).
• Regularly check warning paintings and renew them, if necessary.
• All warning information for the roller press must be kept complete and in legible condition.
• Observe the intervals specified for maintenance and inspection (refer to section
"Maintenance/Maintenance and inspection list") and have these works performed only by
skilled staff.
• Only use genuine spare parts, as these meet the technical requirements of the manufacturer.
If other spare parts are used, a warranty cannot be claimed.
• Generally, all works at the roller press must be carried out during a standstill only and with the
machine being safeguarded.
• Upon works to be done at the hydraulic system, make sure that, prior to opening a hydraulic
line or another hydraulic element, the hydraulic system is pressureless.
Page 4 of 5; BA 475-0143-02 en
BA 475-0143-02 en; Page 5 of 5
Safety and health
• In case of failures occurring on design-tested pressure limiting valves, repairs must not be
made.
• During operation, guards at the machine must be in their protecting position.
For filling the reservoirs, only nitrogen may be used and, by no

means, oxygen or air.
Risk of explosion!
3. Use as directed
• The roller press is only permitted to be used under the conditions specified in section
"Customer-specific characteristic and technical data / Field of application".
• Any use beyond the specification is considered not as directed. The manufacturer will not be
liable for resulting defects; the risk is exclusively borne by the operator.
• For example, a damage source is exceeding of the admissible oil pressure in the pressing
device (see section customer-specific characteristic and technical data). Higher pressures are
not necessary for the process; they affect the machine, in particular the roller surface, and
favour the development of wear.
• The use as directed also comprises the observation of the instructions of the manufacturer
regarding the conditions for installation, dismantling and reinstallation, commissioning as well
as for operation and maintenance and other directives given in the Technical Machine
Documentation.
BA 475-0143-02 en; Page 5 of 5

Design and functioning BA 475-0143-03 en
Page 1 of 19
Contents Page
1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.1 Frame (order group 11). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.1.1 Roller enclosure (order group 32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.1.2 Operating platform (order group 48) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.2 Roller support (order group 12). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Previous edition:
2.2.1 Antifriction bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2.2.2 Sealing, lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.2.5 Central grease lubrication of the labyrinths (order group 15) . . . . . . . . . . . . . . . . . . . . . . .8
2.2.6 Accompanying heating for the central lubrication of the labyrinths (order group 16) . . . . .9
2.2.7 Bearing guiding (order group 82) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.2.8 Temperature monitoring, bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.3 Roller (order group 21/24). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.3.1 Pressing device (order group 27) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.3.2 Rubber thrust bearing (Order group 81) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.3.3 Resetting unit (Order group 80) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.3.4 Water cooling for roller (order group 34/35) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.4 Drive with articulated shaft (order group 36) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.4.1 Planetary plug-on gear with oil cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.4.2 Safety clutch with articulated shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.4.3 Torque supports (order group 38) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.4.4 Maintenance drive with chain sprocket (order group 44) . . . . . . . . . . . . . . . . . . . . . . . . .14
2.4.5 Guard (order group 46, 47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2.5 Feeding device (order group 29/30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2.6 Electrical measuring instruments (order group 33) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.6.1 Roller gap monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.6.2 Roller limit disconnection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2.6.3 Rotation monitoring / standstill monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2.6.4 Standstill- and temperature monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2.6.5 Temperature monitoring at the main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2.6.6 Lubrication monitoring of the main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2.6.7 Feed material - temperature measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2.7 Assembly- and repair tools and accessories (order group 50) . . . . . . . . . . . . . . . . . . . . .17
2.7.1 Assembly device gear (order group 75) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2.7.2 Roller displacing device (order group 85) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2.7.3 Transport carriage for roller with support (order group 86) . . . . . . . . . . . . . . . . . . . . . . . .19
Page 2 of 19; BA 475-0143-03 en
Design and functioning
1 General description
For survey over the order groups, see following illustration.
The new generation of the Humboldt Wedag roller press, below referred to as RP, is based on
the practical experience of many years considering the results of extensive studies made by
research and development.
Roller presses are designed for the comminution of medium to hard materials of coarse and fine
grain size. Roller presses are used in the cement and minerals area and their design is matched
to these applications.
The machine described here is a horizontal roller press with gravity feeding, i.e. the rollers are
arranged horizontally in the frame and the feed material is vertically fed to the roller gap by the
dead weight of the material.
Page 2 of 19; BA 475-0143-03 en

BA 475-0143-03 en; Page 3 of 19
2 Design
BA 475-0143-03 en; Page 3 of 19

Page 4 of 19; BA 475-0143-03 en
Item (TPG) No. Sub-assembly
11 Frame
12, 82 Bearing and bearing guide
13, 14 Oil circulation lubrication, accompanying heating
15, 16 Central lubrication, accompanying heating
21/24 rollers
27 Pressing device
29/30 Feeding device
32 Roller enclosure
33 Measuring instruments
36 Drive
38 Torque support
39 Accessories
44 Maintenance drive
46, 47 Guard
48 Operating platform
75 Gear dismantling device
77 Bridge frame
80 Re-setting device
81 Rubber pressure bearing
85 Roller displacement device
Note!
As a supplement to the description in this chapter, we

recommend also to read the description in the supplier’s
documentation (see section "List of the separate
documentations").
The pictures shown are partly simplified and not true to scale;
they are not binding for the execution.
Page 4 of 19; BA 475-0143-03 en

BA 475-0143-03 en; Page 5 of 19
2.1 Frame (order group 11)

The machine frame comprises several welded elements connected among them with screws and
bolts. The rollers with support, one of them designed as floating roller with hydraulic support, the
other one as fixed roller, are floatingly guided in the frame at low friction.
The closed frame takes over the pressing forces in radial and axial direction.
On the fixed roller side, the frame can be easily and rapidly opened so that the rollers with
support can be slid into an off the frame over the sliding paths (rapid roller change).
Pressing cylinder, feeding device, roller lining and other components are arranged at the frame.
Note!
Also refer to Technical Data in section "Customer-specific

characteristic and technical data".
2.1.1 Roller enclosure (order group 32)
The rollers are enclosed by a sheet casing. Doors at the front side permit to check the roller
surface and to measure the roller wear upon a standstill of the machine. Minor repairs, e.g.
break-outs at the roller surface (possible consequence upon the passage of foreign bodies) can
be repaired locally.
To perform the regeneration welding of the roller surface, the upper covers can be dismantled
(see chapter "Maintenance", only applicable for CHF-rollers).
The enclosure is designed such that it ensures a completely even platform. Moreover, the lining
is designed such that a good access to the roller front sides is ensured.
The roller lining comprises different individual components so that it may be easily mounted and
dismantled.
The lateral wall with a door on the fixed roller side can be folded down with the aid of a rope hoist
(not included in the scope of supply).
2.1.2 Operating platform (order group 48)
For reasons of safety, for the operating- and maintenance staff, an operating platform has been
provided for comprising chequered plates, railing and the access ladder with safety yoke to
ensure a safe access to the roller press.
Secured maintenance platforms are provided for in front of the doors of the enclosure on the
front side.
BA 475-0143-03 en; Page 5 of 19

Page 6 of 19; BA 475-0143-03 en
2.2 Roller support (order group 12)
2.2.1 Antifriction bearing
On each roller side, one four-line cylindrical roller bearing is installed. Cylindrical roller bearings,
compared with self-aligning roller bearings, have smaller dimensions at identical load rating and
can be better sealed against emerging oil, since they do not permit turning movements.
On the fixed bearing side (opposite side to the drive), two axial self-aligning roller bearings are
arranged in X-shape for taking the axial forces.
An axial displacement of the roller upon expansion and oblique position is possible in the floating
bearing (drive side) between bearing inner ring and friction bodies.
2.2.2 Sealing, lubrication
On either side, the bearings are provided with one twin seal, each.
The twin seal comprises 2 radial shaft sealing rings arranged back to back with the lantern ring
installed between them.
The inner one of the two radial shaft sealing rings seals against emerging oil, the outer one
against the ingress of dirt and grease from the outside.
The lantern ring permits to return leakage oil from the space between the two seals via a
ventilated leakage oil line into the return line of the lube oil circuit.
On the bearing inner side as well as on its outer side, a labyrinth is installed in front of the twin
seals. Bearing inner side means the side of the bearing which shows towards the machine
interior. Accordingly, the bearing outer side is the side on the outside of the machine.
These labyrinth gaps are completely enclosed on the outer sides of the bearing and are supplied
with a very little grease volume only to avoid running dry of the seals.
The labyrinths on the bearing inner side are lubricated with grease via a central grease
lubrication system. Then, excessive grease emerges to the outside and forms a closed grease
collar at the ring gaps. A continuous grease supply into the gaps arranged in front of the outer
radial sealing ring forms an effective seal against the ingress of dirt into the labyrinth gap.
Emerging grease is scraped off and collected in the grease collection boxes provided for that
purpose.
A V-ring seal is integrated on the labyrinth on the bearing inner side as an additional dust guard.
In front of this grease-lubricated labyrinth, a dust labyrinth is connected as primary seal.
Negative pressure in the inner space of the enclosure caused by a sucking phenomenon
underneath the roller enclosure generates a continuous air flow through defined gaps between
enclosure and roller and avoids that dust can emerge from the enclosure to the outside.
This design is especially meant for avoiding heavy dust loads on the inner labyrinth.
Page 6 of 19; BA 475-0143-03 en

BA 475-0143-03 en; Page 7 of 19
2.2.3 Oil circulation lubrication system (order group 13)
The lube oil supply system essentially comprises:

• Oil supply set with
– Container with return and supply chamber
– Return and supply pump (pumps are identical)
– Bypass filter behind the return pump (twin filter reversible with high dirt-retention
capacity)
– Tank heating for heating up the oil to operating temperature
– Oil cooler for back-cooling the oil to operating temperature
– Oil collection basin underneath the set
– Terminal box, wired,
• Volumetric flow indicator for splitting and indicating the lube oil flow,
• Piping, connection hoses with quick-acting couplings for rapid dismantling and mounting,
• Leakage oil return
• Electrical monitoring of oil volumes, oil temperatures, filter contamination and tank filling
levels.
• Accompanying heating for keeping the temperature of the lube oil in the return lines
(Order group 14)
The lube oil supply system serves for the continuous supply of the antifriction bearings with
filtered lube oil of the specified temperature.
Advantages of an oil circulation lubrication:
• improved transporting off of solid particles
• Permanent filtering out of the solid particles via a reversible twin filter.
• With an oil circulation lubrication, the heat volume generated by the antifriction bearing is
directly dissipated (good cooling effect by cooling of the bearings via the lube oil)
• Optimal lubricant distribution: The antifriction bearing lubrication is managed better with an oil
circulation lubrication than with a grease lubrication (e.g. cylindrical roller bearing with pin-
type cage).
• very long lubricant changing intervals upon regular quality control of the oil
- reduced operating costs, reduced maintenance requirement
• Filter change during operation of the roller press thanks to reversible twin filter with electrical
contamination indication.
The oil circulation set is installed in a closed low-dust room (service room) directly underneath
the roller press and together with the barrel pump and the hydraulic set.
For a more rapid dismantling and mounting of the rollers with bearing, the lubricating connections
comprise quick-acting couplings.
The required oil volumes must be taken from the lubricating list.
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Note!
Also refer to the enclosed suppliers' documentation in section

"List of the separate documentations".
2.2.4 Accompanying heating for the oil lubrication (order group 14)
As standard equipment for the oil lubrication system, an accompanying heating for the supply
and return pipeline is included in the supply. It comprises heating cables fastened to the
pipelines and the necessary monitoring systems and temperature gauges for controlling the
temperature.
The necessary insulation of the heated piping is made by the customer (see section "Customer-
specific characteristic and technical data).
2.2.5 Central grease lubrication of the labyrinths (order group 15)
The electrically monitored and controlled automatic central grease lubrication essentially
comprises:
• the grease lubrication pump with barrel,
• the pump elements,
• the progressive distributors,
• the hose lines with connection screw unions and the quick-acting couplings for a more rapid
dismantling and mounting.
• Wall-mounted crane for lifting the barrel pump upon a change of the grease barrel
• Electrical monitoring of the lubricant flow and of the barrel filling level.
The central lubrication continuously supplies the progressive distributors via the barrel pump.
From there, according to the grease volumes required for the labyrinths, the grease is reliably
distributed to the individual lubricating points.
For a more rapid dismantling and mounting of the rollers with bearing, the lubricating connections
comprise quick-acting couplings.
The required grease volume may be taken from the lubrication list (see section "Customer-
specific characteristic and technical data").
Caution!
Lifting of the grease barrels with the wall-mounted crane is not

permitted.
Note!
Also refer to the enclosed suppliers' documentation in section

"List of the separate documentations".
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BA 475-0143-03 en; Page 9 of 19
2.2.6 Accompanying heating for the central lubrication of the labyrinths

(order group 16)
The accompanying heating for the central lubrication comprises:

• Barrel bottom heating
For the barrel bottom heating, a heat source is mounted underneath the barrel.
Pipeline heating
For the pipeline heating, heating cables are fastened to the pipelines and heat the lubricating line
in this area.
Suitable monitoring systems and temperature sensors to control the temperature are included in
this sub-assembly.
The necessary insulation of the heated piping is made by the customer (see section "Customer-
specific characteristic and technical data).
2.2.7 Bearing guiding (order group 82)
The sub-assembly "bearing guiding" comprises two functional groups:

1. Horizontal, low-friction sliding of the hydraulically supported floating roller in the frame thanks
to the slide pair of Teflon / polished chromium plate.
Teflon slide plates sub-divided into chambers are fastened on top and at the base of the
bearing housings. Polished chromium plates tacked or bolted to the frame serve as mating
slide surfaces.
The slide plates sub-divided into chambers (wear component) can be replaced - in installed
condition of the rollers in the frame with support.
2. Outer guiding, two units at the fixed bearing and one at the floating bearing.
The outer guiding axially keeps the rollers in position in the frame and directs the axial forces
into the frame. Moreover, the outer guiding permits the horizontal movement and the oblique
position of the floating roller in the frame.
The outer guidings as well are equipped with the slide pair Teflon / polished chromium plate.
2.2.8 Temperature monitoring, bearing
Resistance thermometers screwed into the load zone of the bearing monitor the temperature of
the antifriction bearings.
With an oil lubrication, the support is cooled by the oil proper and with a grease lubrication by
ducts in the bearing housing rinsed with water.
2.3 Roller (order group 21/24)

The roller surface is provided with a stud lining where material is depositing between the studs
and is such forming an autogenous wear protection.
The roller surfaces are subjected to wear and must be regularly (monthly) measured with a
measuring template. The new condition of the roller has already been measured and entered
into the wear point measuring log (see section "Customer-specific characteristic and technical
data").
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For documenting the wear rate, the measurements to be made monthly must also be noted in
the wear point measuring log. The procedure for measuring with the template is described in
chapter "Maintenance".
The roller front sides are provided with a hardfacing which must be regularly checked and re-
welded.
Caution!
The roller front surfaces are excluded from the wear warranty
given for the surface with stud lining.
Note!
The first wear measurement (zero measurement) of the roller

surface must be made after 8 operating hours. The measured
values are documented in the protocol of wear measuring points.
For the measuring procedure, see chapter "Maintenance"
The filled in protocol of wear measuring points has to be sent via

e-mail to the Humboldt Wedag project manager.
2.3.1 Pressing device (order group 27)
The pressing device essentially comprises

• the flat cylinders,
• the control blocks with reservoirs,
• the hydraulic starting system,
• the intermediate tank,
• the pressure control,
• the hydraulic pump set.
Together with the hydraulic accumulators (reservoirs), one horizontally arranged flat cylinder,
each, forms an enclosed hydro-pneumatic resilient system. The flat cylinders transmit the
pressing forces onto the floating roller and preload the system in this way. Counter-movements
of the floating roller are transmitted to the hydraulic reservoirs as pressure.
Note!
Also refer to the Technical Data, section "Customer-specific

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2.3.2 Rubber thrust bearing (Order group 81)
Every rubber pressure bearing comprises the intermediate piece, the pressure element and the
rubber plate. These parts are flexibly bolted together to form one unit.
Functioning rubber pressure bearing floating roller side:
1. The rubber pressure bearing on the floating-roller side can balance the slight angular
movements originating from the oblique position, if any, of the floating roller.
2. The rubber pressure bearings ensure a homogeneous load distribution onto the antifriction
bearings which positively influences the service life.
Functioning rubber pressure bearing fixed roller side:

1. The rubber plates in the rubber pressure bearings balance manufacturing tolerances and
ensure a homogeneous load distribution onto the antifriction bearings which positively
influences the service life.
2. In the basic execution (new condition), with the aid of spacer plates, the order-dependent zero
gap (minimal distance between the roller surfaces floating roller to fixed roller) can be preset.
Caution!
Generally, it must be made sure that the rollers cannot touch each
other.
Caution!
The roller gap monitoring system must be set according to the

zero gap.
Note!

2.3.3 Resetting unit (Order group 80)
The resetting device comprises various spacer plates and spacers.

The resetting unit has two functions:
1. In the basic execution (new condition), with the aid of spacer plates, the order-dependent zero
gap (minimal distance between the roller surfaces floating roller to fixed roller) can be preset.
2. In case of wear of the rollers, these shall be reset by replacing spacer plates of different
thickness and spacers to reach again the zero gap adjusted upon the basic setting.
Resetting can be done on either side up to 40 mm.
(also see rubber pressure bearing, order group 81)
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Page 12 of 19; BA 475-0143-03 en
Caution!
Generally, it must be made sure that the rollers cannot touch each
other.
Caution!
The roller gap monitoring system must be set according to the

zero gap.
Note!

2.3.4 Water cooling for roller (order group 34/35)
(if included in the scope of supply)

The lines for the water cooling of the roller are pre-assembled on a frame. The frame is fastened
to the foundation and the connections connected with the respective supply systems.
The cooling water outlet temperature from the roller is limited to min. 50? by a fixedly set
thermostat valve. This avoids an excessive temperature deviation in the roller.
Note!
for warranty claims:

A chemical analysis of the cooling water should be made for the
first time when beginning the first starting up, then every 5000
hours and finally every half year. Moreover, an according
assessment of the water regarding its corrosive aggressiveness
should be available. This analysis must be made by an
independent institute including a respective protocol. The results
must be made available to the Humboldt Wedag GmbH during the
warranty time.
In case of non-observance, warranty claims are null and void.
To determine the causes in a damage case outside the warranty

period, this procedure should be continued by the plant operator
filing the pertaining documents.
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BA 475-0143-03 en; Page 13 of 19
2.4 Drive with articulated shaft (order group 36)

The drive is sub-divided into:
• Planetary plug-on gear with oil cooling
• Coupling with articulated shaft
• Main drive motor (normally provided by the customer).
Each of the rollers is individually driven via main drive motor, cardanic shaft, coupling and
planetary plug-on gear. The planetary plug-on gear is plugged onto the drive journal of the roller
and fastened with a shrinking disc. The reaction forces of the drive torque are taken by the
torque support described under item 2.4.3.
2.4.1 Planetary plug-on gear with oil cooling

The planetary plug-on gear is a multi-stage, compact and sturdy gear .
The gear oil is cooled by preheater and gear oil pump. The oil circuit is controlled via temperature
monitoring systems.
2.4.2 Safety clutch with articulated shaft

The articulated shaft serves for transmitting the force from the stationary drive motor via the
coupling to the gear. It balances assembly imprecisions and permits the required displacement
movement of the hydraulically supported movable roller (floating roller). As overload protection of
the drive, a safety clutch is mounted to the gear input shaft
2.4.3 Torque supports (order group 38)
The torque supports essentially comprise:

• Support
• Torsion shaft
• Gear holder
• Bearing housing
The planetary plug-type gear arranged on the roller shaft in an overhung manner requires a
support of the reaction forces from the gear power take-off torque. This is realised via the gear
holder connected to the torsion shaft via two columns.
The special two-arm support offers the advantage that the roller support as well as the gear shaft
support are freed from any cross-acting forces in radial direction except for the weight forces.
The torsion shaft absorbs shocks and torque deviations.
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2.4.4 Maintenance drive with chain sprocket (order group 44)
With frequency-controlled motor and remote adjustment.

For turning the rollers:
- upon welding, grinding and measuring of the roller surfaces.
The remote adjustment permits the connection and disconnection as well as the speed
adjustment of the rollers over a distance.
2.4.5 Guard (order group 46, 47)
Group 46: A closed, dust-tight cover between the floating bearing and the gear holder is
meant for the following:
- Cover for the rotary parts
- Dust protection for the labyrinth gap
Group 47 Protective box for coupling and articulated shafts
2.5 Feeding device (order group 29/30)

The feeding device arranged above the roller gap essentially comprises:
• the housing and the chute,
• the lateral walls for covering the front sides of the rollers,
• the lateral wall tips,
• the suspensions of the lateral walls,
• the brackets for taking the pressure bolts with spring plate package and
• the gate.
The shaft with frame is joined to the feed elements of the plant.
The lateral wall cover the front area of the two rollers rotating towards each other. Considering
the material friction, the lateral walls and the chute are lined with low-wear sheets.
The lateral wall tips are fitted with hard metal and can also be replaced.
If the roller position is correct (in parallel, flushing at the front side and rectangular to the
longitudinal machine axis), the headwalls are not in contact with the roller faces. A minimum gap
must exist (about 1 mm). The lateral wall tip is adjusted to a gap measure of 10 mm.
The gap is adjustable and may be readjusted for balancing wear.
Upon oblique setting of the floating roller, the movably suspended lateral walls are horizontally
displaced against a pressure bolt preloaded with plate springs. In the upper area, a screw spring
support is sufficient considering the smaller forces.
Setting values for the spring preloading forces as per section "Customer-specific characteristic
and technical data".
Note!
See Technical Data in section "Customer-specific characteristic

and technical data".
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BA 475-0143-03 en; Page 15 of 19
With the gate, the feed material guiding is influenced and, thus, an optimal flake thickness set.
The gate is equipped with a gate extension which can be dismantled. In this way, the gate length
can be matched to the requirements of the process.
The locking flaps are only permitted to be opened for

maintenance purposes upon a standstill of the rollers and with
empty shaft!
2.6 Electrical measuring instruments (order group 33)

The order group "Electrical measuring instruments" is sub-divided into:
• Roller gap monitoring
• Roller limit disconnection.
• Rotation monitoring at the shrinking disc
• Standstill and temperature monitoring at the turbo coupling (if included in the scope of
supply)
• Temperature monitoring at the main bearings
• Lubrication monitoring of the main bearings
• Feed material temperature measurement (if included in the scope of supply)
In view of the risk of damage during transport and assembly, the complete Order group 33"Feed
material temperature measurement" is included in the supply separately packed.
2.6.1 Roller gap monitoring

The roller gap monitoring comprises:
• Transsonar way transmitter
• Connection bracket
• Optical indication
The roller gap monitoring is meant for continuously indicating the roller gap generated during
operation via an evaluation and indication instrument (this instrument not being part of the scope
of supply. If the optimum roller gap is exceeded or fallen below or in case of an oblique position
of the floating roller, a correction may be made via the pressing device.
The way transmitters (way pick-ups) are fastened to the frame as one unit, each.
The pointers with the switching lugs are bolted to the bearing housings of the floating roller.
Via an optical indication (plate with pointer), it can be recognised at the roller press direct, in
which position are the pistons of the flat cylinder. If it is indicated that the pistons are working
within the red range, the roller press must be disconnected in view of the risk that the pistons can
fall off the cylinders.
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2.6.2 Roller limit disconnection.

The two inductive approximation switches which are mounted to the unit roller gap monitoring/
roller limit disconnection, together with the switch vanes fastened to the bearing housing of the
movable roller, represent an additional guard for the roller press against inadmissible load
(passage of foreign bodies) or an excessive feed volume.
If, upon displacement of the movable roller, a bearing housing should exceed the specified
working area, the switch vane moves into the switching area of the approximation switch. The
main drives are disconnected. To brake the masses, a residual disconnection path of 10 mm is
available. Thus, an increase of the drive torque up to the tilting moment of the motor is avoided.
2.6.3 Rotation monitoring / standstill monitoring

An inductive approximation switch mounted at the guard for the shrinking disc is triggered by a
bolt head at the hydraulic shrinking disc. This signal serves for monitoring the rotation of the
roller (standstill monitoring).
2.6.4 Standstill- and temperature monitoring

In the guard underneath the fluid coupling, an electric pick-up is mounted recording the rotary
movement and the temperature of the coupling via a transmitter.
2.6.5 Temperature monitoring at the main bearings

By means of four resistance thermometers (4 PT 100), the temperatures of the antifriction
bearings of the roller press are measured. Setting values for alarm and disconnection as per
section "Customer-specific characteristic and technical data".
2.6.6 Lubrication monitoring of the main bearings

The lube oil volume is optically and electrically monitored. If the set value of a volumetric flow
indicator is fallen below or the indicator should fail, a failure message is released. After one
minute, the preliminary pump is disconnected and after 15 minutes the roller press shut down.
The labyrinth lubrication is monitored by two approximation switches. These switches count the
strokes (cycles) of the delivery pistons in the progressive distributors. If the specified minimum
number of cycles is not achieved, a failure message is released. After a period of 6 hours, the
roller press is shut down, if the failure is not eliminated up to then.
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BA 475-0143-03 en; Page 17 of 19
2.6.7 Feed material - temperature measurement

(Temperature monitoring of the rollers, not for single-material rollers)
Two resistance thermometers bolted to the lateral wall of the feeding device indicate the
temperature in the roller gap; this approximately corresponds to the temperature at the roller
surfaces.
There are two alarm points in the monitoring system:
1. Alarm at 100 ?.
After this failure indication, counter-measures should be taken to avoid that the temperature
further increases.
2. Alarm at 120 ?.
The critical temperature has been reached. From this temperature, the operational safety of the
joint between bandage and shaft is jeopardized. The roller press is slowed down.
(if included in the scope of supply.)
2.7 Assembly- and repair tools and accessories

(order group 50)
For performing and facilitating assembly- and repair works, the following tools and accessories
will serve:
• Suspension device for displacing and lifting of the rollers with complete support.
• Hydraulic pump with accessories for the hydraulic shrinking disc at the drive and the
clamping device for the frame screws (only for type RP).
• Filling- and testing device for filling the reservoirs.
• Nitrogen charging system (if included in the scope of supply).
• Suspension device for hydraulic flat cylinders.
• Suspension device for the rubber thrust bearings.
• Hydraulic loading device for frame bolts.

(omitted for type RP-S)
• Measuring device for wear measurement on the roller surface
• various slinging whirls.
• Setting tool for the lateral walls of the feeding device (depending on the design of the
pressing device).
• Parts set for aligning the roller front side.
• Mounting and dismantling device for the fluid coupling (if included in the scope supply).
• Hydraulic screw driver for gear screws (if included in the scope of supply).
• Pipe cutter for the simpler installation of the pipelines (if included in the scope of supply)
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2.7.1 Assembly device gear (order group 75)

The mounting and dismantling device for gears essentially comprises:
• a supporting frame
• a suspension scaffolding
• one basin
• one travelling device with cylinder holder and lifting units (500 bar)
• two forcing girders, frame side, incl. hydraulic cylinder (500 bar)
• a hand pump with 2-fold connector for the frame-side hydraulic cylinder 500 bar
• a hand pump with 3-fold connector for lifting units of hydraulic cylinder 500 bar
A stationary lifting facility or a mobile crane are only required for transporting the gears to and off
the site.
The gear dismantling device serves for mounting and withdrawing the planetary gear with
shrinking disc connection (positive connection) from the roller drive journal.
The design is characterized by it that the gear axle and the shaft axles can be exactly aligned
horizontally and vertically to each other thanks to hydraulic lifting units which can be
independently triggered. In this way, jamming of the gear hollow shaft to the roller drive journal
and, thus, damage to the fittings seats is avoided.
This is a main characteristic compared with dismantling and mounting with a gear suspended in
a crane. Here, a horizontal alignment of the gears is difficult, as the suspension points of the
gears are not in the center of gravity).
After having been withdrawn from the shafts, the mobile gears lying on the basins remain in their
„parking position“ on the supporting frames ready for being installed again.
Thus, the most important preconditions for a rapid and safe mounting and dismantling of the
gears without crane are fulfilled with, at the same time, a drastically minimized risk of damage for
the pressing fits.
2.7.2 Roller displacing device (order group 85)
The roller displacement device serves for mounting and dismantling of the rollers. It is a rigid
connection between transport carriage and roller press.
The roller displacement device comprises the following:
• Steel girder structure with friction carriage for the low-friction displacement of the roller with
support
• Slinging holder for rope guiding
• Reversing rollers
• Ropes and slinging whirls
• Cover for friction carriage.
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BA 475-0143-03 en; Page 19 of 19
2.7.3 Transport carriage for roller with support (order group 86)

Upon a roller change, the rollers with support can be transported off the machine or to it with the
aid of the roller transport carriage on rails (rails to be provided by customer). The advantages
are:
• Economic use for several roller presses, installed in a row and in a building.
• Crane-independent placing of the roller presses in the building, as the rollers with support
can be directed to the building opening and the crane.
The transport carriage comprises the following:

• Chassis with drive motors
• Steel structure as platform for transport wagon for the low-friction displacement and for taking
a roller with support
• two units mounted rope hoists for withdrawing and drawing the rollers with support from or
into the frame
Control units for rope hoists and drive motors.
BA 475-0143-03 en; Page 19 of 19

Transport and storage BA 475-0143-04 en
Page 1 of 10
Contents Page
1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety in general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Chapter-related safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Degree of decomposition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Previous edition:
4 Sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5 Scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6 Intermediate storage of roller press sub-assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6.1 Intermediate storage in the open air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6.2 Intermediate storage in closed, ventilated rooms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6.3 Intermediate storage in closed, ventilated rooms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6.4 Intermediate storage in closed, air-conditioned rooms . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7.1 Storage of spare-, reserve- and wear parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

7.2 Storage of the lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7.3 Storage, auxiliary materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7.4 Storage of damaged parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
8 Dismantling and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1 Safety
1.1 Safety in general
The safety references contained in the individual chapters supplement chapter "Safety and
health" of these operating Instructions.
Therefore, it is absolutely necessary to thoroughly read chapter "Safety and health" prior
to starting any works with and onthe roller press and to observe the included safety
references.
1.2 Chapter-related safety

The safety references in the text and the pertaining pictures must also be observed!
Only the slinging whirls included in the supply, see sub-assembly

tools and accessories, are permitted to be screwed into the
respective threaded bores for slinging the heavy components.
Annular bolts must not be used.

Page 2 of 10; BA 475-0143-04 en
Transport and storage
The roller press or its sub-assemblies are only permitted to be slung at

the points marked in the decomposition plan and in the drawings of the
sub-assembly. The slinging means and lifting facilities must be selected
according to the weights indicated in the decomposition plan.
Decomposition plan as per Technical Machine Documentation, section

"Documents for the assembly of the machine".
Depending on the kind and duration of the transport, suitable transport

guards have been provided for.
The heaviest individual component, roller with support, is only

permitted to be slung with one crane (procedure as per chapter
"Assembly/Installing the roller with roller support in the frame").
Lifting, e.g. with two individual cranes, is not permitted.

Risk of falling!
2 Packing
A factor also decisive for the type of packing is the transport way. Unless otherwise contractually
agreed, the packing corresponds to the packing regulations HPE determined by
the"Bundesverband Holzpackmittel, Paletten, Exportverpackung e.V." and the "Verband
Deutscher Maschinen- und Anlagenbau e.V.".
Observe the symbols on the packing.
e.g.:
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BA 475-0143-04 en; Page 3 of 10
3 Degree of decomposition
The degree of decomposition of the roller press depends on the transport conditions, the local
conditions and the lifting facilities and transport means available.
The order-bound degree of decomposition may be taken from the enclosed decomposition plan
(see section „List of the documentation- and spare parts drawings“).
4 Sensitivity
Caution!
During the transport of the roller press and its boxes with individual
components, proceed with particular care to avoid damage due to force or
incautious loading and unloading.
During the transport, avoid the formation of condensed water due to high temperature
differences.
Upon a transport by ship, make sure that the freight compartment is dry and that no sea water
can enter during the transport.
Shocks and vibrations are harmful to the components and must be avoided.
The roller press must be handled with care.
5 Scope of supply
The contents of the packages is indicated in the package lists the completeness of which must
be checked upon receipt.
Caution!
Immediately report all damage to the forwarding agent and the supplier. A
copy of the damage report has to be forwarded to the Humboldt Wedag
GmbH.
BA 475-0143-04 en; Page 3 of 10

Page 4 of 10; BA 475-0143-04 en
6 Intermediate storage of roller press sub-assemblies

The roller press is packed and preserved according to the degree of decomposition specified for
the respective order.
If the roller press or the individual sub-assemblies are not mounted directly after their delivery,
the following must be observed:
6.1 Intermediate storage in the open air
Duration: 6 months at a maximum

If it cannot be avoided, a storage in the open air should only come into question for large
components. In this case, the storage place must be roofed and covered with a canvass. It must
be made sure that no splash water or similar can enter the packings and components and that
the outer preservation is not damaged.
Caution!
The roller press or the frame - standing on a wooden structure - must be

placed on a plain base. By no means, the roller press or the frame are
permitted to be directly placed on the ground.
The relative humidity must be <65%.
If the intermediate storage should exceed this period of time, the preservation must be renewed
(also see Chapter "Operation/Measures to be taken after an extended standstill").
Note!
The storage- and preservation instructions of the suppliers must

be observed - see "List of the separate documentations".
6.2 Intermediate storage in closed, ventilated rooms
Duration: 12 - 24 months, with intact original packing

Generally, all parts packed in wooden boxes and with welded aluminium compound foil incl.
dessicant must be stored in closed rooms.
6.3 Intermediate storage in closed, ventilated rooms
Duration: 24 months, with intact original packing

This storage time applies to the roller with mounted support.
Note!
The storage- and preservation instructions of the suppliers must

be observed - see "List of the separate documentations".
Page 4 of 10; BA 475-0143-04 en

BA 475-0143-04 en; Page 5 of 10
6.4 Intermediate storage in closed, air-conditioned rooms
Duration: 5 years
Standard conditions:
– Temperature 279-298 K (6-25°C),

short-term temperature 303 K (30°C)
– Temperature differences (day/night) <281 K (<8°C)
– Relative humidity <65%
The storage time applies to the antifriction bearings under the mentioned conditions and with
intact original packing of the supplier.
7 Storage
7.1 Storage of spare-, reserve- and wear parts
The same conditions apply as under item "Intermediate storage"
For seals and/or other parts of rubber, the special storage instructions of the respective suppliers
must be observed (see section "List of the separate documentations").
7.2 Storage of the lubricants
Lubricants such as oils and greases are only permitted to be stored in closed original containers
to avoid the entrance of dust and dirt and to keep the oxidizing effect of the air as small as
possible. The storage place must be dry and cool.
Note!
Detailed information on transport, marking and storage of

lubricants may be taken from our BA 822-0001 (see section
"Operating instructions").
7.3 Storage, auxiliary materials
When storing the individual roller press components, the references given in the descriptions to
the individual sub-assemblies must be observed!
The storage place of the roller press components must be secured against unauthorised access.
When transporting and storing the auxiliary materials, observe the references given in operating
instructions BA 822-0001.
Unsuitable packings for the auxiliary materials are not permitted to be used.
Only admitted pressure liquids may be used.
Note!
In addition, the safety regulations included in the description of

the individual sub-assemblies and those included in the enclosed
supplier's documentation must be observed.
BA 475-0143-04 en; Page 5 of 10

Page 6 of 10; BA 475-0143-04 en
7.4 Storage of damaged parts
All damaged parts shall be stored in a separate locked store and be disposed of, if required.
8 Dismantling and disposal
Note!
This chapter only applies, if all parts shall be scrapped or

disposed of. A re-use of the parts is not recommended, as an
assessment of their qualitative condition after their use is
expensive or can partly not be made at all.
Note!
Disposal of the lubricants

More detailed information of the used lubricants may be taken
from BA 822-0001, see section "Operating instructions".
Note!
The dismantled components must be properly disposed of. As far

as possible, the materials must be separated by types.
Only the slinging whirls included in the supply, sub-assembly tools and
accessories, are permitted to be screwed into the respective threaded
bores for slinging heavy components.
The position of the most important slinging points is represented in the

drawings.
Ropes, chains, lifting loops, lifting belts and other slinging means to be
made available by the customer as well as the lifting facilities proper
must be selected on the basis of the weights indicated in the
decomposition plan.
Order group 46, ZN 375-046-000297
Dismantle guards from the drive system.
Page 6 of 10; BA 475-0143-04 en

BA 475-0143-04 en; Page 7 of 10
Order group 36, ZN 475-47-047-000046, Drive
On gear, coupling, oil supply- and cooling system, drain oil, see documentation of the sub-
suppliers, and properly dispose of it. On the cooling system, drain cooling water, see
documentation of the sub-suppliers.
For dismantling of the gear (item 2), see chapter "Maintenance".
Dismantling of the oil supply- and cooling system (item 4)
Order group 38, ZN 475-046-000819, torque support
Dismantle the residual parts of the torque support.
Note!
Observe dismantling direction of the stepped bolts (Item 17) as

indicated in the drawing!
Risk of stumbling due to foundation bolts! Avoid this risk by removing

the bolts protruding from the floor or by securing them.
Order group 75, ZN 375-075-000465, dismantling device gear
Dismantle the steel structures.
Order group 44, ZN 375-044-000063, maintenance drive
Dismantle the maintenance drive in parallel to withdrawing of the dismantling device gear.
Order group 29/30, ZN 375-029-000764, Feeding device
Dismantle shaft above the feeding device or suitably secure.
Dismantle helical lifting gear and clean it from grease, remove grease.
Unfix screw unions on the supporting brackets (Item 50).
Withdraw the dismantling device.
Order group 32, ZN 375-032-000821, Roller enclosure
Dismantling of the sheet parts of the enclosure
BA 475-0143-04 en; Page 7 of 10

Page 8 of 10; BA 475-0143-04 en
Order group 48, ZN 375-048-000192, Operating platform
Dismantling platform railing and base.
Risk of falling without platform railing and base
Order group 13, ZN 375-013-000080, oil circulation lubrication
Disconnecting the oil pump
Separating the pipe- and hose lines
Suitably dispose of pipes and hoses in view of the oil residues
Properly dispose of oil
Order group 15, ZN 375-015-000001, Central lubrication
Disconnect grease pump
Separating the pipe- and hose lines
Suitably dispose of pipes and hoses in view of the grease residues
Properly dispose of grease
Rollers with support
Order group 21, ZN 375-021-000073, Roller
Order group 12, ZN 375-012-000061, Roller support
Dismantling the rollers with bearing as per chapter "Maintenance"
Clean material from adhering oil and grease and then dispose of.
Properly dispose of oil and grease from support.
Order group 27, ZN 375-027-000077, Pressing device
Drain oil and properly dispose of
Dismantling the pressing device as per chapter "Maintenance"
Order group 85, ZN 375-085-000300, Roller displacing device
Dismantling the frame section
Page 8 of 10; BA 475-0143-04 en

BA 475-0143-04 en; Page 9 of 10
Order group 86, ZN 375-086-000026, Transport carriage
Dismantling the frame section
Dismantling of the rope hoists
(Properly dispose of oil from rope hoist)
Order group 33, ZN 475-029-000260, Measuring instruments and electr. cablings
Incl. customer's provision
Dismantling the measuring instruments and removing the electric cabling
Proper disposal of the components.
Order group 14, 16, ZN 475-084-000136, ZN 475-084-000230, accompanying heating
Removing the cabling and insulation (customer's provision)
Proper disposal of the components
Order group 34/35, ZN 375-034-000005, cooling water line
Draining the cooling water
Dismantling the lines
Order group 53, ZN 475-007-000617, Supply line
Remove oil and grease from the lines and dispose of as specified
Clean components and dispose of as specified
BA 475-0143-04 en; Page 9 of 10

Page 10 of 10; BA 475-0143-04 en
Order group 11, ZN 375-011-000465, frame
Dismantling the residual frame parts
Risk of falling.
Risk of stumbling due to foundation bolts! Avoid this risk by removing

the bolts protruding from the floor or by securing them.
After having removed the roller press, the site must be secured.
Page 10 of 10; BA 475-0143-04 en

Assembly BA 475-0143-05 en
Page 1 of 67
Contents Page
1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.1.1 Safety in general. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.1.2 Chapter-related safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2 Installation conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Dimensions, space requirement and weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.2 Lifting device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Previous edition:
2.3 Assembly tools and -accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.4 Survey of drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Measures prior to starting installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.2 Foundation and frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.2.1 Frame roller press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.2.2 Roller displacement device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.3 Transport carriage (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.4 Pressing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.4.1 Installation flat cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.4.2 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.4.2.1 Hydraulic set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.4.2.2 Control block with reservoir and intermediate tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.4.2.3 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.4.2.4 Starting cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.4.2.5 Hydraulic lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.4.2.6 Installation instructions for sectional ring screw unions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.4.3 Filling the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.4.3.1 Filling procedure and corrections, if any, of the reservoir pressures as per supplier's documentation 21
3.4.3.2 Rinse the mounted hydraulic lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.4.3.3 Venting the pressing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.5 Roller enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
3.6 Feeding device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
3.7 Operating platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
3.8 Roller with roller support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
3.8.1 Installation bearing guiding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3.9 Roller installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3.9.1 Lifting the floating roller with support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3.9.2 Installation rubber pressure bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
3.9.3 Installation setting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
3.9.4 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
3.10 Installation of the rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
3.10.1 Floating roller with support; draw into the frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
3.10.2 Fixed roller with support; draw into the frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
3.10.3 Installation on the frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
3.11 Alignment and setting works. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
3.11.1 Aligning the roller front sides (fixed bearing side). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
3.11.2 Aligning the floating bearings (fixed roller and floating roller). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
3.11.3 Aligning the roller lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
3.11.4 Aligning the rubber thrust bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
3.11.5 Installation and adjustment of the lateral walls for the feeding device . . . . . . . . . . . . . . . . . . . . . . . . .40
3.12 Closing the roller lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
3.13 Water cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
3.14 Central lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
3.15 Mounting the accompanying heating of the supply- and return line . . . . . . . . . . . . . . . . . . . . . . . . . . .45
3.15.1 Mounting the barrel bottom heating and accompanying heating of the grease lines . . . . . . . . . . . . . .46
3.16 Drive, torque support and guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
3.16.1 Main drive motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
3.16.2 Installation device roller press gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
3.16.3 Installation torque support, gear holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Page 2 of 67; BA 475-0143-05 en
Assembly
3.16.4 Installation dismantling device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

3.16.5 Mount gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.17 Guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.18 Electrical measuring instruments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.4.3.1 Filling procedure and corrections, if any, of the reservoir pressures as per supplier's documentation 21
3.4.3.2 Rinse the mounted hydraulic lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.4.3.3 Venting the pressing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.18 Electrical measuring instruments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.18.1 Roller gap monitoring / Roller limit disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.18.2 Temperature monitoring at the main bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.18.3 Rotation monitoring system for shrinking disc (drawing ZN 475-029-000260, sheet 2) . . . . . . . . . . . 58
3.18.4 Standstill- and temperature monitoring at the fluid coupling.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.18.5 Feed material - temperature measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.18.6 Monitor the rocker arm closed position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.19 Final works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4 Preparations to the test without material and interlocking tests . . . . . . . . . . . . . . . . . 60

4.1 Check points safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.2 Mechanic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.3 Electric system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5 Tests without material and interlocking tests without material . . . . . . . . . . . . . . . . . . 62

5.1 Tests without material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.2 Interlocking tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.3 Modes of operation for the idle tests and the interlocking tests without material . . . . . . . . . . . . . . . . 63
5.3.1 Individual mode (local mode). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.3.1.1 Zero gap setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.3.2 Unlocked mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.3.3 Interlocked mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Page 2 of 67; BA 475-0143-05 en

BA 475-0143-05 en; Page 3 of 67
Assembly
1 General information
The roller press must absolutely be assembled by staff trained in the respective technical areas.
We strongly recommend to have assembly and commissioning be carried out or supervised by
Humboldt Wedag staff.
We will not be liable for damage to persons and machine due to

improper execution.
The roller press is mounted and aligned on the site.
The order-related degree of decomposition or the pre-assembled condition may be taken from
the dismantling plan included in section "Documents for the assembly of the machine".
Note!
The graphic representations of the assembly drawings in the text are

partly simplified.
Note!
After the assembly of the roller press has been completed, the
protocols and measuring sheets pertaining to the individual sub-
assemblies must be submitted via e-mail to Humboldt Wedag.
E-mail-address: measure@khd.com
1.1 Safety
1.1.1 Safety in general

The safety items indicated in the individual chapters supplement chapter "Safety and health" of
the operating instructions.
Therefore, it is absolutely necessary to thoroughly read chapter Safety and Health prior to
starting any works with and atthe roller press and to observe the included safety references.
BA 475-0143-05 en; Page 3 of 67

Page 4 of 67; BA 475-0143-05 en
Assembly
1.1.2 Chapter-related safety

The safety references in the text and in the pertaining drawings must also be observed!
Only the slinging whirls included in the supply, see sub-assembly tools
and accessories, are permitted to be screwed into the respective
threaded bores for slinging the heavy components.
The position of the most important slinging points is represented in the

drawings.
The roller press or its sub-assemblies are only permitted to be slung at

the points marked in the decomposition plan and in the drawings of the
sub-assembly. The slinging means and lifting facilities must be
selected according to the weights indicated in the decomposition plan.
Dismantling plan as per section "Documents for the assembly of the

machine".
The heaviest individual part Roller with support may only be slung with
one single crane.
Lifting, e.g. with two individual cranes, is not permitted. Risk of falling!
Caution!
The carrying capacity must at least correspond to the weight of the heaviest
individual part (roller with roller support or gear). For information, see
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Assembly
After having removed the roller from the roller press frame, the opening
of the outlet shaft is completely free.
The openings such as outlet shaft/inlet shaft must be completely

secured.
2 Installation conditions
Take care that sufficient space is available around the roller press to facilitate assembly and
repair works. Machines connected in front and behind must be accordingly arranged. Keep traffic
ways free.
The roller press may be installed on a concrete foundation or a suitably dimensioned steel
structure.
The installation drawing containing general information on the assembly of the roller press
including dimensions, weights, loads, design information (connections) etc. is enclosed to the
documentation.
Note!
The order-specific "Customer-specific characteristic and technical

data" contain, among others, all necessary information such as:
– for aligning and mounting the roller press
– admissible tolerances for aligning the roller press
– bolts with tightening torques
These information must be considered for setting up the roller press.
2.1 Dimensions, space requirement and weights

Dimensions:
Main dimensions of the roller press with drive components and main drive motors in mounted
condition:
(see section “Customer-specific characteristic and technical data/Dimensions“, installation
drawing and/or dismantling plan).
Space requirement:
Additionally required space for replacing spare and wear parts:
(see section “Customer-specific characteristic and technical data/Space requirement“,
installation drawing and/or dismantling plan).
Weights:
Roller press without main drive motor: (see section “Customer-specific characteristic and
technical data//Weights“).
Installation drawing and/or decomposition plan
Gear components:
(see section "Customer-specific characteristic and technical data").
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Assembly
2.2 Lifting device

If for the assembly and maintenance of the complete roller press a crane movable into any
direction should not be available:
• the heavy components such as roller with support and gear to be positioned with a mobile
crane,
• suitable girders with load-carrying hooks for chain hoists or similar must be provided for
above the suspended loads indicated in the installation drawing.
Caution!
The carrying capacity must at least correspond to the indicated weights. Data
as per section "Customer-specific characteristic and technical data".
Note!
If a mobile gantry crane should not be installed above the roller press,
the customer must make sure that the heavy components such as gear
and roller with support can be reached with a mobile crane also for
maintenance and repair works (e.g. replacement of the components).
Page 6 of 67; BA 475-0143-05 en

2.3 Assembly tools and -accessories
For performing and facilitating assembly- and repair works, the following tools and accessories will serve:
Custome
Item Supply r's
Required for Type of auxiliaries Drawing-No. Comprising Remark
No. HW provisio
n
Measuring device
Wear measurement 375-050-000001 - See spare parts list in section VI X
Order group 50
Dismantling of
Pressure element, Dismantling device
475-081-000259 - See spare parts list in section VI X
Intermediate piece, Order group 50
flat cylinder
* Attention! Do not use an adapter for dismantling rubber pressure bearings on the
fixed roller side. This part is not suitable for the RPS execution.
Filling and testing of Filling- and testing
475-008-000333 - 1 x filling- and testing device complete X
the reservoirs device
Cylinder bleeding Taken from

Measuring hose 475-081-000333 - 2 x measuring hose X
device order group 50
BA 475-143-05 en; Page 7 of 67

„Special
equipment“
BA 475-143-05 en; Page 7 of 67
Setting of the
grease volume (only
Setting key 475-008-000332 - 1 x key X
for grease
lubrication)
Assembly
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Page 8 of 67; BA 475-143-05 en
Assembly
Custome
Item Supply r's
No. HW provisio
n
Transport carriage
(if included in the - Transport carriage with drive, rope
375-086-000026 optional
scope of supply) hoists and friction carriage
Order group 86
Roller displacing
- Frame with drive, rope hoists and
device (if included in 375-085-000300 X
friction carriage
Roller dismantling the scope of supply)
Transport
accessories 475-081-000756 - See spare parts list in section VI
Order group 50
Dismantling /
Mounting tools 375-050-00029 - Drive, rope hoists, reversing pulleys X
Order group 50
Floating bearing Spacer

475-081-000756 - 4 x spacer X
fixing Order group 50
Parts set for aligning

Roller alignment the roller front sides 475-081-000748 - Cylinder LKO 6/20 X
AGR 50
Re-setting of the
Re-setting device
rollers upon wear 375-080-000121 - See spare parts list in section VI
Order group 80
(only for stud lining)
Setting of
Re-setting device
the zero gap 375-080-000121 - Spacer elements as per drawing
Order group 80
(order-related)
Setting tool lateral

Setting lateral wall 475-081-000607 - 1 x key x if required
wall AGR 50
Custome
Item Supply r's
No. HW provisio
n
- See spare parts list in section VI

Open and close Hydraulic system Taken from
rocker arms rocker arms order group 50
(if existing) Order group 70 - Pump set EDP 10122101 X
„Special
equipment“
Taken from
Fastening and order group 50
Slinging means - see spare parts list in section VI X
transport „Special
equipment“
Maintenance drive
Turning the rollers 375-044-000063 - See spare parts list in section VI
Order group 44
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Assembly
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Assembly
Custome
Item Supply r's
No. HW provisio
n
- See spare parts list in section VI
- Protocol cylinder operating pressures x
- 2 x chain hoist for lifting the guards and Useful load

the articulated shaft, for displacing the x 16000 N
travelling carriages (1.6 t)
Dismantling device - Wooden wedges x
for gear
375-075-000645
Order group 75 - Rope guards x
Mounting and (optional)
dismantling of gear - Standard tools
x
(spanners etc.)
- Withdrawing device for the bolts on the

x
torque support
for gear
- 2 x clamping belt x
fixing to item 33
Pump for hydraulic

shrinking disc - 1 x hydraulic hand pump X
Order group 50
Folding open the Chain hoist / - Chain/rope, drawing facility,

x
front-side enclosure Lifting facility Fastenings
BA 475-0143-05 en; Page 11 of 67
Assembly
2.4 Survey of drawings
Note!
Drawings see section "List of the documentation and spare parts

drawings".
3 Installation
The installation (assembly) takes place according to the local conditions and as laid down in the
installation plan.
During installation, particularly observe the working procedures and information given below.
Aligning of the roller press components as per measuring protocol (see customer-specific
characteristic and technical data) and information given in chapter "Assembly".
Caution!
The particularly marked parts of the roller press (impressed markings,

notched marks) must be mounted or dismantled absolutely observing the
markings.
3.1 Measures prior to starting installation
Caution!
To avoid installation errors, also generally observe the enclosed suppliers'

documentations (see section "List of the separate documentations").
• Check the specified measures as per installation drawing
• Determine and fix the axes (e.g. centre of machine, centre of drives)
• Determine the height reference points with the aid of a levelling instrument.
• Measuring the complete foundation!

Measuring data entered into the measuring protocol (see customer-specific characteristic and
technical data).
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Assembly
3.2 Foundation and frame
3.2.1 Frame roller press

(order group 11, ZN 375-011-000465)
Procedure for the case that the frame is delivered completely mounted:
• When the foundation dimensions have been checked and executed as specified, the
installation of the frame can be started (see measuring sheet under customer-specific
characteristic and technical data).
• Place completely mounted frame onto the foundation and align it according to the foundation
openings for material feed system and discharge as well as to the foundation bolts and the
specified axes as per installation plan, frame drawing and measuring sheet.
• Level frame bottom sections (1 + 2) to the height of the worked surface observing the
admissible tolerance (see "Customer-specific characteristic and technical data/Frame").
For lining, mount the according sheets (item 105 -108) at the points indicated in drawing
ZN 375-011-000465 to be installed at the indicated points.
Procedure for the case that the frame is delivered partly mounted:
• The two frame sides comprising frame bottom section, frame top section, end piece and
auxiliary support (1-4, 13, 99) are placed onto the foundation and aligned. A necessary lining
can be made with the aid of the sheets (105 - 108) included in the supply. The alignment
measures can be taken from the drawing.
• Mount girders between the two frame sections and laterally align.
• The frame must be fixed on the foundation.
Procedure for the case that the frame is delivered in individual parts:
• The frame is delivered in the sub-assemblies indicated in the decomposition plan (drawing,
ZN 375-001-000118).
• First, the two frame bottom sections are placed onto the foundations and aligned. A
necessary lining can be realised with the aid of the sheets included in the supply (105 - 108,
ZN 375-011-000465). The alignment measures can be taken from the installation drawing.
• Mount girders (36, 40) between the two frame bottom sections and laterally align.
• The bottom sections must be fixed on the foundation with foundation bolts..
• Insert shearing bolts into the frame bottom sections.
• Place end pieces (13) onto the lower runs and tighten by hand with screw bolts (14, 15, 16).
• Place auxiliary supports (99) onto the frame bottom section and screw in place.
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BA 475-0143-05 en; Page 13 of 67
Assembly
• Place frame top sections, align them, until the milled surfaces are facing each other without
offset as per frame drawing, and temporarily fasten them.
• Mount the outer girders (36, 41) between the two frame top sections and laterally align frame.
See measuring sheet under Customer-specific characteristic and technical data.
• Fasten shearing bolts with holders (66) and screws (67, 68) to the frame.
• Tighten screw unions. Here, the tightening torques indicated in table "Tightening torques for
the screws" in chapter "Customer-specific characteristic and technical data" and in the
drawings must be observed.
• Screw stop plates (91) to frame.
Caution!
Reduced tightening torque as per drawing
• Mount bridge frame (25-27).
• After having mounted and tightened the screws, weld cleats in place according to the frame
drawing.
• When assembling with slide plates (92, 93), align centering rings (96) as per frame drawing
and weld in place.
Caution!
The finally placed and mounted frame must be measured on the basis of the
measuring protocol, see "Customer-specific characteristic and technical
data".
Note!
Measuring results must be documented in the "Measuring protocol

frame" (see section "Customer-specific characteristic and technical
data").
If the installation has been correctly performed, now, the foundation screws can be poured in and
the frame bottom section be grouted. When the concrete has set, the foundation bolts must be
tightened again.
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Assembly
3.2.2 Roller displacement device

(Order group 85, drawing ZN 375-085-000300)
The roller displacement device must be aligned centrically to the roller press. The height level is
aligned using shims (23-26). Then, the displacement device is connected with the frame (9).
To ensure a safe support of the platform (34), item 34.1 must be welded to the frame!
After the correct installation, the foundation bolts can be poured in and the support be grouted
with non-shrinking mortar. When the concrete has set, the foundation bolts are tightened.
3.3 Transport carriage (optional)

Installation of the transport carriage:
• Mount chassis (10).

(see separate supplier's documentation)
• Mount support (1) to the chassis (10).
• Mount frame parts (24, 25) and spacer girder (26) to the supports (1) and set the height level
using the shims (7-9).
• Screw stop block (4, 3) to the frame part (24, 25).
• Fasten rope hoists (optional) (11, 12) to the frame parts (24, 25).
• Weld stop points (14) and fasten shackle (27).
• Fasten switch box for rope hoists and travelling drive to the spacer girder (26).
• Bring transport carriage with hydraulic cylinders, see ZN 375-085-000300, to the height level
of the roller displacing unit. Withdraw cylinder with accessories from TPG 75.
3.4 Pressing device

Note!
See separate documentation in section "List of separate

documentations".
Mount hydraulic lines as per drawing ZN 375-027-000077 and control diagram (see enclosed
supplier's documentation in section "List of the separate documentations").
The pipelines, among others also for connecting hydraulic set and cylinder block, must be
mounted duly considering the following installation instructions for sectional ring screw unions.
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BA 475-0143-05 en; Page 15 of 67
Assembly
Caution!
During assembly works at the hydraulic system, ensure utmost cleanliness.
3.4.1 Installation flat cylinders

Note!
Also see enclosed separate supplier's documentation in section "List

of separate documentations".
• Screw spacer element (20) and spacer sheets (25, 26) of sub-assembly resetting device
(order group 80, drawing ZN 375-080-000121, representation "Basic design" - new condition -
) to the end piece of the frame. Also see references for setting the zero gap.
Note!
Mount spacer plate and spacer element such that the passage holes for
fastening the flat cylinder are congruent without offset.
The piston of the flat cylinder does not have an inner stop. During
installation of the flat cylinder, take care that the piston does not fall
out.
The transport guards may be removed only directly prior to drawing in

the rollers with support.
• Screw bolts (7) into the flat cylinder (6).
• Mount slide shoe (if included in the scope of supply) to flat cylinder. Or screw the cleat (20.1,
ZN 375-080-000121) to the spacer element.
• Loosely screw fixing discs (4-5) to spacer sheet (20, drawing 375-080-000121).
• Screw flat cylinder (6) to the dismantling device included in the supply (drawing ZN 475-081-
000259, order group 50 "Tools and accessories") and sling to crane. (If required), suspend
spacer plate to the screws (7) on the flat cylinder (6). The spacer sheet is supported on the
slide shoe (if included in the scope of supply).
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Assembly
During the transport, the spacer plate (121) must be secured against
falling down.
• Insert the screw bolts at the flat cylinder into the bores of the sheets at the end piece and
tighten them.
• Mount bellows (22) with clip (23) to flat cylinder (6).
Note!
The order-related zero gap can be found in the Customer-specific

characteristic and technical data.
3.4.2 Hydraulic system
Upon working on the hydraulic system, make sure that, prior to

opening a hydraulic line or another hydraulic element, the hydraulic
system is not pressurised.
Caution!
Technical knowledge and a considerable degree of cleanliness are required

during the installation of the hydraulic components to ensure a trouble-free
operation of the hydraulic system.
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Assembly
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Assembly
3.4.2.1 Hydraulic set

(see Fig. 475-418, Page17)
Mount hydraulic set with oil pan as illustrated in the installation drawing in a low-dust room. Upon
installation, take care that the exchange of air is sufficient.
Caution!
To ensure draining of the oil, the hydraulic set must be placed deeper than
the intermediate tank (Drawing ZN 375-027-000077). All return lines between
roller press balancing tank and hydraulic set must be laid with an inclination.
3.4.2.2 Control block with reservoir and intermediate tank

(30, drawing ZN 375-027-000077)
The control block is bolted to the flat cylinder.
The intermediate tank is fastened to the end piece of the frame.
3.4.2.3 Control unit

(56, drawing ZN 375-027-000077)
The control unit is arranged between U- and I-girder underneath the platform.
3.4.2.4 Starting cylinders

(95, 96, drawing ZN 375-027-000077)
The single-effect starting cylinders are mounted between the bearing housings of the floating-
and the fixed roller.
3.4.2.5 Hydraulic lines

Mount hydraulic lines as per drawing ZN 375-027-000077 and control diagram.
(for control plan, see supplier's documentation in section "List of the separate documentations")
The pipelines, e.g. for connecting hydraulic set and cylinder block, must be mounted duly
considering the following installation instructions for sectional ring screw unions.
Caution!
Saw pipelines to size and debur them. Then, rinse and blow out with
compressed air.
Amount of rinsing liquid as required.
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BA 475-0143-05 en; Page 19 of 67
Assembly
3.4.2.6 Installation instructions for sectional ring screw unions
• Saw tube rectangularly and de-bur it not using pipe

cutters. If possible, use sawing machine. Slightly
de-bur tube ends internally and externally. Clean
thoroughly.
• Slide union nut and sectional ring onto the tube as

illustrated.
• Press tube against stop in the screw socket.

Manually tighten union nut.
• Tighten union nut, until the sectional ring seizes the

tube. This point may be recognised via the
increasing torque rise.
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Assembly
• Then, finish installation with 1 rotation.
Keep screw socket with wrench.
Check:
• Check section of the cutting edge. Visibly raised
collar must fill the space in front of profile ring face.
The profile ring may turn but not permit axial
displacement.
Minimum length for straight tube end in case of

tube bends:
• For tube bends, the straight tube end must
correspond to twice the height of the union nut up to
the beginning of the bending radius.
3.4.3 Filling the hydraulic system

• Fill tank of the hydraulic set with oil as per list of lubricating points (see "List of lubricating
points").
Caution!
The hydraulic set may only be filled via the filling socket "E" (see Fig. 475-418,
Page17). The use of a filtering element for accelerating filling is not permitted!
To ensure that the hydraulic oil becomes absolutely free from bubbles, we
recommend, if possible, to let the oil rest overnight.
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BA 475-0143-05 en; Page 21 of 67
Assembly
• Fill the reservoirs as described in the suppliers' documentation for reservoirs.
As gas, only nitrogen is permitted to be used, by no means oxygen or

air.
RISK OF EXPLOSION!
Observe identification of the nitrogen bottle.
• For first filling, adjust the indicated nitrogen pressures as per section "Customer-specific
The reservoir pressures are selected as a function of the intended mode of operation and
are optimised during commissioning.
Note!
The required nitrogen bottles (filling pressure 200 bar) for filling the
reservoirs must be provided by the customer, unless otherwise laid
down in the contract.
To achieve a complete utilisation of the nitrogen bottles or if these should no more be

available at a filling pressure of 200 bar, we recommend the use of a nitrogen charging
system. This system is installed between the filling- and testing device and the nitrogen
bottle.
The nitrogen charger (optional) is not part of the standard scope of supply! Contents of the
scope of supply as per contract!
3.4.3.1 Filling procedure and corrections, if any, of the reservoir pressures

as per supplier's documentation
Check gas valve with soap suds for leaks and tightness.
Caution!
Leakages at the gas valves of the reservoirs must be immediately eliminated,

as they will absolutely lead to a destruction of the reservoir cores.
3.4.3.2 Rinse the mounted hydraulic lines

opening a hydraulic line or another hydraulic element, the hydraulic
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Assembly
Control block and valves must not be rinsed! RISK OF

CONTAMINATION!
These components have been rinsed in the manufacturer's works!
Caution!
To avoid that contaminations in the hydraulic lines will enter the hydraulic
parts, it is recommended to clean the mounted hydraulic lines as described
below.
• Unfix pipelines at the roller press frame.
• Keep oil collection basin available.
• Connect hydraulic set.
• Set pressure limiting valve at the hydraulic set to about 5 to 10 bar and rinse pipelines with
hydraulic oil.
• Disconnect hydraulic set.
• Connect the pipes to the roller press and check for tightness.
3.4.3.3 Venting the pressing device
Caution!
Prior to first starting up, upon any maintenance and after any repair, the plant
must be bleeded.
Note!
The item numbers refer to the control plan of the supplier's documentation in
section "List of separate documentations."
To ensure proper functioning of the hydraulic control, the entire hydraulic system must be
bleeded. To that end, we recommend the following procedure:
• Extract pressing cylinder.
• Emergency-off valve (2.14) switched.
• Ball cock (2.8.1/2) opened.
• Connect motor (1.8).
• Set pressure limiting valve (3.4) to 40 bar.
• Actuate the valves (3.5.1 and 3.5.2).

After the actuation of the valves, the pressure oil flows through the supply line via the
consumer connections "A1" and "A2" into the control block (2.1.1 and 2.1.2) and into the flat
cylinder.
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BA 475-0143-05 en; Page 23 of 67
Assembly
Maximum pressure upon bleeding: 40 bar.

At the mini-measuring socket (on top of the cylinder) and at the control block, a venting line is
connected. The bleeding procedure is carried out, until the hydraulic oil flows into a collection
tank free from bubbles and foam.
The cylinders are bled one after the other.
The lines for the hydraulic starting system are bled as follows:
• Switch way valve (4.4).

Via the supply line, the hydraulic oil, which can be throttled, flows into the single-acting piston
cylinders.
• For venting, a venting line is connected to the mini measuring socket installed above the
single-acting cylinder. The venting process is continued, until the hydraulic oil is flowing into a
collecting basin free from bubbles and foam.
The cylinders are bled one after the other.
Caution!
Lock the complete hydraulic system and check it for tightness!
The protective grates (Item 110, Drawing ZN 375-027-000077) must be

mounted prior to starting the machine to prevent entering the spaces of
the bearing housings of the movable rollers with the hand.
Note!
After having set the pressing device, the protocol for the pressing
device must be filled in, see customer-specific characteristic and
technical data.
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Assembly
3.5 Roller enclosure

The individual parts must be mounted into the inner space of the frame as indicated in the
drawing.
• Check, whether all doors and flaps on the floating roller side are tightly closed.
If not so, close them.
• Using chain hoist or lifting facility (by customer, see table "Assembly tools and accessories"),
sling to lateral wall with door (1).
• Unfix screws (3, 6) at the lateral wall with door (1) and lower door with rope hoist.
• Check foldable lateral wall with doors for turning and closing function and leave it in folded
down condition! (Preparation for the installation of the rollers with support).
Caution!
No persons may stay in the turning area of the lateral wall.
• Remove lifting facility.
3.6 Feeding device

(Order group 29/30, ZN 375-029-000764)
The feeding device is delivered mounted as sub-assembly (except for the lateral walls with
suspension (60), the brackets (50) and the cover (68)). The brackets (50) are bolted to the frame
(order group 11) (51-53). The feeding device is fastened to the brackets (50) (52,53,55).
The lateral walls are mounted only later on after having installed the rollers with support
Electrically connect the spindle lift drives and measuring instruments according to the enclosed
supplier's documentation.
To facilitate dismantling and mounting of the feeding device, an intermediate piece must be
provided at a height of 1000 mm at a min. and be installed between material supply and feeding
device of the roller press.
Provide for a lockable opening in the material supply system directly above the connection flange
of the intermediate piece permitting checking and cleaning works in the feeding device.
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BA 475-0143-05 en; Page 25 of 67
Assembly
3.7 Operating platform

(order group 48, drawing ZN 375-048-000192)
The operating platform and the maintenance platforms are included in the supply unpacked.
Assembly according to drawing.
During the assembly, secure the working area for the assembly staff
according to the local conditions to exclude risks for the staff by falling
down.
3.8 Roller with roller support

Preparation for drawing into the frame
(order groups 21 and 18)
The rollers with supports are delivered assembled.
• Remove grease ties from the labyrinths of the roller support.
• The bearing guiding, order group 82, drawing ZN 375-082-000059, is also mounted.
Caution!
The roller with roller supports is mounted such that they correspond to the
drive arrangement and that it is determined via this arrangement, which roller
must be mounted as fixed roller and which one as movable roller into the
frame.
Reference characteristics for installation:
• Drive journal as per installation drawing
• The lubricating connections on the bearing housings of the support are located "on top" on
the right and the left of the machine center.
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Assembly
3.8.1 Installation bearing guiding
Note!
Support roller with support such that all bearing guide elements can be
comfortably mounted.
Do not place onto the slide plates (1) and outer guidings.
(see drawing 475-081-000756, transport accessories)
• Clamp slide plates (1) without gap to the bearing housing together with the guide strip (2) and
the screw-type butt strap (3).
To that end, only cylinder bolts as per DIN 6912 (4) may be used!
• Complete guide bolt (6) with the slide shoe (9) and the other outer guiding parts (7-17).
• Screw complete outer guiding with connection strip to the bearing housings (22, 23).
Note!
Tightening torques for high-strength bolts as per Customer-specific

characteristic and technical data!
3.9 Roller installation
3.9.1 Lifting the floating roller with support

onto the roller displacing device or the transport carriage (optionally)
(Drawings:
Roller support, ZN 375-018-000061,
Frame, ZN 375-011-000465,
Transport accessories, ZN 475-081-000756,
Transport carriage, ZN 375-086-000026,
Roller displacing device ZN 375-085-000300,
Lining ZN 375-032-000821)
The heaviest individual part "Roller with support" may only be slung with one
single crane.
Lifting with two or more individual cranes is not admissible.
Risk of falling!
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BA 475-0143-05 en; Page 27 of 67
Assembly
Note!
The carrying capacity of the slinging means and lifting facilities must at
least correspond to the weight of the heaviest individual part "Roller
with support".
According data are given in section "Customer-specific characteristic
and technical data/Weights".
Caution!
Without spacers (2,4,5, drawing ZN 475-081-000756), the rollers with roller

support must not be transported because of the hazard of damage to the
antifriction bearings.
Caution!
The split sockets (12, drawing ZN 375-012-000061) must not be mounted here.
Caution!
Prior to slinging to the suspension bolts, dismantle upper cover to the

bearing water cooling system (see instruction on drawing ZN 475-081-
000756).
a) The slinging bolts (drawing ZN 475-081-000756) are fixed in the bearing housings. Sling
roller with support there.
b) Dismantle cover (23, drawing ZN 375-086-000026 / 16, drawing ZN 375-085-000300)!

Remove dirt from the friction carriage (8), if necessary.
c) Lift floating roller onto the frame of the roller displacing device or transport carriage
(optionally).
Caution!
Do not place the Teflon slideways onto the friction carriage (15, drawing
Place ZN 375-085-000300 / ZN 375-086-000026).
d) Dismantle spacers (2,4,5, drawing ZN 475-081-000756)!
e) Mount spacers (9) for fixing the floating bearings.
f) Mount upper cover for bearing water cooling system again!
g) Mount split socket (12, drawing ZN 375-012-000061) and align it.
h) Screw sealing plates (60, 63-68 / ZN 375-032-000821) to the sockets (12, drawing ZN 375-
012-000061).
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Assembly
3.9.2 Installation rubber pressure bearing

(order group 81, Drawing ZN 475-017-000685)
Screw the pre-assembled rubber pressure bearings (1, 2, 4) to the bearing housings of the
floating roller (13, 14, 30).
Caution!
The threaded bolt (12) must show towards the inside of the roller press.
Only in this way, the rubber pressure bearing can be replaced with the roller
being installed.
Rubber thrust bearing (pre-mounted unit comprising: Screw supporting plate (20), rubber plate
(21), pressure piece (23) and spacer element (28), drawing ZN 475-017-000685) to the bearing
housings of the fixed roller.
3.9.3 Installation setting device

The zero gap (see customer-specific characteristic and technical data) can be preset in
connection with order group 80 to 10 mm and 25 mm.
Depending on the zero gap, between the bearing housings, the mechanical stops (1-9, 27-31)
must be fastened.
Caution!
Generally, it must be made sure that the rollers cannot touch each other.
3.9.4 Frame
• Dismantle both supports (99).
• Unfix countersunk screws at the outer guidings and remove slide plates(49), spacer plates
(50-51) from yokes (46) and frame.
The parts at the outer guiding are marked according to the marking at the frame: I, II, …, VI.
Caution!
During dismantling, the parts must not be exchanged and must be installed
again according to their marking at the right place.
During dismantling, combine plates (50-51) arranged one behind the other with adhesive
tape and identify them with the respective marking on the frame.
Example: Outer plates "l/outside" or inner plates "l/inside".
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Free slide plates (92, 93, 95) from dust and dirt and repair defects!
• Remove the rocker arm retaining element (98, 103, 63).
• Sling plug-type end piece ("Rocker arm pair" welded 76) into a lifting facility and withdraw it
upwards from the frame.
3.10 Installation of the rollers

Drawings:
Roller displacing device ZN 375-085-000300
Transport carriage, optional ZN 375-086-000026
Dismantling and mounting of the rollersZN 375-050-000029
Frame ZN 375-011-000465
Rubber thrust bearing ZN 475-017-000685
Pressing device ZN 375-027-000077
Roller support ZN 375-018-000061
Roller lining ZN 375-032-000821
3.10.1 Floating roller with support; draw into the frame

(ZN 375-085-000300)
• Screw slinging whirl (9, ZN 375-050-00029) into the lower guide bolts of floating roller and
stop holder (27, 28).
Preliminary works (ZN 375-050-000029), equipment optional
• Mount rope hoists 1, 2, onto transport device or transport carriage (optional), unless already
mounted.
• Mount switch box (6) to transport device or transport carriage (optional), unless already
mounted.
• Align slinging elements (7) to the rope hoists and weld in place, unless already mounted.
Upon roller change (ZN 375-050-000029)
• Screw slinging whirl (9) into bracket.
• Screw slinging whirl (9) at the lower guide bolt (6, drawing ZN 375-082-000059) of the roller to
be moved including bearing.
• Suspend wire rope block (12) into slinging whirl (9).
• Suspend ropes as indicated in the drawing.
• Suspend wire rope block (13) and ropes as indicated in the drawing.
Note!
Observe differences between floating and fixed roller as well as

between drawing in and out (drawing ZN 375-085-000300 sheet 2).
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• Free slide plates and sheets (92, 93, 95, drawing ZN 375-011-000465) from dust and dirt
and repair defects!
• Also free the mating slide surfaces of Teflon from dust and dirt and repair defects, if any.
No persons may stay in the hazardous area of the wire ropes.
Caution!
When drawing in the roller, make absolutely sure that the Teflon slideways at
the bearing housing do not jam at the chromium plates or hit against them. If
necessary, correct again the height level of the transport carriage to the roller
displacing device using the hydraulic cylinders (see ZN 375-085-000300,
cylinder from TPG 75).
Draw in the roller with support centrally aligned to the frame.
Avoid an oblique position!
Note!
The rope hoists (1, 2, drawing ZN 375-050-000029) can be separately

controlled via a remote control. In this way, an oblique position, if any,
can be corrected.
• Pull floating roller with mounted rubber thrust bearing (drawing ZN 475-017-000685) up to
the flat cylinders (6, drawing ZN 375-027-000077) using the rope hoists (sub-assembly 50).
Risk of squeezing!
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3.10.2 Fixed roller with support; draw into the frame

(ZN 375-050-000029)
• Screw slinging whirl (9) into the bearing housing to be moved.
• Suspend ropes as indicated in the drawing
• Observe item "Lifting the rollers with support onto the roller displacing device or transport
carriage (optionally)"!
• Screw sockets (12, drawing ZN 375-012-000061) to either side of the bearing cover.
• Screw sealing plates (60, 63-68, ZN 375-032-000821) to the sockets (12, drawing ZN 375-
012-000061).
• Further procedure as under item "Floating roller with support; drawing into the frame".
Note!
The correct position of the fixed roller in the frame requires the
following:
1. The piston of the flat cylinder is completely retracted!
The floating roller is in contact with the pistons of the flat cylinders with
the rubber thrust bearing!
3. The mechanical stops (1-9, 27, drawing ZN 375-080-000121, group

resetting unit) are mounted! The spacer plates installed here consider
the specified zero gap (see section "Customer-specific characteristic
and technical data").
On that basis, a distance between the mechanical stops for working

cycle + disconnection cycle - 5 mm gap for introducing the plug-type
end pieces = preliminary position of the fixed roller for further assembly
results!
For working cycle and disconnection cycle, see (see section

"Customer-specific characteristic and technical data").
As an approximate measure, a wooden strip of the determined measure

for the distance can be taken as checking tool!
Risk of squeezing
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No persons may stay in the hazardous area of the wire ropes.
Caution!
Remove wooden strip again without delay!
3.10.3 Installation on the frame

• Sling plug-type end piece ("rocker arm pair" welded, 76) to a lifting facility and insert from
above into the frame (the slinging plates (64) are opposite here), until it is supported in the
slide bearing (78).
• Press plug-type end piece against the slinging plates, clamp in adapter element (63) and
secure with threaded bolt (98).
3.11 Alignment and setting works
3.11.1 Aligning the roller front sides (fixed bearing side)

Drawings:
Frame, ZN 375-011-000465,
Roller support, ZN 375-018-000061,
Parts set for alignment ZN 475-081-000748
If distance measures for setting of the outer guides should already have been determined during
the Humboldt Wedag works assembly, the spacer plates marked during dismantling (see item
"Roller with roller support / frame") are inserted again at the respective outer guidings.
If the rollers and the roller support have not been aligned without offset or if the outer
guidings have not been preset, proceed as follows:
Contents:
1. Pre-conditions for the roller installation
2. Preparation
3. Aligning the fixed roller (fixed bearing side)
4. Aligning the floating roller (fixed bearing side)
1. Pre-conditions for the roller installation:
On the axial side of the roller support, the upper and lower run are aligned towards each other
free from offsets and plane (see picture "Measurement after roller installation).
This must be checked with the aid of the frame measuring protocol (see Customer-specific and
technical data) and be documented.
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2. Preparation
Position both rollers with support centrally into the frame.
Then, perform the following measurements:
a1 = a2 for the fixed roller
Measurements after roller installation:
Note!
The following text describes the roller press variants "RP" as well as
the variant "RPS"!
Only observe the texts for the roller press variant delivered!
3. Aligning the fixed roller (fixed bearing side)
3.1. With a1 = a2, first at
outer guiding RP,

the lower inner area (a3) between frame run and outer guiding (behind the polished
chromium plates) is filled with spacer sheets 43-45. (See picture "Outer guiding RP").
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:Outer guiding RP,
Outer guiding RPS

the lower inner area (a3) between frame run and outer guiding (behind the slide plates)
is filled with spacer sheets 50-51. (See picture "Outer guiding RPS").
Outer guiding RPS:
3.2 When the distance a3 equals a4, on top (a4), the same number of spacer sheets 43-
45 (50, 51) must be placed behind; otherwise, proceed with 3.3.
3.3 If the distance a3 does not equal a4, the space (a4) must be filled with the necessary
number of spacer plates.
3.4 The still remaining distance between outer guiding and (a3, a4) after having inserted
the spacer sheets must be minimised by displacing the roller with support against the
spacer sheets.
On the inner side, the gap is (a3, a4) then = 0 mm
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3.5 Thereafter, the outer space (x1, x2) between frame belts and outer guiding must be
filled with spacer sheets.
Set gap at the outer side of the outer guiding: x1, x2 = 0.1 - 0.5 mm
4. Aligning the floating roller (fixed bearing side)
4.1 Align the floating roller to the fixed roller so that the roller front sides are flushing
towards each other. (See picture "Roller front sides RP or roller front sides RPS")
Roller front sides RP:
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Roller front sides RPS:
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4.2 When the front sides of the rollers are in a flushing position, first, the lower inner area
(a3) between frame run and outer guiding (behind the polished chromium plates or
slide plates) is filled with spacer sheets 43-45 (50, 51).
4.3 When the distance a3 equals a4, on top (a4), the same number of spacer sheets 43-
45 (50, 51) must be placed behind; otherwise, proceed with 4.4.
4.4 If the distance a3 does not equal a4, the space must be filled with the necessary
number of spacer plates.
4.5 The still remaining distance between outer guiding and (a3, a4) after having inserted
the spacer sheets must be minimised by displacing the roller with support against the
spacer sheets.
On the inner side, the gap is (a3, a4) then = 0 mm
4.6 Then, the outer space between frame runs and outer guiding (behind the polished
chromium plates or slide plates) must be filled with spacer sheets.
Set gap at the outer side of the outer guiding: x1.x2 = 0.1 - 0.5 mm
3.11.2 Aligning the floating bearings (fixed roller and floating roller)
(Drawings:
Frame, ZN 375-011-000465,
Roller support, ZN 375-012-000061)
Contents:
1. Alignment of floating and fixed roller (floating roller side)
2. Changing the offset measure during operation
Note!
Dismantle spacers (9, drawing ZN 475-081-000756, transport

accessories) from the outer sides of the floating bearing.
1. Alignment of floating and fixed roller (floating roller side)
If the floating bearing housing is displaced outwards towards the roller end, it is slid back so that
the floating bearing is mounted free from offsets. If the floating bearing housing is displaced
inwards towards the roller, it is slid back so that:
1.1 the offset of x4=15mm* is maintained with already welded-on assembly ring of the
guard.
* the measure x4 must be checked after welding-on of the assembly ring and be
documented.
With x4 = 15, an offset of 15 mm must be set.
With x4 = (e.g.) 16 mm after welding-on of the assembly ring, a measure of 16 mm
must be set etc.
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1.2 or an offset of 0 mm must be maintained with the assembly ring not yet being welded
on.
1.2 If the pre-conditions as per 5.1 or 5.2 have been fulfilled, on the floating and the fixed
roller, the inner area (behind the polished chromium plates or slide plates) (a5)
between frame run and outer guiding, must be filled with spacer plates 43-45 (50, 51).
On the inner side, the gap is (a5) then = 0 mm
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1.3 Then, the outer space (x3) between frame runs and outer guiding (behind the polished
chromium plates or slide plates) must be filled with spacer sheets.
Set gap at the outer side of the outer guiding: x3 = 0.1 - 0.5 mm
2. Changing the offset measure during operation:
If during operation the offset measure (15 mm) should strongly change (<5 mm), e.g. due to high
operating and cooling water temperatures, between frame run and slide shoe (a=5) on the
floating-bearing side of the floating and the fixed roller, a further shim must be placed.
e.g. sheet t=2mm to be added => offset = 17mm or (+) 2mm
3.11.3 Aligning the roller lining

(ZN 375-032-000821)
The sealing plates (60, 63-69) are sealing elements between bearing and lining.
The gaps between the sealing plates and the adjacent parts must be kept as small as possible.
However, the gaps between the sealing plates must be such large that a contactless
displacement is ensured or an oblique position of the floating roller.
The sealing plates (67-69) seal the area between lining and support of the fixed roller.
Both sealing plates (67 and 68) fastened to the socket of the support are screwed in an
adjustable manner to the sealing plates (69) so that the different distances between support and
lateral wall (1) can be set when re-adjusting due to wear. Here, the sealing plates (69) are in
gapless contact with the foam rubber seal of the lateral wall with door (1).
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3.11.4 Aligning the rubber thrust bearings

(Drawings:
Rubber thrust bearing, ZN 475-017-000685,
Pressing device, ZN 375-027-000077,
Resetting device, ZN 375-080-000121)
Note!
Bearing housing, rubber thrust bearing and flat cylinder must be on a

horizontal and vertical central axis and, therefore, be aligned towards
each other!
• The slide shoes (if included in the scope of supply) must be supported on the stainless steel
plate.
• The flat cylinders (6, drawing ZN 375-027-000077) are supported on the slide shoe or the
cleat and can be aligned to the end piece in the horizontal after having loosened the fastening
screws (3, 7, 8, 17, drawing ZN 375-027-000077) and eccentric discs (4-5). To that end, sling
a chain hoist between the flat cylinders and draw the respective loose flat cylinder (the other
one is fixed) towards the inside. Or, if necessary, press it outwards against the fixed flat
cylinder using an assembly cylinder and a suitably long wooden beam applied between the
tow flat cylinders. The alignment can be made within the clearance of the bolt holes.
• The flat cylinders are correctly aligned towards the rubber pressure bearing (1,2,4 / drawing
ZN 475-017-000685), if the alignment gaps on the right and the left of each rubber thrust
bearing have the same measure!
Caution!
A rubber thrust bearing not adjusted in parallel to the contact surface of the
bearing housing can cause the premature wear of the rubber plates (2,
drawing ZN 475-017-000685)!
• After the alignment, tighten the loosened screws, turn the eccentric discs into position and
fasten them. Screw the rubber thrust bearings to the pistons of the flat cylinders (drawing ZN
375-027-000077).
Required torques (see section "Customer-specific characteristic and technical data")
• Then, fasten bellows (22, ZN 027-000077) to the rubber thrust bearing using the clip (23).
3.11.5 Installation and adjustment of the lateral walls for the feeding device
(Order group 30, drawing ZN 375-029-000764, 375-029-000770,
375-029-000769)
a) Installation of the lateral wall (ZN 375-029-000770)
• Fasten the lower row of screws (61,63, ZN 375-030-000541) to the frame of the roller
press and place the bracket (1) of the pressing device onto these two screws. Then, move
the bracket towards the frame and insert the two upper screws (61,63, ZN 375-029-
000764).
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• Screw the brackets of the lateral walls (1) to the frame (61-63, ZN 375-030-000541) and
place the lateral walls (3,10) on these brackets. Now, draw the lateral walls against the
roller front sides and fasten them to these brackets.
• Set the required gap of about 1 mm between roller face and lateral wall as described
below.
b) Adjust the lateral wall (ZN 375-039-000599)
• Unfix counter nut (29) and remove the anti-twist guard (28). Press the lateral wall to the
roller front side via the pressure bolt (27) by turning the nut (25) and then turning it back by
half a rotation (gap between lateral wall and roller front side ca. 1 mm). Counter the two
nuts (25, 29).
Caution!
Check plate spring preload as indicated in the drawing

ZN 375-029-000769 and reset, if necessary.
Drawing ZN 375-029-000770
• Check gap in the upper area between lateral wall and roller face, re-set, if necessary. For
setting the gap, the threaded rod (22) is displaced by turning the nuts (5) at the spherical
joint (18, 19) and countered with the counter nut (17).
• The measure 76 mm is corrected after this setting by turning the nut (7) at the spring plate
(24).
• Check the gap of about 1 mm between lateral wall (60, ZN 375-029-000764) and the
housing (1, ZN 375-029-000764) of the feeding device; re-adjust, if required.
• Re-adjusting is made via the vertical threaded rod (15) by turning the upper nut (5) Secure
with counter nut (17).
• Mount cover (68, ZN 375-029-000764) as indicated in the drawing.
Note!
After having set the feeding device, the protocol for the feeding device
must be filled in, see customer-specific characteristic and technical
data.
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3.12 Closing the roller lining

• Using chain hoist or lifting facility (by customer, see table "Assembly tools and accessories"),
sling to lateral wall with door (1).
• Secure lateral wall with door (1) upwards and secure it in closed condition with screws (3, 4,
6).
• Remove rope hoist and auxiliaries, if any.
The door of the roller enclosure may only be closed, when no person is
staying within the enclosure.
No persons may stay in the turning area of the lateral wall.
3.13 Water cooling system
(order group 34, drawing ZN 375-034-000005, roller support, drawing ZN

375-012-000061)
• The water cooling system is installed acc. to drawing ZN 375-034-000005.
• Dismantle end cover fixed bearing (130, drawing ZN 375-012-000061).
• Introduce coolant pipe (3) with slide bearing (4) and O-ring (9) into the rollers and fasten with
screws (15, 16). Screw in locking plug with sealing ring (13, 14).
• Mount flange (1, 2) with O-ring (6) and screws (10, 11). (Observe left-hand and right-hand
thread).
Caution!
Right flange (2) has right-hand thread, installed in anti-clockwise rotating

roller.
Left flange (1) has left-hand thread, installed in clockwise rotating roller.
• Mount end cover fixed bearing again (130, drawing ZN 375-012-000061).
• Screw immersion pipe (5) into the rotary passages (7, 8). Use thread-sealing and securing
agent here.
• Mount rotary passage (7, 8) (observe left- and right-hand thread) and screw torque support
(19) in place (70-74).
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• Fasten hood (12) (17, 18). The rubber sleeve encloses the rotary passage. The plug (39)
closes a control opening.
• The hood (12) must remain dust-tight.
Caution!
No holes or other openings are permitted to be applied!
Caution!
The plug (39) must not be permanently removed!
• The frame (52) with the mounted installation is fastened on the foundation on either side of
the roller press.
• Mount hoses (20) for the water supply and for draining as per sub-assembly drawing.
• Supply line (internal line) to be connected by customer to gate (38).
• Drain line (external line) to be also connected by customer.
• Connections (38) G 11/2.
• The temperature opening point of the volume control valves (44) for roller cooling is fixedly
set. The temperature opening point of the volume control valves (43) for bearing cooling is
also fixedly set. (See section "Customer-specific characteristic and technical data").
Note!
References for warranty claims:
A chemical analysis of the cooling water should be made for the first
time at the beginning of first starting-up, then every 500 hours and
finally every half year. An assessment of the water regarding its
corrosive aggressiveness should be available. This analysis must be
made by an independent institute including a respective protocol. The
results must be made available to the KHD Humboldt Wedag during the
warranty time.
In case of non-observance, warranty claims are null and void.
To determine the causes in a damage case outside the warranty period,

this procedure should be continued by the plant operator filing the
pertaining documents.
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3.14 Central lubrication

The oil central lubrication system is installed according to the construction drawing of the sub-
assembly and the enclosed supplier's documentation.
Observing the installation instructions for sectional ring screw unions (see chapter "Pressing
device"), mount the pipelines.
Caution!
Saw pipelines to size and debur them. Then, rinse (volume of rinsing liquid at
option) and blow out with compressed air.
Note!
To avoid installation errors, observe the enclosed supplier's

documentation.
Prior to the trial run of the roller press, perform the following works:
• Install wall-mounted crane (14) as per installation drawing.
• Insert barrel pump unit into the respective 200 l barrel.
Caution!
For lubricating the roller press main antifriction bearings, only lubricants are
admitted which are specified in section "Customer-specific characteristic and
technical data/List of lubricating points".
Caution!
Only genuine units of grease barrels are permitted to be used. These grease
barrels may be opened only prior to inserting the grease barrel pump.
Refilling of grease into another tank is not permitted in view of the risk that
dirt can enter and cause a failure in the central grease lubrication system.
Ensure absolute cleanliness during a barrel change.
• Electrically connect the system and perform trial run, until oil-free grease emerges at the
hose (27).
Note!
Procedure as per enclosed supplier's documentation.
• Make the connection between hose (27) and roller press.
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Caution!
Bleed the lines to the roller press.
• Connect pump and have it run, until grease has emerged from all connection lines (hoses 37).
• Connect hoses (37) according to the assignment made.
Grease emerging from the labyrinths is collected in grease boxes.
3.15 Mounting the accompanying heating of the supply- and return line
Note!
In addition to the supplier's documentation, during the installation of

the accompanying heating, the following must be observed:
a) Return line
• Mount and connect the regulators with power units in the pump room as described in
the supplier's documentation.
• For the return line, 2 heating strips are required.
Prior to cutting the heating strips, measure their length.
After having cut the heating strips to length, the individual cutting points of the lines must
be connected (see supplier's documentation).
• Every heating strip is connected with a regulator (see supplier's documentation).
• The heating strips are mounted from the terminal box (6) in the specified laying direction
as per drawing ZN 475-84-136.
• For fastening the heating strips, plastic binders or adhesive aluminium tape are included
in the supply with which the strips are fastened to the tube. In this way, a safe and close
contact of the heating strips to the pipelines is achieved (also see supplier's
documentation in section "List of the separate documentations").
b) Supply line
• Mount and connect the regulators with power units in the pump room as described in
the supplier's documentation.
• For the supply line, 2 heating strips are required.
• Prior to cutting to length, measure the lines.
• Mounting takes place similar to the return line. In view of the small pipe cross section,
however, the heating strip is laid in parallel to the pipes.
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c) Installation of the temperature sensors

• For monitoring the temperature of the supply and return lines, one temperature sensor,
each, has been provided for.
• Mount temperature sensor Pt100 (5) as indicated in drawing ZN 475-84-136.
Then, connect as per supplier's documentation (see section "List of the separate
documentations").
d) Checking the accompanying heating

• for correct laying of the heating strips
• for the correctness of the electrical connections.
e) To avoid heat losses, the pipes must be insulated. The insulation must be provided and
installed by the customer.
See section "Customer-specific characteristic and technical data", Item "Accompanying
heating/Insulation of the lines".
Caution!
Starting up and operating the roller press upon cold ambient

temperatures without insulation can entail considerable problems.
3.15.1 Mounting the barrel bottom heating and accompanying heating of the
grease lines
a) Barrel bottom heating/heating strip
Mount the barrel bottom heating/heating strip included in the supply unpacked as per
drawing ZN 475-084-000230.
Note!
To avoid installation errors, observe the enclosed supplier's

documentation (see section "List of the separate documentation").
b) Supply line
• Mount and connect the regulators with power unit in the pump room as described in the
supplier's documentation.
• For the grease line, 2 heating strips are required.
• Prior to cutting to length, measure the lines.
• In view of the small pipe cross section, during the installation, the heating strip is laid in
parallel to the pipes.
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Assembly
c) Installation of the temperature sensors
• For monitoring the temperature of the supply and return lines, one temperature sensor,
each, has been provided for.
Mount temperature sensor Pt100 as indicated in drawing ZN 475-084-000230.

Connect as per supplier's documentation (see section "List of the separate
documentations").
3.16 Drive, torque support and guard

(Drawings:
Drive, ZN 475-047-000046,
Torque support, ZN 475-046-000819,
Guard, ZN 375-046-000297,
Guard, ZN 375-047-000335)
The drive (order group 36) is delivered in the following part groups:
1. Main drive motors (normally provided by customer).
2. Planetary plug-on gear (2) with plugged-on chain sprocket (3) for the maintenance drive
and coupling (5).
3. Cooling system (4) with connection hoses.
4. Articulated shafts (7) and flexible coupling (9) for motor shaft journal.
5. Torque support (order group 38, drawing ZN 475-046-000819).
6. Guard for shrinking disc and coupling/articulated shaft.
(order group 46/47)
3.16.1 Main drive motors

The main drive motors must be aligned as per installation drawing and bolted to the foundation
or the platform as directed by the manufacturer.
3.16.2 Installation device roller press gear

(Optional, if included in the scope of supply!)
Note!
Prior to mounting the gear, the spacer ring (19-21, ZN 375-039-000032,)

must be mounted. The hydraulic connections (bore for oil pressure
test) at the shrinking disc are in the 'noon' position. One of the recesses
of the spacer ring (order group 39) is located opposite to the oil
pressure-test bore at the shrinking disc.
Caution!
Also parts of the guard (ZN 375-046-000297) must be pre-mounted (see item
"Guards").
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The design is characterised by it that the gear- and shaft axles can be exactly aligned
horizontally and vertically. The vertical alignment is made via three hydraulic lifting units which
can be independently triggered. They can be additionally displaced into horizontal direction with
the aid of simple forcing screws. The vertical alignment remains constant over the entire
displacement path. After having been withdrawn from the shafts, the gears remain in a "parking
position" on the supporting scaffolding of the dismantling- and mounting device and are ready for
being installed again. The required space is provided by the previous dismantling of the
articulated shaft. Thus, the most important preconditions are fulfilled with, at the same time, a
drastically minimised risk of damage for the pressing fits.
Stationary lifting facilities or a mobile crane are only required for transporting the gears to and off
the site.
Prior to starting the works, all working means such as supporting frames, forcing-off girders,
travelling devices, basin, ropes, tools etc. must be checked. Damaged tools, slinging means or
auxiliaries may not be used.
3.16.3 Installation torque support, gear holder

Mount the gear holder (1) to the planetary plug-on gear (tightening torques for the screws as per
section "Characteristic and technical data").
Mount the shrinking disc as per supplier's documentation (see section "List of the separate
documentations") to the hollow gear shaft.
Note!
The screws for securing the shrinking disc must previously be

removed. After having mounted the gear on the roller, these screws
must be inserted again.
Then, position the planetary gear on the gear displacing device (see item "Mounting gear").
3.16.4 Installation dismantling device

(Optional, if included in the scope of supply!)
The distance between fixed and floating roller must be maintained as indicated in the installation
drawing
(drawing ZN 375-001-000116, sheet 1).
Mount the two supporting frames (1) with foundation bolts (2) onto the foundation (F21,
installation drawing ZN 375-001-000116). Aligning the two supporting frames to the same height
level using the shims (3-6) included in the supply.
Mounting the suspension scaffolding (7) between the two supporting frames (1).
Place the travelling devices (19) onto the supporting frame (1). Upon the installation, check the
displaceability of the displacing device without weight of the gear.
Insert the three hydraulic cylinders (500 bar), each, with threaded plates (21) onto the displacing
device on the left and the right.
Place the basins (33) onto the travelling device (19).
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Adjust the hydraulic cylinders (21) with the two threaded spindles (see Fig. 475-81-717_Doku
01) in the dismantling device, until the piston protection plates (26) of the cylinders are positioned
correctly fitting underneath the cylinder guidings of the basin (33).
Piston protection plates
Cylinder guiding
Threaded spindles
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3.16.5 Mount gear.

During the installation works, no person is permitted to stay in the

displacing area of the dismantling device.
If the scope of supply does not comprise a dismantling device for dismantling and mounting of
the gears, the gears must be slung with the aid of a mobile bridge crane such that they can be
aligned to the longitudinal roller press axis with their longitudinal axis being absolutely horizontal
or in parallel! The gears must be mounted to the rollers without angular offset.
Avoid jamming, risk of seizing!
Do not stay underneath suspended loads!
The parts of the guard, which can no more be mounted after having
mounted the gears, must be previously installed, see item "Guards"
below!
Assemble the lifting unit and connect it with the three hydraulic cylinders (21, drawing
ZN 375-075-000117) via the hoses to the distributor valve at the manual pump.
(see Fig. 475-492).
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Assembly
Hydraulic set 500 bar
Item 1 Three cylinders (21, drawing ZN 375-075-000117)
Item 2 Three piston protection plates (26)
Item 3 Three plug-type coupling sleeves (24)
Item 4 Three hose lines (27)
Item 5 Three pressure gauge units 0-600 bar (25)
Item 6 One 4-way distributor valve (22)
Item 7 One connection element (32)
Item 8 One plug-type coupling nipple (31)
Item 9 One plug-type coupling sleeve (29)
Item 10 One hose line (30)
Item 11 One Hand pump (28)
Check oil filling in the hydraulic manual pump (28, ZN 375-075-000117) and renew it, if required,
or refill (see lubricating list in section "Customer-specific characteristic and technical data").
The three hydraulic cylinders (21, ZN 375-075-000117) must be extracted (ca. 15 mm), until all of
the three piston protection plates (26, ZN 375-075-000117) are perfectly fitting inside the cylinder
guide on the basin (33, ZN 375-075-000117).
Fix the position of the hydraulic cylinder (21, ZN 375-075-000117 ) with the threaded spindles
(see Fig. 475-81-717_Doku 01) from either side.
Using stationary lifting devices or a mobile crane, place the gear onto the basin (33, ZN 375-075-
000117) (see Fig. 475-81-717_Doku 04).
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Assembly
Caution!
The distance "X" between gear holder and front support of the basin must be
observed.
Note the pressure per lifting device = supporting force

(important for dismantling plus weight of oil).
X = ca. 356
Gear Basin Gear holder
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Assembly
Fasten rope hoists to ribs in the frame
Fig. 375-075-000117_Docudrawing_mount gear
As a slinging point for the rope hoist, in the upper bore in the gear holder (1, ZN 475-046-
000819) the threaded pin is screwed in with the shackle (41, 66, ZN 375-075-000645) and
fastened to the opposite ribs in the frame (see Fig. 375-075-000117
Dokuzeichnung_Getriebe_aufziehen, i.e. documentation drawing_mount_gear).
Check the fits of hollow- and pressure shaft for damage and absolute freedom from grease.
Uniformly and slowly pull the gear with the rope hoist, until a minimal distance between the front
sides of hollow- and pressure shaft is reached.
Exactly align the hollow shaft to the roller vertically and horizontally using lifting units (see Fig.
475-492) and threaded spindle (see
Fig. 475-81-717_Doku 01). Check with the feeler gauge.
Sliding the hollow shaft of the gear up to its end position (stop ring, order group 39, drawing ZN
475-047-000046) using rope hoists.
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Loading of the shrinking disc (see supplier's documentation in section "List of the separate
documentations").
Note!
To avoid assembly mistakes with the planetary plug-type gears and the
shrinking discs, observe the enclosed suppliers' documentations (see
section "List of the separate documentations").
In addition to the supplier's documentation, among others, the following must be observed when
mounting the shrinking disc:
The bore of the gear hollow shaft and the shaft seat of the roller must be absolutely free from
grease and must not show any damage. To permit that all grease residues can be completely
removed, the fitting surfaces must be covered with lime milk and be cleaned again after having
dried.
After having mounted the gear on the roller, the screws must be inserted again to secure the
shrinking disc.
• The bearing blocks (14, drawing ZN 475-046-000819) of the torque support with the
supporting plates (21) must be aligned according to the installation drawings, tightened on the
foundation and secured with the counter nuts.
• The gear holder (1, drawing ZN 475-046-000819) must be connected with the support (9)
using the bolts (17).
Caution!
Observe direction of installation and dismantling of the offset bolt (17) as

indicated in the drawing!
Insert bolt with assembly paste.
• Then, secure bolt (17) with retaining plate (19).
Note!
To avoid errors when mounting the articulated shafts, observe the

enclosed supplier's documentation (see section "List of separate
documentations").
• The flexible couplings (9, drawing ZN 475-047-000046) must be mounted onto the motor
shaft and be secured.
• Then, the articulated shaft (7, drawing ZN 475-047-000046) can be flanged between motor-
side flexible coupling and gear-side safety clutch (5). (For required torque for the flange
screws, see enclosed suppliers' documentation in section "List of the separate
documentations")
• Do not separate the spline toothing of the length extension, i.e. extracting it completely. The
hinges must have the same length on either side (marking). Extension in installed condition
about 100 mm.
For flange parallelism to the articulated shaft, see enclosed supplier's documentation in
section "List of the separate documentations".
• Mount the second gear (see item "Mount gear").
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Assembly
• After having completed the works, the displacing devices and the basin must remain directly
on the supporting frame.
• The hydraulic cylinders (21, drawing 375-075-000117) remain in the travelling device.
Other accessories must be dismantled after having terminated the works and be stored at a
protected place, e.g. a tool cabinet.
3.17 Guards
(Drawings:
Shrinking disc, ZN 375-046-000297,
Coupling and articulated shaft, ZN 375-047-000335)
The guard comprises the following:
a) Cover for the shrinking discs (order group 46)

(Drawing ZN 375-046-000297)
Assembly sequence before mounting the gear:

1. Mount spacer ring (19, ZN 475-047-000046).
2. Weld item 1 to the cover of the bearing
3. Screw item 3, 4 to item 1 (2, 6)
Caution!
Observe position of the bore!
4. Mount guard elements (8,9) to the gear holder (order group 38).
5. Uniformly fasten rubber disc (11) between the flanges (12-15).
Caution!
The guard must remain dust-tight. No holes or other openings may be made.
b) Coupling- and articulated shaft guard (order group 47)

(drawing ZN 375-047-000335)
1. Place and align the scaffolding (5), then dowel it to the floor using the foundation bolts
(20).
2. Suspend protective hood (1) into 5 and screw into place (15, 16, 17). Then, suspend
cover (8) into 1 and screw into place (16, 17, 18).
3. Insert the displaceable protective hood (2) into 1. After the alignment, tack-weld in
place (1) and screw together with cover (6) (16, 17).
4. Screw (14, 15, 16, 17) protective hood (3) to 5 and then to cover (9) (17, 18)
5. Finally, align the protective plate (4) and screw it to 3 (17,19)
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Assembly
Note!
After having mounted all components of the drive system and the
guards, fill in the protocol for the drive under customer-specific
characteristic and technical data.
3.18 Electrical measuring instruments

The electrical equipment (order group 33) is pre-assembled as partial units and then mounted
according to the sub-assembly drawing together with the necessary hardware towards the end of
the entire roller press assembly.
3.18.1 Roller gap monitoring / Roller limit disconnection
Caution!
The switch point for the roller limit position disconnection and for roller gap
monitoring during the idle test is set as follows:
The floating roller moved against the mechanical stop. The distance between the rollers is then
10 mm and the scale in the measuring system is set such that the pointer indicates "60" (start of
working cycle).
The output signal of the inductive way transmitter is >4.1 mA in this position.
Via the hydraulic starting system, the movable roller is retracted by 50 mm (check measure at
mechanical stop).
The pointer is then on "10" (end of working cycle).
Here, the output signal of the transsonar way transmitter is about 12.1 mA.
The approximation switch must finally be set such that the working stroke is disconnected, when
the pointer is in position "10" (end of working stroke).
Caution!
The covers of the movable parts have not yet been mounted, as these would
hinder the setting procedures.
Risk of squeezing
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Assembly
3.18.2 Temperature monitoring at the main bearings

(drawing ZN 475-029-000260, sheet 2)
Screw resistance thermometers (36) into the housings as indicated in the drawing
3.18.3 Rotation monitoring system for shrinking disc

(drawing ZN 475-029-000260, sheet 2)
Install approximation switch (50) for rotation monitoring to the shrinking disc cover.
Screw in bolt (52) (2-4 units) into the shrinking disc as a pulse transmitter.
The nut (51) is tacked to the inner side of the hood near the bore.
Place hood in position (see item "Guards") and turn shrinking disc, until a pulse transmitter (52)
is in a central position to the acceptance bore of the approximation switch.
The distance between the approximation switch (50) and the pulse transmitter (52) muss be 3-
8 mm. To that end, turn in/out the approximation switch (50) or use washers (53).
Note!
After the electrical connection of the approximation switch (50), the

correct distance to the pulse transmitter (52) is indicated by lighting up
of the pilot light on the approximation switch (to be determined by
screwing in and subsequent unscrewing). The minimal distance to the
pulse generator may be taken from the supplier's documentation (see
section "List of the separate documentations").
After setting, tighten counter-nut.
The guards must be mounted prior to starting the machine.

Rotating parts!
3.18.4 Standstill- and temperature monitoring at the fluid coupling.

(omitted for the execution with Safe Set coupling)
The holder for the sensor (32) is fastened from the inside, underneath the coupling in the
coupling- and articulated shaft guard. To that end, the cover must be removed from the guard.
The transmitters are screwed into the coupling.
For that purpose, the sensor (32) must be set at a distance of about 2 mm.
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Assembly
The guards must be mounted prior to starting the machine. All flaps
and covers must be tightly closed with screws.
Rotating parts!
3.18.5 Feed material - temperature measurement
(Temperature monitoring at the rollers)

(not included for single-material rollers or cold feed material)
Fasten resistance thermometer (40) to the lateral walls of the feeding device using bolt (41).
The electrical lines must be drawn through the protective tube.
To simplify dismantling and installing of the lateral walls, install the socket included in the supply
at the vertical wall of the frame.
3.18.6 Monitor the rocker arm closed position

(drawing ZN 475-029-000260, sheet 3)
(omitted for the version with plug-type end piece)

Approximation switches monitor the closed rocker arms!
In case of unintended loosening or opening of the rocker arms, a pulse for stopping the roller
press is released!
During a roller change with opened rocker arms, these approximation switches in addition avoid
unintended connection of the roller press!
Mount and set approximation switches as indicated in the drawing.
Note!
After having mounted the electrical measuring systems, the protocol

for the electrical measuring systems must be filled in, see customer-
specific characteristic and technical data.
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3.19 Final works

After completion of the installation of the roller press, it is checked again via the 6 measuring
points, whether the roller press is aligned within the admissible height tolerances (see item 3.2
"Foundation and frame" and "Characteristic and technical data" of order group 11 "Frame").
In the case of a concrete foundation, additionally, the following works must still be performed.
• Grout foundation bolts in the foundation.
• After setting of the concrete, tighten foundation bolts.
• Check again via the 6 measuring points, whether the roller press is aligned within the
admissible height tolerances (see item 3.2 "Foundation and frame" and section "Customer-
specific and characteristic and technical data" of order group 11 "Frame") and re-adjust, if
necessary.
Note!
The measuring results must be entered into the measuring protocol in

section "Customer-specific characteristic and technical data", item
2.1.1.2 "Measurement table frame" .
Note!
Assembly tools, transport devices and guards such as spacers,

suspension facilities, slinging devices, protective sheets etc. must
carefully be kept for subsequent repair works.
4 Preparations to the test without material and interlocking tests

After the completion of the roller press assembly prior to first feeding of the material, the following
must be checked or performed:
4.1 Check points safety.

Prior to starting the roller press, perform the following checks!
Note!
Also see "Check list safety" in section "Customer-specific

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4.2 Mechanic system

• Tighten all screw unions with a torque wrench. The specified tightening torques must be
checked (see section "Characteristic and technical data" of the order groups).
• Check the position of the lubrication lines.
• Close line system of the central lubrication system (order group 15) and operate grease
pump, until grease visibly emerges at the inner labyrinths.
• Close line system of the oil circulation lubrication system (order group 13).
• Close line system of the pressing device (order group 27). Vent pressing device according to
item 3.4.3.3 "Venting the pressing device".
• Check connection of the line system of the water cooling to the water supply system of the
customer and lock it.
• Check correct installation of the electrical measuring instruments (order group 33) (way
transmitter, approximation switch, resistance thermometer).
• Check inner space (roller gap) and feeding device (order group 30) of the roller press as well
as the material supply system for foreign bodies (wood, forgotten tools etc.)
• Check filling level of the hydraulic set (see "List of lubricating points").
• Check filling level of the planetary gear (see "List of lubricating points").
• Check filling level of oil circulation lubrication system (see "List of lubricating points").
4.3 Electric system

• Check sense of rotation of the main drive motors.
Caution!
The sense of rotation of the main drive motors may only be checked, if the
spacer (transport guard) between roller and bearings is removed.
• Check the proper electric installation as per available documentation.
• Check and adjust the guards/motor protection relay, counters etc.
• Test of the entire control and measuring equipment.
• Test the machine guard.
• Test the applied protective measures (e.g. earthing resistance).
• Resistance measurement of the insulation of all motors.
Electrical adjusting values as per section "Customer-specific characteristic and technical data" of
the respective order groups.
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5 Tests without material and interlocking tests without material
Caution!
The roller press may only be started, when the checks under item "Check
points safety" have been performed up to item "Electric system".
The roller press may only be started with empty roller gap.
5.1 Tests without material

After the completion of the installation of the roller press and of the preparations for the "Idle and
interlocking tests", first, the idle tests must be performed. This means starting of the roller press,
its auxiliary sets (e.g. central lubrication system) and its material discharge groups (e.g. belt
conveyors) to evidence the proper condition and trouble-free functioning of the individual
machines.
The tests without material are terminated, if all required readjusting works and those having
become necessary have been completed and it is ensured that the mechanical sets may be
operated for the time of the interlocking tests without further supervision.
The idle tests require that the drives coming into question are ready for being connected after the
termination of the mechanical and electrical installation and that the sense of rotation has been
checked.
5.2 Interlocking tests

After the termination of the idle tests, the persons in charge of the electrical and mechanical
installation release the plant for the interlocking tests. The interlocking programme has
previously been internally checked within the scope of the assembly works.
During the interlocking tests, no mechanical readjusting works must be

carried out.
The interlocking test are meant for demonstrating the operation of, first, individual plant sections
among them and then the plant sections in combination such that, in case of a failure of one
drive, it is ensured that drives connected in front within the interlocking chain are disconnected
immediately or after a specified time. It is absolutely required that all drives are correctly
connected within the interlocking chain and that the control system properly works.
During the interlocking tests, all motors must be running. To ensure this, couplings must be
disengaged, if required.
Note!
A simulation of running drives at withdrawn fuses or electrical draw-in

units shall be avoided in the interest of the subsequent commissioning.
For controllable drives, the "ready for operation" message also applies to the control. The
pertaining indicating instruments must be checked for proper functioning.
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Assembly
5.3 Modes of operation for the idle tests and the interlocking tests without
material
5.3.1 Individual mode (local mode)

• Set selection switch to individual mode.
• Connect oil circulation lubrication and bring lube oil to the specified temperature via the
indicated heating-up circuits.
• Connect gear oil pumps.
• Open cooling water supply valves.
• Connect accompanying heating of the lubricant supply system.
• Connect barrel pump of the central grease lubrication to the labyrinth seal.
• Connect oil circulation lubrication system
• Connect main drive motors.
• Bring hydraulic pressing system to specified pressure.
• Operate roller press and auxiliary sets for about 2 hours without load.
In these 2 hours, the following checking and adjusting works must be performed:
Accompanying heating /barrel bottom heating:
Depending on the ambient temperature at the roller press, the accompanying heating must be
set such that the grease volume adjustment described below may be performed trouble-free.
Grease volume setting of the central lubrication system to the labyrinth seal:
• Grease quality as per "Characteristic and technical data/List of lubricating points" (Check
lettering of the grease barrel).
• Disconnect all lubrication hoses from the bearing housings (order group 12).
• Fasten transparent plastic bags to the lubrication hoses.
• Check, whether the pump element has been set to maximum delivery (see supplier's
documentation).
• Connect barrel pump (order group 15) for about 3 hours of continuous operation.
• Weigh grease volumes (see section "Customer-specific characteristic and technical data")
and set the operating time according to the required grease volume per bearing and hour in
the program control system or at the operating time relay.
• The resting time must also be entered or set at the resting time relay.
• Connect lubricating hoses again and check lubricating system for tightness.
• Set barrel pump to continuous operation, until fresh grease emerges from the labyrinths or a
grease collar has formed.
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Assembly
Further checking and adjusting works:
All other lubricating points must be supplied as per section "Customer-specific characteristic and
technical data/List of lubricating points".
• Functional check of the accompanying heating.
• Check cooling water supply system for tightness.
• Check the exact adjustment of the switch point of the roller limit disconnection and correct, if
required (for values see section "Customer-specific characteristic and technical data" of order
group 21 "Roller").
• Adjustment of the roller limit disconnection
The inductive approximation switches (18, drawing ZN 475-29-260) serve for the safety
disconnection of the roller press immediately disconnecting the motors as soon as the
movable roller is displaced more than admissible due to foreign bodies passing. The
approximation switches must be adjusted such that a limit disconnection takes place when
the residual stroke in the piston of the flat cylinder is 10 mm. If, in new condition, the movable
bearing housings are in contact with the spacers as described above, the piston of the
cylinder is extracted by 50 mm (drawing ZN 475-29-260). By displacing the approximation
switch, the switch point may be set very precisely.
• Set transsonar way transmitter;
• (also see item "Required re-setting works upon roller wear" in chapter "Maintenance").
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• During the assembly, determine the minimum distance of the roller surfaces, when the
movable bearing housing is in contact with the spacer of the centre element. To that end, the
movable bearing housings should be pressed against the spacer elements at a pressure of
about 40 bar. In this position, the transsonar way transmitter must be balanced by an
electrician and indicate an output current of >4.1 mA (see documentation "Machine control").
Now, the zero point of the transsonar way transmitter is determined. The distance between
the roller surfaces is best determined with the aid of a solidly formed small ball of aluminium
paper which is dropped through the roller gap. The pressed thickness of the small aluminium
paper ball is the constant which must be entered into the control program.
Caution!
If the original spacers are replaced or changed, the way transmitter must be
newly balanced.
• Monitor bearing temperatures of the antifriction bearings, feed material temperature

measurement (with resistance thermometer) and planetary gear (with temperature governor).
Values as per section "Customer-specific characteristic and technical data" of the respective
order groups.
• Observe abnormal running noise of the roller press.
• Thoroughly vent hydraulic system as per item "Venting of the pressing device".
Caution!
Repeat venting of the hydraulic pressing system after 4 to 5 hours.
If the oil level in the hydraulic set tank is too high, upon completely retracting
the movable roller, the displaced hydraulic oil cannot be totally taken by the
oil tank. Therefore, the oil tank shall be filled up to the upper mark only with
the movable roller completely retracted.
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5.3.1.1 Zero gap setting
• During the assembly, determine the minimum distance of the roller surfaces, when the
movable bearing housing is in contact with the spacer of the centre element. To that end, the
movable bearing housings should be pressed against the spacer elements at a pressure of
about 40 bar. In this position, the transsonar way transmitter must be balanced by an
electrician and indicate an output current of >4.1 mA (see documentation "Machine control").
Now, the zero point of the transsonar way transmitter is determined. The distance between
the roller surfaces is best determined with the aid of a solidly formed small ball of aluminium
paper which is dropped through the roller gap. The pressed thickness of the small aluminium
paper ball is the constant which must be entered into the control program.
The zero-gap distance between the two roller surfaces (pressed thickness of the aluminium
paper balls) as per section "Customer-specific characteristic and technical data").
Note!
If the original spacers are replaced or changed, the way transmitter

must be newly balanced.
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5.3.2 Unlocked mode

• Set selection switch to the automatic mode.
• Set "Unlocked-interlocked switch" to unlocked.
• Actuate starting alarm switch and wait for release for connecting the roller press.
Start the roller press order group (central lubrication system, roller press main drive motors
etc.).
• Test interlocking of the roller press order group

(see chapter "Interlocking scheme = function plan).
5.3.3 Interlocked mode

• Set selection switch to the automatic mode.
• Set "Unlocked-interlocked switch" to interlocked.
• Actuate starting alarm switch and wait for release for connecting the roller press.
• Start the material discharge groups.
• Start the roller press order group.
• Start the material supply group.
• Test interlocking (e.g. actuate local switch of the material discharge group; the entire material
chain must stop).
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Commissioning BA 475-0143-06 en
Page 1 of 10
Contents Page
1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Safety in general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2 Chapter-related safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Check list safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Previous edition:
3 Trial run with feed material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 First starting up of the roller press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.2 List of the main control circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Miscellaneous. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Wear measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5.2 Training customer's staff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.3 Acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Electrical measuring instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.1 Roller gap monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6.2 Roller gap monitoring / Roller limit disconnection . . . . . . . . . . . . . . . . . . . . . . . 9
6.3 Temperature monitoring at the main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.4 Rotation monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.5 Feed material - temperature measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Page 2 of 10; BA 475-0143-06 en
Commissioning
1 Safety

the Technical Machinery Documentation, Section "Operating instructions".
Therefore, it is absolutely necessary to thoroughly read chapter Safety and Health prior to
starting any works with and atthe roller press and to observe the included safety references.
The safety references in the text and the pertaining drawings

must also be observed!
1.3 Check list safety
Prior to the release for starting the roller press after assembly,
repairs, maintenance etc., a responsible person must make the
checks indicated in section: "Customer-specific characteristic
and technical data" under "Check list safety".
It is urgently recommended to copy the original lists and to file the filled in copies for later
evidence.
Page 2 of 10; BA 475-0143-06 en

BA 475-0143-06 en; Page 3 of 10
Commissioning
2 Information
Caution!
The interlockings determined by the Humboldt Wedag GmbH (process automation)

documented in the interlocking plan must be checked for proper functioning prior
to commissioning.
Functioning must be recorded and the protocol be undersigned by the customer.
In case of deviations, an operation requires the approval of the Humboldt Wedag

GmbH, Department Design.
If modifications should subsequently be made without the approval of the Humboldt

Wedag GmbH, the warranty granted by the Humboldt Wedag GmbH will expire.
Caution!
Prior to commissioning the roller press, proper functioning of all

contractually agreed guards such as metal discharge, metal
detector, sieves etc. must be checked and recorded in a protocol.
If the arrangement or the function of the protective guards should

not be as agreed and/or laid down in the contract, the warranty
granted by the Humboldt Wedag GmbH will expire.
If modifications are made without the approval of the Humboldt

Wedag GmbH, the warranty granted by the Humboldt Wedag GmbH
will expire.
To avoid delays, the first activities of the commissioner should comprise the following:
• Handing over the commissioning program to the responsible person of the customer for
discussing and matching it, if necessary.
• Determining the staff requirement for sampling and sample evaluation
• Checking the sampling points
• Checking and, if necessary, production of the sampling equipment
• Checking the evaluation instruments for their availability
The first commissioning has a decisive influence on the optimal operation of the roller press. In
this period, not only the roller press proper, but also the system together with the plant
components connected up- and downstream are optimally matched to each other.
The optimal performance and the operating behaviour of the roller press is essentially influenced
by feed material parameters such as
• physical properties,
• grain size distribution,
• grain distribution over the roller width,
• moisture,
• temperature.
BA 475-0143-06 en; Page 3 of 10

Page 4 of 10; BA 475-0143-06 en
Commissioning
Moreover, the uniformity of the fed material volume is of high importance. Therefore, the
following applies:
Caution!
Above the roller gap, a material bed must always exist. This requires
a continuous material supply, i.e. the bin arranged above the roller
press must always have a sufficient filling level. The height of the
filling level is monitored via the superior plant control and is kept as
constant as possible.
An interrupted material supply leads to an irregular operation of the

roller press and, thus, to product losses during the starting- /
slowing-down phases and the stabilisation of the circuits.
The use of roller pairs with different surfaces and / or diameters

requires the expressed approval of the Humboldt Wedag GmbH.
On the roller press, the following operating parameters can be pre-selected via ROLCOX®:
• Pressure
It directly influences the pressing result and also determines the flake thickness = roller
gap.
• Circumferential speed (only for frequency control)

Primary influence on the throughput rate
• Gate position of the feeding device

Influence on the optimal roller gap = flake thickness and, thus, also on the throughput rate
In view of these multifarious influences and setting options, we urgently recommend to take the
services of Humboldt Wedag staff for commissioning.
This should not be done only for reasons of warranty but because, at the same time, the
following advantages are offered:
• The roller press and - depending on the contractual agreement - the overall plant are
checked and examined for transport damage, assembly mistakes, if any, etc.
• The operating staff is intensely instructed.
• Additionally, recommendations for the operation of the roller press or the plant are given
including maintenance and repairs.
• The roller press is optimally matched to the plant-specific conditions to yield a high degree
of efficiency.
Detailed descriptions on design and functioning of the individual sub-assemblies may be taken
from chapter "Design and functioning".
Page 4 of 10; BA 475-0143-06 en

BA 475-0143-06 en; Page 5 of 10
Commissioning
3 Trial run with feed material

The target of the trial run is the preparation of roller press and overall plant for the acceptance
test to meet the contractual product requirements regarding grain size, throughput rate and
energy consumption at minimally possible pressure. In this way, energy consumption, wear of
the roller surface as well as load on the drive elements can be minimized.
After the completion of the "Tests without material and interlocking tests", the roller press is fed
with feed material according to the contractual specification.
The later normal operation of the roller press is realised, controlled and monitored in a nearly
completely automatic manner via the ROLCOX®-control. In view of the complexity, only the main
functions will be dealt with below for a better understanding.
The procedure for the first feeding differs as follows from normal operation:
3.1 First starting up of the roller press

• Place persons with two-way radios at all important points
• AUTO-start of the roller press according to ROLCOX® control circuit I; pre-conditions:
– Shut-off gate CLOSED (manual)

– Gate of the feeding device on min.-position (manual)
– SET-pressure 40 bar
– Way-/pressure control deactivated
– Pull-down menu "Manual control" opened
• Shut-off gate OPEN (if available)
• Manually open gate of the feeding device by steps; after every step, wait and observe
reaction on roller press and overall plant; operate system with minimal throughput
• Operate plant without change for about 30 minutes and attentively observe it
• Further open gate of the feeding device manually by steps →, until about 50% of the rated
throughput rate are reached;
• Activate way-/pressure control
• Slowly increase SET-pressure by steps of 10 bar to 60-70 bar
• Operate roller press with this setting for 2-3 hours; observe temperatures of the bearings /
gears as well as operating behaviour of the roller press
• Shut-off gate CLOSED (if available)
• Gate of the feeding device manually on min.-position
• Run roller press empty, then shut it down
• Check roller surface for material deposits (autogenous wear protection) and damage
BA 475-0143-06 en; Page 5 of 10

Page 6 of 10; BA 475-0143-06 en
Commissioning
The maintenance doors of the enclosure may only be opened

after a standstill of the rollers and securing of the motors!
Depending on the operating behaviour, in this phase, it is decided in which operating mode the
roller press shall be operated:
"Floating"
→ The N2-pressure in the reservoirs is about 10 - 20 bar below the operating oil pressure.
During operation, a certain oil volume is always in the reservoir and compresses the gas in
the bladder.
→ the system reacts on pressure changes "softer".
"Rigidly"
→ The N2-pressure in the reservoirs is about 10 - 20 bar above the operating oil pressure.
During operation, no oil is in the reservoir
→ the system reacts on pressure changes "harder".
3.2 List of the main control circuits
All control circuits are contained as program modules in the ROLCOX®-software.
Control circuit AUTO-Start
Control circuit AUTO-Stop
Control circuit EMERGENCY-OFF disconnection
Control circuit way-/pressure control
Control circuit overload protection main motors
Control circuit temperature monitoring bearings
Control circuit feeding device
Control circuit planetary gear
Page 6 of 10; BA 475-0143-06 en

BA 475-0143-06 en; Page 7 of 10
Commissioning
4 Sampling
By the systematic sampling of roller press feed material and roller press discharge material as
well as the simultaneous recording (data logging) of all relevant operating data of the roller press
at short intervals, secured data are obtained documenting under which operating parameters
which comminution work takes place.
After a test series with always changed operating parameters such as pressure, gap width,
circumferential speed etc., it is relatively simple to determine the optimal SET-values for normal
operation.
Every test series is assigned to only one feed material/material mixture, i.e. for several feed
materials, the test series must be repeated.
Upon changes of product data and/or material properties, short-term repetition tests and the
comparison of the events with the initial test considerably facilitate the determination of the
causes.
Without disturbing production operation, the operating data of every test can be easily copied
from the control system onto an external data carrier and be further processed with MS-EXCEL.
The scope of the test programme depends on the plant and is determined together with the
customer prior to starting commissioning. The target is to determine optimal operating
parameters for the acceptance test.
To facilitate data processing, respective form sheets for individual tests and summary may be
taken from section "Customer-specific characteristic and technical data" and from the data
carrier.
Beyond the roller press discharge material, samples of the roller press feed material are taken
and analysed with a normal box to be provided by the customer.
The preparation of the samples and their evaluation is under the responsibility of the
commissioner or the laboratory staff.
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Page 8 of 10; BA 475-0143-06 en
Commissioning
5 Miscellaneous
5.1 Wear measurement

After 10 - 20 operating hours with feed material, the reference wear measurement has to be
made using the supplied device. It serves as a basis for the future regular wear measurements. It
is recommended to perform the two next wear measurements at intervals of about 300 operating
hours. On the basis of the determined wear increases, the further measurements can be made at
reasonable intervals.
For entering the measured values and their evaluation, respective form sheets may be taken
from section "Customer-specific characteristic and technical data". They are also available as
software.
Note!
We are urgently asking to transmit to us every measurement as

data file to the address indicated below. Thus, we are in a
position, to recognise plant anomalies in time and to recommend
remedial measures.
HUMBOLDT WEDAG GmbH

Abt. P-GS
e-mail: measure@khd.com
5.2 Training customer's staff

In most cases, the training of the customer's staff is part of the contract. This is done as an
accompanying measure during commissioning, i.e. theoretically and locally, by the Humboldt
Wedag commissioner.
It is recommended that the later operating staff is already available in the beginning of
commissioning, thus, very closely familiarizing the workers with all necessary setting works and
the different operating behaviour of the roller press.
5.3 Acceptance test

Following the test series and the reference wear measurement, the contractually specified
process-related acceptance test is run with the determined optimal operating parameters.
If the contractual values are met, the reached values are entered into an "Acceptance
certificate", which is signed by the parties involved.
With the same date, the process guarantees are considered fulfilled. The roller press is released
for production operation and the responsibility is passed on to the customer.
Check list safety
Note!
Also see "Check list safety" in section "Customer-specific

Page 8 of 10; BA 475-0143-06 en

BA 475-0143-06 en; Page 9 of 10
Commissioning
6 Electrical measuring instruments
6.1 Roller gap monitoring

The trans-sonar way transmitters continuously record the distance of the two rollers (recording of
the movement of the floating roller in the frame). The pertaining program stored in the roller press
control system permanently calculates the gap width with a constant to be entered and the
produced flake thickness.
During commissioning, the minimum distance of the roller surfaces must be determined, when
the movable bearing housing is in contact with the original spacer element. To that end, the
movable bearing housings should be pressed against the spacer elements at a pressure of about
40 bar. In this position, the way transmitter must be balanced by an electrician and indicate an
output current of >4,1 mA (see section "Customer-specific characteristic and technical data").
Now, the zero point of the way transmitter is determined. The distance between the roller
surfaces is best determined with the aid of a small lead block which is repeatedly dropped
through the roller gap. The pressed thickness of the lead is the constant which must be entered
into the control program.
Caution!
If the original spacer elements are replaced or changed, the zero-

balance of the way transmitter must be repeated. All other data in the
control system remain unchanged
6.2 Roller gap monitoring / Roller limit disconnection

The inductive approximation switches serve for the safety disconnection of the roller press which
immediately shuts down the motors as soon as, upon inadmissible stress (e.g. due to foreign
bodies), the movable roller is displaced more than permitted and, consequently, the machine can
be damaged. The approximation switch must finally be set such that the working stroke is
disconnected, when the pointer is in position "10" (end of working stroke). By displacing the
approximation switch, the switch point may be set very precisely.
Note!
For further electrical monitoring systems, see operating

instructions, chapter "Design and functioning" and "Assembly"
as well as the Technical Machinery Documentation, section
"Customer-specific characteristic and technical data".
6.3 Temperature monitoring at the main bearings

One resistance thermometer Pt 100, each, screwed into the bearing housing, with sensor
contact to the antifriction bearing monitor the temperatures during operation.
If the temperature indicated in section "Customer-specific characteristic and technical data"

should be exceeded, the roller press is disconnected.
In this way, the antifriction bearings are protected against overheating due to a defect, if any.
BA 475-0143-06 en; Page 9 of 10

Page 10 of 10; BA 475-0143-06 en
Commissioning
6.4 Rotation monitoring

An approximation switch at the shrinking disc monitors the rotary movement of the rollers. If the
rollers should be blocked during operation, the motor is disconnected via the approximation
switch.
In this way, the drive elements are protected against overload.
6.5 Feed material - temperature measurement

Via a resistance thermometer Pt 100 mounted to the lateral walls of the feeding device, the
temperature of the feed material is indirectly measured.
Page 10 of 10; BA 475-0143-06 en

Operation BA 475-0143-07 en
Page 1 of 22
Contents Page
1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Safety in general. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2 Chapter-related safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Check list safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Pressing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Previous edition:
4 Feeding device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Shutdown of the roller press. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.1 AUTO-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.2 EMERGENCY-OFF disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6 Starting the roller press after EMERGENC-OFF-disconnection . . . . . . . . . . . . . . . . . . . . . . . 9
7 Changing the roller speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 Behaviour upon failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8.1 Safety disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

8.2 Electrical/optical/acoustical failure indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.3 Check list failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.4 Re-starting after a failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9 Measures prior to and after an extended standstill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
9.1 Prior to an extended standstill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

9 Measures prior to and after an extended standstill. . . . . . . . . . . . . . . . . . . . . . . . . . 12
10 General remarks to the sequence of measuring, controlling and interlocking (MSR) . . . . . 14
10.1 Connection and disconnection sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

10.2 Interlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10.3 Measuring and control equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
11 Check list failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Page 2 of 22; BA 475-0143-07 en
Operation
1 Safety

the Technical Machinery Documentation, Section "Operating instructions".
Therefore, it is absolutely necessary that all involved persons carefully read them prior to starting
any work with and on the roller press and that the given safety references are thoroughly
observed!
The safety references in the text and the pertaining drawings

must also be observed!
1.3 Check list safety
Prior to the release for starting the roller press after assembly,
repairs, maintenance etc., a responsible person must perform the
checks indicated in the "Check list safety", see section
"Customer-specific characteristic and technical data".
It is urgently recommended to copy the original lists and to file the filled in copies for later
evidence.
Caution!
The electric monitoring systems such as temperature measuring

systems, way transmitters, approximation switches et al. are safety
devices ensuring the operational safety of the machine.
If the electrical systems should not exist or they are not properly
functioning, the warranty will expire.
Page 2 of 22; BA 475-0143-07 en

BA 475-0143-07 en; Page 3 of 22
Operation
2 Normal operation
Irrespective of the following references, for the operation of the

roller press, in any case the local safety regulations will apply
and the safety references given in chapter "Safety and health".
The production operation of the roller press is largely fully automatic. The complex monitoring
and control of all roller press functions as well as of further plant components is realised via the
ROLCOX control. Moreover, it is able to automatically balance the effects of changes in the
material feed such as volume, grain size, moisture etc. within specified limits.
Depending on the contract, ROLCOX® is delivered as stand-alone version or implemented as

software in the superior plant control.
ROLCOX® essentially covers the following main functions:

• Monitoring of all sensors (way transmitters, approximation switches, temperature gauges
etc.)
• AUTOMATIC start
• AUTOMATIC stop (normal)
• EMERGENCY-OFF stop
• Way-/pressure control
• Overload protection roller press and main motors
• Temperature monitoring of the roller supports
• Monitoring of the planetary gears
Moreover, ROLCOX® permits to reverse from the AUTO-mode to the MANU-mode during
operation. In the MANU mode, for example, the operator can influence the hydraulic control
without interrupting the production operation
ROLCOX® is supplemented by a diagnosis box. In this box, important operation- and safety-
relevant data are permanently recorded at very short intervals over an extended period of time.
In addition, from the diagnosis box, all operating parameters important for optimising the roller
press during commissioning and/or upon later control sampling measures can be transmitted to
external data carriers and then be evaluated.
For a better understanding, below, the operational functions of the roller press components are
only globally described. Detailed descriptions may be taken from chapters "Design and
functioning", "Commissioning" as well as from the separate documentation
"ROLCOX®".
BA 475-0143-07 en; Page 3 of 22

Page 4 of 22; BA 475-0143-07 en
Operation
3 Pressing device

opening of lines and/or other hydraulic elements, the hydraulic
Exclusively NITROGEN may be used as gas for operating the

reservoirs, by no means e.g. oxygen, air or similar is permitted to
be used.
OTHERWISE, THERE IS THE RISK OF AN EXPLOSION!
The filling procedure and the pressure test must be made

according to the enclosed supplier's documentation for
reservoirs (see section "List of the separate documentations").
The pressing device with the hydro-pneumatic spring system is the most important system for an
optimal operation and overload protection of the roller press. In connection with ROLCOX® , the
automatic pressing device ensures the automatic maintenance of the operating parameters
determined during commissioning or intermediate sampling upon a material change within the
admissible tolerance limits.
Exceeding of these tolerance limits regarding pressure and/or oblique position of the floating
roller are exclusively material-related; they can, however, be balanced within certain limits by the
hydraulic pressing system/ROLCOX .
If the tolerance values are further exceeded, this must be stopped via suitable measures in the
roller press feed, e.g. by homogenisation of the material distribution.
In case of sudden changes of the material properties or for test purposes, ROLCOX® includes
the option for the operator, to shortly change over during press operation to the MANU-mode.
A pull-down menu with 6 virtual "Pushbuttons" appears:
The "pushbuttons" are activated via mouse curser as long as the left mouse key remains
pressed. Upon a pressure rise, simultaneously, the hydraulic pump is started and the respective
valves switched; upon pressure reduction, only the valves are activated.
The decrease of the gap width via pressure increase is material-dependent and, therefore, only
possible within relatively narrow limits. This option must not be used over a longer period of time
for reducing the throughput rate and/or keeping constant the level in the roller press bin.
Overpressing of the material with increased wear and higher energy consumption would result.
Page 4 of 22; BA 475-0143-07 en

BA 475-0143-07 en; Page 5 of 22
Operation
The task of reducing the gap width can be better realised by the gate in the feeding device.
4 Feeding device
Covers may only be opened upon a standstill of the rollers.
Caution!
Changes at the gate of the feeding device may only be made after having
consulted the Humboldt Wedag GmbH.
The gate of the feeding divide influences the material volume fed to the roller gap and, thus,
directly the roller gap (according flake thickness) and the throughput rate. The roller gap is
controlled via ROLCOX® as well as by the operator. In both cases, a specified percentage is
aimed at.
When starting the roller press and prior to opening the shut-off gate arranged above, the roller
gap must be in the minimal position, i.e. the gate edge has a minimum distance to the surface of
the fixed roller. In this way, it is avoided that by the rapid opening of the shut-off gate, too much
material enters the roller gap and leads to a high pressure rise or the floating roller is slid into the
zone of roller limit disconnection.
After having opened the shut-off gate, the roller gap is increased by steps, until the desired gap
width is reached. The intervals between the steps must be sufficient to have the way-/pressure
control react on the pressure change.
Upon slowing down or stopping the roller press, the roller gap must be moved again into the
minimal position.
5 Shutdown of the roller press

In ROLCOX®, two types of roller press disconnection are programmed:
AUTO-stop and
EMERGENCY-OFF-disconnection
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Page 6 of 22; BA 475-0143-07 en
Operation
5.1 AUTO-Stop
AUTO-Stop means the normal slowing down of the roller press, i.e. after the release of a STOP
signal, the automatic slowing-down sequence of ROLCOX® starts. It is identified by respective
buffer times between the individual control steps.
The STOP-signals can be released via

• STOP-command by operator
• Roller press sensors
• Support
• Hydraulic system
• Lubricating system
• Drives
• Discharge system plant
• Feeding system plant
• Temperature material (optional)
Then, represented in a simplified manner, the following control steps automatically take place:
Feeding system STOP
Run roller press bin empty
Shut-off gate CLOSED and gate feeding device to MIN.-position
Way-/pressure control DEACTIVATED
Hydraulic pressure → 0 bar?
Floating roller to starting position, incl. balancing of oblique position
Depending on the duration:

DISCONNECT main motors
Discharge system STOP
Except for the STOP command given by the operator, all other STOP-signals are filed in the
history of failures.
Page 6 of 22; BA 475-0143-07 en

BA 475-0143-07 en; Page 7 of 22
Operation
5.2 EMERGENCY-OFF disconnection
Prior to starting any works on the roller press and/or on plant sections
connected in front or behind, these must be secured against unintended
connection by lockable switches (in the MCC or locally). Otherwise, the
applicable accident prevention regulations of the national employers'
liability insurance associations or comparable organisations will apply.
Released by a failure according to criterion II - III, during pressing operation, i.e. under load and
with material in the roller gap, the roller press is immediately disconnected. Upon criterion I,
under certain pre-conditions, another procedure can be followed (described below).
In view of the different counter-acting measures, there are 3 criteria leading to an immediate
disconnection. They comprise:
Criterion I failure discharge system
Criterion II activation EMERGENCY-OFF-switch locally

Rotation monitoring floating- and fixed roller
Monitoring fluid clutch
Failure of a main motor
Criterion III activation roller limit disconnection
Depending on the criterion, in the interlocking chain, the following sequences take place, partly
simultaneously:
Criterion I pre-conditions 1 and 2 are fulfilled
1 volume roller press discharge chute is

>volume roller press bin
2 discharge belt conveyor can be started again under load
Feeding system STOP
Shut-off gate CLOSED (if available)
Gate feeding device to MIN.-position
Floating roller to starting position, incl. balancing of oblique position
For local checks/measures, see Item 6Starting the roller press after
EMERGENC-OFF-disconnection9.
BA 475-0143-07 en; Page 7 of 22

Page 8 of 22; BA 475-0143-07 en
Operation
Criterion I pre-conditions 1 and 2 are not fulfilled

Same procedure as under criterion II
Criterion II both main motors STOP
Feeding system STOP
Gate feeding device to MIN.-position
Pressure relief valve OPEN
Local checks/measures, see Item 6.
Criterion III both main motors STOP
Feeding system STOP
Pressure relief valve OPEN
Local checks/measures, see Item 6Starting the roller press after

EMERGENC-OFF-disconnection9.
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BA 475-0143-07 en; Page 9 of 22
Operation
6 Starting the roller press after EMERGENC-OFF-disconnection
Covers may only be opened upon a standstill of the rollers.

Special precautionary measures must not be taken, if material is
in the shaft. It must be avoided, e.g. by supporting wooden
beams, that the material column in the shaft abruptly presses
open the cover upon opening.
Depending on the disconnection criteria, the following counter-acting measures must be taken.
Criterion I pre-conditions 1 and 2 are fulfilled
Local checks/measures
1. Secure discharge system against being connected
2. Eliminate cause of disconnection
3. Acknowledge / release electric system
Shut-off gate OPEN (if available)
Gate feeding device to OPERATING-position
Way-/pressure control ACTIVE
Criterion II Local checks/measures

1. Secure roller press against being connected again
2. Eliminate cause of disconnection
Roller press AUTO-start ACTIVE
Criterion III Local checks/measures

1. Secure roller press against being connected again
2. Reverse to MANU-mode
3. Move gate of the feeding device to MAX
4. Clear roller gap; remove foreign bodies
5. Move floating bearing off the disconnection zone of the limit switches
6. Move gate of the feeding device to MIN-position
Roller press AUTO-start ACTIVE
BA 475-0143-07 en; Page 9 of 22

Page 10 of 22; BA 475-0143-07 en
Operation
7 Changing the roller speed

Depending on the plant conception, the roller press is operated at constant or variable speed.
Constant speed is selected, if the material parameters do not change at all or only slightly and
the press discharge is intermediately stored in a bin.
If, for process reasons, the speed must be changed, this is only possible by changing the gear
transmission ratio.
Essentially more flexible is the operation of the roller press via variable sped. Here, the motor
speed is steplessly changed via a frequency control. Matching of the motor speed can take place
e.g. via the filling level in the main bin; this is possible automatically or by an according setting of
the operator in the screen.
The frequency control has a decisive advantage: For example upon different roller diameters due
to wear, the circumferential speeds of both rollers can be optimally matched to each other by an
intelligent programming of the frequency control, i.e. the motors are running in torque balance.
The effects:
• Both motors have nearly the same power consumption → the same torques
• Minimal friction in the roller gap → reduced wear
• Increased motor power available
8 Behaviour upon failures
Irrespective of the following references, for the operation of the roller

press, in any case the local safety regulations and the safety references
given in chapter "Safety and health" in section "Operating instructions"
will apply.
8.1 Safety disconnection
A lockable local switch must be installed, which avoids an unintended

connection of the roller press upon repairs or failures.
Otherwise, we make reference to the applicable accident prevention
regulations of the respective employers' liability insurance associations.
Shut down roller press group with the "Emergency-off-switch".
Page 10 of 22; BA 475-0143-07 en

BA 475-0143-07 en; Page 11 of 22
Operation
8.2 Electrical/optical/acoustical failure indication

The following failures may be indicated:
• Failure indication due to rise of oil temperature in the gear.
• Indication of the filter contamination at the gear oil cooler.
• Temperature rise or speed control at the fluid coupling (if existing).
• Failure indication on the oil circulation lubrication system (only for oil-lubricated bearings).
• Indication of filter contamination on the oil circulation lubrication system (only for oil-
lubricated bearings).
• Failure indication of the central grease lubrication system for the labyrinths or the support
and labyrinths.
• Failure indication by temperature rise at the antifriction bearings of the roller press or at
the gears and couplings.
• Failure indication by temperature rise in the feed material.
• Damage to components of the roller press.
Caution!
In case of doubt, generally, the roller press must be slowed down

and the after-sales service of the Humboldt Wedag GmbH be
consulted (see chapter "Spare parts keeping and after-sales
service").
For the individual failure indications released in the roller press control, warning times are
installed which permit an elimination of the failure within that time or, depending on the extent of
the damage, the roller press is immediately shut down.
8.3 Check list failures

See item 11 Check list failures
8.4 Re-starting after a failure

See chapters "Assembly" and "Commissioning".
BA 475-0143-07 en; Page 11 of 22

Page 12 of 22; BA 475-0143-07 en
Operation
9 Measures prior to and after an extended standstill

If the roller press shall be shut down for a longer time (max. 3 months), the following measures
are required:
9.1 Prior to an extended standstill

• Run RP empty and completely clean it.
• For the main antifriction bearings, two alternatives for the preservation are available:
a) Fill the bearing with a preservation agent compatible with the lube oil, have the
system shortly (abt. 15 min.) run without load, then drain the oil again.
Preferably, use the preservation agent DECORDYN 350 of Messrs. Fuchs
Lubritech
b) Have the rollers run without load with the oil circulation lubrication system every 4
weeks for a time of 1 - 2 hours.
Upon a standstill of more than 3 months up to 1 year at a maximum, preserve as described under
item a).
For filling the main bearings with the preservation agent, the hose lines (supply- and return line)
must be dismantled from the bearing, the return openings be closed and the preservation agent
be filled into the bearing using a filling device.
• After having turned the bearings, drain preservation agent.
Close drain- and supply openings at the bearing with threaded locking bolts.
• Completely fill labyrinth gaps with fresh grease via the central grease lubrication system, the
rollers being turned.
• Fill central lubrication system with the respective grease and protect it against moisture and
heat. (see list of lubricating points).
• Cover labyrinth seals of the antifriction bearings with grease ties to avoid that dust and
moisture may enter.
• Roller press, run empty feeding- and discharging systems and completely clean them.
• Completely lubricate lubricating points (see list of lubricating points).
• Relieve pressure from pressing device
• Reduce N2-pressure in reservoir to 10 bar.
• Completely run empty cooling system and, in particular upon temperatures of <0°C, blast
with air.
• Treat planetary gear and pressing device as described in the suppliers' documentation.
• Preserve blank parts (e.g. with DECORDYN 350; protection time about 12 months) and
protect them against damage.
• Protect motors and sensors against moisture, contamination and damage.
Page 12 of 22; BA 475-0143-07 en

BA 475-0143-07 en; Page 13 of 22
Operation
9.2 After an extended standstill

• Drain preservation agent in the antifriction bearing at the drain screws.
• Fill circulation lube oil into the bearing (3-5 litres per bearing). Have roller press run, then
drain oil.
Then, connect oil supply lines of the oil circulation lubrication.
• Render central lubrication system, planetary gear, oil circulation lubrication system and
pressing device operable according to the enclosed suppliers' documentation.
• Prior to re-starting, observe chapter "Commissioning".
• Increase N2-pressure to operating value before the standstill.
• Remove grease ties at the labyrinths.
• Lubricate lubricating points.
• Fill water cooling system.
• Check functioning of the sensors.
Prior to re-starting, observe chapter "Commissioning".
Note!
For list of lubricating points, see section "Customer-specific

For suppliers' documentations, see "List of the separate

documentations".
BA 475-0143-07 en; Page 13 of 22

Page 14 of 22; BA 475-0143-07 en
Operation
10 General remarks to the sequence of measuring, controlling and

interlocking (MSR)
The order-specific MSR equipment including information on the scope of supply as well as circuit
diagrams and interlocking plans may be taken from the separate documentation for the
measuring- and control engineering (see section "List of the separate documentations").
10.1 Connection and disconnection sequence

A roller press always operates in combination with other plant sections such as transport
facilities, screens, mixers etc.
Generally, the following applies:
Connection opposite to the material flow.
Disconnection with the material flow.
Connection sequence:
1 All sets behind the roller press (discharge conveyor etc.)

2 Roller press.
3 All sets in front of the roller press.
Disconnection sequence:
Disconnection takes place in reverse sequence. Take care that sufficient time is available for
running the plant empty.
1 All sets in front of the roller press

2 Roller press
3 All sets behind the roller press
Page 14 of 22; BA 475-0143-07 en

BA 475-0143-07 en; Page 15 of 22
Operation
10.2 Interlocking
Interlocking of the roller press with the directly adjacent sets is only part of the overall interlocking
and must be reasonably integrated into the same.
Connection sequence:
The connection and activation of all sets and supervision devices at the roller press described
below must take place in the specified sequence:
• Oil circulation lubrication
(Previously, bring lubrication system to operating temperature)
• Accompanying heating of the grease labyrinth lubrication and oil circulation lubrication
• Grease labyrinth lubrication
• Bearing temperature
• Gear temperature
• Rotation monitoring
• Feed material temperature (if available)
Main drive motors on:

• Gap control
• Observe pressing device as per item 3..
• Housing gate open.
• Dosing system or material supply on.
Caution!
For re-starting the roller press after an immediate disconnection

(roller gap and feeding system filled with material), starting
bridging of the roller limit disconnection is required as the
opened roller gap does not meet the starting conditions for the
main drive motors.
Immediate disconnection:
An immediate disconnection of the plant takes place upon failure or response of:
• Discharge sets behind the roller press.
• Rotation monitoring of the rollers.
• Gear monitoring (bearing temperature 373 K / 100 °C)
• Roller bearing temperature 333 K / 60 °C.
• Contamination indication, twin filter, oil circulation lubrication system.
• Feed material - temperature 393 K / 120 °C (if available)
BA 475-0143-07 en; Page 15 of 22

Page 16 of 22; BA 475-0143-07 en
Operation
An immediate disconnection of the plant is not required upon the following failure indications:
• Oil circulation lubrication system
Upon a failure message: Alarm, after 1 minute, preliminary pump off,
after 15 minutes, shut down roller press.
• Grease labyrinth lubrication system

Upon a failure message: Alarm, shut down machine after 6 hours.
• Contamination indication, twin filter, gear oil cooling system.

Reverse to second filter, replace contaminated filter.
• Gear temperature monitoring:

At a temperature of 358 K / 85 °C, an alarm is released
• Roller bearing temperature.

At 328 K / 55 °C, an alarm is released.
• Hydraulic pump and hydraulic oil temperature (see separate documentation in section "List
of the separate documentations").
• Feed material temperature (if available):

Alarm is released at 373 K / 100 °C
Caution!
In case of a failure releasing a second alarm message, the roller

press is generally disconnected.
The failure cause must be eliminated.
Note!
The electric monitoring systems such as temperature measuring

systems, way transmitters and approximation switches are safety
devices ensuring the operational safety of the machine.
If the electrical systems should not exist or they are not properly
functioning, the warranty will expire.
Page 16 of 22; BA 475-0143-07 en

BA 475-0143-07 en; Page 17 of 22
Operation
10.3 Measuring and control equipment

Scope of supply as per contract.
Equipment control system:

Function:
• Setting of operating pressure, operating pressure limit values, gap geometry via keyboard.
• Indication of RATED/ACTUAL values on the monitor.
• Monitoring of all operating values.
• Detailed failure signalising.
• Triggering of the hydraulic set.
• Triggering of the solenoid valves.
• Control of the operating pressure and of the gap geometry.
• Control/interlocking of the roller press lubricating system.
• Storage of operating data.
• Visualised representation of the roller press and its operation.
• Interactive monitor control for the operator.
• Printing and indication of operation- and trend curves.
• Storage place for control/interlocking of sets of the supply and discharge system.
Place of installation:
Control centre.
BA 475-0143-07 en; Page 17 of 22

11 Check list failures
Page 18 of 22; BA 475-0143-07 en

Page 18 of 22; BA 475-0143-07 en
Operation
Check point Characteristics Causes Measures
Roller press in general Product performance - Pressure too small - Compare pressure SET value with actual pressure, correct,
decreases if necessary
- Too much finest material in roller press - Reduce portion of finest material
feeding material
- Roller gap too large - Position gate of feeding device excessively opened,
correct, if necessary
- Close gate of the feeding device; replace
- Remove material deposits between spacer elements
- Roller surface uniformly worn down - Repair welding / possible only for welded surface)
- Bearing distance "Lmin" fallen below - Check position gate of feeding device, correct, if necessary
- Material volume too small ===> increase
- Correct parameter values
- Check width of spacer element, replace, if necessary
Shocks / vibrations - Feed lumps too large - Discharge oversize material; for admissible size, see
section "Customer-specific characteristic and technical
data"
- Too high pressure at at too much finest - Reduce finest material

material in the roller press feed
- Foundation bolts loose - Check foundation bolts, tighten, if necessary.
- Roller surface damaged - Check surface and repair, if necessary
- Irregular accretions on roller surface - Remove accretions
- possibly, change pressure or material moisture

Frame Movement between - Screws loose - Tighten screws with specified torque
(order group 11) frame parts
Movement between - Clamping screws loose - Tighten screws with specified torque
frame and rocker arms
Roller support Horizontal movement - Close slide pair outer guiding - Replace slide pair
(order group 12/18) bearing housing
Vertical movement - Lock slide pair frame/bearing housing - Replace slide pair
bearing housing
Oil emerging from the - Sealing damaged or worn down - Check shaft sealing ring, replace, if necessary
labyrinths
- Check screw unions, replace O-rings, if necessary
- Renew gaskets
- Check lubrication system
- Rinse leakage oil lines
Bearing temperature - Function water cooling - Check water cooling

too high
- Lubrication insufficient - Check lubricating system
- Lubricant selection incorrect - Check lubricant with the table of lubricants.
BA 475-0143-07 en; Page 19 of 22

BA 475-0143-07 en; Page 19 of 22
Operation
Page 20 of 22; BA 475-0143-07 en
Page 20 of 22; BA 475-0143-07 en
Operation
rollers Temperature too high - Temperature feed material too high - Reduce pressure; cool down material by circuit operation
(order group 21/24)
Roller gap too large - Position gate feeding device excessively - Correct gate position
opened
- Close gate edge - Replace gate
- Material deposits between spacer elements - Remove material accretions
- Pressure too small - Compare pressure SET value with actual pressure, correct,
if necessary
- Way transmitter wrongly calibrated - Newly adjust way transmitter
- Roller surface worn down - Perform wear measurement, replace rollers, if necessary
Roller gap too small - Way transmitter wrongly calibrated - Newly adjust way transmitter
- insufficient material volume in roller gap - Correct gate position
Rollers blocking - Foreign bodies in roller gap - Remove foreign bodies
Rollers do not rotate - Motor defective - Repair or replace motor
- Oil lack in fluid clutch - Check fluid clutch, re-fill oil, if necessary
- Safe-set coupling released - Newly pre-load Safe-Set coupling
- Planetary gear defective - Repair or replace planetary gear
- Shrinking disc connection loose - Newly load shrinking disc
- Rotation monitoring defective - Replace approximation switch
Permanent oblique - Material distribution irregular - Optimise material distribution

position floating roller
- Check ROLCOX parameters, correct, if necessary
Pressing device Horizontal movement - N2-pressure too low - Increase N2-pressure

(order group 27) floating roller too large
Oil emerging from gas - Reservoir defective - Replace reservoir

valve reservoir
Reservoir valve hitting - Differential pressure between N2-pressure - The N2-pressure must always be about 10 bar above
and oil pressure („rigid“ mode) or below („floating“ mode) operating oil
pressure
No pressure indication - Pressure pick-up defective - Electrically check pressure pick-up, replace, if necessary
- Oil level too low - Refill hydraulic oil
- Hydraulic pump defective - Replace hydraulic pump
- Solenoid valves defective - Check hydraulic system, replace valve, if necessary
Hydraulic oil too hot - Connection time hydraulic pump too long - Check hydraulic system, eliminate leakages, if necessary
- Check triggering of solenoid valves
- Check Rolcox parameters, correct SET-value, if necessary
Feeding device No re-adjustment gate - Motor defective - Check electric system, replace motor, if necessary
(order group 29/30) of feeding device
- Material accretions in the adjusting zone - Remove accretions
- Articulation points jammed - Check articulation points, replace, if necessary
- Guidings jammed - Check guidings, repair/replace motor, if necessary
BA 475-0143-07 en; Page 21 of 22

- Rotation transmitter defective - Check electric system, replace, if necessary
BA 475-0143-07 en; Page 21 of 22
- Material flows besides the rollers - Check feeding device for wear, replace worn down parts, if
necessary
- Check setting of the headwalls, correct, if necessary
- Check wear condition of headwalls and and headwall tips,
Operation
replace parts, if necessary
Page 22 of 22; BA 475-0143-07 en
Page 22 of 22; BA 475-0143-07 en
Operation
Roller enclosure Material/dust emerging - Housing plate worn through - Repair worn down areas
(order group 32)
- Sealing plate distorted - Repair sealing zone
- Seals missing - Renew seals
- Flange bolts loose - Tighten screws
Central grease No grease emerging - Grease supply interrupted - Check electric system motor barrel pump, replace, if
lubrication from labyrinths necessary
(order group 15)
- Check delivery pump of barrel pump, clean, if necessary
- Check lines/screw unions
- Check pump element, replace, if necessary
- Grease barrel empty, replace
Grease emerging from - Overpressure valve defective - Replace pressure valve

overpressure valve
- Pressure setting wrong - Replace pressure valve
- Line/distributor blocked - Check complete line system and eliminate blockage
Note!
As a supplement, the failure elimination measures of the suppliers according to their documentations in
Section "List of the separate documentations" must be observed!
Spare parts keeping and BA 475-0143-09 en
after-sales service Page 1 of 1
Contents Page
1 Spare parts keeping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Contact addresses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1 Spare parts keeping

Keeping the most important spare and wear parts on stock at the place of installation is an
Previous edition:
essential precondition for permanent functioning and readiness to be operated of the roller
press.
Only the use of original spare parts will guarantee a maximum of operational safety and a
long service life of the machine.
We grant a guarantee only for the genuine spare parts supplied by us.
The warranty granted by the Humboldt Wedag GmbH will expire, if spare parts and
auxiliary equipment are installed or attached, which were not supplied by us. Please
observe that for our own parts and those supplied by other companies, there are special
manufacturing and delivery specifications and that we are offering to you always spare
parts meeting the latest state of the art and the latest legal regulations.
Caution!
For ordering spare parts, please use the spare parts list.
The required parts may be identified on the pertaining spare parts drawings and specified
with the aid of the spare parts list.
The following information are absolutely required for ordering:

Spare parts list no.
Item-no. of the spare parts list
Unit number
Designation
The following additional information facilitate the internal assignment:

Ordering-no.
Machine-No.
Humboldt Wedag order-no.
2 Contact address
Humboldt Wedag GmbH
Colonia-Allee 3
51067 Köln
Germany
Phone: +49 (0)221 6504-0

URL: http://www.khd.com

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Technical Machinery Documentation State: 03.

Index of the operating BA 475-0143 en

State 03.2012 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BA 475-0143-01 en

State 03.2012 Design and functioning . . . . . . . . . . . . . . . . . . . . . . . .BA 475-0143-03 en

* Changing the roller speed

2. Explanation of symbols and references. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

The illustrations are not binding for the execution!

2. Explanation of symbols and references

2.1 Safety symbol

This symbol is found at all safety references in these operating

2.2 Attention reference

This reference is found in these operating instruction at items to

This reference draws your attention to general operating

2.4 Ear protection reference

This symbol is found at all safety references in these operating

Prior to using the roller press beyond the contractually agreed

Humboldt Wedag GmbH

Phone: +49 (0)221 6504-0

BA 475-0143-01 en; Page 3 of 3

Safety and health BA 475-0143-02 en

1. Explanation of symbols and references. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.2 Safety references for persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1. Explanation of symbols and references

1.1 Safety symbol

This symbol is found at all safety references in these

1.2 Attention reference

This reference is found in these operating instruction at

Safety and health

This reference draws your attention to general operating

1.4 Ear protection reference

This symbol is found at all safety references in these operating

2.1 General safety references

• The competences for assembly, disassembly or re-installation, commissioning, operation and

• During any works regarding installation, dismantling and reinstallation, commissioning,

• Platforms, ladders, stairs etc. must be kept free from contaminations.

Safety and health

2.2 Safety references for persons

It is recommended to the operator to have this confirmed in

Wear the prescribed personal ear protection.

Wear protective clothing.

BA 475-0143-02 en; Page 3 of 5

Safety and health

2.3 Safety references for machinery

• Only suitable and properly functioning lifting tools may be used.

• Regularly check warning paintings and renew them, if necessary.

Safety and health

• During operation, guards at the machine must be in their protecting position.

For filling the reservoirs, only nitrogen may be used and, by no

BA 475-0143-02 en; Page 5 of 5

Design and functioning BA 475-0143-03 en

2.2.1 Antifriction bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Design and functioning

Page 2 of 19; BA 475-0143-03 en

Design and functioning

BA 475-0143-03 en; Page 3 of 19

Design and functioning

Item (TPG) No. Sub-assembly

12, 82 Bearing and bearing guide

13, 14 Oil circulation lubrication, accompanying heating